Oxidation discoloration resistant polyurethane foam
AssigneeWm. T. Burnett IP, LLC
InventorScott Christopher Magness
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Abstract
A flexible polyurethane foam with improved resistance to discoloration from oxidation is disclosed. Such discoloration may be due to exposure to oxides of nitrogen, for example, the oxides commonly found in burnt gas fumes. The foam may be used for applications such as intimate apparel and other consumer products that need extended term color stability. The foam composition includes high levels of reactive and non-reactive phosphite esters that improve color stability without disadvantage to the foam's physical and aesthetic properties during and after production.
Claims33
A polyurethane foam produced from a formulation comprising:
- a polyol;
- an isocyanate;
- a blowing agent;
- a first phosphite ester, the first phosphite ester being reactive with at least one of the polyol and the isocyanate;
- and
- a second phosphite ester, the second phosphite ester being substantially non-reactive with each of the polyol, the isocyanate, and the first phosphite ester,
- wherein the polyurethane foam is resistant to discoloration from oxides and resistant to scorch;
- wherein the formulation further comprises a surfactant, and the polyurethane foam is an open cell foam;
- wherein the total weight percentage of the first and second phosphite esters combined in the formulation is up to about 15%;
- and
- wherein the first phosphite ester is present in an amount of at least about 5 parts per hundred parts polyol, and the second phosphite ester is present in an amount of at least 5 parts per hundred parts polyol.
A polyurethane foam produced from a formulation comprising:
- a polyether polyol;
- an aromatic diisocyanate;
- a blowing agent;
- about 5% by weight tris(dipropyleneglycol)phosphite;
- and
- about 10% by weight poly(dipropyleneglycol)phenyl phosphite;
- wherein the foam is sufficiently open cell so as to have an air permeability of about 1.5 cfm, the foam is resistant to discoloration from oxides, and the foam is resistant to scorch.
A polyurethane composition produced from a formulation comprising:
- a polyol;
- an isocyanate;
- a first phosphite ester, the first phosphite ester being reactive with at least one of the polyol and the isocyanate;
- and
- a second phosphite ester, the second phosphite ester being substantially non-reactive with each of the polyol, the isocyanate, and the first phosphite ester;
- wherein the polyurethane composition is resistant to discoloration from oxides and resistant to scorch;
- wherein the first phosphite ester comprises tris(dipropyleneglycol)phosphite;
- wherein the second phosphite ester comprises poly(dipropyleneglycol)phenyl phosphite;
- wherein the total weight percentage of the first and second phosphite esters combined in the formulation is up to about 15%;
- and
- wherein the first phosphite ester is present in an amount of at least about 5 parts per hundred parts polyol, and the second phosphite ester is present in an amount of at least 5 parts per hundred parts polyol and up to 10 parts per hundred parts polyol.
Dependencies are inferred from the claim text.