Compositions – Compositions containing a single chemical reactant or plural... – Organic reactant
Patent
1996-08-07
1997-09-16
Foelak, Morton
Compositions
Compositions containing a single chemical reactant or plural...
Organic reactant
25218226, 521137, 521174, 524377, C08K 300, C08G 1832
Patent
active
056683782
DESCRIPTION:
BRIEF SUMMARY
The present invention relates to polyol compositions, their use in the preparation of high resilience polyurethane foams and to foamed articles prepared from formulations containing such polyol formulation.
High resilience (HR) polyurethane foams are widely used in automotive, furniture and other applications due to their superior comfort, support and higher resilience characteristics. ASTM Method D-3770 sets specific guidelines for defining HR polyurethane foams. In practice, a wider class of polyurethane foams is known as high resilience foams. It is the intent of this invention to encompass this broader classification as well as the so called combustion modified high resilience (CMHR) polyurethane foams.
HR polyurethane foams are typically produced using formulations comprising (1) a polymer polyol, (2) water, (3) a crosslinking agent/chain extending agent such as diethanolamine, (4) a silicone-based foam stabilizer, (5) amine and tin catalysts, (6) toluene diisocyanate and (7) various other additives such as auxiliary blowing agents, fillers and flame retardant agents.
Processing characteristics of commercial HR polyurethane foams are usually characterized by the diethanolamine and isocyanate index ranges that give acceptable processing. A broad range is desirable both for processing and grade flexibility since load decreases as the diethanolamine level increases and isocyanate index decreases. The lower diethanol level is characterized by excessive collapse while, at the upper level, the foam will shrink. The diethanol level will typically depend on factors such as isocyanate index, water level, catalyst types and their levels, surfactants and machine parameters.
Numerous methods and polyurethane formulations employing polymer polyol compositions and/or various polyol blends have been used in the preparation of high resilience polyurethane foams, see for example, U.S. Pat. No. 4,111,865; U.S. Pat. No. 3,857,800; British Patent 1,339,442; Japanese Patents SHO 57-13312, SHO 57-195113, SHO 57-195725 and SHO 59-100125; U.S. Pat. No. 4,544,678; British Patent 1,480,972 and U.S. Pat. No. 4,690,955. In general, these methods and formulations did not provide desirable latitude for varying formulation components without adversely affecting processing and physical properties. These HR polyurethane formulations show deficiency in processing as the water level in the formulation is increased to make lower density foams, and/or as the crosslinking agent level is increased or decreased beyond the currently established limits. These limitations restrict the range of foam grades, that is density and load, that can be produced and limit the applications in which these foams can be used.
For years, lower density foams have been produced by incorporating an auxiliary blowing agent into the polyurethane formulation. The most commonly used auxiliary blowing agents are halogen containing low boiling point liquids such as CFC-11. The use of this type of auxiliary blowing agents is now seen as undesirable due to concerns about their environmental effects and efforts are being made to avoid their use by using water as the only blowing agent in foam formulations.
German Offenlegungsschrift 2,263,205 discloses a process for the preparation of cold-cured, soft polyurethane foams by the reaction of toluene diisocyanate with a polyether in the presence of water and/or organic blowing agents, amine catalysts and silicone based foam stabiliser, characterised in that the polyether is a 6 to 8 functional polyether having a molecular weight from 6000 to 30000 and at least 10 weight percent of primary hydroxyl groups or a mixture of this polyether with up to 50 weight percent of a 2 to 5 functional polyether having a molecular weight from 2000 to 8000 and at least 10 weight percent primary hydroxyl groups.
U.S. Pat. No. 5,011,908 and European Patent Application Publication No. 0,350,868 disclose a polymer polyol composition comprising (1) a high functionality polyol or polyol blend with an equivalent weight between 1000 and 3000 which p
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Knaub Philippe Martin
Treboux Jean-Paul Rene
Foelak Morton
Polyol International B.V.
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