Dow Global Technolgoies LLC

Dow Italia Divisione Commerciale S.r.l.

Alessio Sabadini

Francois M Casati

Jean-Paul Masy

Luigi L Bertucelli

Gianluca Casagrande

Silvia Scussolin

Andrea Benvenuti

Alessia Battistini

Elisa Corinti

Brian Dickie

Luciano Zanacchi

Luigi Bertucelli

The present disclosure provides for a polyurethane elastomer foam formed by reacting a mixture that includes 60 to 50 weight percent (wt. %) of a polyol formulation and 40 to 50 wt. % isocyanate pre-polymer (wt. % based on the total weight of the mixture). The polyol formulation includes 85 to 92 wt. % of a polytetramethylene ether glycol (PTMEG) with a weight average molecular weight of 1900 to 2100 and a hydroxyl number of about 53 to about 60; 4 to 10 wt. % of monoethylene glycol; a blowing agent; a catalyst; and a surfactant (wt. % values for the polyol formulation based on the total weight of the polyol formulation). The isocyanate pre-polymer includes 55 to 70 wt. % of a isocyanate blend having at least 90 wt. % of 4,4'-diphenylmethane diisocyanate; and 30 to 45 wt. % of the PTMEG, where the isocyanate pre-polymer has an isocyanate content of 16 to 21 wt. % based on the total weight of the isocyanate pre-polymer, and the polyurethane elastomer foam has a ball rebound of at least 50% measured according to ASTM D3574 on a 10 mm thickness test plate.

Low density polyurethane elastomer foam with high ball rebound

Embodiments of the invention provide for viscoelastic polyurethane foams. The foams are made from reaction system which includes (a) an isocyanate reactive component, (b) a isocyanate component, (c) one or more blowing agents, (d) a catalyst component, and (e) a silicone based surfactant. The isocyanate reactive component includes at least (i) from 25 to 80% by weight of at least one polyoxyethylene capped polyoxypropylene/polyoxyethylene polyol having a combined number average equivalent weight from 1300 to 1700, a polyoxyethylene percentage of between 75% and 95% by weight of the combined amounts of polyoxypropylene and polyoxyethylene, and a primary OH percentage of between 80 and 95% of the total number of OH groups of the polyoxyethylene capped polyoxypropylene/polyoxyethylene polyol, and (ii) from 5 to 30% by weight of the isocyanate reactive component of at least one low functionality polyol having a functionality of between 1.5 and 2.5, a combined number average equivalent weight from 500 to 1500 and an OH number of 40 to 70.

Viscoelastic foam

Polyurethane foams are made using a biuret-modified MDI and/or PMDI as the isocyanate component. The isocyanate is characterized by having a high content of biuret-containing oligomers and, preferably, a low proportion (if any) of biuret-urea oligomers. Flexible, resilient foams made using this biuret-modified isocyanate perform well on flammability tests such as the UNI 9175 CS. E. RF4 test, even without added flame retardants.

Flame retardant polyurethane foams containing biuret linkages

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Reggio Emilia, Italy

Alessio Sabadini