Polyurethane Gel-Like Polymers, Methods and Use in Flexible Foams
AssigneePeterson Chemical Technology, Inc.
InventorsBruce W. Peterson, Mark L. Crawford
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Abstract
Combinations of open cell flexible foams with polyurethane gel-like polymers, in forms such as layers of different forms and shapes, solid sheets, perforated sheets, and particles, and methods of making the combinations are described using a variety of procedures. Alternatively, the resin to make the polyurethane gel-like polymers may be infused into the polyurethane foams. The open cell flexible foam may partially or wholly comprise polyurethane foam and latex foam.
Claims37
A composition comprising a combination of open cell flexible foam and polyurethane gel-like elastomer produced by the method comprising:
- a. reacting one or more polyols with hydroxyl values from 10-170 and with functionality greater or equal to 3;
- one or more polyols with hydroxyl values from 170-1400 and with functionality of 2;
- and one or more polyisocyanates with NCO functionality of 2 to 8, where the gel-like polymer has a polyisocyanate index between 0.6 to 1.0, where the polyurethane gel-like polymer resin is prepared in the presence of at least one gelation catalyst, and at least one phase change material, to make a polyurethane gel-like polymer resin;
- b. infusing at least a portion of the polyurethane gel-like polymer resin in the open cell flexible foam;
- and
- c. at least partially reacting the polyurethane gel-like polymer resin to form the polyurethane gel-like elastomer;
- where the polyurethane gel-like elastomer and open cell flexible foam are attached by interlocking of polyurethane gel-like elastomer around open cell flexible foam struts.
A composition comprising a combination of open cell flexible polyurethane foam and polyurethane gel-like particles produced by the method comprising:
- a. reacting one or more polyols with hydroxyl values from 10-170 and with functionality greater or equal to 3;
- one or more polyols with hydroxyl values from 170-1400 and with functionality of 2;
- and one or more polyisocyanates with NCO functionality of 2 to 8, where the gel-like polymer has a polyisocyanate index between 0.6 to 1.0, where the polyurethane gel-like elastomer is prepared in the presence of at least one gelation catalysts and at least one phase change material, to make a polyurethane gel-like elastomer;
- b. reducing the polyurethane gel-like elastomer into particles having an average particle size between the range of about 0.01 to about 12 millimeters;
- c. introducing the polyurethane gel-like particles into a mixture of polyurethane foam-forming components comprising a polyol and an isocyanate;
- d. polymerizing the polyol and the isocyanate to form an open cell flexible polyurethane foam;
- where said polyurethane gel-like particles are added in the range of about 0.1 to about 200 parts per hundred of the polyol component of polyurethane foam.
A composition comprising a combination of latex foam and polyurethane gel-like particles produced by the method comprising:
- a. reacting one or more polyols with hydroxyl values from 10-170 and with functionality greater or equal to 3;
- one or more polyols with hydroxyl values from 170-1400 and with functionality of 2;
- and one or more polyisocyanates with NCO functionality of 2 to 8, where the gel-like polymer has a polyisocyanate index between 0.6 to 1.0, where the polyurethane gel-like polymer is prepared in the presence of at least one gelation catalyst, at least one phase change materials, to make a polyurethane gel-like elastomer;
- b. reducing the polyurethane gel-like elastomer into particles having an average particle size between the range of about 0.01 to about 12 millimeters;
- c. introducing the polyurethane gel-like particles into a mixture of latex foam-forming components;
- and
- d. polymerizing the latex foam-forming components to form an open cell flexible latex foam;
- where said polyurethane gel-like particles are added in the range of about 0.1 to about 200 parts per hundred of the latex foam-forming components.
Dependencies are inferred from the claim text.