Catalyst compositions and methods for making foam
AssigneeEvonik Degussa GmbH
InventorsRobert Francis Hoffman, James Douglas Tobias, Jean Louise Vincent, Timothy J. Miller
Life of this patent
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Abstract
A composition and process to make polyisocyanurate or polyurethane foam using a catalyst composition comprising at least one bismuth carboxylate catalyst and one or more co-catalysts selected from the group of alkali metal carboxylates and quaternary ammonium carboxylate salts, such that the resultant foam has improved insulation properties. The polyisocyanurate or polyurethane foams produced by this catalyst composition and method are useful for laminated boardstock, construction panels, appliance insulation, and spray-applied insulation.
Claims16
A catalyst composition for making a polyisocyanurate/polyurethane foam comprising at least one bismuth carboxylate salt selected from the group consisting of bismuth neodecanoate, bismuth octoate, bismuth versalate, bismuth naphthenate, bismuth pivalate, bismuth acetate, bismuth subcarbonate, and bismuth citrate and at least one member selected from the group consisting of potassium carboxylate salts and quaternary ammonium carboxylate salts,
- wherein a molar ratio of the potassium carboxylate or quaternary ammonium carboxylate to the Bismuth carboxylate is between 44 to 1 and 50 to 1;
- wherein the use level of potassium carboxylate or quaternary ammonium carboxylate is 2.5-3.5% by weight of the total resin;
- and wherein the use level of bismuth carboxylate is 0.2-0.3% by weight of the total resin.
A method for producing a polyisocyanurate foam by contacting at least one isocyanate with at least one polyol in the presence of at least one amine catalyst, at least one blowing agent, and at least one carboxylate catalyst comprising at least one bismuthcarboxylate selected from the group consisting of bismuth neodecanoate, bismuth octoate, bismuth versalate, bismuth naphthenate, bismuth pivalate, bismuth acetate, bismuth subcarbonate, and bismuth citrate and at least one of ammoniumcarboxylate and potassiumcarboxylate salts,
- wherein a molar ratio of the potassiumcarboxylate or ammoniumcarboxylate to the bismuthcarboxylate is between 44 to 1 and 50 to 1;
- wherein the use level of potassium carboxylate is 2.5-3.5% by weight of the total resin;
- and wherein the use level of bismuth carboxylate is 0.2-0.3% by weight of the total resin.
A method for preparing a polyisocyanurate/polyurethane foam which comprises contacting at least one polyisocyanate with a premix comprising at least one polyol, at least one blowing agent, and a catalytic amount of a catalyst composition comprising a solution of at least one member selected from the group of bismuth neodecanoate, bismuth octoate, bismuth versalate, bismuth naphthenate, and bismuth pivalate;
- and at least one member selected from the group consisting of potassium pivalate, tetramethylammonium pivalate, potassium octoate, potassium acetate, potassium acrylate 2-hydroxylpropyltrimethylammonium pivalate, 2-hydroxylpropyltriethylammonium pivalate, tetraethylammonium pivalate, tetrapropylammonium pivalate, tetrabutylammonium pivalate, potassium triethylacetate, tetramethylammonium triethylacetate, 2-hydroxylpropyltrimethylammonium triethylacetate, 2-hydroxylpropyltriethylammonium triethylacetate, tetraethylammonium triethylacetate, tetrapropylammonium triethylacetate, tetrabutylammonium triethylacetate, potassium neoheptanoate, tetramethylammonium neoheptanoate, 2-hydroxylpropyltrimethylammonium neoheptanoate, 2-hydroxylpropyltriethylammonium neoheptanoate, tetraethylammonium neoheptanoate, tetrapropylammonium neoheptanoate, tetrabutylammonium neoheptanoate, potassium neooctanoate, tetramethylammonium neooctanoate, 2-hydroxylpropyltrimethylammonium neooctanoate, 2-hydroxylpropyltriethylammonium neooctanoate, tetraethylammonium neooctanoate, tetrapropylammonium neooctanoate, and tetrabutylammonium neooctanoate, and wherein a molar ratio of the potassium carboxylate or quaternary ammonium carboxylate to the Bismuth carboxylate is between 44 to 1 and 50 to 1;
- wherein the use level of potassium carboxylate is 2.5-3.5% by weight of the total resin;
- and wherein the use level of bismuth carboxylate is 0.2-0.3% by weight of the total resin.
Dependencies are inferred from the claim text.