US 4,717,518 AGranted

Novel process for making polyurethane products which require reduced crushing in preventing said products from substantially shrinking or changing dimensionally upon cooling

AssigneeUnion Carbide Corporation

InventorKeith D. Cavender

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Abstract

A process for making molded high resilience polyurethane cellular products which require reduced crushing in preventing the products from substantially shrinking or changing dimensionally upon cooling which comprises: exposing the curing product to atmospheric pressure while in contact with the confines of the mold at a time when the cell walls of the curing polyurethane cellular product have cured sufficiently to develop sufficient strength to partially resist bursting by the pressure of said expansion gases contained within the cell walls upon exposure to atmospheric pressure, but before the cell walls have cured sufficiently to develop sufficient strength so that exposure to atmospheric pressure does not result in a reduction of the crushing force necessary to prevent the products from substantially shrinking or changing dimensionally.

Claims9

Dependent claims

A process for making molded high resilience polyurethane cellular products which require reduced crushing in preventing said products from substantially shrinking or changing dimensionally upon cooling comprising:

(a) introducing a liquid foamable polyurethane reaction mixture into a mold adopted to expose the mixture to atmospheric pressure during the curing of said product and said mold adapted to be closed;
(b) closing said mold;
(c) permitting said reaction mixture to expand into contact with the confines of the mold to form a curing molded polyurethane cellular product containing cells having cell walls of curing polyurethane and pressurized expansion gases contained within and supporting said cell walls;
(d) exposing said curing product to atmospheric pressure while in contact with the confines of the mold at a time when said cell walls of said curing polyurethane cellular product have cured sufficiently to develop sufficient strength to partially resist bursting by the pressure of said expansion gases contained within said cell walls upon exposure to atmospheric pressure, but before said cell walls have cured sufficiently to develop sufficient strength so that exposure to atmospheric pressure does not result in a reduction of the crushing force necessary to prevent said products from substantially shrinking or changing dimensionally;
(e) allowing said curing polyurethane product to continue to cool and cure in said mold until it has developed sufficient strength to be removed from the mold without permanently distorting its shape;
(f) removing said product from said mold;
and
(g) crushing said product to prevent shrinkage or dimensional change.

5 more elements

A process for making molded high resilience polyurethane cellular products which require reduced crushing in preventing said product from substantially shrinking or changing dimensionally upon cooling comprising:

(a) introducing a liquid foamable polyurethane reaction mixture into a mold adopted to expose the mixture to atmospheric pressure during the curing of said product and said mold adapted to be closed;
(b) closing said mold;
(c) permitting said reaction mixture to expand into contact with the confines of the mold to form a curing molded polyurethane cellular product containing cells having cell walls of curing polyurethane and pressurized expansion gases contained within and supporting said cell walls;
(d) exposing said curing product to atmospheric pressure while in contact with the confines of the mold at a time when said cell walls of said curing polyurethane cellular product have cured sufficiently to develop sufficient strength to partially resist bursting by the pressure of said expansion gases contained within said walls upon exposure to atmospheric pressure, but before said cell walls have cured sufficiently to develop sufficient strength so that exposure to atmospheric pressure does not result in a reduction of crushing force of at least 25% in a regular demold system in the crushing step necessary to prevent said products from substantially shrinking or changing dimentionally;
(e) allowing said curing polyurethane product to continue to cool and cure in said mold until it has developed sufficient strength to be removed from the mold without permanently distorting its shape;
(f) removing said product from said mold;
and
(g) crushing said product to prevent shrinkage or dimensional change.

5 more elements

Dependencies are inferred from the claim text.