Basf Corporation

Basf Se Corporation

Theodore Michael Smiecinski

Steven E Wujcik

Donald Charles Mente

Wassana Apichatachutapan

Raymond A Neff

Oscar M Grace

Cheng-Le Zhao

Rajesh Kumar

Todd J Green

James A Mullins

Yeonsuk K Roh

David Kaczan

Heinz-Dieter Lutter

Duane A Heyman

Thomas B Lee

Berend Eling

Steven D Gagnon

Daniel Freidank

Stephan Goettke

Yogesh C Trivedi

Jens Mueller

Suzanne Dakin

Thomas R Benevenuti

Stephan Göttke

Chad Alan Rogers

Steven Edward Wujcik

Thomas Bernard Lee

Jens Müller

The subject disclosure provides a viscoelastic polyurethane foam and a method of forming the viscoelastic polyurethane foam. The viscoelastic polyurethane foam comprises the reaction product of a toluene diisocyanate and an isocyanate reactive component. The isocyanate reactive component comprises a first polyether triol, a second polyether triol, an amino alcohol chain extender, and a hydrolyzable polyether polydimethylsiloxane copolymer. The first polyether triol has a weight-average molecular weight of from 500 to 5,000 g/mol, at least 60 parts by weight ethyleneoxy units, based on the total weight of the first polyether triol, and at least 10% ethyleneoxy end caps. The second polyether triol, which is different from the first polyether triol, has a weight-average molecular weight of from 5,000 to 10,000 g/mol and at least 80% ethyleneoxy end caps.

Viscoelastic polyurethane foam

The invention relates to a process for producing viscoelastic flexible polyurethane foams by reacting

Process for producing viscoelastic flexible polyurethane foams

A single layer flexible foam includes the reaction product of an (A) isocyanate component and a (B) isocyanate-reactive component. The isocyanate component and the isocyanate-reactive component react in the presence of a (C) polyurethane gel. The polyurethane gel has a viscosity of from about 3,000 to about 12,000 cps at 25&#xb0; C. and includes the reaction product of a polyol component and a second isocyanate component which react at an isocyanate index of from about 10 to about 70. The flexible foam also includes a plurality of agglomerated gel substrates that are formed from the polyurethane gel and that are dispersed in the flexible foam. The flexible foam is formed using a method including the steps of providing (A), providing (B), providing (C), and combining (C) with (A) and (B), such that (A) and (B) react in the presence of (C) to form the flexible foam.

Single layer flexible foam including polyurethane gel

A flexible polyurethane foam comprises the reaction product of an isocyanate component and an isocyanate-reactive component in the presence of a blowing agent. The isocyanate component comprises a polymeric diphenylmethane diisocyanate component and a monomeric diphenylmethane diisocyanate component. The monomeric diphenylmethane diisocyanate component comprises 2,4'-diphenylmethane diisocyanate and 4,4&#x2032;-diphenylmethane diisocyanate. The flexible polyurethane foam is substantially free of supplemental flame retardant additives and exhibits flame retardance under flammability tests according to California Technical Bulletin 117 regulations.

Flexible polyurethane foam and method of producing same

A resin composition includes a compound having at least two reactive hydrogen atoms and a polyurethane encapsulated particle including a core particle and a polyurethane layer disposed about the core particle. The resin composition may be used in an article and in a method of making the article. The article includes the reaction product of the resin composition and an isocyanate that are reacted in the presence of the polyurethane encapsulated particle. The method of making the article includes providing the core particle in a vessel. The method also includes introducing and combining a polyol component and an isocyanate component to encapsulate the core particle. The method further includes introducing and combining the resin composition and the isocyanate, in the presence of the polyurethane encapsulated particle, to form the article.

Article formed from a resin composition having a polyurethane encapsulated particle

A flexible polyurethane foam comprises the reaction product of an isocyanate component and an isocyanate-reactive component in the presence of a blowing agent. The isocyanate component comprises a polymeric diphenylmethane diisocyanate component and a monomeric diphenylmethane diisocyanate component. The monomeric diphenylmethane diisocyanate component comprises 2,4'-diphenylmethane diisocyanate and 4,4&#x2032;-diphenylmethane diisocyanate. The isocyanate-reactive component comprises a polyether polyol having a molecular weight of from about 700 to about 20,000 and a plurality of terminal caps which are substantially free of ethylene oxide groups. The flexible polyurethane foam is substantially free of supplemental flame retardant additives and exhibits flame retardance under flammability tests according to California Technical Bulletin 117 regulations.

A polyol includes the reaction product of an epoxidized oil and an organic acid. The epoxidized oil and the organic acid are reacted in the presence of a Lewis base catalyst including at least one of a phosphorous atom or a nitrogen atom. The polyol is formed by a method that includes the step of reacting the epoxidized oil with the organic acid in the presence of the Lewis base catalyst.

Polyol formed from an epoxidized oil

Polyol formed from an EPOXIDIZED oil

An apparatus includes a container that defines an interior. The interior is isolated from ambient atmosphere for receiving a composition that includes isocyanate. A conduit extends into the container and defines a channel therethrough. An interior of the container is in fluid communication with the ambient atmosphere through the channel for conveying a gaseous waste stream that includes vaporized unreacted isocyanate out of the container and into the ambient atmosphere. A medium is disposed in the channel and has free isocyanate-reactive groups for reacting with unreacted isocyanate. The free isocyanate-reactive groups remove the unreacted isocyanate from the gaseous waste stream. The medium, by including the free isocyanate-reactive groups, relies on a chemical reaction to remove the unreacted isocyanate.

Apparatus for removing vaporized unreacted isocyanate from a gaseous waste stream

The subject invention provides a viscoelastic polyurethane foam being flame retardant and having a density of greater than two and a half pounds per cubic foot that comprises a reaction product of an isocyanate component, an isocyanate-reactive blend, and a chain extender. The isocyanate-reactive blend includes a first isocyanate-reactive component and a second isocyanate-reactive component. The first isocyanate-reactive component includes at least 60 parts by weight of ethylene oxide (EO) based on 100 parts by weight of the first isocyanate-reactive component and the second isocyanate-reactive component includes at most 30 parts by weight of EO based on 100 parts by weight of the second isocyanate-reactive component. The chain extender is reactive with the isocyanate component and has a backbone chain with from two to eight carbon atoms and is present in an amount of from 5 to 50 parts by weight based on 100 parts by weight of the foam. A composition useful in making the viscoelastic polyurethane foam is also disclosed.

The subject invention provides a method of forming high resilience slabstock polyurethane foam having random cell structures to produce latex-like feel and characteristics. The method includes the first step of providing an isocyanate-reactive component and an isocyanate component to react with the isocyanate-reactive component. A first nucleation gas is provided under low pressure and is added into at least one of the isocyanate-reactive component and the isocyanate component to produce a first cell structure in the polyurethane foam. A second nucleation gas is provided under low pressure, being different than the first nucleation gas, and is added into at least one of the isocyanate-reactive component and the isocyanate component to produce a second cell structure in the polyurethane foam that is different than the first cell structure.

Method of forming high resilience slabstock polyurethane foam

The subject invention provides a method of forming high resilience slabstock polyurethane foam having random cell structures and displaying latex-like feel and characteristics with superior physical performance to latex foam, including complying with California Technical Bulletin 117 and British Standard 5852:Crib 5 flame tests. The method includes the first step of providing an isocyanate-reactive component and an isocyanate component substantially free of toluene diisocyanate comprising diphenylmethane-2,4&prime;-diisocyanate present in an amount of from 15 parts by weight to 55 parts by weight based on 100 parts by weight of the isocyanate component and diphenylmethane-4,4&prime;-diisocyanate present in an amount from 45 parts by weight to 85 parts by weight based on 100 parts by weight of the isocyanate component to react with the isocyanate-reactive component. A first nucleation gas is provided under low pressure and is added into at least one of the isocyanate-reactive component and the isocyanate component to produce a first cell structure in the polyurethane foam. A second nucleation gas different than the first nucleation gas is provided under low pressure and is added into at least one of the isocyanate-reactive component and the isocyanate component to produce a second cell structure in the polyurethane foam different than the first cell structure.

Method of forming high resilience slabstock polyurethane foam displaying latex-like characteristics

The invention pertains to flame retardant flexible polyurethane foams prepared by reacting a polyether polyol and an organic isocyanate in the presence of a blowing agent and incorporating melamine and an effective amount of another flame retardant. The organic isocyanate comprises carbodiimide-uretonimine-modified diphenylmehtane diisocyanate and toluene diisocyanate. The polyurethane foams exceed conventional flame retardancy standards and exhibit flame spread index values of less than 25 as measured under flame test procedure ASTM D3675-90.

Flame retardant polyurethane foams

A flexible open-cell polyurethane is described that is the reaction product of a mixture comprising

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Woodhaven, MI, United States of America

Theodore Michael Smiecinski