Basf Corporation

Wassana Apichatachutapan

Theodore Michael Smiecinski

Todd J Green

James A Mullins

Donald Charles Mente

Thomas B Lee

Raymond A Neff

Steven E Wujcik

Suzanne Dakin

Thomas R Benevenuti

Thomas Bernard Lee

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

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.

Viscoelastic polyurethane foam

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

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Woodhaven, MI, United States of America

Wassana Apichatachutapan