CA2158654A1 - Preparation of pour-in-place articles employing elastomer coating - Google Patents
Preparation of pour-in-place articles employing elastomer coatingInfo
- Publication number
- CA2158654A1 CA2158654A1 CA002158654A CA2158654A CA2158654A1 CA 2158654 A1 CA2158654 A1 CA 2158654A1 CA 002158654 A CA002158654 A CA 002158654A CA 2158654 A CA2158654 A CA 2158654A CA 2158654 A1 CA2158654 A1 CA 2158654A1
- Authority
- CA
- Canada
- Prior art keywords
- mold
- covering
- coating
- pour
- foamable composition
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
- B29C44/1261—Avoiding impregnation of a preformed part
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
Abstract
A process for preparing a material covered, pour-in-place article is disclosed, comprising the steps of: (a) applying a polymeric coating, which is prepared by reacting a polyisocyanate and an isocyanate reactive material at an isocyanate index in the range of 30 to 1500, to one side of a material covering before or after placing the material covering in a mold; (b) pouring a liquid foamable composition onto the coated side of the material; (c) foaming the liquid foamable composition; and (d) removing the resulting foamed, laminated, material covered article from the mold. Articles prepared with the process are also disclosed.
Description
~W094/~937 21 S 8 6 ~ 4 PCT/GB94/00776 PREPARATION OF POUR-IN-PLACE ARTICLES
EMPLOYING ELASTOMER COATING
.. .
Field of the Invention This invention relates to the preparation of pour-in-place articles. More particularly, this invention relates to the employment of coatings in the preparation of pour-in-place, material covered articles.
Backqround of the Invention Pour-in-place articles are generally prepared by placing a material covering, such as a piece of vinyl or fabric, into a mold and then pouring a liquid foam forming reaction mixture, such as a polyurethane composition, into the mold. A vacuum is often used to insure that the material covering snugly fits the contour of the mold. For example, U.S. Patent No.
4,806,088 discloses an apparatus for preparing textile covered cushions in which a fabric cover is adapted to the contour of a mold cavity by the application of a vacuum and then a foam forming reaction mixture is introduced into the mold. U.S. Patent Nos. 4,046,611 and 4,637,789 also disclose the preparation of cushions by vacuum molding.
After the foam forming reaction mixture is poured into the mold and the foam cures, the foam and the material covering are firmly adhered to one another thereby producing a material covered molded article.
However, one problem encountered with this procedure is that the liquid foamable composition has a tendency to seep through the interstices of the material covering to the outer surface of the material causing disruptio~ and discoloration of the material's exterior surface. This phenomenon is known as W094l~937 PCT/GB94100776 21S~F~S4 ~
"strike-through." The problem of strike-through is made much worse by the application of a vacuum.
To prevent strike-through, a variety of methods have been employed. For example, in U.S. Patent No.
3,932,252, a strippable coating is sprayed onto one side of a fabric, the fabric is placed in a mold cavity so that the coating will be between the fabric and the mold, a vacuum is applied to the fabric, a foamable compound is placed into the mold, the compound is foamed, and then the strippable coating is removed from the molded article.
The most common method, however, of preventing strike-through is to adhere a film or sheet to the back side of the covering. For example, U.S. Patent No. 4,610,923 discloses a process for preparing laminated fabric structures in which a flexible elastomeric skin containing microspheres is adhered to a stretchable fabric, the laminate is placed into a vacuum mold, and a liquid foamable composition is added to the mold and foamed.
While solving the problem of strike-through, the use of such films and sheets generates other problems.
one problem is that the film must be adhered to the material covering in order for there to be sufficient adhesion between the covering, the film and the foam substrate of the upholstered article. The film or sheet is usually adhered to the covering by using an adhesive or by flame bonding. Attaining the appropriate adhesion adds a step to the preparation of material covered articles thereby increasing the cost and time of production. Another problem is that many of the thermoplastic films employed and/or the methods used to adhere the film to the covering give the _W094/~937 PCT/GB94/00776 ~ 21S8~S,~
covering a boardy and uncomfortable feel, i.e. a "poor hand".
Another way to avoid strike-through is to first prepare a foam body and then adhere the material covering to the foam body. For example, U.S. Patent No. 4,975,135 discloses a process for preparing a vehicle seat in which a composite insert is prepared by laminating a porous fabric to a polymeric foam sheet, placing the composite into a vacuum mold, and adhering a foam bun to the composite insert. This method, however, is not as convenient as preparing the foamed body in the mold by the pour-in-place method and adds an additional step to the preparation of material covered articles, namely the step of adhering the material to an already formed foam body.
In U.S. Patent No. 4,740,417, a process is disclosed for preparing an article wherein a flexible polyurethane foam is laminated to the backside of a fabric, the laminated fabric is placed in a vacuum mold, and a thermoplastic substrate is heated until it sags and flows into the mold.
Accordingly, there is a need for a process for preparing an article covered by a material which avoids the step of adhering an already formed film or sheet to a material covering and the step of adhering a material covering to an already formed foam body.
There is a further need for an efficient and economical process for preparing material covered foamed articles. There is also a need for a process for producing pour-in-place molded articles which eliminates strike-through while providing a material cover with a good hand.
W094/~937 ~ S 4 PCTIGB94/0077~
It is therefore an object of this invention to provide an efficient and economical method of preparing material covered articles.
It is another object to provide a means of preparing vacuum molded articles that have a material covering which is not stiff or boardy.
It is yet another object to provide a process for preparing material covered molded articles that eliminates strike-through.
It is a further object to provide material covered articles that have excellent properties.
These and other objects are obtained by the process of this invention.
summarY of Invention The invention is a process for preparing material covered, pour-in-place articles comprising the steps of:
(a) applying a polymeric coating, which is prepared by reacting a polyisocyanate and an isocyanate reactive material at an isocyanate index in the range of 30 to 1500, to one side of a material covering before or after placing the material covering in a mold;
(b) pouring a liquid foamable composition onto the coated side of the material;
(c) foaming the liquid foamable composition; and (d) removing the resulting foamed, laminated, material covered article from the mold.
In a preferred embodiment, a textile fabric is used as the material covering and the process comprises the steps of:
(a) applying a polymeric coating, which is prepared by reacting a polyisocyanate and an ~0 94nu937 ~SO~s~ PCT/GB94/00776 isocyanate reactive material at an isocyanate index in the range of 30 to 100, to one side of a textile fabric covering before or after placing the covering in a vacuum mold;
(b) pouring a liquid foamable composition onto the coated side of the textile fabric covering in the mold;
(c) foaming the liquid foamable composition; and (d) removing the resulting foamed, laminated, fabric article from the mold.
The present invention further comprises a process for preparing an upholstered, vacuum molded pour-in-place article, comprising the steps of:
(a) applying a polymeric coating, which is prepared by reacting a polyisocyanate and a polyol at an isocyanate index in the range of 30 to 1500, to one side of a textile fabric covering before or after placing the covering in a mold;
(b) vacuum forming the textile fabric covering in the mold;
(c) pouring a liquid foamable composition onto the coated side of the textile fabric covering in the mold;
(d) foaming the liquid foamable composition; and (e) removing the resulting foamed, laminated, fabric article from the mold.
The material covered, pour-in-place, article ~ produced by the present process is comprised of:
(a) a material covering;
(b) a polymeric coating, prepared by reacting a polyisocyanate and an isocyanate reactive material at an isocyanate index in the range of 30 to 1500, affixed to one side of the material covering; and (c) a foam body adhered to the coating.
W094/~937 ~ ~S~l6S PCT/GB94/0077~
The process can be used to make a wide variety of upholstered articles. It is particularly useful for making upholstered seats for vehicles.
Detailed Descri~tion of the Invention The articles prepared according to the process of this invention are foamed articles having a material covering. The material covering can be any material to which the polyurethane coating firmly adheres.
Suitable materials include vinyl, leather, and textile fabric coverings. The preferred covering is a textile fabric covering. As used herein, the term "textile fabric covering" includes any porous fabric or cloth that can be employed as a covering. The textile fabric covering can be made from synthetic or natural fibers or a blend of synthetic and natural fibers.
The size and shape of the material covering of course depends upon the type of foamed article being prepared. The material covering is usually comprised of a single piece of material which has been cut to fit the contour of a mold. However, the material covering can be prepared from several pieces of material which are attached to each other, e.g. by sewing.
After the material covering is prepared so that it has the desired shape, the material covering is coated on one side with a polymeric coating. The - coating can be applied either before or after the material covering is placed into a mold. If the coating is applied before the material covering is placed into the mold, the covering is placed into the mold so that the uncoated side is against the interior surface of the mold. Preferably, the material covering is vacuum formed after being placed into the ~ 094/~937PCT/GB94/00776 ~1S~65~
mold so that the material snugly fits the contour of the mold. If the material coating is placed into a vacuum mold before being coated, it is preferred to coat one side of the material covering before the 5covering is vacuum formed.
The polymeric coating applied to the material covering is preferably a polyurethane and/or polyurea coating (i.e. a polyurethane coating, a polyurea coating, or a coating having both polyurethane and 10polyurea linkages). More preferably, the coating is a polyurethane coating. The coating can be prepared at an isocyanate index in the range of 30 to 1500.
However, an isocyanate index above 200 will generally only be used when a coating having isocyanurate 15linkages is used or when a moisture-cure system is used to prepare the coating. As used herein, "isocyanate index" is the ratio of isocyanate (-NCO) equivalents to the total number of equivalents of isocyanate-reactive groups expressed as a percentage.
20Preferably after curing, the polyurethane and/or polyurea coating is soft and flexible so that the material covering is not boardy or stiff, and the coating is strong enough so that if it is stretched by a vacuum, it remains intact. In order to achieve 25these properties, the polyurethane and/or polyurea coating is preferably prepared at an isocyanate index in the range of 30 to 100, more preferably in the range of 40 to 80, still more preferably in the range of 45 to 60, and most preferably in the range of 45 to 3055. Although it is possible to use an isocyanate index below 30, the resulting coating will be tacky and will not completely cure. As a result, the coa.ted material covering will be difficult to handle and to process. On the other hand, if the isocyanate index W094/~937 PCT/GB94/0077~_ 2158S~ ~
exceeds about lOO, the covering may be stiff and boardy once the coating cures.
The organic polyisocyanates which may be used in the preparation of the polyurethane coating include any of the aliphatic, cycloaliphatic,. araliphatic or aromatic polyisocyanates known in polyurethane or polyurea chemistry, especially those that are liquid at room temperature. Examples of suitable polyisocyanates include ethylene diisocyanate, 1,6-hexamethylene diisocyanate, isophorone diisocyanate, cyclohexane 1,4-diisocyanate, 4,4'-dicyclohexylmethane diisocyanate, 1,4-xylylene diisocyanate, 1,4-phenylene diisocyanate, 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, 4,4'-diphenylmethane diisocyanate (4,4'-MDI), 2,4'-diphenylmethane diisocyanate (2,4'-MDI), polymethylene polyphenylene polyisocyanates (crude MDI) and 1,5-naphthylene diisocyanate. Mixtures of polyisocyanates can be used and also polyisocyanates which have been modified by the introduction of urethane, allophanate, urea, biuret, carbodiimide, uretonimine or isocyanurate residues.
In general, the aromatic polyisocyanates are preferred. The most preferred aromatic polyisocyanates are 4,4'-diphenylmethane diisocyanate, 2,4'-diphenylmethane diisocyanate, polymeric MDI, MDI
variants, and mixtures thereof. Suitable MDI variants include compounds in which the MDI has been modified by the introduction of urethane, allophanate, urea, biuret, amide, carbodiimide, uretonimine or isocyanurate residues.
Isocyanate-terminated prepolymers may also be employed and are prepared by reacting an excess of polyisocyanate with polyols, including aminated polyols, imine or enamine polymers, or polyamines. A
~W094/~937 ~S~ PCTIGB94/00776 particularly preferred isocyanate terminated prepolymer is the reaction product of a polymeric MDI
and a polyether polyol. Pseudo-prepolymers may also be employed. A pseudo-prepolymer is a mixture of a prepolymer and one or more monomeric di- or poly-isocyanates. Examples of suitable materials include Rubiflex 26A available from ICI Americas.
The isocyanate reactive resins that are useful in the preparation of the polyurethane and/or polyurea coatings include polymeric polyols, amines, imino-functional and enamino-functional compounds having molecular weights in the range of 1500 to 12,000.
Preferably, the isocyanate reactive material is a polyol.
Suitable polyols that may be used to prepare polyurethane coatings include those selected from the group consisting of polythioether, polyester, polyester amide, polycarbonate, polyacetal, polyolefin, polysiloxane and polyether polyols.
Polyether polyols are preferred.
Suitable polyether polyols include products obtained by the polymerization of a cyclic oxide, for example ethylene oxide, propylene oxide or tetrahydrofuran in the presence, where necessary, of polyfunctional initiators. Suitable initiator compounds contain a plurality of active hydrogen atoms and include water, polyols, for example ethylene glycol, propylene glycol, diethylene glycol, resorcinol, bisphenolA, glycerol, trimethylolpropane, 1,2,6-hexanetriol, triethanolamine, pentaerythritol, sorbitol or sucrose, ammonia, primary monoamines, for example aniline or benzylamine, polyamines, for example ethylene diamine, hexamethylene diamine, toluene diamines, diaminodiphenylmethanes and W094/~937 PCTIGB94/0077~
2ol~8 6 5 4 polymethylene polyphenylene polyamines obtained by the condensation of aniline and formaldehyde, and amino alcohols, for example ethanolamine and diethanolamine.
Mixtures of initiators and/or cyclic oxides may be used.
Especially useful polyether polyols include polyoxypropylene, polyoxyethylene, and poly(oxyethylene-oxypropylene) diolsand triols, which are obtained by the simultaneous or sequential addition of ethylene and propylene oxides to appropriate di- or tri-functional initiators as fully described in the prior art. Mixtures of the diols and triols are also useful. -The most preferred polyether polyols are polyoxyethylene capped polyoxypropylene diols and triols.
Polyester polyols which may be used include hydroxyl terminated reaction products of polyhydric alcohols such as ethylene glycol, propylene glycol, diethylene glycol, 1,4-butanediol, bis(hydroxyethyl) terephthalate, glycerol, trimethylolpropane or pentaerythritol or mixtures thereof with polycarboxylic acids, especially dicarboxylic acids or their ester-forming derivatives, for example, succinic, glutaric and adipic acids or their dimethyl esters, sebacic acid, phthalic anhydride, tetrachloroph~halic anhydride or dimethyl terephthalate. Polyesters obtained by the polymerization of lactones, for example caprolactone, in conjunction with a polyol, may also be used.
Polyesteramides may be obtained by the inclusion of aminoalcohols such as ethanolamine in polyesterification mixtures.
Polythioether polyols which may be used include products obtained by condensing thiodiglycol either 094/1937 ~ S8 ~CTIGB94/00776 alone or with other glycols, dicarboxylic acids, formaldehyde, aminoalcohols or aminocarboxylic acids.
Polycarbonate polyols which may be used include products obtained by reacting diols such as 1,3-propanediol, 1,4-butanediol, 1,6-hexanediol, diethylene glycol or tetraethylene glycol with diaryl carbonates, for example diphenyl carbonate or with phosgene.
Polyacetal polyols which may be used include those prepared by reacting glycols such as diethylene glycol, triethylene glycol or hexanediol with formaldehyde. Suitable polyacetals may also be prepared by polymerizing cyclic acetals.
Suitable polyolefin polyols include hydroxy-terminated butadiene homo- and copolymers, and suitable polysiloxane polyols include polydimethylsiloxane diols and triols.
Examples of suitable polyols for use in the present invention include FFS-2805 available from ICI
Americas.
The types of amino functional compounds suitable for the preparation of a polyurea coating are well known to those skilled in the art. Suitable imino-functional and enamino-functional compounds for preparing polyurea coatings are disclosed in U.S.
Patent Nos. 4,749,129, 4,866,103, and 4,910,279, which are incorporated herein by reference. Preferably, the amino-, imino- and enamino-functional compounds are compounds in which all or part of the OH groups on a polyol have been replaced by the respective functional groups.
In preparing the polyurethane and/or polyurea coatings, one or more polyisocyanates are reacted with one or more isocyanate reactive materials at an W094/~937 ~ ~ PCT/GB94/0077 isocyanate index in the ranges given above under substantially anhydrous conditions at a temperature in the range of room temperature to 180C. Chain extenders and cross-linkers, such as amines, glycols, imines and enamines, may be included in the reaction mixture. Generally, the chain extenders and cross-linkers will have molecular weights below about 1500.
In addition, the polyisocyanates and isocyanate reactive materials can optionally be reacted in the presence of catalysts known in the art, such as dibutyltin dilaurate and tertiary amines such as triethylene diamine. Suitable catalysts are disclosed in U.S. Patent No. 4,7g4,129, which was previously incorporated by reference. Optionally, a molecular sieve can be included in the reaction mixture to serve as a water scavenger so that any water that is present will not blow and cause the coating to foam. Suitable catalysts and molecular sieves for use in a specific formulation will be evident to one skilled in the art from the present disclosure.
The polyisocyanate and the isocyanate reactive material (as well as any catalysts, chain extenders, and other ingredients) are usually mixed just prior to applying the coating to one side of the material covering. The isocyanate reactive material and the polyisocyanate can be mixed and applied to the material covering by any suitable means. For example, they can be mixed with a drill mixer and applied by hand, such as with a spatula or knife. However, it is preferred that the isocyanate reactive material and the polyisocyanate be applied by spraying. Most preferably, the isocyanate reactive material and the polyisocyanate are impingement mixed in a spraying apparatus, and the coating is sprayed onto the fabric.
~CV. ~'OI~i: EP~A-,MUENCHEN 2 . 14-_ ~-95 : _16: 14 +32 2 758990~-- +49 8'd 23994465; # 4 ~ny ~on~entional sprayQr for spr~yln~ polyurethane and .pGlyure~ material~ known to thas~ skilled in th~ art may ~e ~ployed.
Pr~ferably, the spraying de~ice has a compart~ent in which the poly~ socyanate can be ~tor~ and a ~o~p~rtmcnt in which the iso~yanate reactiv~ ~ateria}
f~s well ~5 chain ext~ndQrs ~nd othor lngredients) c~n b~ s~ored. Such ~ sprayer should hav~ a moans to pump the p~lyLs~yanats and the isocyanats reac~c lo m~te~ial from the comp~rtments into a sprayhead.
0 ~en~rally, the polyisocyanate and the i~ccyan~te r~actiYe csmpounds ~re imp~nge~snt mixed in the n~ls o~ the spr~yer. A sulta~l~ sp~ayln~ apparat~ i8 a Graco.Hydra C~t sprayor and pump unl~, which i~
t S aYaila~le ~rom Graco, equipped with a Gusm~r GX7 sprayhead, which is ~Yail~ble fro~ G~ r. Pric~ to be~ ixed, the po~yisocyanate ant the isocyanate reactive ~at~rial are maintalned in their re~pective co~partments ~t a tQmperaturc in the range of 18 3C to about SOqC. The polyisocyanate and th~ isocyanate rQactive matexial ~r~ usually ~etered tog~ther at a pressure in ~he rang~ o ~600 to 2000 ps$~ and t~e pressure ~n eac~ co~p~nent is usually th~ sa~e.
C I~ is, o~ co~rse t pOSS lble to rsaCt the ~5 isccy~nate and the i30cyAn~te re~ctiv~ m~te~al b~or~
applyin~ ~hQ coAt~n~ ~ long ~s the r~su~ting prep~lymer c~n be rQ~d$1y ~ppli~d to ~h~ mat~rlal covering ~he coat~ng i5 us~ally appli~d ~t ~ ~hicknoss of abou~ 0.05 milliweter~ up to abcut ~iv~ mlll~eters to one s~de of the material co~-~in~. ~he coating i~
allow~d to cur~ ~c~ s~eral s~nds to se~eral ~nutes lgeneral~y n~t ~ore th~n ab~t two ~nut~s) beforo th~
coated covering is placed into a moLd. The length a~
r Y~ ~0 ~a ~
o~o S~
-W094/~937 ~ 65 PCT/GB94/0077 cure time varies with the type of formulation used to prepare the coating.
Either before or after being coated, the covering is placed into a mold. The shape of the mold will of course depend upon the type of article that is desired. After the covering is placed into the mold, it is preferred to pull a vacuum so that the material covering snugly fits the contour of the mold.
The types of vacuum molds suitable for use are well known to those skilled in the art. Suitable vacuum molds are described in U.S. Patent Nos.
4,046,611, 4,637,789, 4,740,260, 4,860,415 and 4,975,135, all of which are incorporated herein by reference.
After the coated material covering is in the mold, a liquid foamable composition is poured onto the coated side of the covering and foamed. The type of liquid foamable composition is not critical, and virtually any type of composition which can be poured into a mold and foamed and which will adhere to the polyurethane and/or polyurea coating can be employed.
Neither is the type of foam produced from the liquid foamable composition critical. Both flexible and rigid foams may be used, depending upon the end use of the product which is produced. The type of product being prepared will determine the type of liquid foamable composition that is needed as well as the nature of the resulting foam (i.e. flexible or rigid) that is needed. The preferred liquid foamable compositions are polyurethane, polyurea and/or polyisocyanurate liquid foamable compositions.
The preparation of polyurethane, polyurea and/or polyisocyanurate foams is well known. When the foam body is a polyurethane foam, the liquid foamable :C~. VON EPA-MI '~ENCHEN 2 ~ ~ _ 14- 3-95 : _16: 14 +.3~ 2 7589904-- +49 89 23g~34465: # 5 ` ' S86,S~
- teaction sys~em from which the polyur~than~ foam is prepared ls comprised of one or ~ore polyisocyanates, on~ or more polyols, and a blowing agent. When the li~uid ~oa~able composition i8 ~ poly~r~a liquid S foa~able composition, it will ~e ca~prised of one or ~or~ polyisocya~ates, on~ or m~r~ amino, lmin~ or en~m$no f~ncti~nal compounds, ~nd a blowing agcnt.
W~en the compo~ on $s a polyisocyanu~ate, lt will be prepa~ed ~t an i~ocyar.at~ index excas~ln~ a~out 200 an~ with d catalys~ suita~e for thQ i6ccyanurats O react~on. Such c~talysts and the preparation of ~- pclyi~ocy~nurata foams a~e well known ~n t~e art.
Suitabl~ co~ponents us~ful to ~orm specific fo~ms ln a par~u1ar appl~cation will be evident to those 1~ ~ki~d in the 2~t fro~ ~he present sp~ific~t~on. A
pr~s~ntly preferred ~oam is tha~ formed ~y ~e r~action ~f Rubi~l~x 25A i~ocyan~te prepolymer and PF5-30~8 p~lyol, ~oth availa~le ~ron ~CI A~ericas.
The polyisocyanat~s lis~et ~bo~ whlch are suit~ble ~Qr preparing tha polymeric coating nay be used to prepare the 1~ d ~o~mabl~ c~mpo~t~on. All th~ isocyanate reactive resi~s li~t~d aho~e a8 ~einq R~itabl~ ~or pr~p~ri~g th~ coa~ing may be us~d to pr~p~re a l~quid foa~lQ co~pos~t~on. ~it~hle ~lo~ing ag~nts ine~ude ~ater, di~solved or disper~ad ~a~3, such ~s air, car~on diox~de, n~tr~g~n cxides and n~trogen, ~n~ low bo~l~ng ha~og~n~t~d hy~oc~rbons, such as meth~lon~ chlor~de and trichloromono~l~cro~thane. ~h~ amo~nt o~ b~awlng ag~nt us~d is preferab~y less than abo~t ~our perccn~
by w~ght o f th~ ~otal ~eactants.
Wh~n a li~uid ~oa~ble compos~tlon $~ used, any of the convantiona~ ch~i~ ex~enders and ~dtitlve~, such a3 sur~ac~ants, ~oa~n stabiliz~rs, fire retard~nts ~ S~
W094/~937 21 S 8 6 S 4 PCTIGB94/007 ~
and fillers, known in the art may also be employed.
Suitable examples of such chain extenders and additives are described in U.S. Patent No. 4,935,460, which is incorporated herein by reference.
Since the coating on the material covering is preferably prepared at an isocyanate index in the range of 30 to 100, there may be unreacted sites in the coating which can react with the liquid foamable composition. As a result, the coating and the foam body produced from the liquid foamable composition will, in most cases, be strongly bonded to one another.
The process of this invention can be used to prepare a wide variety of upholstered articles. The process finds particular application in the automotive industry where it can be used to prepare interior trim parts of vehicles, such as door panels and package trays, head rests and seats. The most preferred application of the process is to prepare pour-in-place upholstered vehicle seats. The vacuum molds disclosed in U.S. Patent Nos. 4,740,260, 4,860,415, and 4,975,135 can be used to prepare such seats. The articles prepared by the process of this invention can have material coverings which are soft and flexible, have a good hand, and are not marred by strike-through.
The invention is illustrated with reference to ~ the following non-limiting examples.
cr~ IVG~ ACI~ ~ ~ 1~ ; t~5~U~-- ~`
~ 21S86S
FxAMPL ES
In e~ch o~ the ~ollow-nq examples, all parts are by weight unles3 speci~ied.
~xa~e 1 A ~8 c~nti~eter by 38 centimate~ pl~ca of automotlve ~abric was placed flat on a table. The palyurethane coa~'ns was prepar~d by ~ixing 5.4 par~-s o~ ~u~lflcx 26A, wh~ch i~ availabl~ from ~CI America~
Inc. and w~ich is an M~I prepolymer havin~ ~ free I O isocyanate contsnt of 2 S . 3 to 2 6 . ~ p~rcent and C pr~pared by reacting a ~nixture of ~, 4 t -M~I and 4, 4 ~-! ~D~ with a po~yoxypropylene polyol ~nd then with a poly(oxyethy~ne-oxypropyl~n-~ tricl, 100 parts af F~S-280S, whi~h is an ethylene ox~de diol ~nd wh~ch ~s i5 avalla~ ro~ ICI A~erica~ Inc., 2 part~ of Uni~ e ~a~te, wh~ch ~ ~ so~id molecul~r ie~e aYail~ble fro~
U~P c~ Pl~nQs, Illin~l~, and 1 part o~ ~a~co 33LV, ~ ~riet~yLene ~ia~in~ in glycoli catalyst ~alla~le from A~r Product~, Inc. Th8 Unis ~e Pa~ta served as a w~ter scaveng~r and preves~ted th~ coating frorn foa~ing. The i~ocyanate indQx o~ th~ coatin~ was SO .
C Th~ ingred~ ents were ~lxe~l ln a ~esse~ w~th a dri~l s~lxer at ~ ~00 RPM for ~ scond~. The reaction ~lxt~re ~as t~en p~ured frc~ the v~s~l direct~y onto ~hs expo3ed slde ~ th~ ~a~ric and ~pre~d eYcnly w~th a ~p~tula to for~n ~ co~ting ha~ ~ng a th~clcnc~s of 2 to 5 ~ ~eter~. A~t~r th~ coating c~r~d, tl~e coat~
~abric wa~ placed ~ nto a vacuu~n ~no~d ~o tt~at th~
uncoated side was ln c~ntact w~th the $nterio~ sur~ace of th~ ~old. A vacu7~m was ~p~ d to draw the fabric to th~ shape of the mc~
O S~
~ o6~sl A polyu~ethane liquid foa~able compo~ition was ~ then prepar~d by m~xing Ru~i~lex 26A (the ~A
.co~ponent~ nd FFS-30~6B ~th~ "~ co~ponent~l~, both avai~abl~ fro~ ICI Ameri~as Inc., in a r~t~o of 0.589 (~ubiflex 2~A to FFS-3066~. The co~ponents wer~
~ix~ in a high ~pingement pouring ~achin~. The co~posit~on wa~ then pour~ on~o the coatin~ on th~
fabr~c, ~oam~d ~nd allowed to cure. ~h~ fabrLc on the res~ltant article had a soft ~eel and thQre w~s no str~ke-through of the ~oam.
~xam~l~ 2 Exampls 1 W~5 repeated except that the ingr~dients for thQ ~oat~ng were placed into a high p~ess~rs sprayRr dnd were impin~e~ent m~xed as they 1~ w~r~ fed into the ~pray nozzle a~d the po}yur~than~
coatin~ wa~ sprayed onto the ~a~ric at ~.thlcknes~ o~
ab~ut 2 to 3 ~llll~eter~. Th2 ~brlc o~ th~
resul~ing a~ticl~ had a soft ~eel, ~nd t~er2 was no strike-~hrough o~ the ~Qam.
2 0 C~xam~ 1~ 3 Exa~ple 1 wa~ repeat~d ex~ept that the amo~nts of C~ ~ubi~l~x 2~A ~nd FFs-~aQ5 were ad~u~te~ ~o th~t the yanate ind~x o~ the coating was 25. Although t~e resultln~ art~ had a fabric co~ring wlth a ~cod ~g h~nd, the polyu~ethan~ coatlng wa~ qu~tQ t~c~y th~r~y ma~in~ it di~f~c~l~ t~ handle ~h~ f~bric ~en ~he ~abric was placed into the ~acuum m~ld.
~xam~l- 4 . Example 1 wa~ repeated except that thc amount~ o~
Rukifl~x 26~ an~ FF5-28QS wer~ ad~ustsd so that the isocyana~ index ~ th~ coatin~ was lOS. Th~
,~S~
result~n~ a~ticl~ had a fabri~ covering whlch was stiff and boardy.
Th~ exa~ples ~llustrate th~t upholstered f~bric cove~ed zrtlcle8 witho~t strike-through and w~th ~ood hand can ~e prepared ~y th~ p~ur-in-plac~ method.
~h~ exa~ple~ further illus~rate that va~u~m ~ormed articles wlth g~od exterior propertie~ can be prepared without the ~tap of adher~ng a pr~formed fllm or sheet to th~ ~aterl~l co~erin~ to ~ravent ~tri~e-thraugh.
lt can also be sa~n from the exsmples that wh~n the c i~ocyanate index is too low, thB polyurethane coatin~
~s too taG~ to be easily handled, and that when th~
~._ ~ocyanat~ ind~x is too h~h, the materi~l covering ~ay be Sti~f and bcardy.
l~ ~x~m~le Exa~pl~ 1 wa~ rep~at~d, ~x~ept that the ~ollo~in~
fo~m2bl~ composition wa~ used. Thc foam ~o~ui~tlon compris~d 100 parts o~ F280S; 80.5 p~rts o~ Rubi~lex 26A; 1.~ part of X-8~62; 1.0 part o~ SPF, 2.0 pa~s of 2û Unilin~4200; and ~. ~ parts o~ water. F2so5 is a poly~l a~railable ~rom ICI Amerlcas; X-8~S~ is an a~inQ
catalyst ~vall~ ro~ ~ir Prcducts ~nc.; SPF is an c amine catalyst avallable from Toyo Soda; and Unilink 42~a i~ a chain ext-nde~ av~ilable fro~ UOP.
The foam for~ulaticn w~ mixed using a dr~11 pre~6 and a mixln~ blade. The fa~r~c ~s th~n coated with the fo~mulation and th~ fab~ic Wa~ then ~laced into a YaCUUm mold 5~ that th~ uncoat~d ~ide of the fa~ric was in contact with the interior ~urface of thQ
mold. A Yacuu~ was appli~d to draw the fabrLc to thQ
shap~ c~ th~ ~ld. ~Q ~oam fo~mulation was then pour~d dir-ctly onto the fabric and was a~Lowed to cure.
. _ p,~E~E~ SHEE~
W094/23937 ~5 ~ PCTIGB94/0077 The foamed article had a soft feel and there was no strike-through of the foam.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, reference should be made to the appended claims rather than to the foregoing specification as indicating the scope of the invention.
EMPLOYING ELASTOMER COATING
.. .
Field of the Invention This invention relates to the preparation of pour-in-place articles. More particularly, this invention relates to the employment of coatings in the preparation of pour-in-place, material covered articles.
Backqround of the Invention Pour-in-place articles are generally prepared by placing a material covering, such as a piece of vinyl or fabric, into a mold and then pouring a liquid foam forming reaction mixture, such as a polyurethane composition, into the mold. A vacuum is often used to insure that the material covering snugly fits the contour of the mold. For example, U.S. Patent No.
4,806,088 discloses an apparatus for preparing textile covered cushions in which a fabric cover is adapted to the contour of a mold cavity by the application of a vacuum and then a foam forming reaction mixture is introduced into the mold. U.S. Patent Nos. 4,046,611 and 4,637,789 also disclose the preparation of cushions by vacuum molding.
After the foam forming reaction mixture is poured into the mold and the foam cures, the foam and the material covering are firmly adhered to one another thereby producing a material covered molded article.
However, one problem encountered with this procedure is that the liquid foamable composition has a tendency to seep through the interstices of the material covering to the outer surface of the material causing disruptio~ and discoloration of the material's exterior surface. This phenomenon is known as W094l~937 PCT/GB94100776 21S~F~S4 ~
"strike-through." The problem of strike-through is made much worse by the application of a vacuum.
To prevent strike-through, a variety of methods have been employed. For example, in U.S. Patent No.
3,932,252, a strippable coating is sprayed onto one side of a fabric, the fabric is placed in a mold cavity so that the coating will be between the fabric and the mold, a vacuum is applied to the fabric, a foamable compound is placed into the mold, the compound is foamed, and then the strippable coating is removed from the molded article.
The most common method, however, of preventing strike-through is to adhere a film or sheet to the back side of the covering. For example, U.S. Patent No. 4,610,923 discloses a process for preparing laminated fabric structures in which a flexible elastomeric skin containing microspheres is adhered to a stretchable fabric, the laminate is placed into a vacuum mold, and a liquid foamable composition is added to the mold and foamed.
While solving the problem of strike-through, the use of such films and sheets generates other problems.
one problem is that the film must be adhered to the material covering in order for there to be sufficient adhesion between the covering, the film and the foam substrate of the upholstered article. The film or sheet is usually adhered to the covering by using an adhesive or by flame bonding. Attaining the appropriate adhesion adds a step to the preparation of material covered articles thereby increasing the cost and time of production. Another problem is that many of the thermoplastic films employed and/or the methods used to adhere the film to the covering give the _W094/~937 PCT/GB94/00776 ~ 21S8~S,~
covering a boardy and uncomfortable feel, i.e. a "poor hand".
Another way to avoid strike-through is to first prepare a foam body and then adhere the material covering to the foam body. For example, U.S. Patent No. 4,975,135 discloses a process for preparing a vehicle seat in which a composite insert is prepared by laminating a porous fabric to a polymeric foam sheet, placing the composite into a vacuum mold, and adhering a foam bun to the composite insert. This method, however, is not as convenient as preparing the foamed body in the mold by the pour-in-place method and adds an additional step to the preparation of material covered articles, namely the step of adhering the material to an already formed foam body.
In U.S. Patent No. 4,740,417, a process is disclosed for preparing an article wherein a flexible polyurethane foam is laminated to the backside of a fabric, the laminated fabric is placed in a vacuum mold, and a thermoplastic substrate is heated until it sags and flows into the mold.
Accordingly, there is a need for a process for preparing an article covered by a material which avoids the step of adhering an already formed film or sheet to a material covering and the step of adhering a material covering to an already formed foam body.
There is a further need for an efficient and economical process for preparing material covered foamed articles. There is also a need for a process for producing pour-in-place molded articles which eliminates strike-through while providing a material cover with a good hand.
W094/~937 ~ S 4 PCTIGB94/0077~
It is therefore an object of this invention to provide an efficient and economical method of preparing material covered articles.
It is another object to provide a means of preparing vacuum molded articles that have a material covering which is not stiff or boardy.
It is yet another object to provide a process for preparing material covered molded articles that eliminates strike-through.
It is a further object to provide material covered articles that have excellent properties.
These and other objects are obtained by the process of this invention.
summarY of Invention The invention is a process for preparing material covered, pour-in-place articles comprising the steps of:
(a) applying a polymeric coating, which is prepared by reacting a polyisocyanate and an isocyanate reactive material at an isocyanate index in the range of 30 to 1500, to one side of a material covering before or after placing the material covering in a mold;
(b) pouring a liquid foamable composition onto the coated side of the material;
(c) foaming the liquid foamable composition; and (d) removing the resulting foamed, laminated, material covered article from the mold.
In a preferred embodiment, a textile fabric is used as the material covering and the process comprises the steps of:
(a) applying a polymeric coating, which is prepared by reacting a polyisocyanate and an ~0 94nu937 ~SO~s~ PCT/GB94/00776 isocyanate reactive material at an isocyanate index in the range of 30 to 100, to one side of a textile fabric covering before or after placing the covering in a vacuum mold;
(b) pouring a liquid foamable composition onto the coated side of the textile fabric covering in the mold;
(c) foaming the liquid foamable composition; and (d) removing the resulting foamed, laminated, fabric article from the mold.
The present invention further comprises a process for preparing an upholstered, vacuum molded pour-in-place article, comprising the steps of:
(a) applying a polymeric coating, which is prepared by reacting a polyisocyanate and a polyol at an isocyanate index in the range of 30 to 1500, to one side of a textile fabric covering before or after placing the covering in a mold;
(b) vacuum forming the textile fabric covering in the mold;
(c) pouring a liquid foamable composition onto the coated side of the textile fabric covering in the mold;
(d) foaming the liquid foamable composition; and (e) removing the resulting foamed, laminated, fabric article from the mold.
The material covered, pour-in-place, article ~ produced by the present process is comprised of:
(a) a material covering;
(b) a polymeric coating, prepared by reacting a polyisocyanate and an isocyanate reactive material at an isocyanate index in the range of 30 to 1500, affixed to one side of the material covering; and (c) a foam body adhered to the coating.
W094/~937 ~ ~S~l6S PCT/GB94/0077~
The process can be used to make a wide variety of upholstered articles. It is particularly useful for making upholstered seats for vehicles.
Detailed Descri~tion of the Invention The articles prepared according to the process of this invention are foamed articles having a material covering. The material covering can be any material to which the polyurethane coating firmly adheres.
Suitable materials include vinyl, leather, and textile fabric coverings. The preferred covering is a textile fabric covering. As used herein, the term "textile fabric covering" includes any porous fabric or cloth that can be employed as a covering. The textile fabric covering can be made from synthetic or natural fibers or a blend of synthetic and natural fibers.
The size and shape of the material covering of course depends upon the type of foamed article being prepared. The material covering is usually comprised of a single piece of material which has been cut to fit the contour of a mold. However, the material covering can be prepared from several pieces of material which are attached to each other, e.g. by sewing.
After the material covering is prepared so that it has the desired shape, the material covering is coated on one side with a polymeric coating. The - coating can be applied either before or after the material covering is placed into a mold. If the coating is applied before the material covering is placed into the mold, the covering is placed into the mold so that the uncoated side is against the interior surface of the mold. Preferably, the material covering is vacuum formed after being placed into the ~ 094/~937PCT/GB94/00776 ~1S~65~
mold so that the material snugly fits the contour of the mold. If the material coating is placed into a vacuum mold before being coated, it is preferred to coat one side of the material covering before the 5covering is vacuum formed.
The polymeric coating applied to the material covering is preferably a polyurethane and/or polyurea coating (i.e. a polyurethane coating, a polyurea coating, or a coating having both polyurethane and 10polyurea linkages). More preferably, the coating is a polyurethane coating. The coating can be prepared at an isocyanate index in the range of 30 to 1500.
However, an isocyanate index above 200 will generally only be used when a coating having isocyanurate 15linkages is used or when a moisture-cure system is used to prepare the coating. As used herein, "isocyanate index" is the ratio of isocyanate (-NCO) equivalents to the total number of equivalents of isocyanate-reactive groups expressed as a percentage.
20Preferably after curing, the polyurethane and/or polyurea coating is soft and flexible so that the material covering is not boardy or stiff, and the coating is strong enough so that if it is stretched by a vacuum, it remains intact. In order to achieve 25these properties, the polyurethane and/or polyurea coating is preferably prepared at an isocyanate index in the range of 30 to 100, more preferably in the range of 40 to 80, still more preferably in the range of 45 to 60, and most preferably in the range of 45 to 3055. Although it is possible to use an isocyanate index below 30, the resulting coating will be tacky and will not completely cure. As a result, the coa.ted material covering will be difficult to handle and to process. On the other hand, if the isocyanate index W094/~937 PCT/GB94/0077~_ 2158S~ ~
exceeds about lOO, the covering may be stiff and boardy once the coating cures.
The organic polyisocyanates which may be used in the preparation of the polyurethane coating include any of the aliphatic, cycloaliphatic,. araliphatic or aromatic polyisocyanates known in polyurethane or polyurea chemistry, especially those that are liquid at room temperature. Examples of suitable polyisocyanates include ethylene diisocyanate, 1,6-hexamethylene diisocyanate, isophorone diisocyanate, cyclohexane 1,4-diisocyanate, 4,4'-dicyclohexylmethane diisocyanate, 1,4-xylylene diisocyanate, 1,4-phenylene diisocyanate, 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, 4,4'-diphenylmethane diisocyanate (4,4'-MDI), 2,4'-diphenylmethane diisocyanate (2,4'-MDI), polymethylene polyphenylene polyisocyanates (crude MDI) and 1,5-naphthylene diisocyanate. Mixtures of polyisocyanates can be used and also polyisocyanates which have been modified by the introduction of urethane, allophanate, urea, biuret, carbodiimide, uretonimine or isocyanurate residues.
In general, the aromatic polyisocyanates are preferred. The most preferred aromatic polyisocyanates are 4,4'-diphenylmethane diisocyanate, 2,4'-diphenylmethane diisocyanate, polymeric MDI, MDI
variants, and mixtures thereof. Suitable MDI variants include compounds in which the MDI has been modified by the introduction of urethane, allophanate, urea, biuret, amide, carbodiimide, uretonimine or isocyanurate residues.
Isocyanate-terminated prepolymers may also be employed and are prepared by reacting an excess of polyisocyanate with polyols, including aminated polyols, imine or enamine polymers, or polyamines. A
~W094/~937 ~S~ PCTIGB94/00776 particularly preferred isocyanate terminated prepolymer is the reaction product of a polymeric MDI
and a polyether polyol. Pseudo-prepolymers may also be employed. A pseudo-prepolymer is a mixture of a prepolymer and one or more monomeric di- or poly-isocyanates. Examples of suitable materials include Rubiflex 26A available from ICI Americas.
The isocyanate reactive resins that are useful in the preparation of the polyurethane and/or polyurea coatings include polymeric polyols, amines, imino-functional and enamino-functional compounds having molecular weights in the range of 1500 to 12,000.
Preferably, the isocyanate reactive material is a polyol.
Suitable polyols that may be used to prepare polyurethane coatings include those selected from the group consisting of polythioether, polyester, polyester amide, polycarbonate, polyacetal, polyolefin, polysiloxane and polyether polyols.
Polyether polyols are preferred.
Suitable polyether polyols include products obtained by the polymerization of a cyclic oxide, for example ethylene oxide, propylene oxide or tetrahydrofuran in the presence, where necessary, of polyfunctional initiators. Suitable initiator compounds contain a plurality of active hydrogen atoms and include water, polyols, for example ethylene glycol, propylene glycol, diethylene glycol, resorcinol, bisphenolA, glycerol, trimethylolpropane, 1,2,6-hexanetriol, triethanolamine, pentaerythritol, sorbitol or sucrose, ammonia, primary monoamines, for example aniline or benzylamine, polyamines, for example ethylene diamine, hexamethylene diamine, toluene diamines, diaminodiphenylmethanes and W094/~937 PCTIGB94/0077~
2ol~8 6 5 4 polymethylene polyphenylene polyamines obtained by the condensation of aniline and formaldehyde, and amino alcohols, for example ethanolamine and diethanolamine.
Mixtures of initiators and/or cyclic oxides may be used.
Especially useful polyether polyols include polyoxypropylene, polyoxyethylene, and poly(oxyethylene-oxypropylene) diolsand triols, which are obtained by the simultaneous or sequential addition of ethylene and propylene oxides to appropriate di- or tri-functional initiators as fully described in the prior art. Mixtures of the diols and triols are also useful. -The most preferred polyether polyols are polyoxyethylene capped polyoxypropylene diols and triols.
Polyester polyols which may be used include hydroxyl terminated reaction products of polyhydric alcohols such as ethylene glycol, propylene glycol, diethylene glycol, 1,4-butanediol, bis(hydroxyethyl) terephthalate, glycerol, trimethylolpropane or pentaerythritol or mixtures thereof with polycarboxylic acids, especially dicarboxylic acids or their ester-forming derivatives, for example, succinic, glutaric and adipic acids or their dimethyl esters, sebacic acid, phthalic anhydride, tetrachloroph~halic anhydride or dimethyl terephthalate. Polyesters obtained by the polymerization of lactones, for example caprolactone, in conjunction with a polyol, may also be used.
Polyesteramides may be obtained by the inclusion of aminoalcohols such as ethanolamine in polyesterification mixtures.
Polythioether polyols which may be used include products obtained by condensing thiodiglycol either 094/1937 ~ S8 ~CTIGB94/00776 alone or with other glycols, dicarboxylic acids, formaldehyde, aminoalcohols or aminocarboxylic acids.
Polycarbonate polyols which may be used include products obtained by reacting diols such as 1,3-propanediol, 1,4-butanediol, 1,6-hexanediol, diethylene glycol or tetraethylene glycol with diaryl carbonates, for example diphenyl carbonate or with phosgene.
Polyacetal polyols which may be used include those prepared by reacting glycols such as diethylene glycol, triethylene glycol or hexanediol with formaldehyde. Suitable polyacetals may also be prepared by polymerizing cyclic acetals.
Suitable polyolefin polyols include hydroxy-terminated butadiene homo- and copolymers, and suitable polysiloxane polyols include polydimethylsiloxane diols and triols.
Examples of suitable polyols for use in the present invention include FFS-2805 available from ICI
Americas.
The types of amino functional compounds suitable for the preparation of a polyurea coating are well known to those skilled in the art. Suitable imino-functional and enamino-functional compounds for preparing polyurea coatings are disclosed in U.S.
Patent Nos. 4,749,129, 4,866,103, and 4,910,279, which are incorporated herein by reference. Preferably, the amino-, imino- and enamino-functional compounds are compounds in which all or part of the OH groups on a polyol have been replaced by the respective functional groups.
In preparing the polyurethane and/or polyurea coatings, one or more polyisocyanates are reacted with one or more isocyanate reactive materials at an W094/~937 ~ ~ PCT/GB94/0077 isocyanate index in the ranges given above under substantially anhydrous conditions at a temperature in the range of room temperature to 180C. Chain extenders and cross-linkers, such as amines, glycols, imines and enamines, may be included in the reaction mixture. Generally, the chain extenders and cross-linkers will have molecular weights below about 1500.
In addition, the polyisocyanates and isocyanate reactive materials can optionally be reacted in the presence of catalysts known in the art, such as dibutyltin dilaurate and tertiary amines such as triethylene diamine. Suitable catalysts are disclosed in U.S. Patent No. 4,7g4,129, which was previously incorporated by reference. Optionally, a molecular sieve can be included in the reaction mixture to serve as a water scavenger so that any water that is present will not blow and cause the coating to foam. Suitable catalysts and molecular sieves for use in a specific formulation will be evident to one skilled in the art from the present disclosure.
The polyisocyanate and the isocyanate reactive material (as well as any catalysts, chain extenders, and other ingredients) are usually mixed just prior to applying the coating to one side of the material covering. The isocyanate reactive material and the polyisocyanate can be mixed and applied to the material covering by any suitable means. For example, they can be mixed with a drill mixer and applied by hand, such as with a spatula or knife. However, it is preferred that the isocyanate reactive material and the polyisocyanate be applied by spraying. Most preferably, the isocyanate reactive material and the polyisocyanate are impingement mixed in a spraying apparatus, and the coating is sprayed onto the fabric.
~CV. ~'OI~i: EP~A-,MUENCHEN 2 . 14-_ ~-95 : _16: 14 +32 2 758990~-- +49 8'd 23994465; # 4 ~ny ~on~entional sprayQr for spr~yln~ polyurethane and .pGlyure~ material~ known to thas~ skilled in th~ art may ~e ~ployed.
Pr~ferably, the spraying de~ice has a compart~ent in which the poly~ socyanate can be ~tor~ and a ~o~p~rtmcnt in which the iso~yanate reactiv~ ~ateria}
f~s well ~5 chain ext~ndQrs ~nd othor lngredients) c~n b~ s~ored. Such ~ sprayer should hav~ a moans to pump the p~lyLs~yanats and the isocyanats reac~c lo m~te~ial from the comp~rtments into a sprayhead.
0 ~en~rally, the polyisocyanate and the i~ccyan~te r~actiYe csmpounds ~re imp~nge~snt mixed in the n~ls o~ the spr~yer. A sulta~l~ sp~ayln~ apparat~ i8 a Graco.Hydra C~t sprayor and pump unl~, which i~
t S aYaila~le ~rom Graco, equipped with a Gusm~r GX7 sprayhead, which is ~Yail~ble fro~ G~ r. Pric~ to be~ ixed, the po~yisocyanate ant the isocyanate reactive ~at~rial are maintalned in their re~pective co~partments ~t a tQmperaturc in the range of 18 3C to about SOqC. The polyisocyanate and th~ isocyanate rQactive matexial ~r~ usually ~etered tog~ther at a pressure in ~he rang~ o ~600 to 2000 ps$~ and t~e pressure ~n eac~ co~p~nent is usually th~ sa~e.
C I~ is, o~ co~rse t pOSS lble to rsaCt the ~5 isccy~nate and the i30cyAn~te re~ctiv~ m~te~al b~or~
applyin~ ~hQ coAt~n~ ~ long ~s the r~su~ting prep~lymer c~n be rQ~d$1y ~ppli~d to ~h~ mat~rlal covering ~he coat~ng i5 us~ally appli~d ~t ~ ~hicknoss of abou~ 0.05 milliweter~ up to abcut ~iv~ mlll~eters to one s~de of the material co~-~in~. ~he coating i~
allow~d to cur~ ~c~ s~eral s~nds to se~eral ~nutes lgeneral~y n~t ~ore th~n ab~t two ~nut~s) beforo th~
coated covering is placed into a moLd. The length a~
r Y~ ~0 ~a ~
o~o S~
-W094/~937 ~ 65 PCT/GB94/0077 cure time varies with the type of formulation used to prepare the coating.
Either before or after being coated, the covering is placed into a mold. The shape of the mold will of course depend upon the type of article that is desired. After the covering is placed into the mold, it is preferred to pull a vacuum so that the material covering snugly fits the contour of the mold.
The types of vacuum molds suitable for use are well known to those skilled in the art. Suitable vacuum molds are described in U.S. Patent Nos.
4,046,611, 4,637,789, 4,740,260, 4,860,415 and 4,975,135, all of which are incorporated herein by reference.
After the coated material covering is in the mold, a liquid foamable composition is poured onto the coated side of the covering and foamed. The type of liquid foamable composition is not critical, and virtually any type of composition which can be poured into a mold and foamed and which will adhere to the polyurethane and/or polyurea coating can be employed.
Neither is the type of foam produced from the liquid foamable composition critical. Both flexible and rigid foams may be used, depending upon the end use of the product which is produced. The type of product being prepared will determine the type of liquid foamable composition that is needed as well as the nature of the resulting foam (i.e. flexible or rigid) that is needed. The preferred liquid foamable compositions are polyurethane, polyurea and/or polyisocyanurate liquid foamable compositions.
The preparation of polyurethane, polyurea and/or polyisocyanurate foams is well known. When the foam body is a polyurethane foam, the liquid foamable :C~. VON EPA-MI '~ENCHEN 2 ~ ~ _ 14- 3-95 : _16: 14 +.3~ 2 7589904-- +49 89 23g~34465: # 5 ` ' S86,S~
- teaction sys~em from which the polyur~than~ foam is prepared ls comprised of one or ~ore polyisocyanates, on~ or more polyols, and a blowing agent. When the li~uid ~oa~able composition i8 ~ poly~r~a liquid S foa~able composition, it will ~e ca~prised of one or ~or~ polyisocya~ates, on~ or m~r~ amino, lmin~ or en~m$no f~ncti~nal compounds, ~nd a blowing agcnt.
W~en the compo~ on $s a polyisocyanu~ate, lt will be prepa~ed ~t an i~ocyar.at~ index excas~ln~ a~out 200 an~ with d catalys~ suita~e for thQ i6ccyanurats O react~on. Such c~talysts and the preparation of ~- pclyi~ocy~nurata foams a~e well known ~n t~e art.
Suitabl~ co~ponents us~ful to ~orm specific fo~ms ln a par~u1ar appl~cation will be evident to those 1~ ~ki~d in the 2~t fro~ ~he present sp~ific~t~on. A
pr~s~ntly preferred ~oam is tha~ formed ~y ~e r~action ~f Rubi~l~x 25A i~ocyan~te prepolymer and PF5-30~8 p~lyol, ~oth availa~le ~ron ~CI A~ericas.
The polyisocyanat~s lis~et ~bo~ whlch are suit~ble ~Qr preparing tha polymeric coating nay be used to prepare the 1~ d ~o~mabl~ c~mpo~t~on. All th~ isocyanate reactive resi~s li~t~d aho~e a8 ~einq R~itabl~ ~or pr~p~ri~g th~ coa~ing may be us~d to pr~p~re a l~quid foa~lQ co~pos~t~on. ~it~hle ~lo~ing ag~nts ine~ude ~ater, di~solved or disper~ad ~a~3, such ~s air, car~on diox~de, n~tr~g~n cxides and n~trogen, ~n~ low bo~l~ng ha~og~n~t~d hy~oc~rbons, such as meth~lon~ chlor~de and trichloromono~l~cro~thane. ~h~ amo~nt o~ b~awlng ag~nt us~d is preferab~y less than abo~t ~our perccn~
by w~ght o f th~ ~otal ~eactants.
Wh~n a li~uid ~oa~ble compos~tlon $~ used, any of the convantiona~ ch~i~ ex~enders and ~dtitlve~, such a3 sur~ac~ants, ~oa~n stabiliz~rs, fire retard~nts ~ S~
W094/~937 21 S 8 6 S 4 PCTIGB94/007 ~
and fillers, known in the art may also be employed.
Suitable examples of such chain extenders and additives are described in U.S. Patent No. 4,935,460, which is incorporated herein by reference.
Since the coating on the material covering is preferably prepared at an isocyanate index in the range of 30 to 100, there may be unreacted sites in the coating which can react with the liquid foamable composition. As a result, the coating and the foam body produced from the liquid foamable composition will, in most cases, be strongly bonded to one another.
The process of this invention can be used to prepare a wide variety of upholstered articles. The process finds particular application in the automotive industry where it can be used to prepare interior trim parts of vehicles, such as door panels and package trays, head rests and seats. The most preferred application of the process is to prepare pour-in-place upholstered vehicle seats. The vacuum molds disclosed in U.S. Patent Nos. 4,740,260, 4,860,415, and 4,975,135 can be used to prepare such seats. The articles prepared by the process of this invention can have material coverings which are soft and flexible, have a good hand, and are not marred by strike-through.
The invention is illustrated with reference to ~ the following non-limiting examples.
cr~ IVG~ ACI~ ~ ~ 1~ ; t~5~U~-- ~`
~ 21S86S
FxAMPL ES
In e~ch o~ the ~ollow-nq examples, all parts are by weight unles3 speci~ied.
~xa~e 1 A ~8 c~nti~eter by 38 centimate~ pl~ca of automotlve ~abric was placed flat on a table. The palyurethane coa~'ns was prepar~d by ~ixing 5.4 par~-s o~ ~u~lflcx 26A, wh~ch i~ availabl~ from ~CI America~
Inc. and w~ich is an M~I prepolymer havin~ ~ free I O isocyanate contsnt of 2 S . 3 to 2 6 . ~ p~rcent and C pr~pared by reacting a ~nixture of ~, 4 t -M~I and 4, 4 ~-! ~D~ with a po~yoxypropylene polyol ~nd then with a poly(oxyethy~ne-oxypropyl~n-~ tricl, 100 parts af F~S-280S, whi~h is an ethylene ox~de diol ~nd wh~ch ~s i5 avalla~ ro~ ICI A~erica~ Inc., 2 part~ of Uni~ e ~a~te, wh~ch ~ ~ so~id molecul~r ie~e aYail~ble fro~
U~P c~ Pl~nQs, Illin~l~, and 1 part o~ ~a~co 33LV, ~ ~riet~yLene ~ia~in~ in glycoli catalyst ~alla~le from A~r Product~, Inc. Th8 Unis ~e Pa~ta served as a w~ter scaveng~r and preves~ted th~ coating frorn foa~ing. The i~ocyanate indQx o~ th~ coatin~ was SO .
C Th~ ingred~ ents were ~lxe~l ln a ~esse~ w~th a dri~l s~lxer at ~ ~00 RPM for ~ scond~. The reaction ~lxt~re ~as t~en p~ured frc~ the v~s~l direct~y onto ~hs expo3ed slde ~ th~ ~a~ric and ~pre~d eYcnly w~th a ~p~tula to for~n ~ co~ting ha~ ~ng a th~clcnc~s of 2 to 5 ~ ~eter~. A~t~r th~ coating c~r~d, tl~e coat~
~abric wa~ placed ~ nto a vacuu~n ~no~d ~o tt~at th~
uncoated side was ln c~ntact w~th the $nterio~ sur~ace of th~ ~old. A vacu7~m was ~p~ d to draw the fabric to th~ shape of the mc~
O S~
~ o6~sl A polyu~ethane liquid foa~able compo~ition was ~ then prepar~d by m~xing Ru~i~lex 26A (the ~A
.co~ponent~ nd FFS-30~6B ~th~ "~ co~ponent~l~, both avai~abl~ fro~ ICI Ameri~as Inc., in a r~t~o of 0.589 (~ubiflex 2~A to FFS-3066~. The co~ponents wer~
~ix~ in a high ~pingement pouring ~achin~. The co~posit~on wa~ then pour~ on~o the coatin~ on th~
fabr~c, ~oam~d ~nd allowed to cure. ~h~ fabrLc on the res~ltant article had a soft ~eel and thQre w~s no str~ke-through of the ~oam.
~xam~l~ 2 Exampls 1 W~5 repeated except that the ingr~dients for thQ ~oat~ng were placed into a high p~ess~rs sprayRr dnd were impin~e~ent m~xed as they 1~ w~r~ fed into the ~pray nozzle a~d the po}yur~than~
coatin~ wa~ sprayed onto the ~a~ric at ~.thlcknes~ o~
ab~ut 2 to 3 ~llll~eter~. Th2 ~brlc o~ th~
resul~ing a~ticl~ had a soft ~eel, ~nd t~er2 was no strike-~hrough o~ the ~Qam.
2 0 C~xam~ 1~ 3 Exa~ple 1 wa~ repeat~d ex~ept that the amo~nts of C~ ~ubi~l~x 2~A ~nd FFs-~aQ5 were ad~u~te~ ~o th~t the yanate ind~x o~ the coating was 25. Although t~e resultln~ art~ had a fabric co~ring wlth a ~cod ~g h~nd, the polyu~ethan~ coatlng wa~ qu~tQ t~c~y th~r~y ma~in~ it di~f~c~l~ t~ handle ~h~ f~bric ~en ~he ~abric was placed into the ~acuum m~ld.
~xam~l- 4 . Example 1 wa~ repeated except that thc amount~ o~
Rukifl~x 26~ an~ FF5-28QS wer~ ad~ustsd so that the isocyana~ index ~ th~ coatin~ was lOS. Th~
,~S~
result~n~ a~ticl~ had a fabri~ covering whlch was stiff and boardy.
Th~ exa~ples ~llustrate th~t upholstered f~bric cove~ed zrtlcle8 witho~t strike-through and w~th ~ood hand can ~e prepared ~y th~ p~ur-in-plac~ method.
~h~ exa~ple~ further illus~rate that va~u~m ~ormed articles wlth g~od exterior propertie~ can be prepared without the ~tap of adher~ng a pr~formed fllm or sheet to th~ ~aterl~l co~erin~ to ~ravent ~tri~e-thraugh.
lt can also be sa~n from the exsmples that wh~n the c i~ocyanate index is too low, thB polyurethane coatin~
~s too taG~ to be easily handled, and that when th~
~._ ~ocyanat~ ind~x is too h~h, the materi~l covering ~ay be Sti~f and bcardy.
l~ ~x~m~le Exa~pl~ 1 wa~ rep~at~d, ~x~ept that the ~ollo~in~
fo~m2bl~ composition wa~ used. Thc foam ~o~ui~tlon compris~d 100 parts o~ F280S; 80.5 p~rts o~ Rubi~lex 26A; 1.~ part of X-8~62; 1.0 part o~ SPF, 2.0 pa~s of 2û Unilin~4200; and ~. ~ parts o~ water. F2so5 is a poly~l a~railable ~rom ICI Amerlcas; X-8~S~ is an a~inQ
catalyst ~vall~ ro~ ~ir Prcducts ~nc.; SPF is an c amine catalyst avallable from Toyo Soda; and Unilink 42~a i~ a chain ext-nde~ av~ilable fro~ UOP.
The foam for~ulaticn w~ mixed using a dr~11 pre~6 and a mixln~ blade. The fa~r~c ~s th~n coated with the fo~mulation and th~ fab~ic Wa~ then ~laced into a YaCUUm mold 5~ that th~ uncoat~d ~ide of the fa~ric was in contact with the interior ~urface of thQ
mold. A Yacuu~ was appli~d to draw the fabrLc to thQ
shap~ c~ th~ ~ld. ~Q ~oam fo~mulation was then pour~d dir-ctly onto the fabric and was a~Lowed to cure.
. _ p,~E~E~ SHEE~
W094/23937 ~5 ~ PCTIGB94/0077 The foamed article had a soft feel and there was no strike-through of the foam.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, reference should be made to the appended claims rather than to the foregoing specification as indicating the scope of the invention.
Claims (10)
1. A process for preparing a material covered, pour-in-place article comprising the steps of:
(a) applying a polymeric coating, which is prepared by reacting a polyisocyanate and an isocyanate reactive material at an isocyanate index in the range of 30 to 1500, to one side of a material covering before or after placing the material covering in a mold;
(b) pouring a liquid foamable composition onto the coated side of the material;
(c) foaming the liquid foamable composition; and (d) removing the resulting article from the mold.
(a) applying a polymeric coating, which is prepared by reacting a polyisocyanate and an isocyanate reactive material at an isocyanate index in the range of 30 to 1500, to one side of a material covering before or after placing the material covering in a mold;
(b) pouring a liquid foamable composition onto the coated side of the material;
(c) foaming the liquid foamable composition; and (d) removing the resulting article from the mold.
2. A process for preparing an upholstered, vacuum molded, pour-in-place article comprising the steps of:
(a) applying a polymeric coating, which is prepared by reacting a polyisocyanate and an isocyanate reactive material at an isocyanate index in the range of 30 to 1500, to one side of a textile fabric covering before or after placing the covering in a mold;
(b) vacuum forming the textile fabric covering in a mold;
(c) pouring a liquid foamable composition onto the coated side of the textile fabric covering in the mold;
(d) foaming the liquid foamable composition; and (e) removing the resulting article from the mold.
(a) applying a polymeric coating, which is prepared by reacting a polyisocyanate and an isocyanate reactive material at an isocyanate index in the range of 30 to 1500, to one side of a textile fabric covering before or after placing the covering in a mold;
(b) vacuum forming the textile fabric covering in a mold;
(c) pouring a liquid foamable composition onto the coated side of the textile fabric covering in the mold;
(d) foaming the liquid foamable composition; and (e) removing the resulting article from the mold.
3. A process as in claim 1 or 2, wherein said polymeric coating is a polyurethane coating.
4. A process as in claim 1 or 2 wherein said isocyanate reactive material is a polyol.
5. A process as in claim 1 or 2, wherein the isocyanate index is in the range of from 30 to 100.
6. A process as in claim 1 or 2, wherein the polyisocyanate is an aromatic polyisocyanate.
7. A process as in claim 6 wherein the polyisocyanate is selected from the group consisting of 4,4'diphenylmethane diisocyanate, 2,4'diphenylmethane diisocyanate, polymeric MDI, MDI
variants and mixtures thereof.
variants and mixtures thereof.
8. A process as in claim 1 or 2 wherein the liquid foamable composition is selected from the group consisting of a polyurethane, polyurea and a polyisocyanurate liquid foamable composition.
9. A material covered, pour-in-place article prepared by the process of claim 1.
10. An upholstered, vacuum molded, pour-in-place article prepared by the process of claim 2.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US4868793A | 1993-04-16 | 1993-04-16 | |
| US08/048,687 | 1993-04-16 | ||
| PCT/GB1994/000776 WO1994023937A1 (en) | 1993-04-16 | 1994-04-13 | Preparation of pour-in-place articles employing elastomer coating |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2158654A1 true CA2158654A1 (en) | 1994-10-27 |
Family
ID=21955884
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002158654A Abandoned CA2158654A1 (en) | 1993-04-16 | 1994-04-13 | Preparation of pour-in-place articles employing elastomer coating |
Country Status (3)
| Country | Link |
|---|---|
| AU (1) | AU6507894A (en) |
| CA (1) | CA2158654A1 (en) |
| WO (1) | WO1994023937A1 (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2814110B1 (en) * | 2000-09-20 | 2003-05-30 | Cera | METHOD AND DEVICE FOR MANUFACTURING A TRIM, TRIM AND SEAT PROVIDED WITH SAME |
| ES2394689B1 (en) * | 2010-12-02 | 2014-02-11 | Asociacion De Investigación Centro Tecnológico Del Mueble Y La Madera De La Región De Murcia | TREATMENT PROCESS OF FABRICS FOR FOAMED PARTS IN MOLD AND USE OF SUCH FABRIC |
| ES2595932B1 (en) * | 2015-07-01 | 2017-10-24 | Construplas, S.L. | IRON MOLDING PROCEDURE ON SUPPORT |
Family Cites Families (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2151651A5 (en) * | 1971-09-03 | 1973-04-20 | Altramouss Ets | Stool upholstery - of skinned polyurethane foams moulded with traditional surface decorations or inserts |
| GB1458664A (en) * | 1973-01-31 | 1976-12-15 | Storey Brothers & Co | Resilient padded items |
| US4871612A (en) * | 1986-09-05 | 1989-10-03 | Inoue Mtp Kabushiki Kaisha | Interior member for vehicles and method for its manufacture |
| WO1991008886A1 (en) * | 1989-12-11 | 1991-06-27 | Henderson's Industries Pty. Ltd. | Vandal-resistant seat |
-
1994
- 1994-04-13 WO PCT/GB1994/000776 patent/WO1994023937A1/en active Application Filing
- 1994-04-13 CA CA002158654A patent/CA2158654A1/en not_active Abandoned
- 1994-04-13 AU AU65078/94A patent/AU6507894A/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| WO1994023937A1 (en) | 1994-10-27 |
| AU6507894A (en) | 1994-11-08 |
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