Aqueous wax dispersions as cell openers in making polyurethane flexible foams
AssigneeAir Products and Chemicals, Inc.
InventorsJohn Herbert Frey, Allen Robert Arnold, Jr., Timothy Charles Boyer, Kevin Rodney Lassila
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Abstract
A method for preparing a flexible or semi-flexible polyurethane foam by reacting an organic polyisocyanate with a polyol in the presence of urethane catalyst, water as a blowing agent, optionally a silicone surfactant, and a cell opening additive characterized in that the cell opening additive comprises an aqueous dispersion of particles comprising a wax substance and optionally an emulsifier, at least 35% of the particles having a size of 0.2 to 5 microns and a melting point which ranges from 0 to 55.degree. C. below the maximum foam exotherm temperature.
Claims20
In a method for preparing a flexible or semi-flexible polyurethane foam which comprises reacting an organic polyisocyanate with a polyol in the presence of a urethane catalyst, a blowing agent, optionally a silicone surfactant cell stabilizer, and a cell opening additive, the reaction generating foam exotherm, the improvement which comprises as the cell opening additive an aqueous dispersion of particles comprising a wax substance and optionally an emulsifier, at least 35% of the particles having a size of 0.2 to 5 microns and a melting point within a 55.degree. C. range below the maximum foam exotherm temperature.
In a method for preparing a flexible polyurethane foam which comprises reacting an organic diisocyanate which is MDI, TDI, or a MDI/TDI mixture with a polyester or polyether polyol in the presence of urethane catalyst, water, liquid carbon dioxide, CFCs, HCFCs, HFCs, pentane, acetone and mixtures thereof as the blowing agent, optionally a silicone surfactant cell stabilizer, and a cell opening additive, the improvement which comprises as the cell opening additive present at 0.0001-2 pphpp an aqueous dispersion which is 5-60 wt % particles comprising a wax substance and an emulsifier, at least 35% of the particles having a size of 0.2 to 5 microns and a melting point within the range from 30.degree. C. below the maximum foam exotherm temperature to the exotherm temperature of the MDI-based foam, from 50.degree.C. below the maximum foam exotherm temperature to the exotherm temperature of the TDI-based foam or from 40.degree. C. below the maximum foam exotherm temperature to the exotherm temperature of the MDI/TDI-based foam.
A flexible polyurethane foam having a density of 0.6-37.5 lb/ft.sup.3 (10-600 kg/m.sup.3) prepared by reacting a composition comprising the following components in parts by weight (pbw):
- ______________________________________ Polyol 20-100 Polymer Polyol 80-0 Silicone Surfactant 0.5-2.5 Cell Opening Additive 0.05-3 Water 1-8 Auxiliary Blowing Agent 0-4.5 Crosslinker 0.5-2 Catalyst Composition 0.1-5 Isocyanate Index 70-115 ______________________________________
- the cell opening additive comprising an aqueous dispersion of particles comprising a wax substance and optionally an emulsifier, at least 35% of the particles having a size of 0.2 to 5 microns and a melting point which ranges from 0 to 55.degree. C. below the maximum foam exotherm temperature .
Dependencies are inferred from the claim text.