# US 2014/0155506 A1 · Composition for polyurethane foam, preparation for polyurethane foam, polymer polyol preparation for polyurethane foam, production processes therefor, and polyurethane foam

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- Number: US 2014/0155506 A1
- Document ID: US20140155506A1
- Status: Published application
- Kind: A1
- Application number: 14/234,457
- Filed: 2012-07-23
- Published: 2014-06-05
- Earliest claimed: 2011-07-26
- Assignees: Mitsui Chemicals, Inc.
- Inventors: Yusuke Maruoka; Atsushi Miyata; Kazuhiko Okubo; Tsukuru Izukawa; Toru Hiraide; Shinsuke Matsumoto
- Web page: https://patentgrep.com/patent/US20140155506A1

## CPC

- C08G 18/3203: {Polyhydroxy compounds}
- C08G 18/14: {Manufacture of cellular products}
- C08G 18/3206: {aliphatic}
- C08G 18/3271: {Hydroxyamines}
- C08G 18/4072: {Mixtures of compounds of group C08G18/63 with other macromolecular compounds}
- C08G 18/4841: {containing oxyethylene end groups}
- C08G 18/632: {onto polyethers}
- C08G 18/667: {with compounds of group C08G18/32 or polyamines of C08G18/38}
- C08G 18/6677: {having at least three hydroxy groups}
- C08G 18/7621: {being toluene diisocyanate including isomer mixtures}
- C08G 18/7664: {containing alkylene polyphenyl groups}
- C08G 65/2675: {Phosphorus or compounds thereof}
- C08J 9/0023: {containing oxygen}
- C08J 9/0028: {containing nitrogen}
- C08J 9/0033: {containing sulfur}
- C08J 9/0038: {containing phosphorus}
- C08J 9/0061: {characterized by the use of several polymeric components}
- C08J 9/02: using blowing gases generated by the reacting monomers or modifying agents during the preparation or modification of macromolecules
- C08J 9/122: {Hydrogen, oxygen, CO2, nitrogen or noble gases}
- C08J 9/38: Destruction of cell membranes
- C08K 5/5399: Phosphorus bound to nitrogen
- C08L 71/02: Polyalkylene oxides
- C08G 2110/0008: flexible
- C08G 2110/0083: prepared using water as the sole blowing agent
- C08J 2201/022: premixing or pre-blending a part of the components of a foamable composition, e.g. premixing the polyol with the blowing agent, surfactant and catalyst and only adding the isocyanate at the time of foaming
- C08J 2203/06: CO2, N2 or noble gases
- C08J 2203/08: Supercritical fluid
- C08J 2205/05: Open cells, i.e. more than 50% of the pores are open
- C08J 2205/06: Flexible foams
- C08J 2375/08: from polyethers
- C08J 2425/12: with unsaturated nitriles
- C08J 2433/20: Homopolymers or copolymers of acrylonitrile (C08J2455/02 takes precedence)
- 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

The present invention relates to a preparation for a polyurethane foam and a polymer polyol preparation for a polyurethane foam, each of which exhibits high coloration and discoloration inhibition properties over a long period of time when stored, and to a composition for a polyurethane foam, which is excellent in storage stability and is preferable as a resin premix. The composition for a polyurethane foam of the present invention is characterized by comprising (i) at least one polyol selected from a polyoxyalkylene polyol and a polymer polyol wherein polymer fine particles obtained by polymerizing a compound having an unsaturated bond are dispersed in the polyoxyalkylene polyol, (ii) a compound having a P═N bond, (iii) an antioxidant having a hydroxyphenyl group, (iv) at least one acid selected from the group consisting of an acyclic aliphatic monocarboxylic acid of 2 to 25 carbon atoms, a hydroxycarboxylic acid of 2 to 25 carbon atoms, a polycarboxylic acid of 20 to 60 carbon atoms, a specific aromatic monocarboxylic acid, a sulfonic acid and an acid having a sulfuric acid ester group, or its salt, (v) a catalyst for polyurethane foam production and (vi) a blowing agent.

## Claims

### Claim 1

A composition for a polyurethane foam, comprising:
(i) at least one polyol selected from a polyoxyalkylene polyol and a polymer polyol wherein polymer fine particles obtained by polymerizing a compound having an unsaturated bond are dispersed in the polyoxyalkylene polyol,
(ii) a compound having a P═N bond,
(iii) an antioxidant having a hydroxyphenyl group,
(iv) at least one acid selected from the group consisting of an acyclic aliphatic monocarboxylic acid of 2 to 25 carbon atoms, a hydroxycarboxylic acid of 2 to 25 carbon atoms, a polycarboxylic acid of 20 to 60 carbon atoms, an aromatic monocarboxylic acid represented by the following formula (1), a sulfonic acid and an acid having a sulfuric acid ester group, or its salt,
(v) a catalyst for polyurethane foam production, and
(vi) a blowing agent,
wherein R1 is a hydrocarbon group, and m represents a number of hydrogen atoms of a benzene ring having been replaced with R1 and is any one of 0 to 5.

### Claim 2 (depends on 1)

The composition for a polyurethane foam as claimed in claim 1, wherein the molar ratio (a/b) of the acid or its salt (iv) (a) to the compound (ii) (b) is not less than 0.3 but not more than 25.

### Claim 3 (depends on 1)

The composition for a polyurethane foam as claimed in claim 1, wherein the compound (ii) is represented by the following formula (2):
wherein a, b, c and d are each a positive number of 0 to 3 but there is no case where all of a, b, c and d become 0 at the same time, each R is the same or different hydrocarbon group of 1 to carbon atoms and two R on the same nitrogen atom may be bonded to each other to form a cyclic structure, and Q− represents a hydroxyl anion, an alkoxy anion, an aryloxy anion or a carboxy anion.

### Claim 4 (depends on 1)

The composition for a polyurethane foam as claimed in claim 1, wherein the polyol (i) comprises at least one polyol selected from a polyoxyalkylene polyol (p) obtained by addition polymerization of an alkylene oxide compound onto an active hydrogen compound using the compound (ii) as a catalyst and a polymer polyol wherein polymer fine particles obtained by polymerizing a compound having an unsaturated bond are dispersed in the polyoxyalkylene polyol (p).

### Claim 5 (depends on 4)

The composition for a polyurethane foam as claimed in claim 4, which comprises a preparation (c) for a polyurethane foam, the catalyst (v) and the blowing agent (vi), wherein:
the preparation (c) comprises the polyol (i), the compound (ii) having a P═N bond and having been used for the production of the polyol (p), the antioxidant (iii) and the acid or its salt (iv), and
the preparation (c) is obtained by adding the acid or its salt (iv) in such an amount that the molar ratio (a/b) of the acid or its salt (iv) (a) to the compound (ii) (b) becomes not less than 0.3 but not more than 25, and the antioxidant (iii) to the polyol (i).

### Claim 6 (depends on 5)

The composition for a polyurethane foam as claimed in claim 5, which comprises a polymer polyol wherein, by the use of the preparation (c) obtained, polymer fine particles obtained by polymerizing a compound having an unsaturated bond are dispersed in the preparation (c).

### Claim 7 (depends on 4)

The composition for a polyurethane foam as claimed in claim 4, wherein the content ratio of the compound (ii) to the polyol (p) is 150 to 5000 ppm.

### Claim 8 (depends on 1)

The composition for a polyurethane foam as claimed in claim 1, wherein the content ratio of the antioxidant (iii) in the composition for a polyurethane foam is 100 to 15000 ppm.

### Claim 9 (depends on 1)

The composition for a polyurethane foam as claimed in claim 1, wherein the hydroxyl value of the polyoxyalkylene polyol is 10 to 80 mgKOH/g.

### Claim 10

A production process for a composition for a polyurethane foam, comprising a step which comprises adding, to a polyol (i) containing a polyoxyalkylene polyol (p) obtained by addition polymerization of an alkylene oxide compound onto an active hydrogen compound using a compound (ii) having a P═N bond as a catalyst, and the compound (ii) having been used for the production of the polyol (p),
an antioxidant (iii) having a hydroxyphenyl group and an acid or its salt (iv) in such an amount that the molar ratio (a/b) of the acid or its salt (iv) (a) to the compound (ii) (b) having a P═N bond becomes not less than 0.3 but not more than 25, to obtain a preparation (c) for a polyurethane foam and then adding a catalyst (v) for polyurethane foam production and a blowing agent (vi) to the preparation (c), wherein:
the acid or its salt (iv) is at least one acid selected from the group consisting of an acyclic aliphatic monocarboxylic acid of 2 to 25 carbon atoms, a hydroxycarboxylic acid of 2 to 25 carbon atoms, a polycarboxylic acid of 20 to 60 carbon atoms, an aromatic monocarboxylic acid represented by the following formula (1), a sulfonic acid and an acid having a sulfuric acid ester group, or its salt,
wherein R1 is a hydrocarbon group, and m represents a number of hydrogen atoms of a benzene ring having been replaced with R1 and is any one of 0 to 5.

### Claim 11 (depends on 10)

The production process for a composition for a polyurethane foam as claimed in claim 10, which comprises a step of preparing a polymer polyol in the preparation (c), wherein:
the polymer polyol is obtained by dispersing polymer fine particles obtained by polymerizing a compound having an unsaturated bond in the preparation (c).

### Claim 12

A preparation for a polyurethane foam, which is a preparation (c) for a polyurethane foam comprising a polyol (i), a compound (ii) having a P═N bond, an antioxidant (iii) having a hydroxyphenyl group and an acid or its salt (iv), wherein:
the polyol (i) contains a polyoxyalkylene polyol (p) obtained by addition polymerization of an alkylene oxide compound onto an active hydrogen compound using the compound (ii) as a catalyst, and the compound (ii) having been used for the production of the polyol (p),
the acid or its salt (iv) is at least one acid selected from the group consisting of an acyclic aliphatic monocarboxylic acid of 2 to 25 carbon atoms, a hydroxycarboxylic acid of 2 to 25 carbon atoms, a polycarboxylic acid of 20 to 60 carbon atoms, an aromatic monocarboxylic acid represented by the following formula (1), a sulfonic acid and an acid having a sulfuric acid ester group, or its salt,
the preparation (c) is obtained by adding the acid or its salt (iv) in such an amount that the molar ratio (a/b) of the acid or its salt (iv) (a) to the compound (ii) (b) having been used for the production of the polyol (p) becomes not less than 0.3 but not more than 25, and the antioxidant (ii) to the polyol (i), and
the content ratio of the compound (ii) having been used for the production of the polyol (p), to the polyol (p) is 150 to 5000 ppm,
wherein R1 is a hydrocarbon group, and m represents a number of hydrogen atoms of a benzene ring having been replaced with R1 and is any one of 0 to 5.

### Claim 13 (depends on 12)

The preparation for a polyurethane foam as claimed in claim 12, wherein the compound (ii) is represented by the following formula (2):
wherein a, b, c and d are each a positive number of 0 to 3 but there is no case where all of a, b, c and d become 0 at the same time, each R is the same or different hydrocarbon group of 1 to 10 carbon atoms and two R on the same nitrogen atom may be bonded to each other to form a cyclic structure, and Q− represents a hydroxyl anion, an alkoxy anion, an aryloxy anion or a carboxy anion.

### Claim 14 (depends on 12)

A polymer polyol preparation for a polyurethane foam, comprising a polymer polyol wherein polymer fine particles obtained by polymerizing a compound having a unsaturated bond are dispersed in the preparation (c) for a polyurethane foam as claimed in claim 12,
the content of the vinyl polymer particles in said polymer polyol being 3 to 60% by weight based on 100% by weight of the polyol component.

### Claim 15

A production process for a preparation for a polyurethane foam, comprising a step of adding, to a polyol (i) containing a polyoxyalkylene polyol (p) obtained by addition polymerization of an alkylene oxide compound onto an active hydrogen compound using a compound (ii) having a P═N bond as a catalyst, and the compound (ii) having been used for the preparation of the polyol (p),
an antioxidant (iii) having a hydroxyphenyl group and an acid or its salt (iv) in such an amount that the molar ratio (a/b) of the acid or its salt (iv) (a) to the compound (ii) (b) having a P═N bond and having been used for the production of the polyol (p) becomes not less than 0.3 but not more than 25,
the content ratio of said compound (ii) having been used for the production of the polyol (p), to the polyol (p) being 150 to 5000 ppm,
wherein:
the acid or its salt (iv) is at least one acid selected from the group consisting of an acyclic aliphatic monocarboxylic acid of 2 to 25 carbon atoms, a hydroxycarboxylic acid of 2 to 25 carbon atoms, a polycarboxylic acid of 20 to 60 carbon atoms, an aromatic monocarboxylic acid represented by the following formula (1), a sulfonic acid and an acid having a sulfuric acid ester group, or its salt,
wherein R1 is a hydrocarbon group, and m represents a number of hydrogen atoms of a benzene ring having been replaced with R1 and is any one of 0 to 5.

### Claim 16 (depends on 15)

A production process for a polymer polyol preparation for a polyurethane foam, comprising a step of preparing a polymer polyol using the preparation (c) for a polyurethane foam obtained by the production process as claimed in claim 15, wherein:
the polymer polyol is obtained by dispersing, in the preparation (c), polymer fine particles obtained by polymerizing a compound having an unsaturated bond, in such amounts that the content of the vinyl polymer particles in the polymer polyol becomes 3 to 60% by weight based on 100% by weight of the polyol component.

### Claim 17 (depends on 1)

A polyurethane foam obtained by the use of the composition for a polyurethane foam as claimed in claim 1.

### Claim 18 (depends on 13)

A polymer polyol preparation for a polyurethane foam, comprising a polymer polyol wherein polymer fine particles obtained by polymerizing a compound having a unsaturated bond are dispersed in the preparation (c) for a polyurethane foam as claimed in claim 13,
the content of the vinyl polymer particles in said polymer polyol being 3 to 60% by weight based on 100% by weight of the polyol component.

### Claim 19 (depends on 2)

A polyurethane foam obtained by the use of the composition for a polyurethane foam as claimed in claim 2.

### Claim 20 (depends on 5)

A polyurethane foam obtained by the use of the composition for a polyurethane foam as claimed in claim 5.