Us6391935 PDF
Us6391935 PDF
Us6391935 PDF
Example 2O 21 22 23 24 25 C26 C8
Foam Processing
Blowoff, s 157 148 144 2O3 18O 165 Ole 229
Settle, 7% 1.1 1.1 2.9 1.1 1.1 1.6 1.O 6.O
Shrink nil nil nil nil nil slight excessive nil
Foam Properties
Density, pcf 2.71 2.72 2.81 2.62 2.58 2.71 not 3.15
Resilience, 26 8 1O 14 1O 11 13 testable 1O
Air flow, scfm 18 2.O 3.2 4.3 3.7 2.5 O.7
25% IFD, Ibs 11.6 15.2 25.8 6.2 7.5 1O.O 10.6
25% Return, % 65.2 56.3 49.2 81.7 82.2 81.0 87.5
Tensile, psi 11.4 14.4 19.3 5.9 7.6 10.1 9.6
Elongation, % 181 148 97 2OO 215 189 238
Tear, pli O.9 1.1 1.5 O.7 O.7 O.8 O.9
90% CS, (7% 5.7 5.6 6.6 86.9 813 18.5 5.9
75% HACS, (7% 7.5 5.9 6.6 57.0 28.5 18.2 11.4
TABLE 6
Effect of Reactive Monol
Formulation
We claim:
TABLE 7 1. A Viscoelastic polyurethane foam which comprises the
15 reaction product of water, a Surfactant, one or more catalysts,
Description of Monols, Polyols, and Formulation Components a polyisocyanate, and an isocyanate-reactive mixture com
Monols:
prising:
(a) a polyester or polyoxyalkylene monol having a num
MS-1 A blend of monols having an average mol. wt. of about 200 ber average equivalent weight greater than about 1000
used as a starter for making the other monols. 2O and an OH number less than about 56;
M-1 45 OH #, all-PO. (b) a polyester or polyoxyalkylene polyol having a num
M-2 42 OH #, made by double metal cyanide (DMC)-catalyzed
alkoxylation of MS-1 with a 7/93 blend of EO/PO to 1100 ber average equivalent weight leSS than about 600 and
mol. wt., followed by tipping with a 70/30 blend of EO/PO to an OH number greater than about 94; and
M-3
a final mol. wt. of 1335. Total EO content: 20%.
13 OH #, made by DMC-catalyzed alkoxylation of M-6 with 25
(c) optionally, a chain extender or crosslinker;
a 12/88 blend of EO/PO to 3400 mol. wt., followed by wherein the monol comprises from about 15 to about 70 wt.
tipping with 70/30 EO/PO to a final mol wt. of 4315. Total % of the isocyanate-reactive mixture;
EO content: 20%. Primary OH content: 39%. wherein the foam is produced at an isocyanate index of at
M-4 62 OH #, made by propoxylating MS-1. No EO cofeed. least 90, and
M-5 112 OH #, made by alkoxylating allyl alcohol with 3/97 wherein the foam has a resilience less than about 15%.
EO/PO to 210 mol. wt., followed by tipping with 70/30 2. The foam of claim 1 having a 90% compression set less
EO/PO to mol. wt. 501. Total EO content: 45%. 3O than about 15%.
M-6 35 OH #, made by propoxylating MS-1 using DMC catalyst.
No EO cofeed. 3. The foam of claim 1 wherein the monol is a polyox
M-7 4 OH #, made by propoxylating MS-1 using DMC catalyst. ypropylene monol having a number average equivalent
No EO cofeed. weight greater than about 1500.
M-8 20 OH #, made by DMC-catalyzed alkoxylation of M-4 with 4. The foam of claim 1 wherein the monol comprises at
0/90 EO/PO to 2340 mol. wt., followed by tipping with 35 least about 25 wt.% of the isocyanate-reactive mixture.
60/40 EO/PO to mol. wt. 2800. Total EO content: 15%.
Primary OH content: 37%. 5. The foam of claim 1 having a resilience less than about
M-11 6 OH #, made by propoxylation of allyl alcohol, 5%.
<12% primary hydroxyl groups. 6. The foam of claim 1 wherein the monol has a primary
M-12 25 OH #, made by propoxylation of allyl alcohol to mol. wt. hydroxyl end group content within the range of about 15 to
800, followed by capping with EO to a final mol. wt. of 40 about 50%.
2200; >90% primary OH groups.
Polyols 7. The foam of claim 1 wherein the monol has a primary
hydroxyl end group content greater than about 50%.
P-1 68 OH #, made by propoxylating glycerine. 8. The foam of claim 7 wherein the monol has a primary
P-2 Commercial polyol blend used to make viscoelastic foam. It hydroxyl end group content greater than about 90%.
has OH # 145 and a functionality of 3. 45 9. The foam of claim 1 wherein the polyol is a copolymer
P-4 12 OH #, made by propoxylating glycerine. of ethylene oxide and propylene oxide having an oxyethyl
P-5 37 OH # triol made by DMC-catalyzed alkoxylation of a
240 OH # starter triol (propoxylated glycerine) with 8/92 ene content within the range of about 5 to about 50 wt.%.
EO/PO to 1025 mol. wt., followed by tipping with 60/40 10. The foam of claim 1 wherein the chain extender or
EO/PO to mol. wt. 1230. Total EO content: 15%. Primary
OH content: 29%.
crosslinker has a number average molecular weight less than
P-11 240 OH #, made by propoxylating glycerine. 50 about 200 and is used in an amount within the range of about
Other components 0.1 to about 5 wt.% based on the amount of isocyanate
reactive mixture.
DEOA
DEG
diethanolamine
diethylene glycol
11. The foam of claim 1 further comprising from about 0.1
PG propylene glycol to about 30 wt.% of a plasticizer.
DPG dipropylene glycol 55 12. The foam of claim 7 having a non-oily “hand feel.”
MPD 2-methyl-1,3-propanediol 13. The foam of claim 7 having a compression load
C-183
33-LV
Niax C-183 amine catalyst blend
Dabco 33-LV amine catalyst
deflection (40% CLD) value, measured at the first compres
A-1 Niax A-1 amine catalyst sion cycle, within the range of about 0.7 to about 1.5 kPa.
T9 StannOuS Octoate 14. A Viscoelastic polyurethane foam which comprises the
T-12 dibutyltin dilaurate 60 reaction product of water, a Surfactant, one or more catalysts,
L-620 Niax silicone surfactant, product of CK. Witco toluene diisocyanate, and a polyether mixture comprising:
B8002 silicone surfactant, product of Goldschmidt (a) a polyoxyalkylene monol having a number average
FR flame retardant
TDI toluene diisocyanate (standard 80/20 or 6.5/35 blend) equivalent weight greater than about 1000 and an OH
number less than about 56;
65 (b) a polyoxyalkylene polyol having a number average
The preceding examples are meant only as illustrations. equivalent weight less than about 600 and an OH
The following claims define the invention. number greater than about 94,
US 6,391,935 B1
17 18
(c) optionally, a chain extender or crosslinker; 24. The foam of claim 20 having a non-oily “hand feel.”
wherein the monol comprises from about 20 to about 60 wt. 25. The foam of claim 20 having a compression load
% of the isocyanate-reactive mixture; deflection (40% CLD) value, measured at the first compres
wherein the foam is produced at an isocyanate index of at sion cycle, within the range of about 0.7 to about 1.5 kPa.
least 95; and 26. The foam of claim 14 having a residual toluenedi
wherein the foam has a resilience less than about 15%. amine content following curing of less than 5 ppm.
15. The foam of claim 14 having a 90% compression set 27. The foam of claim 20 having a residual toluenedi
less than about 15%. amine content following curing of less than 5 ppm.
16. The foam of claim 14 wherein the polyoxypropylene 28. The foam of claim 14 further comprising from about
monol has a number average equivalent weight greater than 0.1 to about 30 wt.% of a plasticizer.
about 2000.
17. The foam of claim 14 wherein the monol comprises at 29. In a process for making a Viscoelastic polyurethane
least about 25 wt.% of the polyether mixture. foam by reacting water, a Surfactant, one or more catalysts,
18. The foam of claim 14 having a resilience less than a polyisocyanate, and an isocyanate-reactive mixture, the
about 5%. 15 improvement which comprises using as the isocyanate
19. The foam of claim 14 wherein the monol has a reactive mixture:
primary hydroxyl end group content within the range of (a) a polyester or polyoxyalkylene monol having a num
about 15 to about 50%. ber average equivalent weight greater than about 1000
20. The foam of claim 14 wherein the monol has a and an OH number less than about 56;
primary hydroxyl end group content greater than about 50%. (b) a polyester or polyoxyalkylene polyol having a num
21. The foam of claim 20 wherein the monol has a ber average equivalent weight leSS than about 600 and
primary hydroxyl end group content greater than about 90%. an OH number greater than about 94; and
22. The foam of claim 14 wherein the polyol is a copoly (c) optionally, a chain extender or crosslinker;
mer of ethylene oxide and propylene oxide having an wherein the monol comprises from about 15 to about 70 wt.
oxyethylene content within the range of about 5 to about 50 25
% of the isocyanate-reactive mixture;
wt.%.
23. The foam of claim 14 wherein the chain extender or wherein the foam is produced at an isocyanate index of at
crosslinker has a number average molecular weight less than least 90, and
about 200 and is used in an amount within the range of about wherein the foam has a resilience less than about 15%.
0.1 to about 5 wt.% based on the amount of isocyanate
reactive mixture.