CA2343316A1 - Low resilience, low frequency molded polyurethane foam - Google Patents

Low resilience, low frequency molded polyurethane foam Download PDF

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Publication number
CA2343316A1
CA2343316A1 CA002343316A CA2343316A CA2343316A1 CA 2343316 A1 CA2343316 A1 CA 2343316A1 CA 002343316 A CA002343316 A CA 002343316A CA 2343316 A CA2343316 A CA 2343316A CA 2343316 A1 CA2343316 A1 CA 2343316A1
Authority
CA
Canada
Prior art keywords
stream
polyurethane foam
isocyanate
prepolymer
streams
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA002343316A
Other languages
French (fr)
Other versions
CA2343316C (en
Inventor
Mark R. Kinkelaar
Andrew M. Thompson
Daniel P. Krisher
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Bayer Antwerpen NV
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of CA2343316A1 publication Critical patent/CA2343316A1/en
Application granted granted Critical
Publication of CA2343316C publication Critical patent/CA2343316C/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00Polymeric products of isocyanates or isothiocyanates
    • C08G18/06Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00Polymeric products of isocyanates or isothiocyanates
    • C08G18/06Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/28Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
    • C08G18/40High-molecular-weight compounds
    • C08G18/48Polyethers
    • C08G18/4866Polyethers having a low unsaturation value
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00Polymeric products of isocyanates or isothiocyanates
    • C08G18/06Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/08Processes
    • C08G18/10Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00Polymeric products of isocyanates or isothiocyanates
    • C08G18/06Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/28Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
    • C08G18/40High-molecular-weight compounds
    • C08G18/4009Two or more macromolecular compounds not provided for in one single group of groups C08G18/42 - C08G18/64
    • C08G18/4072Mixtures of compounds of group C08G18/63 with other macromolecular compounds
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29BPREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00Mixing; Kneading
    • B29B7/30Mixing; Kneading continuous, with mechanical mixing or kneading devices
    • B29B7/58Component parts, details or accessories; Auxiliary operations
    • B29B7/72Measuring, controlling or regulating
    • B29B7/728Measuring data of the driving system, e.g. torque, speed, power, vibration
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2110/00Foam properties
    • C08G2110/0008Foam properties flexible
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2110/00Foam properties
    • C08G2110/0041Foam properties having specified density
    • C08G2110/005< 50kg/m3
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2110/00Foam properties
    • C08G2110/0083Foam properties prepared using water as the sole blowing agent

Abstract

Molded polyurethane seating foams exhibiting low resonant frequencies and lo w ball rebound are produced by reacting an isocyanate-terminated prepolymer prepared from a polyol component comprising in major part one or more low intrinsic unsaturation substantially polyoxypropylene polyols and/or polymer polyols with a blowing/chain extending stream comprising water and optionall y amines and alkanolamines.

Claims (18)

1. A molded polyurethane foam having a resonant frequency of 7 Hz or lower and a ball rebound of less than 70%, preferably less than 65%, especially less than 60%, such as 50 to 60%, preparable by reacting, in a closed mold, a polyurethane or polyurethane/urea forming composition comprising:
a) an isocyanate-terminated prepolymer prepared by the reaction of a stoichiometric excess of one or more di- or polyisocyanates with a polyol component having an average intrinsic unsaturation of less than 0.025 meq/g and comprising in major part one or more di- or higher functionality low intrinsic unsaturation polyoxyalkylene polyols having an unsaturation less than 0.025 meq/g and an equivalent weight greater than 1000 Da;
with b) an activator stream comprising water and optionally a low molecular weight amine or alkanolamine;
optionally in the presence of c) one or more catalysts which promote the reaction between a) and b).
2. The molded polyurethane foam of claim 1 wherein said polyol component comprises in excess of 80% by weight of one or more low intrinsic unsaturation polyoxypropylene polyols having an unsaturation of 0.015 meq/g or less, preferably of 0.010 meq/g or less.
3. The molded polyurethane foam of claim 1 or 2 wherein said activator stream comprises water and diethanolamine.
4. The molded polyurethane foam of any preceding claim wherein said polyol component further comprises in minor portion, one or more chain extenders or isocyanate-reactive polyoxyalkylene oligomers having a molecular weight less than 1000 Da.
5. The molded polyurethane foam of any preceding claim wherein said polyol component further comprises a polymer polyol.
6. The molded polyurethane foam of claim 5 wherein said polymer polyol comprises a low intrinsic unsaturation polymer polyol.
7. The molded polyurethane foam of any preceding claim wherein at least one of said one or more low intrinsic unsaturation, polyoxyalkylene polyols comprises a polyoxypropylene polyol which also contains from 1.5 weight percent to 30 weight percent oxyethylene moieties.
8. The molded polyurethane foam of any preceding claim wherein said polyol component comprises one or more low intrinsic unsaturation polymer polyols having an intrinsic unsaturation of less than 0.010 meq/g such that said polyol component has an average unsaturation not greater than 0.015 meq/g.
9. The molded polyurethane foam of any preceding claim wherein said activator stream comprises water, an alkanolamine, and optionally a minor amount in mol percent of a diprimary aliphatic glycol or polyol.
10. A vehicular seat having a seating cushion comprising in major portion a foam according to any preceding claim.
11. The vehicular seat of claim 10 wherein said seat is a deep foam seat devoid of spring suspension.
12. A process for the preparation of a molded polyurethane foam according to any preceding claim, said process comprising reacting in a closed mold, a polyurethane/urea forming composition comprising:

23~

a) an isocyanate-terminated low intrinsic unsaturation prepolymer prepared by the reaction of a stoichiometric excess of one or more di-or polyisocyanates with a polyol component having an average intrinsic unsaturation of less than 0.025 meq/g and comprising in major part one or more di- or higher functionality low intrinsic unsaturation substantially polyoxypropylene polyols having an unsaturation less than 0.025 meq/g and an equivalent weight greater than 1000 Da;
with b) an activator stream comprising water and optionally a low molecular weight amine or alkanol amine;
optionally in the presence of c) an effective amount of one or more catalysts which promote the reaction between a) and b).
13. A process according to claim 12 wherein the reactants or product are defined in any of claims 1 to 9.
14. In a process for the manufacture of molded polyurethane foam by reaction of an isocyanate-terminated prepolymer with a water stream, the improvement comprising:
supplying to a mix head, four reactive streams, said four reactive streams comprising:
a) a first, activator stream comprising a major molar proportion of water;
b) a second, isocyanate stream, comprising one or more organic di- or polyisocyanates;
c) a third, low solids prepolymer stream comprising one or more isocyanate-terminated prepolymers, said prepolymers together having a dispersed phase polymer solids content of from 0 weight percent to 10 weight percent based on the weight of the polyols contained in said prepolymer(s) of said low solids prepolymer stream;
d) a fourth, high solids prepolymer stream comprising one or more isocyanate-terminated prepolymers, said fourth stream containing from
15 weight percent to 60 weight percent of dispersed phase polymer solids based on the weight of the polyols contained in said high solids prepolymer stream;
introducing a portion of said first, activator stream, and at least two of said second, third, and fourth streams into said mix head;
mixing said streams in said mixhead to form a reactive polyurethane foam mixture;
introducing said reactive polyurethane foam mixture into a mold; and recovering from said mold a polyurethane foam.
15. The process of claim 14 wherein all polyols in the prepolymers of said low solids prepolymer stream and the prepolymers of said high solids prepolymer stream having equivalent weights of greater than 1000 Da are low intrinsic unsaturation polyols.
16. The process of claim 14 or 15 wherein foam physiochemical properties are altered by varying the ratio of one or more of streams a) through d) without varying the compositional make-up of any single stream.
17. The process of claim 14, 15 or 16 wherein following reaction of streams a) through d) to form a polyurethane/urea foam and curing said foam, the cured foam exhibits a resonant frequency of less than 7 Hz and a ball rebound of less than 70.
18. A process for the preparation of two or more molded polyurethane foams having different physicochemical properties from a single mixhead, said process comprising:
1) supplying to a mixhead a) one or more activator streams a)i) a first activator stream comprising a major molar proportion of water, and a)ii) an alternative first activator stream different from said first activator stream and comprising a major molar proportion of water, said one or more activator streams supplying to said mixhead at least one polyurethane catalyst;
b) two or more isocyanate-functional streams b)i) a second, isocyanate stream comprising one or more organic di- or polyisocyanates;
b)ii) a third, low solids prepolymer stream comprising one or more isocyanate-terminated prepolymers, said prepolymers together having a dispersed phase polymer solids content of from 0 weight percent to about 10 weight percent based on the weight of the polyols contained in said prepolymer(s) of said low solids prepolymer stream;
b)iii) a fourth, high solids prepolymer stream comprising one or more isocyanate-terminated prepolymers, said fourth stream containing from 15 weight percent to 60 weight.
percent of dispersed phase polymer solids based on the weight of the polyols contained in said high solids prepolymer stream;
at least one of said two or more isocyanate-reactive streams being selected from b)ii) or b)iii);
2) mixing in said mixhead a portion of an activator stream derived from a)i), a)ii) or both a)i) and a)ii) and one or more isocyanate reactive stream(s) b)i), b)ii), or b)iii, wherein at least one of said one or more isocyanate reactive stream(s) is a prepolymer-containing stream b)ii) or b)iii, to form a reactive polyurethane foam mixture;
3) introducing said reactive polyurethane foam mixture into a mold; and 4) recovering from said mold a first molded polyurethane foam having a first set of physicochemical properties; and 5) altering the relative proportions of streams a)i), a)ii), b)i), b)ii), and b)iii) mixed in said mixhead in step 2) without altering the supply of streams a)i) through b)iii) supplied in step 1) and repeating steps 2 through 4 to recover a second molded polyurethane foam having physicochemical properties different from said first molded polyurethane foam.
CA2343316A 1998-09-17 1999-08-20 Low resilience, low frequency molded polyurethane foam Expired - Lifetime CA2343316C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US09/154,650 US6051622A (en) 1998-09-17 1998-09-17 Low resilience, low frequency molded polyurethane foam
US09/154,650 1998-09-17
PCT/EP1999/006115 WO2000017836A2 (en) 1998-09-17 1999-08-20 Low resilience, low frequency molded polyurethane foam

Publications (2)

Publication Number Publication Date
CA2343316A1 true CA2343316A1 (en) 2000-03-30
CA2343316C CA2343316C (en) 2011-04-26

Family

ID=22552185

Family Applications (1)

Application Number Title Priority Date Filing Date
CA2343316A Expired - Lifetime CA2343316C (en) 1998-09-17 1999-08-20 Low resilience, low frequency molded polyurethane foam

Country Status (11)

Country Link
US (1) US6051622A (en)
EP (1) EP1145209B1 (en)
JP (1) JP4624560B2 (en)
KR (1) KR100541314B1 (en)
AT (1) ATE308092T1 (en)
AU (1) AU5518199A (en)
BR (1) BR9913859B1 (en)
CA (1) CA2343316C (en)
DE (1) DE69928016T2 (en)
ES (1) ES2249911T3 (en)
WO (1) WO2000017836A2 (en)

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JP4715002B2 (en) * 2001-02-27 2011-07-06 旭硝子株式会社 Method for producing flexible polyurethane foam
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Also Published As

Publication number Publication date
ATE308092T1 (en) 2005-11-15
JP4624560B2 (en) 2011-02-02
US6051622A (en) 2000-04-18
DE69928016D1 (en) 2005-12-01
WO2000017836A3 (en) 2001-11-08
ES2249911T3 (en) 2006-04-01
EP1145209A3 (en) 2002-03-06
CA2343316C (en) 2011-04-26
EP1145209A2 (en) 2001-10-17
DE69928016T2 (en) 2006-07-13
BR9913859A (en) 2001-06-12
EP1145209B1 (en) 2005-10-26
BR9913859B1 (en) 2009-01-13
AU5518199A (en) 2000-04-10
KR100541314B1 (en) 2006-01-16
KR20010079858A (en) 2001-08-22
WO2000017836A2 (en) 2000-03-30
JP2002525396A (en) 2002-08-13

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Effective date: 20190820