Stability of polyurethane polyol blends containing halogenated olefin blowing agent

Abstract

A polyol pre-mix composition includes a blowing agent having a halogenated hydroolefin, a polyol, a catalyst composition, and an antioxidant. The antioxidant may be, for example, a benzene diol or a benzene triol or other polyhydroxy-substituted aromatic compound, which is optionally substituted with one or more substituents such as alkyl groups. A two-part system for producing a thermosetting foam blend includes (a) a polyisocyanate and, optionally, one or more isocyanate compatible raw materials; and (b) the polyol pre-mix composition. A method for producing a thermosetting foam blend includes combining: (a) a polyisocyanate; and (b) the polyol pre-mix composition.

What is claimed is: 
     
         1 . A method for producing a thermosetting foam blend which comprises combining: (a) a polyisocyanate and, optionally, one or more isocyanate compatible raw materials; and (b) a polyol pre-mix composition which comprises a blowing agent comprising a halogenated hydroolefin, a polyol, catalyst composition comprising an amine catalyst, a non-amine catalyst, or a mixture thereof, and an antioxidant. 
     
     
         2 . The method of  claim 1 , wherein the catalyst composition includes an oxygen-containing amine catalyst. 
     
     
         3 . The method of  claim 1 , wherein the oxygen-containing amine catalyst is a compound having the chemical structure:
   R 1 R 2 N(CH 2 ) 2 X   
       wherein:
 R 1  and R 2  are the same or different and are each a C 1 -C 6  alkyl group and/or an alkanol group, 
 X is O(CH 2 ) 2 Y, OH, or NR 3 (CH 2 ) 2 Y, where R 3  is a C 1 -C 6  alkyl group or an alkanol group, and 
 Y is OH or NR 4 R 5 , where R 4  and R 5  are the same or different and are each a C 1 -C 6  alkyl group or an alkanol group, subject to the proviso that the compound contains at least one ether and/or hydroxyl group. 
 
     
     
         4 . The method of  claim 1 , wherein the catalyst composition comprises a non-oxygen-containing amine catalyst. 
     
     
         5 . The method of  claim 1 , wherein non-amine catalyst composition comprises an organometallic salt of tin (Sn) or lead (Pb) or mixtures thereof. 
     
     
         6 . The method of  claim 1 , wherein the blowing agent comprises a halogenated hydroolefin selected from the group consisting of hydrofluoroolefins (HFOs), hydrochloroolefins (HCFOs), and mixtures thereof, and, optionally, one or more hydrofluorocarbons (FMCs), hydrofluoroethers (HFEs), hydrocarbons, alcohols, aldehydes, ketones, ethers/diethers, esters, or CO 2  generating materials, or combinations thereof. 
     
     
         7 . The method of  claim 1 , wherein said hydrocarbons are selected from the group consisting of normal pentane, isopentane, cyclopentane, neopentane, and butane. 
     
     
         8 . The method of  claim 1 , wherein the pre-mix composition further comprises a surfactant. 
     
     
         9 . The method of  claim 8 , wherein the surfactant comprises a polysiloxane polyoxyalkylene block co-polymer silicone surfactant. 
     
     
         10 . The method of  claim 1 , wherein the antioxidant comprises at least one primary antioxidant or at least one primary and at least one secondary antioxidant. 
     
     
         11 . The method of  claim 10 , wherein the at least one primary antioxidant is chosen from polyhydroxy-substituted aromatic compounds comprising at least two hydroxyl groups on an aromatic ring, and optionally comprising one or more substituents other than hydroxyl. 
     
     
         12 . The method of  claim 11 , wherein the at least one primary antioxidant is chosen from substituted and unsubstituted benzene diols and benzene triols, 
     
     
         13 . The method of  claim 12 , wherein the at least one primary antioxidant is chosen from substituted and unsubstituted 1,2-benzenediols, 1,3-benzenediols, and 1,4-benzenediols. 
     
     
         14 . The method of  claim 12 , wherein the at least one primary antioxidant is chosen from substituted and unsubstituted 1,2,3-benzenetriols, 1,2,4-benzenetriols, and 1,3,5-benzenetriols. 
     
     
         15 . The method of  claim 1 , wherein the antioxidant is present in an amount ranging from 1 wt % to 10 wt % antioxidant based on the total weight of the polyol premix. 
     
     
         16 . The method of  claim 10 , wherein the at least one secondary antioxidant is chosen from phenylene diamine, phosphites, sulfides, sulfites, and mercaptides. 
     
     
         17 . The method of  claim 1 , wherein the pre-mix composition further comprises a metal salt. 
     
     
         18 . The method of  claim 1 , wherein the pre-mix composition further comprises a flame retardant or suppressor. 
     
     
         19 . The method of  claim 10 , wherein the at least one primary antioxidant is chosen from monohydroxy-substituted aromatic compounds comprising one hydroxyl group on an aromatic ring, and optionally comprising one or more substituents other than hydroxyl 
     
     
         20 . A mixture suitable for providing a polyurethane or polyisocyanurate foam having uniform cell structure with little or no foam collapse, wherein the mixture comprises: (a) a polyisocyanate and, optionally, one or more isocyanate compatible raw materials; and (b) a polyol pre-mix composition which comprises a blowing agent comprising a halogenated hydroolefin, polyol, a catalyst composition comprising an amine catalyst, a non-amine catalyst, or a mixture thereof, and an antioxidant.