Prepolymer containing a Liquid Hardness Agent For Open Cell Foams
OwnerPaul L. Neill, Warren A. Kaplan +1inventors
InventorsPaul L. Neill, Warren A. Kaplan, Douglas Kip Hillshafer
Life of this patent
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Abstract
The present technology provides at least one prepolymer comprising a polyisocyanate and a ring-containing isocyanate reactive component as a load-bearing capacity improvement agent in flexible polyurethane foam manufacture. The ring-containing component eliminates and/or reduces the need for a copolymer polyol containing suspended solids in the manufacture of flexible foam products. This can reduce production costs, reactivity variations, filter plugging, color variations, foam shrinkage/tightness, foam irregularity, and foam malodor while maintaining an adequate load-bearing capacity.
Claims27
A prepolymer suitable for use in preparing a flexible foam comprising:
- a. at least about 35% by weight of the prepolymer of a ring-containing isocyanate reactive component having load-bearing characteristics, the ring-containing isocyanate reactive component having an isocyanate reactive functionality between 1.7 and 3.5;
- and
- b. no greater than about 65% by weight of the prepolymer of a polyisocyanate.
A prepolymer suitable for use in preparing a flexible foam comprising:
- a. at least about 35% by weight of the prepolymer of a non-halogenated aromatic polyester polyol or polyol blend having a hydroxyl functionality between 1.7 and 3.5, the non-halogenated aromatic polyester polyol being the reaction product of an aromatic dibasic acid, aromatic anhydride, aromatic diester or mixture thereof with a glycol or glycol mixture, the aromatic dibasic acid, aromatic anhydride, aromatic diester or mixture thereof comprising less than 20 mole percent aliphatic monobasic acid, aliphatic dibasic acid, aliphatic anhydride or aliphatic diester;
- the polyol being substantially free of aromatic diamines;
- and
- b. no greater than about 65% by weight of the prepolymer of a polyisocyanate.
A prepolymer comprising:
- a. at least about 35% by weight of the prepolymer of a non-halogenated ring-containing component polyol having a hydroxyl functionality between 1.7 and 3.5, the non-halogenated ring-containing polyol being the reaction product of a ring-containing component aliphatic dibasic acid, ring-containing component aliphatic anhydride, ring-containing component aliphatic diester or mixture thereof with a glycol or glycol mixture, the ring-containing component aliphatic dibasic acid, anhydride, ester or mixture thereof comprising less than 20 mole percent linear aliphatic monobasic acid or aliphatic dibasic acid;
- the polyol being substantially free of aromatic diamines;
- and
- b. no greater than about 65% by weight of the prepolymer of a polyisocyanate.
A prepolymer comprising:
- a. at least about 35% by weight of the prepolymer of a non-halogenated ring-containing component polyol having a hydroxyl functionality between 1.7 and 3.5;
- the non-halogenated ring-containing components polyol comprising a non-polyester polyol;
- the polyol being substantially free of aromatic diamines;
- and
- b. no greater than about 65% by weight of the prepolymer of a polyisocyanate.
A prepolymer comprising:
- a. at least about 35% by weight of the prepolymer of a halogen-containing, ring-containing component polyol or a halogen-containing, ring-containing component polyol blend having a hydroxyl functionality between 1.7 and 3.5, the halogen-containing, ring-containing component polyol being substantially free of any inorganic particulate solids;
- and
- b. no greater than about 65% by weight of the prepolymer of a polyisocyanate.
A flexible foam prepared by reacting ingredients comprising:
- a. a prepolymer comprising at least about 35% by weight of the prepolymer of a ring-containing load-bearing polyol and no greater than about 65% by weight of the prepolymer of a polyisocyanate;
- and
- b. a polyether polyol;
- c. in the presence of a surfactant, a blowing agent and a reaction catalyst;
- said foam having a density of from about 6 to about 240 kg/m2 and a 65% indentation force deflection of from about 250 N/323cm2 to about 500 N/323 cm2.
A foam intermediate composition suitable for use in making a flexible foam, the foam intermediate composition comprising:
- a. a prepolymer comprising at least about 35% by weight of the prepolymer of a ring-containing load-bearing polyol and no greater than about 65% by weight of the prepolymer of a polyisocyanate;
- b. a polyether polyol;
- c. a surfactant;
- d. a blowing agent;
- and
- e. a reaction catalyst.
A method of making a flexible foam comprising the steps of:
- a. forming a prepolymer composition comprising at least about 35% by weight of the prepolymer of a ring-containing load-bearing polyol and no greater than about 65% by weight of the prepolymer of a polyisocyanate;
- and
- b. reacting the prepolymer composition with a polyether polyol in the presence of a surfactant, a blowing agent and a reaction catalyst.
Dependencies are inferred from the claim text.