Stability of polyurethane polyol blends containing halogenated olefin blowing agents

Abstract

A stable polyol pre-mix composition comprises a blowing agent, a polyol, a surfactant, and a catalyst composition comprising an oxygen-containing amine catalyst. The oxygen-containing amine catalyst may be, an alkanol amine, an ether amine, or a morpholine group. containing compound such as, 2.(2.dimethylaminoethoxy)ethanol or N.N.N′.trimethylaminoethylethanolamine. A stabilized thermosetting foam blend comprises: (a) a polyisocyanate and, optionally, isocyanate compatible raw materials; and (b) a polyol pre. mix composition. A method for stabilizing thermosetting foam blends comprises combining: (a) a polyisocyanate and, optionally, isocyanate compatible raw materials; and (b) a polyol pre. mix composition. A polyurethane or polyisocyanurate foam having uniform cell structure with little or no foam collapse comprises a mixture of: (a) a polyisocyanate and, optionally, one or more isocyanate compatible raw materials; and (b) a polyol pre-mix composition. The resultant polyurethane or polyisocyanurate foams have uniform cell structure with little or no foam collapse.

1 . A stable polyol pre-mix composition comprising a blowing agent, a polyol, a surfactant, and a catalyst composition comprising an oxygen-containing amine catalyst, wherein when the catalyst composition comprises more than one amine catalyst, the oxygen-containing amine catalyst comprises greater than 50 wt % of a total of the amine catalysts. 
     
     
         2 . The stable polyol pre-mix composition of  claim 1 , wherein the oxygen-containing amine catalyst is an alkanolamine, ether amine, or a morpholine group-containing catalyst. 
     
     
         3 . The stable polyol pre-mix composition of  claim 1 , wherein the oxygen-containing amine catalyst is a compound having the chemical structure:
   R 1 R 2 N(CH 2 ) 2 X(CH 2 ) 2 Y   
       wherein:
 R 1  and R 2  are the same or different and are each a C 1 -C 6  alkyl group and/or an alkanol group, 
 X is O or NR 3  and/or it can be terminated by OH, where R 3  is a C 1 -C 6  alkyl group or an alkanol group, and 
 Y is OH or NR 4 R 5 , where R 4  and R 5  are the same or different and are each a C 1 -C 6  alkyl group or an alkanol group, subject to the proviso that the compound contains at least one ether and/or hydroxyl group. 
 
     
     
         4 . The stable polyol pre-mix composition of  claim 1 , wherein the oxygen-containing amine catalyst is selected from the group consisting of bis-(2-dimethylaminoethyl)ether; N,N-dimethylethanolamine; N-ethylmorpholine; N-methylmorpholine; N,N,N′-trimethyl-N′-hydroxyethyl-bisaminoethylether; N-(3-dimethylaminopropyl)-N,N-diisopropanolamine; N,N-bis(3-dimethylaminopropyl)-N-isopropanolamine; 2-(2-dimethylaminoethoxy)ethanol; N,N,N′-trimethylaminoethylethanolamine; and 2,2′-dimorpholinodiethylether, and mixtures thereof. 
     
     
         5 . The stable polyol pre-mix composition of  claim 1 , wherein the blowing agent comprises a halogenated hydroolefin and, optionally, one or more hydrocarbons, alcohols, aldehydes, ketones, ethers/diethers, or CO 2  generating materials, or combinations thereof. 
     
     
         6 . The stable polyol pre-mix composition of  claim 5 , wherein the blowing agent comprises a halogenated hydroolefin selected from the group consisting of hydrofluoroolefins (HFOs), hydrochlorofluoroolefins (HCFOs), hydrofluorocarbons (HFCs), hydrofluoroethers (HFEs), and mixtures thereof and optionally one or more hydrocarbons, alcohols, aldehydes, ketones, ethers/diethers or carbon dioxide generating materials. 
     
     
         7 . The stable polyol pre-mix composition of  claim 1 , wherein the surfactant is a silicone or non-silicone surfactant. 
     
     
         8 . The stable polyol pre-mix composition of  claim 7 , wherein the surfactant is a polysiloxane polyoxyalkylene block co-polymer silicone surfactant. 
     
     
         9 . The stable polyol pre-mix composition of  claim 1 , wherein the pre-mix composition further comprises one or more metallic salts. 
     
     
         10 . The stable polyol pre-mix composition of  claim 9 , wherein the metallic salts comprise magnesium formate. 
     
     
         11 - 14 . (canceled) 
     
     
         15 . A method for stabilizing a thermosetting foam blend which comprises combining: (a) a polyisocyanate and, optionally, one or more isocyanate compatible raw materials; and (b) a polyol pre-mix composition which comprises a blowing agent, a polyol, a surfactant, and a catalyst composition comprising an oxygen-containing amine catalyst, wherein when the catalyst composition comprises more than one amine catalyst, the oxygen-containing amine catalyst comprises greater than 50 wt % of a total of the amine catalysts. 
     
     
         16 . The method for stabilizing a thermosetting foam blend of  claim 15 , wherein the oxygen-containing amine catalyst is a compound having the chemical structure:
   R 1 R 2 N(CH 2 ) 2 X(CH 2 ) 2 Y   
       wherein:
 R 1  and R 2  are the same or different and are each a C 1 -C 6  alkyl group and/or an alkanol group, 
 X is O or NR 3  and/or it can be terminated by OH, where R 3  is a C 1 -C 6  alkyl group or an alkanol group, and 
 Y is OH or NR 4 R 5 , where R 4  and R 5  are the same or different and are each a C 1 -C 6  alkyl group or an alkanol group, subject to the proviso that the compound contains at least one ether and/or hydroxyl group. 
 
     
     
         17 . The method for stabilizing a thermosetting foam blend of  claim 15 , wherein the oxygen-containing amine catalyst is selected from the group consisting of bis-(2-dimethylaminoethyl)ether; N,N-dimethylethanolamine; N-ethylmorpholine; N-methylmorpholine; N,N,N′-trimethyl-N′-hydroxyethyl-bisaminoethylether; N-(3-dimethylaminopropyl)-N,N-diisopropanolamine; N,N-bis(3-dimethylaminopropyl)-N-isopropanolamine; 2-(2-dimethylaminoethoxy)ethanol; N,N,N′-trimethylaminoethylethanolamine; and 2,2′-dimorpholinodiethylether; 1-methyl-4-(2-dimethylaminoethyl)piperazine; 1,3,5-tris(3-(dimethylamino)propyl-hexahydro-s-triazine; diethylaminopropylamine; ethylaminoethanol; diethylaminoethanol; isopropylaminoethanol, butylaminoethanol; dibutylaminoethanol; butyldiethanolamine; tert-butylaminoethanol; diethylhydroxylamine and mixtures thereof. 
     
     
         18 . The method for stabilizing a thermosetting foam blend of  claim 15 , wherein the blowing agent comprises a halogenated hydroolefin and, optionally, one or more hydrocarbons, alcohols, aldehydes, ketones, ethers/diethers, or CO 2  generating materials, or combinations thereof. 
     
     
         19 . A polyurethane or polyisocyanurate foam having uniform cell structure with little or no foam collapse comprising a mixture of (a) a polyisocyanate and, optionally, one or more isocyanate-compatible raw materials; and (b) a polyol pre-mix composition which comprises a blowing agent, a polyol, a surfactant, and a catalyst composition comprising an oxygen-containing amine catalyst, wherein when the catalyst composition comprises more than one amine catalyst, the oxygen-containing amine catalyst comprises greater than 50 wt % of a total of the amine catalysts. 
     
     
         20 . (canceled) 
     
     
         21 . A stable polyol pre-mix composition comprising a blowing agent, a polyol, a surfactant, and a catalyst composition comprising an oxygen-containing amine catalyst, wherein when the catalyst composition comprises more than one amine catalyst, the oxygen-containing amine catalyst comprises less than 50 wt % of a total of the amine catalysts. 
     
     
         22 . The stable polyol pre-mix composition of  claim 1 , wherein the oxygen-containing amine catalyst is an alkanolamine, ether amine, or a morpholine group-containing catalyst. 
     
     
         23 . The stable polyol pre-mix composition of  claim 1 , wherein the oxygen-containing amine catalyst is a compound having the chemical structure:
   R 1 R 2 N(CH 2 ) 2 X(CH 2 ) 2 Y   
       wherein:
 R 1  and R 2  are the same or different and are each a C 1 -C 6  alkyl group and/or an alkanol group, 
 X is O or NR 3  and/or it can be terminated by OH, where R 3  is a C 1 -C 6  alkyl group or an alkanol group, and 
 Y is OH or NR 4 R 5 , where R 4  and R 3  are the same or different and are each a C 1 -C 6  alkyl group or an alkanol group, subject to the proviso that the compound contains at least one ether and/or hydroxyl group. 
 
     
     
         24 . The stable polyol pre-mix composition of  claim 1 , wherein the oxygen-containing amine catalyst is selected from the group consisting of bis-(2-dimethylaminoethyl)ether; N,N-dimethylethanolamine; N-ethylmorpholine; N-methylmorpholine; N,N,N′-trimethyl-N′-hydroxyethyl-bisaminoethylether; N-(3-dimethylaminopropyl)-N,N-diisopropanolamine; N,N-bis(3-dimethylaminopropyl)-N-isopropanolamine; 2-(2-dimethylaminoethoxy)ethanol; N,N,N′-trimethylaminoethylethanolamine, and 2,2′-dimorpholinodiethylether; 1-methyl-4-(2-dimethylaminoethyl)piperazine; 1,3,5-tris(3-(dimethylamino)propyl-hexahydro-s-triazine; diethylaminopropylamine, ethylaminoethanol; diethylaminoethanol, isopropylaminoethanol; butylaminoethanol; dibutylaminoethanol; butyldiethanolamine; tert-butylaminoethanol; diethylhydroxylamine and mixtures thereof. 
     
     
         25 . The stable polyol pre-mix composition of  claim 1 , wherein the blowing agent comprises a halogenated hydroolefin and, optionally, one or more hydrocarbons, alcohols, aldehydes, ketones, ethers/diethers, or CO 2  generating materials, or combinations thereof. 
     
     
         26 . The stable polyol pre-mix composition of  claim 5 , wherein the blowing agent comprises a halogenated hydroolefin selected from the group consisting of hydrofluoroolefins (HFOs), hydrochlorofluoroolefins (HCFOs), hydrofluorocarbons (HFCs), hydrofluoroethers (HFEs), and mixtures thereof, and optionally one or more hydrocarbons, alcohols, aldehydes, ketones, ethers/diethers or carbon dioxide generating materials. 
     
     
         27 . The stable polyol pre-mix composition of  claim 1 , wherein the surfactant is a silicone or non-silicone surfactant. 
     
     
         28 . The stable polyol pre-mix composition of  claim 7 , wherein the surfactant is a polysiloxane polyoxyalkylene block co-polymer silicone surfactant. 
     
     
         29 . The stable polyol pre-mix composition of  claim 1 , wherein the pre-mix composition further comprises one or more metallic salts. 
     
     
         30 . The stable polyol pre-mix composition of  claim 9 , wherein the metallic salts comprise magnesium formate. 
     
     
         31 - 34 . (canceled) 
     
     
         35 . A method for stabilizing a thermosetting foam blend which comprises combining: (a) a polyisocyanate and, optionally, one or more isocyanate compatible raw materials; and (b) a polyol pre-mix composition which comprises a blowing agent, a polyol, a surfactant, and a catalyst composition comprising an oxygen containing amine catalyst, wherein when the catalyst composition comprises more than one amine catalyst, the oxygen-containing amine catalyst comprises less than 50 wt % of a total of the amine catalysts. 
     
     
         36 . The method for stabilizing a thermosetting foam blend of  claim 15 , wherein the oxygen-containing amine catalyst is a compound having the chemical structure:
   R 1 R 2 N(CH 2 ) 2 X(CH 2 ) 2 Y   
       wherein:
 R 1  and R 2  are the same or different and are each a C 1 -C 6  alkyl group and/or an alkanol group, 
 X is O or NR 3  and/or it can be terminated by OH, where R 3  is a C 1 -C 6  alkyl group or an alkanol group, and 
 Y is OH or N R 4R 5 , where R 4  and R 5  are the same or different and are each a C 1 -C 6  alkyl group or an alkanol group, subject to the proviso that the compound contains at least one ether and/or hydroxyl group. 
 
     
     
         37 . The method for stabilizing a thermosetting foam blend of  claim 15 , wherein the oxygen-containing amine catalyst is selected from the group consisting of bis-(2-dimethylaminoethyl)ether; N,N-dimethylethanolamine; N-ethylmorpholine; N-methylmorpholine; N,N,N′-trimethyl-N′-hydroxyethyl-bisaminoethylether; N-(3-dimethylaminopropyl)-N,N-diisopropanolamine; N,N-bis(3-dimethylaminopropyl)-N-isopropanolamine; 2-(2-dimethylaminoethoxy)ethanol; N,N,N′-trimethylaminoethylethanolamine; and 2,2′-dimorpholinodiethylether; 1-methyl-4-(2-dimethylaminoethyl)piperazine; 1,3,5-tris(3-(dimethylamino)propyl-hexahydro-s-triazine; diethylaminopropylamine; ethylaminoethanol; diethylaminoethanol; isopropylaminoethanol; butylaminoethanol; dibutylaminoethanol; butyldiethanolamine; tert-butylaminoethanol; diethylhydroxylamine and mixtures thereof. 
     
     
         38 . The method for stabilizing a thermosetting foam blend of  claim 15 , wherein the blowing agent comprises a halogenated hydroolefin and, optionally, one or more hydrocarbons, alcohols, aldehydes, ketones, ethers/diethers, or CO 2  generating materials, or combinations thereof. 
     
     
         39 . A polyurethane or polyisocyanurate foam having uniform cell structure with little or no foam collapse comprising a mixture of: (a) a polyisocyanate and, optionally, one or more isocyanate compatible raw materials; and (b) a polyol pre-mix composition which comprises a blowing agent, a polyol, a surfactant, and a catalyst composition comprising an oxygen-containing amine catalyst, wherein when the catalyst composition comprises more than one amine catalyst, the oxygen-containing amine catalyst comprises less than 50 wt % of a total of the amine catalysts. 
     
     
         40 . (canceled)