Basf Corporation

Todd J Green

John R Tucker

Theodore Michael Smiecinski

Wassana Apichatachutapan

James A Mullins

Thomas R Benevenuti

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

There is now provided a rigid closed cell polyisocyanate based foam for use as a positive flotation material for watercraft which meets the U.S. Coast Guard immersion test (CGD 75-168, 33 C.F.R. .sctn.183.114). As a blowing agent for this foam, a mixture of 1,1,1,2-tetrafluoroethane (R-134a) as a frothing agent and water is used, where the amount of water is less than 2.5 weight percent based on the weight of the formulated polyol composition. Also, in preferable embodiments, the polyols in the polyol composition are initiated by at least one amine; and the polyol composition contains a delayed action tertiary amine catalyst. The foams used in the invention have excellent dimensional stability. In another embodiment, there is also provided a formulated polyol composition of R-134a and a polyol composition having an average OH# of less than 400 and an average functionality of greater than 4 using R-134a and less than 2.5 wt. % of water, where the isocyanate and the formulated polyol composition are reacted in a weight ratio of 0.9:1 to 13:1, to provide a dimensionally stable foam for use as a flotation foam in watercraft.

Rigid closed cell polyisocyanate based foams for use as positive

There is now provided a closed cell rigid polyisocyanate based foam blowing with a C.sub.1 -C.sub.4 hydrofluorocarbon and water as blowing agents, which possesses a uniform density gradient varying by not more than 10 percent. There is also now provided a froth foaming mixture having good flow by employing a hydroxy terminated polyol which is pH neutral and a tertiary amine ether blow catalyst in an amount of 0.5 weight percent or more, using water and a C.sub.1 -C.sub.4 hydrofluorocarbon having a boiling point of 300 K. or less as co-blowing agents. There is also provided a polyol composition having an average OH number of less than 400 and an average functionality of greater than 4, which when reacted with the isocyanate in the presence of a C.sub.1 -C.sub.4 hydrofluorocarbon, yields a rigid closed cell polyisocyanate based dimensionally stable foam. The formulation according to an especially preferred embodiment of the invention simultaneously satisfies the following requirements:

Dimensionally stable closed cell rigid polyisocyanate based foam

There is now provided a rigid closed cell polyisocyanate based foam for use as a positive flotation material for watercraft which meets the U.S. Coast Guard immersion test (CGD 75-168, 33 C.F.R. .sctn.183.114). As a blowing agent for this foam, a mixture of 1,1,1,2-tetrafluoroethane (R-134a) as a frothing agent and water is used, where the amount of water is less than 2.5 weight percent based on the weight of the formulated polyol composition. Also, in preferable embodiments, the polyols in the polyol composition are initiated by at least one amine; and the polyol composition contains a delayed action tertiary amine catalyst. The foams used in the invention have excellent dimensional stability. In another embodiment, there is also provided a formulated polyol composition of R-134a and a polyol composition having an average OH# of less than 400 and an average functionality of greater than 4 using R-134a and less than 2.5 wt. % of water, where the isocyanate and the formulated polyol composition are reacted in a weight ratio of 0.9:1 to 1.3:1, to provide a dimensionally stable foam for use as a flotation foam in watercraft.

There is now provided a closed cell rigid polyisocyanate based foam blowing with a C.sub.1 -C.sub.4 hydrofluorocarbon and water as blowing agents, which possesses a uniform density gradient varying by not more than 10 percent. There is also now provided a froth foaming mixture having good flow by employing a hydroxy terminated polyol which is pH neutral and a tertiary amine ether blow catalyst in an amount of 0.5 weight percent or more, using water and a C.sub.1 -C.sub.4 hydrofluorocarbon having a boiling point of 300 K or less as co-blowing agents. There is also provided a polyol composition having an average OH number of less than 400 and an average functionality of greater than 4, which when reacted with the isocyanate in the presence of a C.sub.1 -C.sub.4 hydrofluorocarbon, yields a rigid closed cell polyisocyanate based dimensionally stable foam. The formulation according to an especially preferred embodiment of the invention simultaneously satisfies the following requirements: 1) a formulated polyol composition having a viscosity of 550 cP or less; 2) the isocyanate stream and the formulated polyol stream dispensable at a 0.9:1 to 1.3:1 weight ratio, respectively; 3) frothing when dispensed from a static mixer; 4) produces a frothing foaming mixture having excellent flow characteristics as demonstrated by a substantially uniform density gradient; 5) and produces a dimensionally stable closed cell foam having a low overall density of 2.5 pcf or less.

There is now provided a closed cell rigid polyisocyanate based foam blowing with a C.sub.1 -C.sub.4 hydrofluorocarbon and water as blowing agents, which possesses a uniform density gradient varying by not more than 10 percent. There is also now provided a froth foaming mixture having good flow by employing a hydroxy terminated polyol which is pH neutral and a tertiary amine ether blow catalyst in an amount of 0.5 weight percent or more, using water and a C.sub.1 -C.sub.4 hydrofluorocarbon having a boiling point of 300.degree. K. or less as co-blowing agents. There is also provided a polyol composition having an average OH number of less than 400 and an average functionality of greater than 4, which when reacted with the isocyanate in the presence of a C.sub.1 -C.sub.4 hydrofluorocarbon, yields a rigid closed cell polyisocyanate based dimensionally stable foam. The formulation according to an especially preferred embodiment of the invention simultaneously satisfies the following requirements: 1) a formulated polyol composition having a viscosity of 550 cP or less; 2) the isocyanate stream and the formulated polyol stream dispensable at a 0.9:1 to 1.3:1 weight ratio, respectively; 3) frothing when dispensed from a static mixer; 4) produces a frothing foaming mixture having excellent flow characteristics as demonstrated by a substantially uniform density gradient; 5) and produces a dimensionally stable dosed cell foam having a low overall density of 2.5 pcf or less.

There is now provided a closed cell rigid polyisocyanate based foam blowing with a C.sub.1 -C.sub.4 hydrofluorocarbon and water as blowing agents, which possesses a uniform density gradient varying by not more than 10 percent. There is also now provided a froth foaming mixture having good flow by employing a hydroxy terminated polyol which is pH neutral and a tertiary amine ether blow catalyst in an amount of 0.5 weight percent or more, using water and a C.sub.1 -C.sub.4 hydrofluorocarbon having a boiling point of 300 K or less as co-blowing agents. There is also provided a polyol composition having an average OH number of less than 400 and an average functionality of greater than 4, which when reacted with the isocyanate in the presence of a C.sub.1 -C.sub.4 hydrofluorocarbon, yields a rigid closed cell polyisocyanate based dimensionally stable foam. The formulation according to an especially preferred embodiment of the invention simultaneously satisfies the following requirements:

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Canton, MI, United States of America

Todd J Green