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US 12,030,293 B2Granted
Semi-rigid polyurethane foam formulation and method for making foamed parts
AssigneeDow Global Technologies LLC
InventorsKelly F. Kiszka, Adam L. Grzesiak, Yujing Tan, Michael D. Donate, Yiqun Zhang
Life of this patent
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Abstract
Composites having a polymer or natural leather skin layer and a polyurethane foam layer are made in a molding process. The polyurethane foam layer is made from a foam formulation that includes certain polyester polyols. The presence of the polyester polyol improves flow characteristics of the foam formulation. The foam so produced has unexpectedly low quantities of VOCs.
Claims8
A process for forming a skinned composite, comprising the steps of
- A) introducing a polymer or natural leather skin layer and optionally a substrate into a cavity of a mold such that the polymer or natural leather skin is positioned against at least one internal surface of the mold, to produce an unfilled region of the mold cavity having a thickness of at most 25.4 mm adjacent to the polymer or natural leather skin layer
- B) introducing a polyurethane foam formulation through one or more injection ports into the unfilled region of the mold cavity;
- C) before or after step B), closing the mold and
- D) curing the polyurethane foam formulation in the closed mold such that the polyurethane foam formulation expands, contacts an exposed surface of the polymer or natural leather skin layer and forms a polyurethane foam that fills the unfilled region of the mold cavity and adheres to the polymer or natural leather skin layer and substrate if present, wherein the polyurethane foam formulation comprises:
- I) isocyanate-reactive materials including
- a) 60 to 90 percent, based on the total weight of all isocyanate-reactive materials, of at least one polyether polyol having a nominal hydroxyl functionality of 2 to 8 and a hydroxyl equivalent weight of 1000 to 3000;
- b) mono-, di- or trialkanolamine in an amount of 0.25 to 1.5 percent of the total weight of all isocyanate-reactive materials;
- c) 5 to 30 percent, based on the total weight of all isocyanate-reactive materials, of at least one hydroxy-functional triglyceride having a hydroxyl equivalent weight of 150 to 1200 and a hydroxyl functionality of 2 to 4 or a mixture thereof with a diethyl adipate polyester;
- and
- d) water;
- II) at least one urethane catalyst;
- and
- III) at least one organic polyisocyanate.
10 more elements
A skinned composite comprising
- 1) an exterior polymeric or natural leather skin and
- 2) a polyurethane layer having a thickness of up to 25.4 mm in contact with and adhered to the polymeric skin,
- wherein the polyurethane layer is a reaction product of a reaction mixture the comprises
- I) isocyanate-reactive materials including
- a) 60 to 90 percent, based on the total weight of all isocyanate-reactive materials, of at least one polyether polyol having a nominal hydroxyl functionality of 2 to 8 and a hydroxyl equivalent weight of 1000 to 3000;
- b) mono-, di- or trialkanolamine in an amount of 0.25 to 1.5 percent of the total weight of all isocyanate-reactive materials;
- c) 5 to 30 percent, based on the total weight of all isocyanate-reactive materials, of at least one hydroxy-functional triglyceride having a hydroxyl equivalent weight of 150 to 1200 and a hydroxyl functionality of 2 to 4 or a mixture thereof with a diethyl adipate polyester;
- and
- d) water;
- II) at least one urethane catalyst;
- and
- III) at least one organic polyisocyanate.
9 more elements
Dependencies are inferred from the claim text.