Process for preparing integral skin polyurethane and polyurethane so obtained

Claim 2

An improved process for preparing integral skin polyurethane foam, wherein a reaction mixture comprising polyol, polyisocyanate the NCO groups of which are not directly bonded to an aromatic group, no more than 0.5 part by weight of water to 100 parts by weight of polyol, and a catalyst is reacted in a mould, said improvement comprising using as the catalyst a synergistic combination of (a) at least one organic initiator containing at least one of a primary or secondary amino functional group, and (b) at least one organic compound of bismuth.

Claim 3

A process as claimed in claim 1, wherein the organic bismuth compound is a compound of the general formula I: ##STR35## wherein: p=q=0 or 1 k+j=2 or 4 when p=q=1 or k=j=0 when p=q=0 m+n=3 or 5 when k=j=p=q=0 or m+n=2 or 4 when p=q=1 m+n≈0, m or n may possibly be equal to 0 but are not, however, simultaneously equal to 0; R 1 is an alkyl (C 1 -C 12 ) radical which is substituted or not, a phenyl radical, a cycloalkyl (C 5 -C 6 ) radical or a halogen atom; Z represents oxygen or sulfur; Y is a halogen atom, a --O--CO--R 2 , --OR 2 , --SR 2 , ##STR36## group wherein R 2 may represent (1) an alkyl (C 1 -C 20 ) radical, an alkenyl (C 2 -C 20 ) radical, a cycloalkyl (C 5 or C 6 ) radical, a phenyl radical, a benzyl radical, which are unsubstituted or substituted by one or more alkyl (C 1 -C 12 ) or alkenyl (C 2 -C 12 ) radicals, one or more halogen atoms, one or more hydroxy, --OR, --N(R) 2 or --SR radicals, or (2) a phenyl radical which is substituted by one or more CHO, --CO--R or COOR groups, R being an alkyl (C 1 -C 12 ), alkenyl (C 2 -C 12 ), cycloalkyl (C 5 -C 6 ), phenyl, or benzyl radical, which is unsubstituted or substituted by one or more alkyl (C 1 -C 12 ) or alkenyl (C 2 -C 12 ) radicals, one or more halogen atoms, or hydroxy radicals, and R 3 is a group (--CR 4 R 5 ) x wherein x=2 or 3 and R 4 and R 5 =H, CH 3 or C 2 H 5 .

Claim 4

A process as claimed in claim 2, wherein the organic bismuth compound is a compound of the formula I wherein R 1 is an alkyl (C 1 -C 4 ) radical, a phenyl radical or a halogen atom.

Claim 5

A process as claimed in claim 2, wherein the organic bismuth compound is a compound of the formula I wherein the halogen atom is chlorine or bromine.

Claim 6

A process as claimed in claim 2, wherein the organic bismuth compound is a compound of formula I wherein Z is oxygen.

Claim 7

A process as claimed in claim 2, wherein the organic bismuth compound is a compound of the formula I wherein R 2 is one of the following substituents: (a) phenyl and benzyl radicals (b) alkyl (C 1 -C 12 ) radicals (c) radicals issuing from naphthenic acid (d) radicals of the formula --CR' s R" r wherein s+r=3, R' and R" are a chlorine or bromine atom or hydrogen; (e) radicals (CH 2 ) i OH, (CH 2 ) i OR, (CH 2 ) i N(R) 2 and (CH 2 ) i SR, wherein i may vary from 1 to 4;

Claim 8

A process as claimed in claim 1 or 2, wherein the organic bismuth compound is a compound of the formula II: (Y).sub.m --Bi--(R.sub.1).sub.n (II) wherein n+m=3 or 5, R 1 is an alkyl, phenyl or cycloalkyl radical and Y is a halogen atom or a group --O--CO--R 2 , in which R 2 is as described in claim 2.

Claim 9

A process as claimed in claim 2, wherein the organic bismuth compound is a compound of the formula III: Bi(Y).sub.m (III) wherein m=3 or 5 and Y is a group --O--CO--R 2 in which R 2 is as described in claim 2.

Claim 10

A process as claimed in claim 2, wherein the organic bismuth compound is a compound of the formula IV: (R.sub.1).sub.k --Bi--Z--Bi(R.sub.1).sub.n (IV) wherein h and n=2 or 4, R 1 is an alkyl, phenyl or cycloalkyl radical and Z is sulfur or oxygen.

Claim 11

A process as claimed in claim 2, wherein the organic bismuth compound is a compound of the formula V: ##STR37## wherein: k+j and n+m=2 or 4; R 1 is an alkyl, phenyl or cycloalkyl radical; Y is a halogen atom or a group --O--CO--R 2 in which R 2 is as described in claim 2, and Z is oxygen or sulfur.

Claim 12

A process as claimed in claim 2, wherein the organic bismuth compound is a compound of the formula I, wherein Y is a --O--CO--R 2 radical or a halogen atom, in which R 2 is as described in claim 2.

Claim 13

A process as claimed in claim 2, wherein the organic bismuth compound is a compound of the formula I and the bismuth is trivalent.

Claim 14

A process as claimed in claim 1 or 2, wherein the organic initiator is at least one 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- or 4-chlorobenzylamine, 1,3-dimethylamine, 2,5-dimethylbenzylamine, o-, m-, or p-methoxybenzylamine, 3-N-dimethyl-(diethyl)amino-1,3-propanediamine, 2-amino-5N-diethylaminopentane, N-(3-aminopropyl)-2-pyrrolidone, diethylamine, di(iso)propylamine, dibutylamine, dioctylamine, dihexylamine, dinonylamine, dicyclohexylamine, N-methyloctadecylamine, N-ethylbenzylamine, 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, ethylene diamine, 1,4-diaminodecane, 1,5-diaminopentane, 1,6-diaminohexane, 1,10-diaminodecane, 1,12-diaminododecane, isophorondiamine, 2,2,4-trimethyl-hexamethylene-diamine, a polyoxypropyleneamine comprising the reaction product of an aliphatic terminally-branched, primary diamine or triamine with polypropylene glycol or triol, 1,4-bis(3-aminopropyl)piperazine, N,N'-dimethyl-(diethyl)-ethylenediamine, 4,4-trimethylenedipiperidine, 3-ethylamino-1-propylamine, 3-butylamino-1-propylamine, 3-ethylpropylamino-1-propylamine, an N-(alkyl)-propylene diamine, an N-(alkyl)-dipropylene triamine, dimethylenetriamine, triethylenetriamine, tetraethylenepentamine, pentaethylenehexamine, N-isopropyl-2-methyl-1,2-propanediamine, N-(2-aminoethyl)-piperazine, 1-(β-aminoethyl)-2-imidazolidone, 3,3'-imino-bispropylamine, bis(2-aminopropyl)-amine, bishexamethylenetriamine, 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, diisopropanolamine, 2-(2,2-aminoethylamino)ethylaminoethanol, N-aminoethylethanolamine, N,N'-bis(2-hydroxyethyl)-1,2-diaminocyclohexane, N,N'-hydroxymethyl)-amino-ethane and 2-(2-methanolaminoethyl)amino-ethanol.

Claim 15

A process as claimed in claim 1, wherein the organic bismuth initiator is a compound comprising at least two functional groups, at least one of which is the functional group of a primary or secondary amine.

Claim 16

A process as claimed in claim 1, wherein as catalyst comprised of the synergistic combination, 0.1 to 10 parts by weight of the organic bismuth compound are used to 100 parts by weight of polyol.

Claim 17

A process as claimed in claim 15, wherein the catalyst, comprises 0.2 to 4 parts by weight of the bismuth compound to 100 parts by weight of polyol.

Claim 18

A process as claimed in claim 1, wherein the catalyst comprises 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 17, wherein the catalyst, comprises 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 13, wherein the catalyst comprises 0.2 to 20 parts by weight of an initiator having at least two functional groups to 100 parts by weight of polyol.

Claim 21

A process as claimed in claim 19, wherein the catalyst comprises 1 to 10 parts by weight of an initiator having at least two functional groups to 100 parts by weight of polyol.

Claim 22

A process as claimed in claim 1, wherein a crosslinking agent is used.

Claim 23

A process as claimed in claim 21, wherein a crosslinking agent is used except when the catalyst comprises more than 2 parts by weight of an initiator having at least two functional groups.

Claim 24

A process as claimed in claim 1, wherein from 2 to 30 parts by weight of a physical swelling agent to 100 parts of polyol is used.

Claim 25

A process as claimed in claim 1, wherein no more than 0.5 part by weight of a chemical swelling agent, such as water, are used to 100 parts by weight of polyol.

Claim 26

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

Claim 27

A process as claimed in claim 2, wherein said halogen atom is a chlorine, bromine, fluorine or iodine atom.

Claim 28

A process as claimed in claim 6, wherein said alkyl radicals (b) are selected from the group consisting of radicals of organic salts of carboxylic acids selected from the group consisting of acetate, propionate, butyrate, amylate, hexoate, octoate, 2-ethylhexanoate, decanoate, monoate, undecanoate, and laurate; and said naphthenic acid radicals (c) are a natural product forming a mixture of substituted cyclopentane of the formula R 2 COOH.

Claim 29

A process as claimed in claim 27, wherein R 2 COOH is selected from the group consisting of ##STR38##

Claim 30

A process as claimed in claim 22, wherein said catalyst comprises more than 4 parts by weight of said initiator.

Claim 31

A process as claimed in claim 23, wherein said swelling agent is trichlorofluoromethane, methylene chloride or a mixture thereof.