# US 12,006,412 B2 · Reaction mixture suitable for manufacturing of foam with reduced aldehyde emission

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- Number: US 12,006,412 B2
- Document ID: US12006412B2
- Status: Granted
- Kind: B2
- Application number: 17/414,134
- Filed: 2018-12-21
- Published: 2022-03-17
- Granted: 2024-06-11
- Earliest claimed: 2018-12-21
- Assignees: Huntsman International LLC
- Applicants: Huntsman International LLC
- Inventors: Bao Luan; Zuxia Rong; Yuefan Zhang; Lies Bonami; Joris Bosman
- Web page: https://patentgrep.com/patent/US12006412B2

## CPC

- C08G 18/4833: {Polyethers containing oxyethylene units}
- C08J 9/0023: {containing oxygen}
- C08G 18/161: {containing two or more components to be covered by at least two of the groups C08G18/166, C08G18/18 or C08G18/22}
- C08G 18/18: containing secondary or tertiary amines or salts thereof
- C08G 18/1825: {having hydroxy or primary amino groups}
- C08G 18/1833: {having ether, acetal, or orthoester groups}
- C08G 18/3275: {containing two hydroxy groups}
- C08G 18/4816: {mixtures of two or more polyetherpolyols having at least three hydroxy groups}
- C08G 18/4841: {containing oxyethylene end groups}
- C08G 18/485: {containing mixed oxyethylene-oxypropylene or oxyethylene-higher oxyalkylene end groups}
- C08G 18/6674: {with compounds of group C08G18/3203}
- C08G 18/6688: {with compounds of group C08G18/3271}
- C08G 18/7664: {containing alkylene polyphenyl groups}
- C08G 18/7671: {containing only one alkylene bisphenyl group}
- C08J 9/125: {Water, e.g. hydrated salts}
- C08K 5/08: Quinones
- C08K 5/132: Phenols containing keto groups {, e.g. benzophenones}
- C08K 5/1535: Five-membered rings
- C08K 5/1545: Six-membered rings
- C08L 75/04: Polyurethanes
- C08G 2110/005: < 50kg/m3
- C08G 2110/0083: prepared using water as the sole blowing agent
- C08J 2203/10: Water or water-releasing compounds
- C08J 2375/12: from compounds containing nitrogen and active hydrogen, the nitrogen atom not being part of an isocyanate group
- C08K 5/0008: {Organic ingredients according to more than one of the "one dot" groups of C08K5/01 - C08K5/59}
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09)
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)

## Abstract

Disclosed is a reaction mixture for the manufacturing of a polyurethane foam, which mixture can be obtained by reacting a polyfunctional isocyanate with an isocyanate-reactive compound, in the presence of a scavenger and at least one catalyst; and curing such reaction mixture enables providing a foam with reduced aldehyde emissions particularly useful in means of transport, such as interior part of cars.

## Claims

### Claim 1

A reaction mixture for the manufacturing of a polyurethane foam, the reaction mixture comprising a polyfunctional isocyanate, an isocyanate-reactive compound, a scavenger and at least one catalyst, wherein the scavenger comprises a compound of the following formula (I):
wherein,
R1 and R2 are independently of one another selected from —OR3, R4 or from the group consisting of hydroxy, ether, halogen, carbonyl, carboxyl, isocyanate, nitro and/or amine groups,
R3 and R4 are independently of one another selected from a combination of saturated linear, saturated branched, cyclic and/or saturated non-cyclic carbon chains, saturated aliphatic hydrocarbons, araliphatic hydrocarbons, aromatic hydrocarbons and mixtures thereof, optionally interrupted by one or more oxygen atoms, nitrogen atoms and/or sulphur atoms, and optionally comprising any functional group selected from hydroxy, ether, halogen, carboxyl, isocyanate, nitro and/or amine groups,
R1 and R2 may be linked to each other essentially forming at least one ring structure.

### Claim 2 (depends on 1)

The reaction mixture according to claim 1, wherein said compound with formula (I) is in an aqueous condition when added to the reaction mixture.

### Claim 3 (depends on 1)

The reaction mixture according to claim 1, wherein said scavenger is added to the reaction mixture at a temperature ranging from 18 to 45° C.

### Claim 4 (depends on 1)

The reaction mixture according to claim 1, wherein R1 is —OR3.

### Claim 5 (depends on 1)

The reaction mixture according to claim 1, wherein said scavenger is made of at least 90 wt % of said compound of formula (I) based on the total weight of said scavenger.

### Claim 6 (depends on 1)

The reaction mixture according to claim 1, wherein R1 and R2 are linked to each other to form a 5 to 12 membered ring structure and comprise unsaturations, aromatic rings and/or heteroatoms.

### Claim 7 (depends on 1)

The reaction mixture according to claim 1, wherein said scavenger has a molecular weight of at most 3000 g/mol.

### Claim 8 (depends on 1)

The reaction mixture according to claim 1, wherein the reaction mixture further comprises a blowing agent.

### Claim 9 (depends on 1)

The reaction mixture according to claim 1, wherein the polyfunctional isocyanate is selected from a polymeric methylene diphenyl diisocyanate, a methylene diphenyl diisocyanate isomer mixture, or a mixtures thereof.

### Claim 10 (depends on 1)

The reaction mixture according to claim 1, wherein the isocyanate-reactive compound is a polyfunctional polyol or a polyfunctional amine.

### Claim 11

A process for the manufacturing of a polyurethane foam, comprising the following steps:
(a) providing a reaction mixture comprising a polyfunctional isocyanate and an isocyanate-reactive compound;
(b) adding a scavenger and at least one catalyst to said reaction mixture, then adding at least one blowing agent to the reaction mixture;
wherein said scavenger comprises a compound of the following formula (I):
wherein,
R1 and R2 are independently of one another selected from —OR3, R4, or from the group consisting of hydroxy, ether, halogen, carbonyl, carboxyl, isocyanate, nitro and/or amine groups,
R3 and R4 are independently of one another selected from a combination of saturated linear, saturated branched, cyclic and/or saturated non-cyclic carbon chains, saturated aliphatic hydrocarbons, araliphatic hydrocarbons, aromatic hydrocarbons and mixtures thereof, optionally interrupted by one or more oxygen atoms, nitrogen atoms and/or sulphur atoms, and optionally comprising any functional group selected from hydroxy, ether, halogen, carboxyl, isocyanate, nitro and/or amine groups,
R1 and R2 may be linked to each other essentially forming at least one ring structure; and
(c) curing said reaction mixture, which comprises at least the reaction product of said polyisocyanate and said isocyanate-reactive compound in the presence of said scavenger and said at least one catalyst, leading to the formation of a polyurethane foam.

### Claim 12 (depends on 11)

The process according to claim 11, wherein said compound with formula (I) is in an aqueous condition when added to the reaction mixture.

### Claim 13 (depends on 11)

The process according to claim 11, wherein, said reaction mixture has an NCO index in the range of from about 0.6 to about 1.5.

### Claim 14 (depends on 11)

The process according to claim 11, wherein, the NCO index of the reaction mixture is in the range of from about 1.05 to about 10.