Basf Se Corporation

Basf Corporation

Joseph Ogonowski

Richard P Harrison

Jon P Pavlinac

L Patrick Chang

Marcus J Hunter

Todd William Wishneski

Mario Jean-Rejouis

Chulhoon Jang

Achara Bowornprasirtkul

Marcus Hunter

A polyurethane foam article comprises the reaction product of an isocyanate component and isocyanate-reactive composition in the presence of a blowing agent. The isocyanate component includes an isocyanate prepolymer comprising the reaction product of a first polyether polyol and a methylene diphenyl diisocyanate. The isocyanate-reactive composition comprises a second polyether polyol having secondary terminal hydroxyl groups and an amine-initiated catalytic polyether polyol having primary hydroxyl groups. A method of making the polyurethane foam article comprises the steps of reacting the first polyether polyol and methylene diphenyl diisocyanate to form the isocyanate prepolymer and reacting the isocyanate prepolymer with the isocyanate-reactive composition in the presence of the blowing agent to form the polyurethane foam article.

Polyurethane foam article and method of forming same

A method minimizes emissions while spraying a mixture of a resin composition and a polyisocyanate onto a surface. The resin composition has a hydroxyl content of at least 400 mg KOH/g and includes a blowing agent that is a liquid under pressure, a first polyol, at least one additional polyol other than the first polyol, and optionally a catalyst, surfactant, and water. The mixture is sprayed onto the surface to form a polyurethane foam having a closed cell content of at least 90 percent. The mixture is also sprayed through a spray nozzle at a spray angle corresponding to a control spray angle of from 15 to 125 degrees measured at a pressure of from 10 to 40 psi using water as a standard. The step of spraying produces less than 50 parts of the polyisocyanate per one billion parts of air according to OSHA Method 47.

Method for minimizing emissions while forming a polyurethane foam

A polyurethane spraying system minimizes emissions of a polyisocyanate while spraying a mixture of a polyisocyanate and a resin composition onto a surface. The system includes a first reactant supply tank including the resin composition. The system also includes a second reactant supply tank including the polyisocyanate. The system further includes a non-gaseous pump that is coupled with the first and second reactant supply tanks, a mixing apparatus that is coupled with the first and second reactant supply tanks for mixing the resin composition and the polyisocyanate prior to spraying, and a particular spray nozzle that is coupled with the mixing apparatus. The polyurethane spraying system produces less than 50 parts of the polyisocyanate per one billion parts of air according to the NIOSH 5521 Impingement Method while spraying the mixture onto the surface.

Polyurethane spraying system used to minimize emissions of a polyisocyanate

The aromatic polyurethane elastomers of the present invention are particularly suited for methods of making objects in a mold cavity. The objects generally include an elastomeric layer formed from an aromatic polyurethane and a foam layer which is subsequently applied to the elastomer. The aromatic elastomer of the present invention lends itself to being precoated with an in-mold coating or being painted after demolding the resulting part.

Decorative components having an elastomeric outer surface and methods of making such components

The method of the present invention is particularly suited for making decorative objects in a mold cavity. The method enables one to form a decorative component having an outer elastomeric layer that is integral with an inner layer of foam. Because the chemical formulation for the outer layer and the inner layer is identical, other than the inner layer includes a foaming agent, the decorative component does not suffer from the drawbacks of the previous methods such as, for example, poor adhesion between the elastomeric layer and the foam layer causing delamination of the two layers, sinks or holes in the foam layer leading to imperfections in the elastomeric layer, and bleed through to the elastomeric layer from the foam layer. The method permits the mold to be pre-coated with an in-mold paint prior to the molding process. Coatings can also be applied after demolding the resulting part.

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Newport, MI, United States of America

Joseph Ogonowski