Catalyst Blend Containing 1,2-Dimethylimidazole

In preparing polyurethane foams advantages have been achieved by the use of the combination of a triethylenediamine-type of amine catalyst and an organic tin salt. With the multiplicity of raw materials used, namely, polyols, isocyanates, blowing agents, surfactants and additives, catalysis of polyurethane reactions has required continual modification mostly because of economic and ecological factors. Shortened demolding times for example, in rigid, flexible and microcellular molding operations are desirable to effect savings in labor and fixed costs. Moreover, the versatility of urethane has lead to the development of numerous production techniques; freerise molding, injection, casting, spray and others. Each require a specific reactivity profile, attainable in most cases only through catalysis. These developments and requirements have created a need for improved catalysts. Moreover, a commonly used catalyst for making urethane foams is triethylenediamine such as DABCO available from Air Products Co., which is a solid material. While effective as a catalyst for this purpose, solid catalysts are somewhat difficult to work with and liquid or semi-liquid catalytic materials would be desirable.

The improved catalyst of the present invention comprises a blend of 1,2-dimethylimidazole and tris(3-dimethylaminopropyl)amine together with 1,8-diazabicyclo-5,4,0-undecene 7 (DBU) blocked with 2-ethylhexanoic acid. The latter materials are available from Abbott Laboratories as POLYCAT 9 and POLYCAT SA-102, respectively. Other salts of DBU can be used such as for example those formed with phenol, formic acid, acetic acid, oleic acid or paratoluene sulfonic acid. A mixture of from about 20-80% 1,2-dimethylimidazole; 8-60% tris(3-dimethylaminopropyl)amine (PC-9); and 2-50% 1,8-diazabicyclo-5,4,0-undecene 7 blocked with 2-ethylhexanoic acid (SA-102) will provide a satisfactory combination. A preferred mixture is from 25-50% 1,2-dimethylimidazole; 40-60% PC-9; and 2-30% DBU salt. If desired, the 1,2-dimethylimidazole and PC-9 can be combined in a blend to be subsequently mixed with the SA-102. A blend of 40% 1,2-dimethylimidazole and 60% PC-9 for example, can be used satisfactorily. The combination catalyst can be used in polyurethane systems such as elastomers, microcellular, rigid semirigid and flexible foams. Specific examples such as shoe soles and integral skin semiflexible foams such as are used in the manufacture of automotive steering wheels.

In order to illustrate the manner in which catalytic combinations of the present invention can be prepared and used, reference is made to the following examples, which, however, are not meant to limit or restrict the scope of the invention in any respect.

The following cup pours were made:

Polyester polyol with 3% trichlorotrifluoromethane (polyol blend): 100 grams

Polyisocyanate: Mondur E501 90 grams

Component temperature=40.degree. C.

Room temperature=71.degree.-73.degree. F.

Relative humidity=42-46%

Cup size=pint

Mixing speed=3000 RPM

Based on the cup pour results of Example 1, a ratio of 2/1: PC9/SA102 was utilized to determine molding characteristics of the two component blend of Example 1.

Mix time=6 seconds

Cream time=13 seconds

Tack free=39-40 seconds

Pull=50-51 seconds.

Mold Dimension: 5.times.10.times.1 inch

Mold temperature=140.degree. F.

Mold release=chem trend P5 Cl

Demold time=3 minutes

Results--Bottom of part green, cheesey, very soft, upper part satisfactory.

Same conditions as Example 2 plus 0.2 or 0.22 1-methyl-imidazole. No improvement noted.

Comparison between Blend A, Blend B (see example 5) and triethylenediamine.

The formulation used in the preparation of the microcellular shoe sole system is shown below:

The results are summarized in the following table.

The following table records the results of a reactivity study as between various imidazole compounds. As is apparent, 1,2-dimethylimidazole produced improved results with respect to a faster initiation time, rise time, foaming time, a faster rate of rise, time to maximum rate of rise, gel time and time to peak pressure. The formulation used comprised 100 parts polyol, 1.5 parts silicone surfactant, 36.5 parts trichlorofluoromethane, 122.8 parts methylene diisocyanate and 1.6 parts of the imidazole catalyst.

Referring to the examples, it can be seen in Example 1 that the two component system approaches but does not produce the reactivity of the commonly utilized solid catalyst, triethylenediamine. In this example, the noted catalyst or combination catalyst was added to the polyol blend and polyisocyanate. In Example 3, no improvement was noted in comparison to the results obtained in Example 2 when 1-methyl imidazole was added to the two component systems. In Example 4, improved results are apparent with the addition of 1,2-dimethylimidazole in comparison to the addition of the 1-methylimidazole added in Example 3 or the two component systems of Example 2.

In Example 5 it can be seen that the combination catalyst of the invention produces results comparable to the commonly used catalyst triethylenediamine with increased amounts of 1,2-dimethylimidazole producing generally more advantageous results. Examples 6 and 7 illustrate the comparable or improved demold time resulting from the use of the combination catalyst of the present invention. Being semiliquid in form, the combination catalyst provides the further advantage of ease of handling as well as faster processing time.