Process for preparing polyurethane with integral skin

Claim 2

An improved process for preparing polyurethane wth integral skin, wherein a composition comprising the following ingredients: polyol, polyisocyanate, at most one part by weight of water to 100 parts by weight of polyol and catalyst, is reacted in a mould so that said polyurethane is formed, wherein the improvement comprises using a polyisocyanate the NCO groups of which are not directly bonded to an aromatic group and, as catalyst, at least one of the following four synergistic combinations: (1) at least an amine containing the structure: ##STR23## in association with at least an alkali metal or alkaline-earth metal salt, alcoholate and/or phenolate of an acid whose dissociation is constant Ka≦10 -1 , preferably Ka≦10 -2 ; (2) at least an organic lead compound in association with at least an organic initiator comprising at least one functional group of primary or secondary amine; (3) at least an organic lead compound in association with at least an amine containing the structure: ##STR24## or, (4) at least an organic lead compound in association with at least an alkali metal or alkaline-earth metal salt, alcoholate and/or phenolate of an acid the dissociation constant of which is Ka≦10 -1 preferably Ka≦10 -2 .

Claim 3

A process as claimed in claim 1, which comprises using as the amine of the structure ##STR25## in said catalyst, at least one compound selected from the group consisting of: (1) diazabicycloalkenes of the formula: ##STR26## wherein m varies from 3 to 7 and n from 2 to 4, and its salts with organic acids whose dissociation constant is Ka 10 -2 (2) substituted guanidines and salts thereof of the formula: ##STR27## wherein R 1 , R 2 , R 3 and R 4 independently represent an alkyl (C 1-C 4 ) radical, an alkyl (C 1 -C 4 ) radical substituted by an alkoxy (C 1 -C 4 ) radical, or a heterocyclic radical (C 5 -C 7 ) containing at most two atoms selected from the group consisting of sulfur and oxygen, R 1 -R 2 and/or R 3 -R 4 being able to form with the adjacent nitrogen atom, a heterocyclic (C 5 -C 7 ) ring containing at most a sulfur or oxygen atom, X represents hydrogen, a phenyl group, a phenyl group substituted by one or more alkoxy (C 1 -C 4 ) radicals, alkyl (C 1 -C 12 ) radicals, or halogens, or represents a radical of the formula: ##STR28## wherein R 5 , R 6 and R 7 independently represent hydrogen, an alkyl (C 1 -C 4 ) radical oran alkyl (C 1 -C 4 ) radical substituted by phenyl, substituted phenyl, alkoxy (C 1 -C 4 ), aryloxy (C 6 -C 15 ), nitrile, carbalkoxy, R 7 may represent an alkyl (C 5 -C 18 ) radical, a substituted phenyl radical or an alkoxy (C 1 -C 4 ) radical, or one or both of the groups R 5 -R 6 , R 5 -R 7 and R 6 -R 7 form a cyclic ring of carbon atoms with at most a nitrogen, sulfur or oxygen atoms, X may be a radical of the formula: ##STR29## wherein z is an integer varying from 2 to 12, R' and R" representing hydrogen or an alkyl (C 1 -C 4 ) radical, R"' and R"" represent an alkyl (C 1 -C 4 ) radical or form with nitrogen a cycloalkyl (C 5 -C 6 ) radical, as well as addition salts of said guanidines, and salts of guanidines wherein at least one of R 1 , R 2 , R 3 and R 4 is hydrogen, with an acid having a dissociation constant Ka≦10 -3 ; (3) substituted biguanidines of the formula: ##STR30## wherein Q 1 to Q 6 independently represent an alkyl (C 1 -C 4 ) radical or a cycloalkyl (C 3 -C 4 ) radical, and X' is hydrogen or a carbamoyl radical of the formula: ##STR31## wherein Z is a monovalent radical remaining after elimination of a isocyanate group of the above-mentioned polyisocyanate, Q 1 to Q 6 , X' and Z may optionally be substituted by chlorine, bromine or alkoxy (C 1 or C 2 ); (4) substituted biguanidines of the formula: ##STR32## wherein M 1 to M 8 independently represent an alkyl (C 1 -C 4 ) radical, Y is a group: ##STR33## wherein M 9 and M 10 represent hydrogen or an alkyl (C 1 -C 4 ) radical, and α is an integer varying from 3 to 12, or represents a divalent cyclohexyl radical, or a divalent isophorone radical.

Claim 4

A process as claimed in claim 2, which comprises using as the amine of the structure: ##STR34## in the above-mentioned catalyst, at least one of the compounds selected from the group consisting of: (1) following diazabicycloalkenes:

Claim 5

5-diazabicyclo(4,3,0)nonene-5, 1,8-diazabicyclo(5,4,0)undecene-7, 1,8-diazabicyclo(5,3,0)decene-7, 1,5-diazabicyclo(5,4,0)decene-5, 1,4-diazabicyclo(3,3,0)octene-4, salts of addition of said diazabicycloalkenes with mono- or dicarboxylic acids having a dissociation constant Ka≦10 -4 , with carbonic acid and with phenols, (2) substituted guanidines of the formula: ##STR35## wherein X represents hydrogen, a methyl, cyclohexyl, decyl, dodecyl, alkylphenyl (C 1 -C 4 ) radical or a radical of the formula: --(CH.sub.2).sub.z N(R"'R""), in which z is equal to 2 or 3, and R"' and R"" are identical or different and represent an alkyl (C 1 -C 4 ) radical, R 1 to R 4 being identical or different and represent a methyl radical of hydrogen, as well as salts of addition of said guanidines and salts of guanidines of the above formula, wherein moreover at least R 1 and R 2 are hydrogen, with carbonic acid and phenol, (3) 1,1,4,4,5,5,-hexamethylisobiguanidine, and (4) substituted biguanidines of the formula: ##STR36## in which Y is a divalent alkylene (C 6 -C 12 ) radical.

Claim 6

5-diazabicyclo(4,3,0)nonene-5, 1,8-diazabicyclo(5,4,0)undecene-7, 1,8-diazabicyclo(5,3,0)decene-7, 1,5-diazabicyclo(5,4,0)decene-5, 1,4-diazabicyclo(3,3,0)octene-4, salts of addition of said diazabicycloalkenes with mono- or dicarboxylic acids having a dissociation constant Ka≦10 -4 , with carbonic acid and with phenols, (2) substituted guanidines of the formula: ##STR35## wherein X represents hydrogen, a methyl, cyclohexyl, decyl, dodecyl, alkylphenyl (C 1 -C 4 ) radical or a radical of the formula: --(CH.sub.2).sub.z N(R"'R""), in which z is equal to 2 or 3, and R"' and R"" are identical or different and represent an alkyl (C 1 -C 4 ) radical, R 1 to R 4 being identical or different and represent a methyl radical of hydrogen, as well as salts of addition of said guanidines and salts of guanidines of the above formula, wherein moreover at least R 1 and R 2 are hydrogen, with carbonic acid and phenol, (3) 1,1,4,4,5,5,-hexamethylisobiguanidine, and (4) substituted biguanidines of the formula: ##STR36## in which Y is a divalent alkylene (C 6 -C 12 ) radical.

Claim 7

A process as claimed in claim 1, which comprises using in the catalyst, in combination with said amine of the structure ##STR37## a salt of an alkali metal salt of an alkali metal selected from the group consisting of salts of sodium and potassium of oleic, 2,3-methylbenzoic, adipic, 2,4-dichlorobenzoic, benzoic, β-chloroacetic, chloro- and bromobenzoic, salicylic, acetic, formic acid, and sodium and potassium phenolates and sodium and potassium methoxides.

Claim 8

A process as claimed in claim 1, which comprises using in said catalyst, as the organic lead compound, a compound selected from the group consisting of: (a) divalent lead organic salts of carboxylic acids containing at least a COOH group, (b) lead dithiocarbamates of the formula: ##STR38## wherein Q' and Q" are identical or different and represent an alkyl (C 1 -C 20 ) radical, (c) tetravelent organic lead compounds of the formula PbQ 4 "', wherein Q"' is an alkyl (C 1 -C 6 ) radical, and (d) divalent lead acetylacetonate.

Claim 9

A process as claimed in claim 5, which comprises using (a) as the divalent organic lead salt of carboxylic acid, a compound selected from the group consisting of lead acetate, adipate, citrate, 2-ethylheroate, laurate, linoleate, naphthenate, octanoate, oleate, oxalate, palmitate, resinate, ricinoleate, salicylate, stearate, tallate, and tartrate; (b) as the dithiocarbamate of the above cited formula, and compound wherein Q' and Q" are a methyl, ethyl, butyl or amyl radical and (c) as the organic compound of formula PbQ 4 "', a compound in which Q"' is a methyl or ethyl radical.

Claim 10

A process as claimed in claim 1, which comprises using as organic initiator, at least a compound selected from the group consisting of ethylamine, butylamine, hexylamine, laurylamine, octylamine, propylamine, pentylamine, heptylamine, nonylamine, decylamine, undecylamine, heptadecylamine, oleylamine, benzylamine, allylamine, N-2-aminoethylmorpholine, N-3-aminopropylmorpholine, cyclohexylamine, 2(3,4)-chlorobenzylamine, 1,3-dimethylbutylamine, 2,5-dimethylbenzylamine, o-(m,p)-methoxybenzylamine, 3N-dimethyl(diethyl)amino-1,3-propanediamine,2-amino-5N-diethylaminopenetane, N(3-aminopropyl)-2-pyrrolidone, diethylamine, di(iso)propylamine, dibutylamine, dioctylamine, dihexylamine, dinonylamine, dicyclohexylamine, N-methyl-octadecylamine, N-ethyl-and-N propylbenzylamine, pyrazole, pyrrole, pyrrolidine, piperidine, morpholine, 2-(2-hydroxyethyl)-piperidine, bis(2-chloroethyl)amine, N,N-bis(2,2-diethoxyethyl)amine, 1,2-diaminopropane, 1,3-diaminopropane, ethylenediamine, 1,4-diaminobutane, 1,5-diaminopentane, 1,6-diaminohexane 1,10-diaminodecane, 1,12-diaminododecane, isophorondiamine, 2,2,4-trimethyl-hexamethylene-diamine, NH 2 CH(CH 3 )CH 2 [OCH 2 CH(CH 3 )] x NH 2 wherein x is selected from values substantially equal to 2.6, 5.6 or 15.9, 1,4-bis(aminopropyl)piperazine, N.N'-dimethyl-(diethyl)-ethylenediamine, 4,4'-trimethylene piperidine, 3-ethylamino-1-propylamine, 3-butylamino-1-propylamine, 3-ethylpropylamino-1-propylamine, N-alkyl-propylene diamines, N-alkyl-dipropylene-triamines, diethylenetriamine, triethylenetriamine, tetraethylenepentamine, pentaethylene hexamine, N-isopropyl-2-methyl-1,2-propanediamine, N-(2-aminoethyl)-piperazine, 1-(β-aminoethyl)-2-imidazolidone, 3,3'-imino-bispropylamine, bis(2-aminopropyl)-amine, bishexamethylene triamine, monoethanolamine, isopropanolamine, 3-amino-1-propanol, 3-amino-1,2-propanediol, 2-amino-2-methyl-1-propanol, 2-amino-2-methyl-1,3-propanediol, 2-amino-1-butanol, 6-amino-1-hexanol, 1,3-diamino-2-propanol, diethanolamine, dilsopropanolamine, 2-(2,2-aminoethylamino)ethylaminoethanol, N-aminoethylethanolamine, N,N'bis(2-hydroxyethyl)-1,2-diamino-cyclohexane, N,N'hydroxyethyl-ethylenediamine, N(3-aminopropyl)-diethanolamine, tris(hydroxymethyl)-aminoethane and 2-(2-methanolamino)-ethylamino-ethanol.

Claim 11

A process as claimed in claim 1, which comprises using as said organic initiator a compound containing at least two functional groups at least one of which is a primary or secondary amine.

Claim 12

A process as claimed in claim 1, which comprises using in the catalyst, 0.1 to 10 parts by weight of said amine of the structure ##STR39## to 100 parts by weight of polyol.

Claim 13

A process as claimed in claim 9, which comprises using in the catalyst, 0.5 to 3 parts by weight of said amine to 100 parts by weight of polyol.

Claim 14

A process as claimed in claim 1 which comprises using in the catalyst, 0.05 to 5 parts by weight of alkali metal or alkaline-earth metal salt, alcoholate and phenolate to 100 parts by weight of polyol.

Claim 15

A process as claimed in claim 11, which comprises using 0.2 to 3 parts by weight of said salt, alcoholate and/or phenolate to 100 parts by weight of polyol.

Claim 16

A process as claimed in claim 1, which comprises using in the catalyst 0.1 to 10 parts by weight of said organic lead compound to 100 parts by weight of polyol.

Claim 17

A process as claimed in claim 13, which comprises using in the catalyst, 0.2 to 4 parts by weight of lead compound to 100 parts by weight of polyol.

Claim 18

A process as claimed in claim 1, which comprises using in the catalyst, 0.2 to 5 parts by weight of a monofunctional initiator to 100 parts by weight of polyol.

Claim 19

A process as claimed in claim 15, which comprises using in the catalyst, 0.2 to 3 parts by weight of a monofunctional initiator to 100 parts by weight of polyol.

Claim 20

A process as claimed in claim 8, which comprises using in the catalyst, 0.2 to 30 parts by weight of an initiator comprising at least two functional groups to 100 parts of polyol. 100

Claim 21

A process as claimed in claim 17, which comprises using in the catalyst, 0.2 to 10 parts by weight of an initiator comprising at least two functional groups to 100 parts by weight of polyol.

Claim 22

A process as claimed in claim 1, which comprises using a cross-linking agent.

Claim 23

A process as claimed in claim 19, which comprises using a cross-linking agent, except when the catalyst comprises more than 2 parts by weight, preferably more than 4 parts by weight, of an initiator comprising at least two functional groups.

Claim 24

A process as claimed in claim 1, which comprises using 2 to 30 parts by weight of a physical swelling agent, such as trichlorofluoromethane, methylene chloride or a mixture of both said products, to 100 parts by weight of polyol.

Claim 25

A process as claimed in claim 1, which comprises using at most 0.5 parts by weight of a chemical swelling agent, such as water, to 100 parts by weight of polyol.

Claim 26

A process as claimed in claim 1, wherein said polyisocyanate is an aliphatic or alicyclic polyisocyanate.

Claim 27

The process of claim 1, wherein said catalyst synergistic combination is said synergistic combination (1).

Claim 28

The process of claim 1, wherein said catalyst synergistic combination is said synergistic combination (2).

Claim 29

The process of claim 1, wherein said catalyst synergistic combination is said synergistic combination (3).

Claim 30

The process of claim 1, wherein said catalyst synergistic combination is said synergistic combination (4).

Claim 31

The process of claim 1, wherein said catalyst provides with said polyisocyanates a reactivity substantially identical to that obtained with aromatic polyisocyanates.