Air Products and Chemicals, Inc.

Basf Corporation

Petrella, Robert G.

Scarpati, Michael

Michael Scarpati

Thirumurti L Narayan

Richard P Harrison

Blair J Zagata

Robert G Petrella

Gary Dale Andrew

Mark E Harakal

George J Wasilczyk

Mark Jason Hughes

Zdzislaw Makus

Zdizslaw Makus

Gary D Andrew

The invention relates to water blown integral skin polyurethane foams made with a particular isocyanate quasi-prepolymer and resin side ingredients to yield a foam having good overall mechanical roperties. The isocyanate quasi-prepolymer component of the present invention comprises from 0.5 weight percent to 30.0 weight percent or less uretonimine-carbodiimide-modified diphenylmethane diisocyanate, from 50 weight percent to 80 weight percent 4,4'-diphenylmethane diisocyanate and reacted with from 15 weight percent to 40 weight percent of a polyether polyol containing predominately secondary hydroxy groups and having an average molecular weight from about 2,000 to 10,000, an average functionality from 1.5 to about 3.2, and a hydroxyl number from about 20 to 60. The resin side component comprises a high molecular weight polyether polyol with an average functionality from 1.5 to about 3.2, water as a blow agent, and optionally an mono- or di-functional alcohol composition having from 8 to about 30 carbon atoms. The components, when injected or poured into a preheated mold, can tolerate mold temperatures from 105.degree. F. to 135.degree. F. and can be demolded in less than 150 seconds to yield and integral skin foam having little or no bubbles or pores visible to the eye. The foam produced thereby has a compression set of 30 percent or less, high tensile strength, and high tear strength.

Water-blown polyurethane integral skin foam

The invention relates to water blown integral skin polyurethane foams made with a particular isocyanate quasi-prepolymer and resin side ingredients to yield a foam having good overall mechanical properties. The isocyanate quasi-prepolymer component of the present invention comprises from 0.5 weight percent to 30.0 weight percent or less uretonimine-carbodiimide-modified diphenylmethane diisocyanate, from 50 weight percent to 80 weight percent 4,4'-diphenylmethane diisocyanate and reacted with from 15 weight percent to 40 weight percent of a polyether polyol containing predominately secondary hydroxyl groups and having an average molecular weight from about 2,000 to 10,000, an average functionality from 1.5 to about 3.2, and a hydroxyl number from about 20 to 60, and optionally with a low molecular weight diol in an amount of from 1.0 weight percent to 10 weight percent, the weight percentages based on the weight of the quasi-prepolymer reactants. The resin side component comprises a high molecular weight polyether compound having isocyanate reactive hydrogens and average molecular weights from about 2,000 to about 10,000 and an average functionality from 1.5 to about 3.2, water as a blowing agent in an amount of from 0.25 weight percent to 3 weight percent, an effective amount of polyurethane and/or polyurea promoting catalyst, a surfactant, and a chain extender, and optionally a mono- or di- functional alcohol composition having from 8 to about 30 carbon atoms. The components, when injected or poured into a preheated mold, can tolerate mold temperatures from 105.degree. F. to 135.degree. F. and can be demolded in less than 150 seconds to yield an integral skin foam having little or no bubbles or pores visible to the eye. The foam produced thereby has a compression set of 30 percent or less, high tensile strength, and high tear strength.

The invention relates to water blown integral skin polyurethane foams made with a particular isocyanate quasi-prepolymer and resin side ingredients to yield a foam having good overall mechanical properties. The isocyanate quasi-prepolymer component of the present invention comprises from 0.5 weight percent to 30.0 weight percent or less uretonimine-carbodiimide-modified diphenylmethane diisocyanate, from 50 weight percent to 80 weight percent 4,4'-diphenylmethane diisocyanate and reacted with from 15 weight percent to 40 weight percent of a polyether polyol containing predominately secondary hydroxyl groups and having an average molecular weight from about 2,000 to 10,000, an average functionality from 1.5 to about 3.2, and a hydroxyl number from about 20 to 60, and optionally with a low molecular weight diol in an amount of from 1.0 weight percent to 10 weight percent, the weight percentages based on the weight of the quasi-prepolymer reactants. The resin side component comprises a high molecular weight polyether compound having isocyanate reactive hydrogens and average molecular weights from about 2,000 to about 10,000 and an average functionality from 1.5 to about 3.2, water as a blowing agent in an amount of from 0.25 weight percent to 3 weight percent, an effective amount of polyurethane and/or polyurea promoting catalyst, a surfactant, and a chain extender, and optionally a mono- or di- functional alcohol composition having from 8 to about 30 carbon atoms.

A method for preparing a polyurethane foam article in a mold by applying to a mold surface a water-based mold release composition which includes a release effective system which is in a solid (hardened) state at the mold pour temperature and a liquid state at the demold temperature, pouring a polyurethane foam composition into the mold, curing the foam composition and demolding the foam article. The use of such release effective system in the aqueous mold release composition provides for a reduction in surface defects of the polyurethane foam article. Also disclosed is the incorporation of a poly(siloxane-glycol) surfactant having a cloud point ranging from 25.degree.-50.degree. C. into a water-based mold release composition including an aqueous emulsion or dispersion of at least one release effective substance and desirably at least one emulsifying agent provides for improved surface quality of the foam product.

Water based mold release compositions for making molded polyurethane foam

A molded flexible polyurethane composition having improved polycarbonate compatibility comprising an organic polyisocyanate, a polyol and reactive tertiary amine catalyst. This catalyst contains at least one active hydrogen and/or hydroxyl group in its structure. Another embodiment of this invention relates to a molded flexible polyurethane composition having improved polycarbonate compatibility comprising an organic polyisocyanate, a polyol, a non-reactive tertiary amine catalyst and, an amine scavenger composition which may or may not also contain reactive tertiary amine catalysts. Also disclosed are processes for making said molded flexible polyurethane compositions having improved polycarbonate compatibility.

Polyurethane/polycarbonate compatibility

The incorporation of a poly(siloxane-glycol) surfactant having a cloud point ranging from 25.degree.-50.degree. C. into a water-based mold release composition comprising an aqueous emulsion or dispersion of at least one release effective substance and desirably at least one emulsifying agent provides for improved surface quality of the foam product. Also disclosed is a method for preparing a polyurethane foam article in a mold by applying to a mold surface a water-based mold release composition which comprises a release effective system which is in a solid (hardened) state at the mold pour temperature and a liquid state at the demold temperature, pouring a polyurethane foam composition into the mold, curing the foam composition and demolding the foam article. The use of such release effective system in the aqueous mold release composition provides for a reduction in surface defects of the polyurethane foam article.

Water based mold release compositions containing poly(siloxane-glycol)

In the preparation of a high resiliency polyurethane foam by reacting a polyisocyanate with a polyurea dispersion-containing polyol based masterbatch composition also containing a tertiary amine catalyst for the polyurethane reaction, the improvement for eliminating cure draft of such stored polyol compositions which comprises employing a catalyst composition consisting essentially of

Polyurethane foam catalysts that eliminate polyurea-containing polyol

In a method for making a molded polyurethane article having a nonwoven material secured to the article's surface which comprises placing the nonwoven material on the internal surface of a mold, adding and foaming a polyurethane composition in the mold and recovering the molded polyurethane article with the nonwoven material attached to the surface of the article, the improvement which comprises coating the nonwoven material with a composition consisting essentially of a fully hydrolyzed polyvinyl alcohol, an organic polyisocyanate and a catalyst for the urethane reaction, and curing the coating on the nonwoven material prior to adding and foaming the polyurethane composition in the mold.

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Trenton, MI, United States of America

Michael Scarpati