# US 10,766,998 B2 · Flexible polyurethane foams

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- Number: US 10,766,998 B2
- Document ID: US10766998B2
- Status: Granted
- Kind: B2
- Application number: 15/819,261
- Filed: 2017-11-21
- Published: 2019-05-23
- Granted: 2020-09-08
- Earliest claimed: 2017-11-21
- Assignees: Covestro LLC
- Applicants: Covestro LLC
- Inventors: Nigel Barksby; Brian L. Neal
- Web page: https://patentgrep.com/patent/US10766998B2

## CPC

- C08G 18/6283: {Polymers of nitrogen containing compounds having carbon-to-carbon double bonds (C08G18/6262, C08G18/6266 take precedence)}
- C08G 18/18: containing secondary or tertiary amines or salts thereof
- C08G 18/4072: {Mixtures of compounds of group C08G18/63 with other macromolecular compounds}
- C08G 18/4804: {Two or more polyethers of different physical or chemical nature}
- C08G 18/4812: {Mixtures of polyetherdiols with polyetherpolyols having at least three hydroxy groups}
- C08G 18/4866: {having a low unsaturation value}
- C08G 18/632: {onto polyethers}
- C08G 18/7621: {being toluene diisocyanate including isomer mixtures}
- C08G 2110/0008: flexible
- C08G 2110/0083: prepared using water as the sole blowing agent
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS

## Abstract

This invention relates to a process for preparing a flexible polyurethane foam in which the isocyanate-reactive component comprises a specific isocyanate-reactive component. The invention also relates to flexible polyurethane foam wherein the isocyanate-reactive comprises the specific isocyanate-reactive component.

## Claims

### Claim 1

A process of preparing a flexible polyurethane foam comprising:
(A) reacting:
(1) toluene diisocyanate;
with
(2) an isocyanate-reactive component comprising:
(a) from 70 to 95% by weight, based on 100% by weight of component (a) and component (b), of an in-situ formed polyol blend having a hydroxyl number of from about 56 mg KOH/g polyol to about 250 mg KOH/g polyol, an average functionality greater than 2 and comprising:
(i) from 25 to 75% by weight, based on 100% by weight of (i) and (ii), of a polyether monol having a hydroxyl number of less than 56 mg KOH/g polyol, and containing less than 20% by weight of copolymerized oxyethylene, based on 100% by weight of (a)(i),
and
(ii) from 25 to 75% by weight, based on 100% by weight of (i) and (ii), of a polyether polyol having a hydroxyl number of about 47 mg KOH/g polyol to about 300 mg KOH/g polyol, an average functionality of greater than 2 to about 6, and containing from about 5 to about 45% by weight of copolymerized oxyethylene, based on 100% by weight of (a)(ii);
and
(b) from 5 to 30% by weight, based on 100% by weight of component (a) and component (b), of a filled polyol;
with the proviso that the isocyanate-reactive component is free of polyether polyols which have a functionality of at least about 2 to about 8 or less, a hydroxyl number of at last about 20 to about 240 or less, and which contain at least 50% of copolymerized oxyethylene, based on 100% by weight of said polyether polyols;
in the presence of
(3) a blowing agent;
(4) a catalyst;
and
(5) a surfactant;
wherein the resultant foam has a 90% compression set of less than or equal to 10% as measured by ASTM D3574-11 at an isocyanate index of at least 100.

### Claim 2 (depends on 1)

The process according to claim 1, wherein (2) said isocyanate-reactive component additionally comprises:
(c) a polyether polyol having a functionality of from about 2 to about 8, a hydroxyl number of from about 10 mg KOH/g polyol to about 300 mg KOH/g polyol, and comprising from 0 to about 45% by weight of copolymerized oxyethylene, based on 100% by weight of component (c).

### Claim 3 (depends on 1)

The process according to claim 1, wherein (a)(ii) comprises at least one polyether diol and at least one polyether triol.

### Claim 4 (depends on 1)

The process according to claim 1, wherein (a)(i) said polyether monol has a hydroxyl number of less than 28 mg KOH/g polyol; (a)(ii) said polyether polyol has a hydroxyl number of about 70 mg KOH/g polyol to about 240 mg KOH/g polyol, and a functionality of about 2.5 to about 3.5; and (b) said filled polyol comprises at least one of: (i) polymer polyols containing styrene-acrylonitrile solids, (ii) polyisocyanate polyaddition polyols, and (iii) polyhydrazodicarbonamide polyols.

### Claim 5 (depends on 1)

The process according to claim 1, wherein (c) said polyether polyol has a hydroxyl number of at least about 20 mg KOH/g polyol to about 150 mg KOH/g polyol and a functionality of at least about 2.5 to about 6.

### Claim 6 (depends on 1)

The process according to claim 1, which additionally comprises reacting a foam modifier and/or a foam processing aid, wherein said foam modifier and/or said foam processing aid each have a hydroxyl number of at least 300 mg KOH/g polyol.

### Claim 7 (depends on 1)

The process according to claim 1, wherein the resultant foam has a 90% compression set of less than or equal to 5% as measured by ASTM D-3574-11 at an isocyanate index of at least 100.

### Claim 8 (depends on 1)

The process according to claim 1, wherein the catalyst comprises a non-fugitive amine catalyst.

### Claim 9 (depends on 1)

The process according to claim 1, wherein the blowing agent comprises water.

### Claim 10 (depends on 1)

The process according to claim 1, wherein the reaction between said isocyanate-functional component and said isocyanate-reactive component occurs in the presence of one or more crosslinkers and/or foam stabilizers.