Patent Publication Number: US-2023151174-A1

Title: A polyurethane foam composition and a method for synthesis thereof

Description:
THE TECHNICAL FIELD OF THE INVENTION 
     Invention relates to polyurethane foam compositions for use in automotive sector, providing lightness of vehicles and helping enhancement of power efficiency, and a method for synthesis thereof. 
     BACKGROUND OF THE INVENTION 
     Fossil fuel-oils use accounts for 80% of CO 2  release in the world. Use of polyurethane is a rational approach also for reducing CO 2  release which is main reason for global warming. Displaying high performance at low cost, polyurethane has a broad area of use ranging from white goods, automotive, construction, ship building medical and glues thanks to is high functionality. 
     Polyurethane is a polymer developed as a result of reactions of NCO group isocyanides with polyols of OH group. Involvement reaction is a totally polymerization reaction and is a sub-group of plastic family. Polyurethane foams are obtained by mixture of four raw materials, mainly polyol, isocyanides, floating gas, and catalyser. In addition to isocyanides and polyol which are two fluids, polyurethane foam of close cell structure is obtained as a result of chemical reactions of activators. Foam composition speeds are controlled by catalyser. Correct formulations of two raw materials and foam reaction control determine polyurethane density, mechanical strength, close cell structure, heat strength, acoustic protection etc. 
     Ecological problems arising due to increase experienced in global climate change have forced several countries and international organizations to take measures. One of those measures is to take under control inflating gases which is one of main components providing cell formation in polyurethane foam, high necessitates use of inflating gases not thinning ozone layer and having low global heating score. Use of current inflating gases available in market is restricted and banned by regulations, new generation inflating agents put into market as alternative of them have high costs. Hydrocarbons used at present and particularly use of hydrocarbons (HCFC) and hydrofluorocarbon (HFC) gases as inflating gases are expected to be banned by Kyoto Protocol soon. In addition, water (H 2 O) can be used as inflating agent for polyurethane materials, but water cannot provide skin formation to provide high acoustic performance and water absorption strength expected in semi integral materials. 
     Therefore, compositions used in production of polyurethane and parameters applied therein are of nature determining areas where final product use is convenient. For instance, Patent document numbered EP1471086B1 in the related art relates to production of polyurethane foams with improved elasticity in particular and discloses a method for production of polyurethanes displaying high elasticity. Use of water as inflating agent is disclosed in the method. In addition, use of two different prepolymer is disclosed. 
     Another document in the related art, patent numbered TR2017/15478 aims to produce hydrolysed resistant polyurethane cast parts convenient for use in steering wheels, seats, arms and shoe soles in particular. The method developed for it discloses use of water as inflating agent and in addition to water use of hydrocarbons. The developed method states that particularly hydrolysis aging is prevented. 
     In addition to four main raw materials for production of said polyurethane, other compounds can also be added into composition to determine functional features of final product. When documents in the related art are examined and broad area of polyurethane use is considered, it is seen that studies conducted are inadequate. It is considered that method for production of polyurethane with enhanced functionality and particularly specialized for specific use areas in particular is needed. 
     BRIEF DESCRIPTION OF THE INVENTION 
     The present invention relates to a polyurethane foam composition and a method for synthesis thereof meeting the needs mentioned above, eliminating all disadvantages, and providing some additional advantages, and a manufacturing method for it. 
     Primary purpose of the invention is to obtain flexible semi-integral polyurethane foam composition with minimised ecological damages and convenient for use in areas wherein lightness and mechanical strength is required in automotive sector. 
     Another purpose of the invention is to obtain polyurethane foams enabling sound skin structure protection for long time together with rigidity when used in automotive sector, particularly semi-integral systems. 
     A further purpose of the invention is to achieve a polyurethane foam production method by use of an inflating agent with low cost, not containing halogen and convenient for global heating regulations. 
     In order to achieve above mentioned purposes, the invention is a method for synthesising polyurethane foam compositions convenient for use in areas wherein rigidity and lightness are required together in automotive sector and comprises process steps of
         conduct of polyol dosage adjustment,   adding inflating reaction catalyser onto polyol of convenient amount and mixing at mechanical mixture,   adding glycerine while mixing is continued,   adding surfactive while mixing is continued,   adding gelling reaction catalyser while mixing is continued,   adding cell opening agent while mixing is continued,   adding mono-ethylene glycol while mixing is continued,   adding at least an inflating agent selected from a group consisting of n-pentane, cyclopentane, c 3 h 8 o 2  gas and c 2 h 4 o 2  gas while mixing is continued,   conduct of temperature adjustment of polyol base mixture,   conduct of isocyanide dosage adjustment in a separate place,   injecting polyol base mixture into reaction container from one side and isocyanides from other side,   conduct of temperature control during reaction and opening mold at the end of reaction and removing final product.       

     To achieve above mentioned purposes, the invention is a polyurethane foam synthesized by use of said method and comprises
         32-34% MDI isocyanides,   50-52% polyether triol,   1-3% cell opening agent,   0.2-0.8% glycerine,   5-7% mono ethylene glycol,   0.3-1% gelling reaction catalyser,   0.1-0.4% inflating reaction catalyser,   0.4-0.8% silicon surfactive,   5-8% n-pentane.       

     The structural and characteristics features, and all advantages of the invention will be understood better with detailed descriptions given below. Therefore, the assessment should be made considering the detailed description. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In this detailed description, a polyurethane foam composition and a method for synthesis thereof being subject of this invention and the preferred applications have been disclosed for the purpose of better understanding of the subject and described in a manner not causing any restrictive effect. 
     Invention is a method for polyurethane foam compositions convenient for use in automotive sector where rigidity and lightness are required and comprises process steps of
         i. conduct of polyol dosage adjustment,   ii. adding inflating reaction catalyser onto polyol of convenient amount and mixing at mechanical mixture,   iii. adding glycerine while mixing is continued,   iv. adding surfactive while mixing is continued,   v. adding gelling reaction catalyser while mixing is continued,   vi. adding cell opening agent while mixing is continued,   vii. adding mono-ethylene glycol while mixing is continued,   viii. adding at least an inflating agent selected from a group consisting of n-pentane, cyclo-pentane, c 3 h 8 o 2  gas and c 2 h 4 o 2  gas while mixing is continued,   ix. conduct of temperature adjustment of polyol base mixture,   x. conduct of isocyanide dosage adjustment in a separate place,   xi. injecting polyol base mixture into reaction container from one side and isocyanides from other side,   xii. conduct of temperature control during reaction and opening mold at the end of reaction and removing final product.       

     In a preferred application of the invention, inflating reaction catalyser mentioned in process step numbered (ii) is selected among tertiary amines. According to the most preferred application, amine catalysers comprising 30% dipropilenglycol by weight is preferred as inflating reaction catalyser. In an application, said catalyser is a third amine with commercial title Teogamine BDE. 
     Glycerine added into mixture at step (iii) functions as cross-bonding and helps providing dimensional stability of final product. In addition, it has an essential role in adjustment of end product rigidity and elasticity. 
     In a preferred application of the invention, surfactive in process step (iv) is silicone. More preferably, silicone surfactive of 1.075±0.01 cm 3  density at room temperature, viscosity 700±150 mPas, 7.4±1.2 pH is preferred. Homogenous and small cell structure is formed to provide final product with high shrinking resistance. In this application, commercial name of said surfactive is TEGOSTAB B 8905. 
     In a preferred application of the invention, gelling reaction catalyser mentioned in process step numbered (v) is selected among tertiary amines. According to a preferred application, catalysers comprising 33% dipropylene glycol by weight is preferred as gelling reaction catalyser. In an application, said catalyser is a third amine with commercial title Teogamine 33. 
     Cell opening agent added to mixture in process step (vi) enables open cell structure required for sound insulation of end product. In a preferred application of the invention, as cell opening agent polyols with KOH number (mg KOH/g polyol) between 30-35 is used. In an application polyether polyol of commercial title Coranol CP 1421 is used. 
     Mono-ethylene glycol added into mixture at step (vii) functions as cross-bonding and helps providing dimensional stability of final product. 
     Inflating agents in process step (viii) not only enables inflating reaction but also provides skin formation in end product. In a preferred application of the invention, as inflating agent in process step (viii) n-penthane is used. In said step said adding process is made by help of a pump in close system in order to prevent evaporation of gas. Mixing rate is also essential for keeping gas in the system. In the said step said mixing process continues preferably 15-30 minutes at 400-600 rpm. According to the most preferred application, mixing process continues 20 minutes at 500 rpm. 
     In a preferred application of the invention, after process step (ix), temperature of polyol base mixture obtained after adding inflating agent lastly is kept at 22-28° C. by help of thermocouple. This value is preferably 25° C. 
     In a preferred application of the invention, in process step (xi) polyol base mixture is injected at 140-180 Pa pressure and isocyanides are injected at 130-170 Pa pressure. The values are preferably 160 Pa for polyol base mixture while 150 Pa for isocyanides. Here another important point is the temperature of reaction container. Temperature of reaction container of the invention is preferably 42-48° C. and the most preferred one is 45° C. 
     Temperature of reaction mold in process step (xii) is at range of 42-48° C. Here temperature value is critical in respect to reaching skin thickness of end product. For completion of reaction, it waits for 3 to 7 minutes and at the end of reaction it takes shape of mold, and polyurethane foam is removed from mold. 
     Execution of the steps applied in the method of the invention in this order and with such parameters is critical. Particularly, by help of synergy developed by parameters such as selection of inflating agent, speed of mixing it with polyol base mixture, mixing temperature and reaction mold temperature, end product has desired rigidity, lightness and dimensional stability while also long use life of product is achieved, and also a skin with high mechanical strength is achieved. 
     The invention is also a polyurethane foam synthesized with said method. In an application of the invention, said polyurethane foam comprises by weight;
         32-34% MDI isocyanides,   50-52% polyether triol,   1-3% cell opening agent,   0.2-0.8% glycerine,   5-7% monoethylene glycol,   0.3-1% gelling reaction catalyser,   0.1-0.4% inflating reaction catalyser,   0.4-0.8% silicon surfactive,   5-8% n-pentane.       

     In an application of the invention, said polyurethane foam comprises by weight;
         33.8% MDI isocyanides,   50.6% polyether triol,   2.2% cell opening agent,   0.7% glycerine,   5.4% monoethylene glycol,   0.4% gelling reaction catalyser,   0.2% inflating reaction catalyser,   0.7% silicone surfactive,   6% n-pentane.       

     In above applications of the invention said gelling reaction catalyser and inflating reaction catalyser is in tertiary amine structure. According to the most preferred application, an amine catalyser comprising 30% dipropilenglycol by weight is preferred as inflating reaction catalyser. According to a preferred application, a catalyser comprising 33% dipropylene glycol by weight is preferred as gelling reaction catalyser. 
     In a preferred application of the invention, as said cell opening agent polyols with KOH number (mg KOH/g polyol) between 30-35 is selected. 
     Polyurethane foam of the invention is achieved as an end product of open cell structure displaying 130-300 gr/dm3 density, skin thickness of 1-2.5 mm, maximum 5% water absorption. Open cell structure and thick skin structure provides high acoustic performance. 
     Another importance of the invention is that method of the invention and polyurethane foam synthesized by the method has minimized ecological damage in comparison to its alternatives at present. By help of method of the invention it is possible to produce a polyurethane foam at low cost, not comprising halogen and conforming to global heating regulations.