Process for preparing flexible polyurethane foams
AssigneeThe Dow Chemical Company
InventorsBilly Quock, Don Howard Kelley, Sehon Lester Warneke
Life of this patent
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Abstract
Menthanediamine, isophorone diamine and the like compounds have been discovered to be an effective substitute for 4,4'-methylenebis(2-chloroaniline) in the preparation of flexible polyurethane foams. This substituted crosslinker is not suspected of being carcinogenic.
Claims22
A process for preparing flexible polyurethane foam having a modulus of at least about 2.3 which comprises subjecting to foaming conditions, a composition comprising:
- A 1. from about 50 to 100 parts by weight of a primary, hydroxyl-containing polyether triol having an average hydroxyl equivalent weight of from about 900 to about 2500,
- 2. from 0 to about 50 parts by weight of a polyol selected from a diol, a triol, a polymer-containing diol, a polymer-containing triol or mixtures thereof wherein said diols and triols have an average hydroxyl equivalent weight of from about 500 to about 2500 and said polymer has an average molecular weight of at least about 5000;
- B. an organic polyisocyanate consisting of
- 1. from about 50% to 100% by weight of 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, NCO-containing prepolymers thereof, and
- 2. from 0 to about 50% by weight of an organic polyisocyanate having an average NCO functionality of at least 2;
- C. from about 1.0 to about 5 parts by weight of water per 100 parts by weight of Component (A);
- D. from about 0 to about 20 parts of a low boiling auxiliary blowing agent per 100 parts by weight of Component (A);
- E. from about 0.1 to about 10 parts per 100 parts by weight of Component (A) of a crosslinker composition consisting essentially of
- 1. from 5 to 100 percent by weight of compounds or mixtures of compounds represented by the formula ##STR15## wherein A is represented by the group ##STR16## each R, R.sub.1 and R.sub.2 are independently hydrogen or an alkyl group having from 1 to about 4 carbon atoms, x has a value from zero to about 4;
- y has a value of 1 or 2;
- z has a value of zero or 1, and when y is 2, z is zero and the sum of y and z is 2, as a primary crosslinker component, and
- 2.
A super-soft flexible polyurethane foa characterized by a modulus of at least about 2.3 and 25% ILD value of <5lbs (2.27 kg).
A process for preparing super-soft flexible polyurethane foams having a modulus of at least about 2.3 and a 25% ILD values of <20lbs (9.07 kg) which process comprises:
- A. a polyol component comprising
- 1. a diol having an equivalent weight of from about 500 to about 2000 and an ethylene oxide content of from about 0 to about 50% by weight;
- 2. a triol having an equivalent weight of from about 500 to about 2000 and an ethylene oxide residue content of from about 0 to about 50% by weight;
- wherein the ratio of hydroxyl equivalents of (1):(2) is from about 0.11:1 to about 1.1:1;
- B. an organic polyisocyanate;
- C. from about 1 to about 4 parts of water per 100 parts by weight of Component (A);
- D. from about 5 to about 40 parts of a low boiling auxiliary blowing agent per 100 parts by weight of Component (A);
- E. from about 0.1 to about 3 parts per 100 parts by weight of Component (A) of a crosslinker selected from the group consisting of compounds or mixtures of compounds represented by the formula ##STR17## wherein A is represented by the group ##STR18## each R, R.sub.1 and R.sub.2 are independently hydrogen or an alkyl group having from 1 to about 4 carbon atoms x has a value from zero to about 4;
- y has a value of 1 or 2;
- z has a value of zero or 1, and when y is 2, z is zero and the sum of y and z is 2;
- F. from about 0.2 to about 3 parts of a catalyst for urethane formation per 100 parts by weight of Component (A);
- G. from about 0.2 to about 3 parts of a silicone oil cell control agent per 100 parts by weight of Component (A);
- and
- wherein Components (A), (B), (C) and (D) are present in quantities so as to provide an NCO:active hydrogen ratio of from about 0.9:1 to about 1.2:1.
Dependencies are inferred from the claim text.