CA2857609C - Washable viscoelastic flexible polyurethane foams - Google Patents
Washable viscoelastic flexible polyurethane foams Download PDFInfo
- Publication number
- CA2857609C CA2857609C CA2857609A CA2857609A CA2857609C CA 2857609 C CA2857609 C CA 2857609C CA 2857609 A CA2857609 A CA 2857609A CA 2857609 A CA2857609 A CA 2857609A CA 2857609 C CA2857609 C CA 2857609C
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- CA
- Canada
- Prior art keywords
- isocyanate
- compounds
- fraction
- koh
- process according
- 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.)
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- 229920005830 Polyurethane Foam Polymers 0.000 title claims abstract description 48
- 239000011496 polyurethane foam Substances 0.000 title claims abstract description 45
- 125000002887 hydroxy group Chemical group [H]O* 0.000 claims abstract description 36
- 150000001875 compounds Chemical class 0.000 claims abstract description 31
- 125000002947 alkylene group Chemical group 0.000 claims abstract description 29
- 239000007858 starting material Substances 0.000 claims abstract description 28
- 229920000642 polymer Polymers 0.000 claims abstract description 27
- IAYPIBMASNFSPL-UHFFFAOYSA-N Ethylene oxide Chemical compound C1CO1 IAYPIBMASNFSPL-UHFFFAOYSA-N 0.000 claims abstract description 25
- 238000000034 method Methods 0.000 claims abstract description 24
- GOOHAUXETOMSMM-UHFFFAOYSA-N Propylene oxide Chemical compound CC1CO1 GOOHAUXETOMSMM-UHFFFAOYSA-N 0.000 claims abstract description 23
- 239000003054 catalyst Substances 0.000 claims abstract description 23
- 229920000233 poly(alkylene oxides) Polymers 0.000 claims abstract description 23
- 230000008569 process Effects 0.000 claims abstract description 22
- 229920001228 polyisocyanate Polymers 0.000 claims abstract description 16
- 239000005056 polyisocyanate Substances 0.000 claims abstract description 16
- 239000004604 Blowing Agent Substances 0.000 claims abstract description 14
- 239000003795 chemical substances by application Substances 0.000 claims abstract description 12
- 239000003431 cross linking reagent Substances 0.000 claims abstract description 8
- 239000011541 reaction mixture Substances 0.000 claims abstract description 8
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 20
- UPMLOUAZCHDJJD-UHFFFAOYSA-N 4,4'-Diphenylmethane Diisocyanate Chemical compound C1=CC(N=C=O)=CC=C1CC1=CC=C(N=C=O)C=C1 UPMLOUAZCHDJJD-UHFFFAOYSA-N 0.000 claims description 12
- 239000012948 isocyanate Substances 0.000 claims description 11
- 150000002513 isocyanates Chemical class 0.000 claims description 10
- DVKJHBMWWAPEIU-UHFFFAOYSA-N toluene 2,4-diisocyanate Chemical compound CC1=CC=C(N=C=O)C=C1N=C=O DVKJHBMWWAPEIU-UHFFFAOYSA-N 0.000 claims description 8
- KWYUFKZDYYNOTN-UHFFFAOYSA-M Potassium hydroxide Chemical compound [OH-].[K+] KWYUFKZDYYNOTN-UHFFFAOYSA-M 0.000 description 72
- 239000006260 foam Substances 0.000 description 35
- 229920005862 polyol Polymers 0.000 description 34
- 150000003077 polyols Chemical class 0.000 description 30
- PEDCQBHIVMGVHV-UHFFFAOYSA-N Glycerine Chemical compound OCC(O)CO PEDCQBHIVMGVHV-UHFFFAOYSA-N 0.000 description 24
- 239000000203 mixture Substances 0.000 description 18
- 229920000570 polyether Polymers 0.000 description 17
- 239000004721 Polyphenylene oxide Substances 0.000 description 15
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 12
- -1 acrylate polyols Chemical class 0.000 description 12
- 150000001298 alcohols Chemical class 0.000 description 12
- WERYXYBDKMZEQL-UHFFFAOYSA-N butane-1,4-diol Chemical compound OCCCCO WERYXYBDKMZEQL-UHFFFAOYSA-N 0.000 description 10
- MTHSVFCYNBDYFN-UHFFFAOYSA-N diethylene glycol Chemical compound OCCOCCO MTHSVFCYNBDYFN-UHFFFAOYSA-N 0.000 description 9
- 238000005406 washing Methods 0.000 description 9
- 125000004432 carbon atom Chemical group C* 0.000 description 8
- 150000001412 amines Chemical class 0.000 description 7
- 125000004435 hydrogen atom Chemical group [H]* 0.000 description 6
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 5
- 150000002009 diols Chemical class 0.000 description 5
- 230000008961 swelling Effects 0.000 description 5
- 239000003190 viscoelastic substance Substances 0.000 description 5
- 108010081873 Persil Proteins 0.000 description 4
- DNIAPMSPPWPWGF-UHFFFAOYSA-N Propylene glycol Chemical compound CC(O)CO DNIAPMSPPWPWGF-UHFFFAOYSA-N 0.000 description 4
- ZJCCRDAZUWHFQH-UHFFFAOYSA-N Trimethylolpropane Chemical compound CCC(CO)(CO)CO ZJCCRDAZUWHFQH-UHFFFAOYSA-N 0.000 description 4
- WNLRTRBMVRJNCN-UHFFFAOYSA-N adipic acid Chemical compound OC(=O)CCCCC(O)=O WNLRTRBMVRJNCN-UHFFFAOYSA-N 0.000 description 4
- 230000001413 cellular effect Effects 0.000 description 4
- 238000013016 damping Methods 0.000 description 4
- 150000001991 dicarboxylic acids Chemical class 0.000 description 4
- XXMIOPMDWAUFGU-UHFFFAOYSA-N hexane-1,6-diol Chemical compound OCCCCCCO XXMIOPMDWAUFGU-UHFFFAOYSA-N 0.000 description 4
- 238000005213 imbibition Methods 0.000 description 4
- 239000012528 membrane Substances 0.000 description 4
- 238000011084 recovery Methods 0.000 description 4
- 239000004970 Chain extender Substances 0.000 description 3
- 239000004971 Cross linker Substances 0.000 description 3
- SJRJJKPEHAURKC-UHFFFAOYSA-N N-Methylmorpholine Chemical compound CN1CCOCC1 SJRJJKPEHAURKC-UHFFFAOYSA-N 0.000 description 3
- ALQSHHUCVQOPAS-UHFFFAOYSA-N Pentane-1,5-diol Chemical compound OCCCCCO ALQSHHUCVQOPAS-UHFFFAOYSA-N 0.000 description 3
- ZMANZCXQSJIPKH-UHFFFAOYSA-N Triethylamine Chemical compound CCN(CC)CC ZMANZCXQSJIPKH-UHFFFAOYSA-N 0.000 description 3
- 230000006835 compression Effects 0.000 description 3
- 238000007906 compression Methods 0.000 description 3
- SZXQTJUDPRGNJN-UHFFFAOYSA-N dipropylene glycol Chemical compound OCCCOCCCO SZXQTJUDPRGNJN-UHFFFAOYSA-N 0.000 description 3
- 238000001035 drying Methods 0.000 description 3
- 150000002148 esters Chemical class 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 229920000728 polyester Polymers 0.000 description 3
- 239000004814 polyurethane Substances 0.000 description 3
- 229920002635 polyurethane Polymers 0.000 description 3
- CXMXRPHRNRROMY-UHFFFAOYSA-N sebacic acid Chemical compound OC(=O)CCCCCCCCC(O)=O CXMXRPHRNRROMY-UHFFFAOYSA-N 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 150000004072 triols Chemical class 0.000 description 3
- DNIAPMSPPWPWGF-VKHMYHEASA-N (+)-propylene glycol Chemical compound C[C@H](O)CO DNIAPMSPPWPWGF-VKHMYHEASA-N 0.000 description 2
- YPFDHNVEDLHUCE-UHFFFAOYSA-N 1,3-propanediol Substances OCCCO YPFDHNVEDLHUCE-UHFFFAOYSA-N 0.000 description 2
- HZAXFHJVJLSVMW-UHFFFAOYSA-N 2-Aminoethan-1-ol Chemical compound NCCO HZAXFHJVJLSVMW-UHFFFAOYSA-N 0.000 description 2
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 description 2
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 2
- VZCYOOQTPOCHFL-OWOJBTEDSA-N Fumaric acid Chemical compound OC(=O)\C=C\C(O)=O VZCYOOQTPOCHFL-OWOJBTEDSA-N 0.000 description 2
- KKEYFWRCBNTPAC-UHFFFAOYSA-N Terephthalic acid Chemical compound OC(=O)C1=CC=C(C(O)=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-N 0.000 description 2
- WYURNTSHIVDZCO-UHFFFAOYSA-N Tetrahydrofuran Chemical compound C1CCOC1 WYURNTSHIVDZCO-UHFFFAOYSA-N 0.000 description 2
- XSQUKJJJFZCRTK-UHFFFAOYSA-N Urea Chemical compound NC(N)=O XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 description 2
- 239000001361 adipic acid Substances 0.000 description 2
- 235000011037 adipic acid Nutrition 0.000 description 2
- 125000003118 aryl group Chemical group 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 229910052797 bismuth Inorganic materials 0.000 description 2
- IISBACLAFKSPIT-UHFFFAOYSA-N bisphenol A Chemical compound C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 IISBACLAFKSPIT-UHFFFAOYSA-N 0.000 description 2
- 150000001735 carboxylic acids Chemical class 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- FOTKYAAJKYLFFN-UHFFFAOYSA-N decane-1,10-diol Chemical compound OCCCCCCCCCCO FOTKYAAJKYLFFN-UHFFFAOYSA-N 0.000 description 2
- 239000003599 detergent Substances 0.000 description 2
- 230000009477 glass transition Effects 0.000 description 2
- 230000007062 hydrolysis Effects 0.000 description 2
- 238000006460 hydrolysis reaction Methods 0.000 description 2
- 230000002209 hydrophobic effect Effects 0.000 description 2
- QQVIHTHCMHWDBS-UHFFFAOYSA-N isophthalic acid Chemical compound OC(=O)C1=CC=CC(C(O)=O)=C1 QQVIHTHCMHWDBS-UHFFFAOYSA-N 0.000 description 2
- 150000002736 metal compounds Chemical class 0.000 description 2
- BDAGIHXWWSANSR-UHFFFAOYSA-N methanoic acid Natural products OC=O BDAGIHXWWSANSR-UHFFFAOYSA-N 0.000 description 2
- BDJRBEYXGGNYIS-UHFFFAOYSA-N nonanedioic acid Chemical compound OC(=O)CCCCCCCC(O)=O BDJRBEYXGGNYIS-UHFFFAOYSA-N 0.000 description 2
- XNGIFLGASWRNHJ-UHFFFAOYSA-N phthalic acid Chemical compound OC(=O)C1=CC=CC=C1C(O)=O XNGIFLGASWRNHJ-UHFFFAOYSA-N 0.000 description 2
- 229920005906 polyester polyol Polymers 0.000 description 2
- 229920000166 polytrimethylene carbonate Polymers 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 235000013772 propylene glycol Nutrition 0.000 description 2
- 239000003381 stabilizer Substances 0.000 description 2
- TYFQFVWCELRYAO-UHFFFAOYSA-N suberic acid Chemical compound OC(=O)CCCCCCC(O)=O TYFQFVWCELRYAO-UHFFFAOYSA-N 0.000 description 2
- 150000005846 sugar alcohols Chemical class 0.000 description 2
- VZCYOOQTPOCHFL-UHFFFAOYSA-N trans-butenedioic acid Natural products OC(=O)C=CC(O)=O VZCYOOQTPOCHFL-UHFFFAOYSA-N 0.000 description 2
- DNIAPMSPPWPWGF-GSVOUGTGSA-N (R)-(-)-Propylene glycol Chemical compound C[C@@H](O)CO DNIAPMSPPWPWGF-GSVOUGTGSA-N 0.000 description 1
- ZBBLRPRYYSJUCZ-GRHBHMESSA-L (z)-but-2-enedioate;dibutyltin(2+) Chemical compound [O-]C(=O)\C=C/C([O-])=O.CCCC[Sn+2]CCCC ZBBLRPRYYSJUCZ-GRHBHMESSA-L 0.000 description 1
- GIWQSPITLQVMSG-UHFFFAOYSA-N 1,2-dimethylimidazole Chemical compound CC1=NC=CN1C GIWQSPITLQVMSG-UHFFFAOYSA-N 0.000 description 1
- FCQPNTOQFPJCMF-UHFFFAOYSA-N 1,3-bis[3-(dimethylamino)propyl]urea Chemical compound CN(C)CCCNC(=O)NCCCN(C)C FCQPNTOQFPJCMF-UHFFFAOYSA-N 0.000 description 1
- RXYPXQSKLGGKOL-UHFFFAOYSA-N 1,4-dimethylpiperazine Chemical compound CN1CCN(C)CC1 RXYPXQSKLGGKOL-UHFFFAOYSA-N 0.000 description 1
- LFSYUSUFCBOHGU-UHFFFAOYSA-N 1-isocyanato-2-[(4-isocyanatophenyl)methyl]benzene Chemical compound C1=CC(N=C=O)=CC=C1CC1=CC=CC=C1N=C=O LFSYUSUFCBOHGU-UHFFFAOYSA-N 0.000 description 1
- RTBFRGCFXZNCOE-UHFFFAOYSA-N 1-methylsulfonylpiperidin-4-one Chemical compound CS(=O)(=O)N1CCC(=O)CC1 RTBFRGCFXZNCOE-UHFFFAOYSA-N 0.000 description 1
- GEEGPFGTMRWCID-UHFFFAOYSA-N 1-n,1-n,1-n',1-n'-tetramethylbutane-1,1-diamine Chemical compound CCCC(N(C)C)N(C)C GEEGPFGTMRWCID-UHFFFAOYSA-N 0.000 description 1
- CVFRFSNPBJUQMG-UHFFFAOYSA-N 2,3-bis(2-hydroxyethyl)benzene-1,4-diol Chemical compound OCCC1=C(O)C=CC(O)=C1CCO CVFRFSNPBJUQMG-UHFFFAOYSA-N 0.000 description 1
- XNWFRZJHXBZDAG-UHFFFAOYSA-N 2-METHOXYETHANOL Chemical compound COCCO XNWFRZJHXBZDAG-UHFFFAOYSA-N 0.000 description 1
- IIVBUJGYWCCLNG-UHFFFAOYSA-N 3-(dimethylamino)propylurea Chemical compound CN(C)CCCNC(N)=O IIVBUJGYWCCLNG-UHFFFAOYSA-N 0.000 description 1
- OSWFIVFLDKOXQC-UHFFFAOYSA-N 4-(3-methoxyphenyl)aniline Chemical compound COC1=CC=CC(C=2C=CC(N)=CC=2)=C1 OSWFIVFLDKOXQC-UHFFFAOYSA-N 0.000 description 1
- BRKHZWFIIVVNTA-UHFFFAOYSA-N 4-cyclohexylmorpholine Chemical compound C1CCCCC1N1CCOCC1 BRKHZWFIIVVNTA-UHFFFAOYSA-N 0.000 description 1
- HVCNXQOWACZAFN-UHFFFAOYSA-N 4-ethylmorpholine Chemical compound CCN1CCOCC1 HVCNXQOWACZAFN-UHFFFAOYSA-N 0.000 description 1
- YPIFGDQKSSMYHQ-UHFFFAOYSA-M 7,7-dimethyloctanoate Chemical compound CC(C)(C)CCCCCC([O-])=O YPIFGDQKSSMYHQ-UHFFFAOYSA-M 0.000 description 1
- FBPFZTCFMRRESA-FSIIMWSLSA-N D-Glucitol Natural products OC[C@H](O)[C@H](O)[C@@H](O)[C@H](O)CO FBPFZTCFMRRESA-FSIIMWSLSA-N 0.000 description 1
- FBPFZTCFMRRESA-JGWLITMVSA-N D-glucitol Chemical compound OC[C@H](O)[C@@H](O)[C@H](O)[C@H](O)CO FBPFZTCFMRRESA-JGWLITMVSA-N 0.000 description 1
- RPNUMPOLZDHAAY-UHFFFAOYSA-N Diethylenetriamine Chemical compound NCCNCCN RPNUMPOLZDHAAY-UHFFFAOYSA-N 0.000 description 1
- PIICEJLVQHRZGT-UHFFFAOYSA-N Ethylenediamine Chemical compound NCCN PIICEJLVQHRZGT-UHFFFAOYSA-N 0.000 description 1
- WQZGKKKJIJFFOK-GASJEMHNSA-N Glucose Natural products OC[C@H]1OC(O)[C@H](O)[C@@H](O)[C@@H]1O WQZGKKKJIJFFOK-GASJEMHNSA-N 0.000 description 1
- KWYHDKDOAIKMQN-UHFFFAOYSA-N N,N,N',N'-tetramethylethylenediamine Chemical compound CN(C)CCN(C)C KWYHDKDOAIKMQN-UHFFFAOYSA-N 0.000 description 1
- AFCARXCZXQIEQB-UHFFFAOYSA-N N-[3-oxo-3-(2,4,6,7-tetrahydrotriazolo[4,5-c]pyridin-5-yl)propyl]-2-[[3-(trifluoromethoxy)phenyl]methylamino]pyrimidine-5-carboxamide Chemical compound O=C(CCNC(=O)C=1C=NC(=NC=1)NCC1=CC(=CC=C1)OC(F)(F)F)N1CC2=C(CC1)NN=N2 AFCARXCZXQIEQB-UHFFFAOYSA-N 0.000 description 1
- UEEJHVSXFDXPFK-UHFFFAOYSA-N N-dimethylaminoethanol Chemical compound CN(C)CCO UEEJHVSXFDXPFK-UHFFFAOYSA-N 0.000 description 1
- AKNUHUCEWALCOI-UHFFFAOYSA-N N-ethyldiethanolamine Chemical compound OCCN(CC)CCO AKNUHUCEWALCOI-UHFFFAOYSA-N 0.000 description 1
- 229920003171 Poly (ethylene oxide) Polymers 0.000 description 1
- OFOBLEOULBTSOW-UHFFFAOYSA-N Propanedioic acid Natural products OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 description 1
- KDYFGRWQOYBRFD-UHFFFAOYSA-N Succinic acid Natural products OC(=O)CCC(O)=O KDYFGRWQOYBRFD-UHFFFAOYSA-N 0.000 description 1
- CZMRCDWAGMRECN-UGDNZRGBSA-N Sucrose Chemical compound O[C@H]1[C@H](O)[C@@H](CO)O[C@@]1(CO)O[C@@H]1[C@H](O)[C@@H](O)[C@H](O)[C@@H](CO)O1 CZMRCDWAGMRECN-UGDNZRGBSA-N 0.000 description 1
- 229930006000 Sucrose Natural products 0.000 description 1
- GSEJCLTVZPLZKY-UHFFFAOYSA-N Triethanolamine Chemical compound OCCN(CCO)CCO GSEJCLTVZPLZKY-UHFFFAOYSA-N 0.000 description 1
- SLINHMUFWFWBMU-UHFFFAOYSA-N Triisopropanolamine Chemical compound CC(O)CN(CC(C)O)CC(C)O SLINHMUFWFWBMU-UHFFFAOYSA-N 0.000 description 1
- ISKQADXMHQSTHK-UHFFFAOYSA-N [4-(aminomethyl)phenyl]methanamine Chemical compound NCC1=CC=C(CN)C=C1 ISKQADXMHQSTHK-UHFFFAOYSA-N 0.000 description 1
- CQQXCSFSYHAZOO-UHFFFAOYSA-L [acetyloxy(dioctyl)stannyl] acetate Chemical compound CCCCCCCC[Sn](OC(C)=O)(OC(C)=O)CCCCCCCC CQQXCSFSYHAZOO-UHFFFAOYSA-L 0.000 description 1
- UKLDJPRMSDWDSL-UHFFFAOYSA-L [dibutyl(dodecanoyloxy)stannyl] dodecanoate Chemical compound CCCCCCCCCCCC(=O)O[Sn](CCCC)(CCCC)OC(=O)CCCCCCCCCCC UKLDJPRMSDWDSL-UHFFFAOYSA-L 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 150000001241 acetals Chemical class 0.000 description 1
- 150000001252 acrylic acid derivatives Chemical class 0.000 description 1
- 239000013543 active substance Substances 0.000 description 1
- 238000007259 addition reaction Methods 0.000 description 1
- 230000003679 aging effect Effects 0.000 description 1
- 150000001335 aliphatic alkanes Chemical class 0.000 description 1
- 125000001931 aliphatic group Chemical group 0.000 description 1
- 150000001338 aliphatic hydrocarbons Chemical class 0.000 description 1
- 150000001409 amidines Chemical class 0.000 description 1
- 150000001414 amino alcohols Chemical class 0.000 description 1
- 150000008064 anhydrides Chemical class 0.000 description 1
- JFCQEDHGNNZCLN-UHFFFAOYSA-N anhydrous glutaric acid Natural products OC(=O)CCCC(O)=O JFCQEDHGNNZCLN-UHFFFAOYSA-N 0.000 description 1
- 150000007514 bases Chemical class 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- HIFVAOIJYDXIJG-UHFFFAOYSA-N benzylbenzene;isocyanic acid Chemical class N=C=O.N=C=O.C=1C=CC=CC=1CC1=CC=CC=C1 HIFVAOIJYDXIJG-UHFFFAOYSA-N 0.000 description 1
- WQZGKKKJIJFFOK-VFUOTHLCSA-N beta-D-glucose Chemical compound OC[C@H]1O[C@@H](O)[C@H](O)[C@@H](O)[C@@H]1O WQZGKKKJIJFFOK-VFUOTHLCSA-N 0.000 description 1
- 239000004305 biphenyl Substances 0.000 description 1
- 235000010290 biphenyl Nutrition 0.000 description 1
- NUMHJBONQMZPBW-UHFFFAOYSA-K bis(2-ethylhexanoyloxy)bismuthanyl 2-ethylhexanoate Chemical compound [Bi+3].CCCCC(CC)C([O-])=O.CCCCC(CC)C([O-])=O.CCCCC(CC)C([O-])=O NUMHJBONQMZPBW-UHFFFAOYSA-K 0.000 description 1
- JCXGWMGPZLAOME-UHFFFAOYSA-N bismuth atom Chemical compound [Bi] JCXGWMGPZLAOME-UHFFFAOYSA-N 0.000 description 1
- ZZUFUNZTPNRBID-UHFFFAOYSA-K bismuth;octanoate Chemical compound [Bi+3].CCCCCCCC([O-])=O.CCCCCCCC([O-])=O.CCCCCCCC([O-])=O ZZUFUNZTPNRBID-UHFFFAOYSA-K 0.000 description 1
- OHJMTUPIZMNBFR-UHFFFAOYSA-N biuret Chemical group NC(=O)NC(N)=O OHJMTUPIZMNBFR-UHFFFAOYSA-N 0.000 description 1
- CDQSJQSWAWPGKG-UHFFFAOYSA-N butane-1,1-diol Chemical class CCCC(O)O CDQSJQSWAWPGKG-UHFFFAOYSA-N 0.000 description 1
- KDYFGRWQOYBRFD-NUQCWPJISA-N butanedioic acid Chemical compound O[14C](=O)CC[14C](O)=O KDYFGRWQOYBRFD-NUQCWPJISA-N 0.000 description 1
- 239000004202 carbamide Substances 0.000 description 1
- 150000001718 carbodiimides Chemical class 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 229910002092 carbon dioxide Inorganic materials 0.000 description 1
- BVKZGUZCCUSVTD-UHFFFAOYSA-N carbonic acid Chemical class OC(O)=O BVKZGUZCCUSVTD-UHFFFAOYSA-N 0.000 description 1
- 230000003197 catalytic effect Effects 0.000 description 1
- 238000006555 catalytic reaction Methods 0.000 description 1
- 239000002666 chemical blowing agent Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000009833 condensation Methods 0.000 description 1
- 230000005494 condensation Effects 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 125000004122 cyclic group Chemical group 0.000 description 1
- ZHMPXIDAUXCKIQ-UHFFFAOYSA-N cyclohexane-1,2,4-triol Chemical compound OC1CCC(O)C(O)C1 ZHMPXIDAUXCKIQ-UHFFFAOYSA-N 0.000 description 1
- PFURGBBHAOXLIO-UHFFFAOYSA-N cyclohexane-1,2-diol Chemical compound OC1CCCCC1O PFURGBBHAOXLIO-UHFFFAOYSA-N 0.000 description 1
- FSDSKERRNURGGO-UHFFFAOYSA-N cyclohexane-1,3,5-triol Chemical compound OC1CC(O)CC(O)C1 FSDSKERRNURGGO-UHFFFAOYSA-N 0.000 description 1
- RLMGYIOTPQVQJR-UHFFFAOYSA-N cyclohexane-1,3-diol Chemical compound OC1CCCC(O)C1 RLMGYIOTPQVQJR-UHFFFAOYSA-N 0.000 description 1
- VKONPUDBRVKQLM-UHFFFAOYSA-N cyclohexane-1,4-diol Chemical compound OC1CCC(O)CC1 VKONPUDBRVKQLM-UHFFFAOYSA-N 0.000 description 1
- 230000006378 damage Effects 0.000 description 1
- 229960002887 deanol Drugs 0.000 description 1
- 230000006837 decompression Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 230000006735 deficit Effects 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- JQZRVMZHTADUSY-UHFFFAOYSA-L di(octanoyloxy)tin Chemical compound [Sn+2].CCCCCCCC([O-])=O.CCCCCCCC([O-])=O JQZRVMZHTADUSY-UHFFFAOYSA-L 0.000 description 1
- PNOXNTGLSKTMQO-UHFFFAOYSA-L diacetyloxytin Chemical compound CC(=O)O[Sn]OC(C)=O PNOXNTGLSKTMQO-UHFFFAOYSA-L 0.000 description 1
- 239000012975 dibutyltin dilaurate Substances 0.000 description 1
- 150000001990 dicarboxylic acid derivatives Chemical class 0.000 description 1
- ZBCBWPMODOFKDW-UHFFFAOYSA-N diethanolamine Chemical compound OCCNCCO ZBCBWPMODOFKDW-UHFFFAOYSA-N 0.000 description 1
- 125000005442 diisocyanate group Chemical group 0.000 description 1
- XXBDWLFCJWSEKW-UHFFFAOYSA-N dimethylbenzylamine Chemical compound CN(C)CC1=CC=CC=C1 XXBDWLFCJWSEKW-UHFFFAOYSA-N 0.000 description 1
- 239000012972 dimethylethanolamine Substances 0.000 description 1
- 239000012971 dimethylpiperazine Substances 0.000 description 1
- PYBNTRWJKQJDRE-UHFFFAOYSA-L dodecanoate;tin(2+) Chemical compound [Sn+2].CCCCCCCCCCCC([O-])=O.CCCCCCCCCCCC([O-])=O PYBNTRWJKQJDRE-UHFFFAOYSA-L 0.000 description 1
- 239000000975 dye Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 150000002170 ethers Chemical class 0.000 description 1
- PLONEVHFXDFSLA-UHFFFAOYSA-N ethyl hexanoate;tin(2+) Chemical compound [Sn+2].CCCCCC(=O)OCC PLONEVHFXDFSLA-UHFFFAOYSA-N 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 239000004872 foam stabilizing agent Substances 0.000 description 1
- 238000005187 foaming Methods 0.000 description 1
- 235000019253 formic acid Nutrition 0.000 description 1
- 239000001530 fumaric acid Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 239000008103 glucose Substances 0.000 description 1
- 150000008282 halocarbons Chemical class 0.000 description 1
- 125000000623 heterocyclic group Chemical group 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 150000005165 hydroxybenzoic acids Chemical class 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- IQPQWNKOIGAROB-UHFFFAOYSA-N isocyanate group Chemical group [N-]=C=O IQPQWNKOIGAROB-UHFFFAOYSA-N 0.000 description 1
- ZFSLODLOARCGLH-UHFFFAOYSA-N isocyanuric acid Chemical compound OC1=NC(O)=NC(O)=N1 ZFSLODLOARCGLH-UHFFFAOYSA-N 0.000 description 1
- 150000002576 ketones Chemical class 0.000 description 1
- 150000002596 lactones Chemical class 0.000 description 1
- VZCYOOQTPOCHFL-UPHRSURJSA-N maleic acid Chemical compound OC(=O)\C=C/C(O)=O VZCYOOQTPOCHFL-UPHRSURJSA-N 0.000 description 1
- 239000011976 maleic acid Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- CRVGTESFCCXCTH-UHFFFAOYSA-N methyl diethanolamine Chemical compound OCCN(C)CCO CRVGTESFCCXCTH-UHFFFAOYSA-N 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- TXXWBTOATXBWDR-UHFFFAOYSA-N n,n,n',n'-tetramethylhexane-1,6-diamine Chemical compound CN(C)CCCCCCN(C)C TXXWBTOATXBWDR-UHFFFAOYSA-N 0.000 description 1
- KYTZHLUVELPASH-UHFFFAOYSA-N naphthalene-1,2-dicarboxylic acid Chemical class C1=CC=CC2=C(C(O)=O)C(C(=O)O)=CC=C21 KYTZHLUVELPASH-UHFFFAOYSA-N 0.000 description 1
- 150000002825 nitriles Chemical class 0.000 description 1
- 230000000399 orthopedic effect Effects 0.000 description 1
- WXZMFSXDPGVJKK-UHFFFAOYSA-N pentaerythritol Chemical compound OCC(CO)(CO)CO WXZMFSXDPGVJKK-UHFFFAOYSA-N 0.000 description 1
- UKODFQOELJFMII-UHFFFAOYSA-N pentamethyldiethylenetriamine Chemical compound CN(C)CCN(C)CCN(C)C UKODFQOELJFMII-UHFFFAOYSA-N 0.000 description 1
- 229960004624 perflexane Drugs 0.000 description 1
- ZJIJAJXFLBMLCK-UHFFFAOYSA-N perfluorohexane Chemical compound FC(F)(F)C(F)(F)C(F)(F)C(F)(F)C(F)(F)C(F)(F)F ZJIJAJXFLBMLCK-UHFFFAOYSA-N 0.000 description 1
- ZUOUZKKEUPVFJK-UHFFFAOYSA-N phenylbenzene Natural products C1=CC=CC=C1C1=CC=CC=C1 ZUOUZKKEUPVFJK-UHFFFAOYSA-N 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 238000006116 polymerization reaction Methods 0.000 description 1
- 229920005903 polyol mixture Polymers 0.000 description 1
- AOHJOMMDDJHIJH-UHFFFAOYSA-N propylenediamine Chemical compound CC(N)CN AOHJOMMDDJHIJH-UHFFFAOYSA-N 0.000 description 1
- ADRDEXBBJTUCND-UHFFFAOYSA-N pyrrolizidine Chemical compound C1CCN2CCCC21 ADRDEXBBJTUCND-UHFFFAOYSA-N 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 239000000376 reactant Substances 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 239000000600 sorbitol Substances 0.000 description 1
- 238000009987 spinning Methods 0.000 description 1
- 239000005720 sucrose Substances 0.000 description 1
- 210000004243 sweat Anatomy 0.000 description 1
- 230000035900 sweating Effects 0.000 description 1
- 238000003786 synthesis reaction Methods 0.000 description 1
- 150000003512 tertiary amines Chemical class 0.000 description 1
- YLQBMQCUIZJEEH-UHFFFAOYSA-N tetrahydrofuran Natural products C=1C=COC=1 YLQBMQCUIZJEEH-UHFFFAOYSA-N 0.000 description 1
- 150000003606 tin compounds Chemical class 0.000 description 1
- IUTCEZPPWBHGIX-UHFFFAOYSA-N tin(2+) Chemical class [Sn+2] IUTCEZPPWBHGIX-UHFFFAOYSA-N 0.000 description 1
- IMFACGCPASFAPR-UHFFFAOYSA-N tributylamine Chemical compound CCCCN(CCCC)CCCC IMFACGCPASFAPR-UHFFFAOYSA-N 0.000 description 1
- IMNIMPAHZVJRPE-UHFFFAOYSA-N triethylenediamine Chemical compound C1CN2CCN1CC2 IMNIMPAHZVJRPE-UHFFFAOYSA-N 0.000 description 1
- AVWRKZWQTYIKIY-UHFFFAOYSA-N urea-1-carboxylic acid Chemical compound NC(=O)NC(O)=O AVWRKZWQTYIKIY-UHFFFAOYSA-N 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
- PAPBSGBWRJIAAV-UHFFFAOYSA-N ε-Caprolactone Chemical compound O=C1CCCCCO1 PAPBSGBWRJIAAV-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
- C08G18/2805—Compounds having only one group containing active hydrogen
- C08G18/2815—Monohydroxy compounds
- C08G18/283—Compounds containing ether groups, e.g. oxyalkylated monohydroxy compounds
- C08G18/2835—Compounds containing ether groups, e.g. oxyalkylated monohydroxy compounds having less than 5 ether groups
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
- C08G18/40—High-molecular-weight compounds
- C08G18/48—Polyethers
- C08G18/4804—Two or more polyethers of different physical or chemical nature
- C08G18/4812—Mixtures of polyetherdiols with polyetherpolyols having at least three hydroxy groups
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
- C08G18/65—Low-molecular-weight compounds having active hydrogen with high-molecular-weight compounds having active hydrogen
- C08G18/66—Compounds of groups C08G18/42, C08G18/48, or C08G18/52
- C08G18/6666—Compounds of group C08G18/48 or C08G18/52
- C08G18/667—Compounds of group C08G18/48 or C08G18/52 with compounds of group C08G18/32 or polyamines of C08G18/38
- C08G18/6674—Compounds of group C08G18/48 or C08G18/52 with compounds of group C08G18/32 or polyamines of C08G18/38 with compounds of group C08G18/3203
- C08G18/6677—Compounds of group C08G18/48 or C08G18/52 with compounds of group C08G18/32 or polyamines of C08G18/38 with compounds of group C08G18/3203 having at least three hydroxy groups
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G2110/00—Foam properties
- C08G2110/0008—Foam properties flexible
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G2110/00—Foam properties
- C08G2110/0041—Foam properties having specified density
- C08G2110/005—< 50kg/m3
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G2110/00—Foam properties
- C08G2110/0041—Foam properties having specified density
- C08G2110/0058—≥50 and <150kg/m3
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G2110/00—Foam properties
- C08G2110/0083—Foam properties prepared using water as the sole blowing agent
Abstract
The present invention relates to a process for producing viscoelastic flexible polyurethane foams having an air flow value of at least 1 dm3/s, which comprises (a) polyisocyanate being mixed with (b) polymeric compounds having isocyanate-reactive groups, (c) optionally chain-extending and/or crosslinking agents, (d) optionally compounds having one isocyanate-reactive group with a hydroxyl number of 100 to 500 mg KOH/g, (e) catalyst, (f) blowing agent, and also optionally (g) addition agents to form a reaction mixture and convert it into flexible polyurethane foam, wherein the polymeric compounds having isocyanate-reactive groups (b) comprise (b1) 10 to 40 wt% of at least one polyalkylene oxide having a hydroxyl number of 90 to 300 mg KOH/g, based on a 3 to 6-functional starter molecule and a propylene oxide fraction, based on the alkylene oxide content, of 80 to 100 wt%, (b2) 5 to 20 wt% of at least one polyalkylene oxide having a hydroxyl number of 10 to 60 mg KOH/g, based on a 2 to 4-functional starter molecule and a propylene oxide fraction, based on the alkylene oxide content, of 80 to 100 wt%, (b3) 10 to 50 wt% of at least one polyalkylene oxide having a hydroxyl number of 10 to 55 mg KOH/g, based on a 2 to 4-functional starter molecule and an ethylene oxide fraction, based on the alkylene oxide content, of 70 to 100 wt%, and (b4) 0 to 20 wt% of at least one polyalkylene oxide having a hydroxyl number of 50 to 200 mg KOH/g, based on a 2-functional starter molecule and an ethylene oxide fraction, based on the alkylene oxide content, of 80 to 100 wt%, and wherein the fraction of compounds b1) to b4), based on the total weight of polymeric compounds having isocyanate-reactive groups (b), is at least 80 wt%. The present invention further relates to a viscoelastic polyurethane foam having an air flow value of at least 1 dm3/s, which is obtainable by such a process, and to the use of such a polyurethane foam for mattresses and cushions.
Description
Washable viscoelastic flexible polyurethane foams Description The present invention relates to a process for producing viscoelastic flexible polyurethane foams having an air flow value of at least 1 dm3/s, which comprises (a) polyisocyanate being mixed with (b) polymeric compounds having isocyanate-reactive groups, (c) optionally chain-extending and/or crosslinking agents, (d) optionally compounds having one isocyanate-reactive group with a hydroxyl number of 100 to 500 mg KOH/g, (e) catalyst, (f) blowing agent, and also optionally (g) addition agents to form a reaction mixture and convert it into flexible polyurethane foam, wherein the polymeric compounds having isocyanate-reactive groups (b) comprise (b1) 10 to 40 wt% of at least one polyalkylene oxide having a hydroxyl number of 90 to 300 mg KOH/g, based on a 3 to 6-functional starter molecule and a propylene oxide fraction, based on the alkylene oxide content, of 80 to 100 wt%, (b2) 5 to 20 wt% of at least one polyalkylene oxide having a hydroxyl number of 10 to 60 mg KOH/g, based on a 2 to 4-functional starter molecule and a propylene oxide fraction, based on the alkylene oxide content, of 80 to 100 wt%, (b3) 10 to 50 wt% of at least one polyalkylene oxide having a hydroxyl number of 10 to 55 mg KOH/g, based on a 2 to 4-functional starter molecule and an ethylene oxide fraction, based on the alkylene oxide content, of 70 to 100 wt%, and (b4) 0 to 20 wt% of at least one polyalkylene oxide having a hydroxyl number of 50 to 200 mg KOH/g, based on a 2-functional starter molecule and an ethylene oxide fraction, based on the alkylene oxide content, of 80 to 100 wt%, and wherein the fraction of compounds b1) to b4), based on the total weight of polymeric compounds having isocyanate-reactive groups (b), is at least 80 wt%. The present invention further relates to a viscoelastic polyurethane foam having an air flow value of at least 1 dm3/s, which is obtainable by such a process, and to the use of such a polyurethane foam for mattresses and cushions.
Viscoelastic flexible polyurethane foams have attained ever greater importance in recent years.
They are used in particular for producing upholstery, pillows, mattresses or for vibration damping, . .
Viscoelastic flexible polyurethane foams have attained ever greater importance in recent years.
They are used in particular for producing upholstery, pillows, mattresses or for vibration damping, . .
2 for example in carpet backfoaming or in-place cavity foaming. Viscoelastic foams are notable for their slow recovery after compression.
Currently there are two different groups of viscoelastic foams, which differ in cell structure and the mechanism of viscoelasticity.
So-called pneumatically (physically) viscoelastic foams (pVEs) are closed-cell flexible PU foams with perforate cellular membrane, the air flow value of which is very low. On compression, the air is squeezed out of the cells of the foam. On decompression, the air flow value limits the rate at which the foam can relax back into its original shape. Recovery time is therefore dependent on the degree of perforation/open-cell content of the flexible PU foam, inter alia. The higher the closed-cell content of the flexible PU foam, the slower the recovery.
Examples of polyurethane foams with pneumatic viscoelasticity have already been extensively described in the literature and patent documents. As far back as 1989, DE3942330 described a process for producing flexible polyurethane foams having viscoelastic, structureborne sound-damping properties and the polyoxyalkylene-polyol mixtures used therefor.
Viscoelastic properties can be achieved in different ways. US6391935, EP
908478 and WO 2005/003206 respectively describe the use of monools; of cyclic and heterocyclic components;
and of certain chain extenders.
Where the patent documents do not differ is that the dominating proportion of polyetherol mixtures is constructed from very hydrophilic building blocks, especially polyethylene oxide units.
Furthermore, the cells of the polyurethane foam are overwhelmingly closed-cell with perforation, and so the viscoelastic effect is predominantly due to the low air flow value of the cellular membranes.
Currently there are two different groups of viscoelastic foams, which differ in cell structure and the mechanism of viscoelasticity.
So-called pneumatically (physically) viscoelastic foams (pVEs) are closed-cell flexible PU foams with perforate cellular membrane, the air flow value of which is very low. On compression, the air is squeezed out of the cells of the foam. On decompression, the air flow value limits the rate at which the foam can relax back into its original shape. Recovery time is therefore dependent on the degree of perforation/open-cell content of the flexible PU foam, inter alia. The higher the closed-cell content of the flexible PU foam, the slower the recovery.
Examples of polyurethane foams with pneumatic viscoelasticity have already been extensively described in the literature and patent documents. As far back as 1989, DE3942330 described a process for producing flexible polyurethane foams having viscoelastic, structureborne sound-damping properties and the polyoxyalkylene-polyol mixtures used therefor.
Viscoelastic properties can be achieved in different ways. US6391935, EP
908478 and WO 2005/003206 respectively describe the use of monools; of cyclic and heterocyclic components;
and of certain chain extenders.
Where the patent documents do not differ is that the dominating proportion of polyetherol mixtures is constructed from very hydrophilic building blocks, especially polyethylene oxide units.
Furthermore, the cells of the polyurethane foam are overwhelmingly closed-cell with perforation, and so the viscoelastic effect is predominantly due to the low air flow value of the cellular membranes.
3 The pneumatically viscoelastic polyurethane foams described in the references cited have the disadvantage that the high closed-cell content greatly limits air interchange.
Without air interchange, there can be no removal of heat for example from the human body, leading to increased sweating, nor of moist air for example from human perspiration or from washing.
.. Furthermore, the high proportion of hydrophilic polyols means that the foam is very hydrophilic, tends to imbibe water and is only slow to release it again, and therefore tends to swell up. A further disadvantage of these viscoelastic polyurethane foams is their low mechanical strength, as reflected more particularly by low values of tensile strength in particular, which are even worse in the wet state.
Furthermore, the high hydrophilicity of the foams leads to high water imbibition, for example in the form of sweat or on attempting to launder the foam. The water can pass into perforate cells as well as into the hydrophilic matrix of the foam, causing substantial swelling up of the foam. These foams cannot be dried nondestructively owing to their low air flow value.
An attempt to dry these wet foams will frequently cause the cellular membranes to burst or rupture, which leads to the viscoelastic behavior being lost and the foam's scaffolding being destroyed.
So-called structurally or chemically viscoelastic flexible polyurethane foams (cVEs) are notable for .. their glass transition temperature being in the vicinity of room temperature. Such cVE foams can be open-cell and yet viscoelastic.
Recovery time here is controlled by using a specific polyether polyol composition as well as a more or less freely choosable isocyanate component. An open-cell foam is of advantage for the special .. comfort expected of mattresses and pillows in particular, since it enables air interchange and provides an improved microclimate.
Examples of open-cell structurally viscoelastic flexible foams (cVEs) have already been extensively described in patent documents and the literature. US7022746 describes an open-cell viscoelastic
Without air interchange, there can be no removal of heat for example from the human body, leading to increased sweating, nor of moist air for example from human perspiration or from washing.
.. Furthermore, the high proportion of hydrophilic polyols means that the foam is very hydrophilic, tends to imbibe water and is only slow to release it again, and therefore tends to swell up. A further disadvantage of these viscoelastic polyurethane foams is their low mechanical strength, as reflected more particularly by low values of tensile strength in particular, which are even worse in the wet state.
Furthermore, the high hydrophilicity of the foams leads to high water imbibition, for example in the form of sweat or on attempting to launder the foam. The water can pass into perforate cells as well as into the hydrophilic matrix of the foam, causing substantial swelling up of the foam. These foams cannot be dried nondestructively owing to their low air flow value.
An attempt to dry these wet foams will frequently cause the cellular membranes to burst or rupture, which leads to the viscoelastic behavior being lost and the foam's scaffolding being destroyed.
So-called structurally or chemically viscoelastic flexible polyurethane foams (cVEs) are notable for .. their glass transition temperature being in the vicinity of room temperature. Such cVE foams can be open-cell and yet viscoelastic.
Recovery time here is controlled by using a specific polyether polyol composition as well as a more or less freely choosable isocyanate component. An open-cell foam is of advantage for the special .. comfort expected of mattresses and pillows in particular, since it enables air interchange and provides an improved microclimate.
Examples of open-cell structurally viscoelastic flexible foams (cVEs) have already been extensively described in patent documents and the literature. US7022746 describes an open-cell viscoelastic
4 foam having an ASTM3574G-95 air flow value of up to 3.9 dm3/s coupled with a maximum value of the loss modulus tan delta at 10-12 C. This reference, which includes improved mechanical properties amongst its objects, further describes viscoelastic polyurethane foams having a tensile strength of 37 to 60 kPa. Two main polyols are used in this reference, each with a weight fraction of 30-70 wt%, one polyol consisting of ethylene oxide building blocks to an extent of 70-100 wt% while the second polyol consists of propylene oxide building blocks to an extent of 70-100%. As a result, this foam is minimally more hydrophobic than the foams obtained with exclusively ethylene oxide-based polyols, but especially the swellability in water as well as the tensile strength of these foams is in need of further improvement.
DE102997061883 describes a slabstock foam system which is said to be open-cell, although it first has to be flexed after manufacture. The polyol used is essentially a polyol constructed nearly half and half of PO and E0 building blocks.
The foam of DE 102997061883 is closed-cell in the as-produced state, it is only after mechanical flexing that the cellular membranes will burst open to some extent. The patent document does not recite any measured DIN air flow value, but does state that an in-house measurement found an air resistance of 350 mm water column, suggesting a very low air flow. Moreover, foams according to DE102997061883 display a very low tensile strength of 36 kPa.
These disadvantages are said to be compensated by using specific polyols.
describes the use of polyetherols initiated on bisphenol A, which should give increased tensile strength, yet the foams obtained display only tensile strengths of up to 65 kPa.
EP1960452 describes recipes comprising a distinctly reduced fraction of hydrophilic polyol. A
person skilled in the art would expect this to result in a distinctly lower water imbibition and lower swelling of the foams. The flexible foams mentioned in the patent document do indeed display reduced swelling in water of just 4-7%. It is likewise stated that the hydrophilic flexible foams mentioned in the prior art are unsuitable owing to their swellability of about 40% in moist media.
The foams recited in the patent document again display only low tensile strengths of up to 63 kPa and therefore are not fit for high mechanical loads despite the low water imbibition.
DE10352100 concerns the swelling behavior of viscoelastic foams in water and describes
DE102997061883 describes a slabstock foam system which is said to be open-cell, although it first has to be flexed after manufacture. The polyol used is essentially a polyol constructed nearly half and half of PO and E0 building blocks.
The foam of DE 102997061883 is closed-cell in the as-produced state, it is only after mechanical flexing that the cellular membranes will burst open to some extent. The patent document does not recite any measured DIN air flow value, but does state that an in-house measurement found an air resistance of 350 mm water column, suggesting a very low air flow. Moreover, foams according to DE102997061883 display a very low tensile strength of 36 kPa.
These disadvantages are said to be compensated by using specific polyols.
describes the use of polyetherols initiated on bisphenol A, which should give increased tensile strength, yet the foams obtained display only tensile strengths of up to 65 kPa.
EP1960452 describes recipes comprising a distinctly reduced fraction of hydrophilic polyol. A
person skilled in the art would expect this to result in a distinctly lower water imbibition and lower swelling of the foams. The flexible foams mentioned in the patent document do indeed display reduced swelling in water of just 4-7%. It is likewise stated that the hydrophilic flexible foams mentioned in the prior art are unsuitable owing to their swellability of about 40% in moist media.
The foams recited in the patent document again display only low tensile strengths of up to 63 kPa and therefore are not fit for high mechanical loads despite the low water imbibition.
DE10352100 concerns the swelling behavior of viscoelastic foams in water and describes
5 pneumatic viscoelastic foams having improved hydrolysis and aging properties. Also described are foams where there are viscoelastic properties over a wide temperature range.
This is achieved through the use of 10-60 wt% of acrylate polyols. Swellability in water is 4%
and the tan delta curve promises viscoelastic behavior over a wide temperature range. Tensile strengths are not reported.
Disadvantages with using acrylate polyols are the high price and especially the high emissions of acrylates, which become unpleasantly noticeable by odor. These foams further also display a high closed-cell content with the recited disadvantages.
W02007/144272 describes hydrophobic viscoelastic open-cell slabstock foams comprising TDI as isocyanate component. Polyol components comprising a high proportion of polymeric polyetherols (graft polyethers) are used. Disadvantages are the low tensile strength, reported as 40-60 kPa, and the low air flow value of just 30-60 L/min.
The use of chemically modified or unmodified polyetherols or monools based on renewable raw materials is currently a frequent topic in newly filed applications. These so-called bio-polyols find use in the sector of viscoelastic open-cell foams in EP1981926, W02009/106240 but also W02009/032894. Low tensile strength is again a disadvantage in that 70 kPa is the maximum reported in any of the cited patent documents.
The present invention has for its object to provide a viscoelastic flexible polyurethane foam having an outstanding air flow value and a high tensile strength by using essentially customary polyols.
The present invention further has for its object to provide a polyurethane foam which can be washed nondestructively, especially in a commercial washing machine using a customary washing powder at temperatures up to 60 C, and subsequently dried without the viscoelastic properties being lost by the washing and drying.
This is achieved through the use of 10-60 wt% of acrylate polyols. Swellability in water is 4%
and the tan delta curve promises viscoelastic behavior over a wide temperature range. Tensile strengths are not reported.
Disadvantages with using acrylate polyols are the high price and especially the high emissions of acrylates, which become unpleasantly noticeable by odor. These foams further also display a high closed-cell content with the recited disadvantages.
W02007/144272 describes hydrophobic viscoelastic open-cell slabstock foams comprising TDI as isocyanate component. Polyol components comprising a high proportion of polymeric polyetherols (graft polyethers) are used. Disadvantages are the low tensile strength, reported as 40-60 kPa, and the low air flow value of just 30-60 L/min.
The use of chemically modified or unmodified polyetherols or monools based on renewable raw materials is currently a frequent topic in newly filed applications. These so-called bio-polyols find use in the sector of viscoelastic open-cell foams in EP1981926, W02009/106240 but also W02009/032894. Low tensile strength is again a disadvantage in that 70 kPa is the maximum reported in any of the cited patent documents.
The present invention has for its object to provide a viscoelastic flexible polyurethane foam having an outstanding air flow value and a high tensile strength by using essentially customary polyols.
The present invention further has for its object to provide a polyurethane foam which can be washed nondestructively, especially in a commercial washing machine using a customary washing powder at temperatures up to 60 C, and subsequently dried without the viscoelastic properties being lost by the washing and drying.
6 We have found that this object is achieved, surprisingly, by a process for producing viscoelastic flexible polyurethane foams having an air flow value of at least 1 dm3/s, which comprises (a) polyisocyanate being mixed with (b) polymeric compounds having isocyanate-reactive groups, (c) optionally chain-extending and/or crosslinking agents, (d) optionally compounds having one isocyanate-reactive group with a hydroxyl number of 100 to 500 mg KOH/g, (e) catalyst, (f) blowing agent, and also optionally (g) addition agents to form a reaction mixture and convert it into flexible polyurethane foam, wherein the polymeric compounds having isocyanate-reactive groups (b) comprise (b1) 10 to 40 wt% of at least one polyalkylene oxide having a hydroxyl number of 90 to 300 mg KOH/g, based on a 3 to 6-functional starter molecule and a propylene oxide fraction, based on the alkylene oxide content, of 80 to 100 wt%, (b2) 5 to 20 wt% of at least one polyalkylene oxide having a hydroxyl number of 10 to 60 mg KOH/g, based on a 2 to 4-functional starter molecule and a propylene oxide fraction, based on the alkylene oxide content, of 80 to 100 wt%, (b3) 10 to 50 wt% of at least one polyalkylene oxide having a hydroxyl number of 10 to 55 mg KOH/g, based on a 2 to 4-functional starter molecule and an ethylene oxide fraction, based on the alkylene oxide content, of 70 to 100 wt%, and (b4) 0 to 20 wt% of at least one polyalkylene oxide having a hydroxyl number of 50 to 200 mg KOH/g, based on a 2-functional starter molecule and an ethylene oxide fraction, based on the alkylene oxide content, of 80 to 100 wt%, and wherein the fraction of compounds b1) to b4), based on the total weight of polymeric compounds having isocyanate-reactive groups (b), is at least 80 wt%.
The open-cell viscoelastic flexible polyurethane foams of the present invention are characterized by an absolute maximum value for the loss modulus tan delta in the temperature range from -10 to 40 C, preferably in the range from 0 to 35 C, more preferably in the range from 10 to 35 C and especially in the range from 15 to 30 C. The absolute maximum value of the loss modulus tan delta corresponds to the ASTM D 4065-99 glass transition temperature. The viscoelastic polyurethane foams of the present invention further have a DIN EN ISO 8307 resilience of below 20% and also a high damping behavior, which is reflected by a tan delta value at 20 C of at least 0.2, preferably at least 0.4 and more preferably at least 0.5. The tan delta is determined using dynamic mechanical
The open-cell viscoelastic flexible polyurethane foams of the present invention are characterized by an absolute maximum value for the loss modulus tan delta in the temperature range from -10 to 40 C, preferably in the range from 0 to 35 C, more preferably in the range from 10 to 35 C and especially in the range from 15 to 30 C. The absolute maximum value of the loss modulus tan delta corresponds to the ASTM D 4065-99 glass transition temperature. The viscoelastic polyurethane foams of the present invention further have a DIN EN ISO 8307 resilience of below 20% and also a high damping behavior, which is reflected by a tan delta value at 20 C of at least 0.2, preferably at least 0.4 and more preferably at least 0.5. The tan delta is determined using dynamic mechanical
7 analysis (DMA) at a frequency of 1 Hz and a temperature range of -80 to +200 C
at a deformation of 0.3% in line with DIN EN ISO 6721-1, DIN EN ISO 6721-2, DIN EN ISO 6721-7.
The temperature program is run in 5 C steps.
The viscoelastic polyurethane foams of the present invention also display a DIN EN ISO 8307 air flow value of at least 1.0 dm3/s, preferably at least 1.2 dm3/s, more preferably at least 1.4 dm3/s and especially at least 1.5 dm3/s. The density of flexible polyurethane foams according to the present invention is less than 150 WI, preferably in the range from 20 to 100 g/I, more preferably in the range from 30 to 80 g/I and especially in the range from 40 to 60 g/I.
Useful polyisocyanates a) include in principle any known compounds having two or more isocyanate groups in the molecule, alone or in combination. Diisocyanates are preferable. The process of the present invention preferably utilizes diphenylmethane diisocyanate (MDI), tolylene diisocyanate (TDI), or MDI-TDI mixtures.
The diphenylmethane diisocyanate used can be monomeric diphenyl diisocyanate selected from the group consisting of 2,2'-diphenylmethane diisocyanate, 2,4'-diphenylmethane diisocyanate or 4,4'-diphenylmethane diisocyanate, or mixtures of two or all three isomers, and also mixtures of one or more monomeric diphenylmethane diisocyanates with higher-nuclear homologs of diphenylmethane diisocyanate. The viscosity of diphenylmethane diisocyanate (al) at 20 C is preferably less than 200 mPas, more preferably less than 150 mPas and more preferably less than 100 mPas. It is particularly preferable for the proportion of 2,2'-diphenylmethane diisocyanate to be less than 5 wt%, based on the total weight of polyisocyanates (a).
When TDI is used, it will usually be mixtures of the 2,4- and the 2,6-isomer which are used.
Commercially available mixtures with 80% 2,4 and 60% 2,6 TDI and 35% 2,4 and 35% 2,6 TDI are particularly preferable.
at a deformation of 0.3% in line with DIN EN ISO 6721-1, DIN EN ISO 6721-2, DIN EN ISO 6721-7.
The temperature program is run in 5 C steps.
The viscoelastic polyurethane foams of the present invention also display a DIN EN ISO 8307 air flow value of at least 1.0 dm3/s, preferably at least 1.2 dm3/s, more preferably at least 1.4 dm3/s and especially at least 1.5 dm3/s. The density of flexible polyurethane foams according to the present invention is less than 150 WI, preferably in the range from 20 to 100 g/I, more preferably in the range from 30 to 80 g/I and especially in the range from 40 to 60 g/I.
Useful polyisocyanates a) include in principle any known compounds having two or more isocyanate groups in the molecule, alone or in combination. Diisocyanates are preferable. The process of the present invention preferably utilizes diphenylmethane diisocyanate (MDI), tolylene diisocyanate (TDI), or MDI-TDI mixtures.
The diphenylmethane diisocyanate used can be monomeric diphenyl diisocyanate selected from the group consisting of 2,2'-diphenylmethane diisocyanate, 2,4'-diphenylmethane diisocyanate or 4,4'-diphenylmethane diisocyanate, or mixtures of two or all three isomers, and also mixtures of one or more monomeric diphenylmethane diisocyanates with higher-nuclear homologs of diphenylmethane diisocyanate. The viscosity of diphenylmethane diisocyanate (al) at 20 C is preferably less than 200 mPas, more preferably less than 150 mPas and more preferably less than 100 mPas. It is particularly preferable for the proportion of 2,2'-diphenylmethane diisocyanate to be less than 5 wt%, based on the total weight of polyisocyanates (a).
When TDI is used, it will usually be mixtures of the 2,4- and the 2,6-isomer which are used.
Commercially available mixtures with 80% 2,4 and 60% 2,6 TDI and 35% 2,4 and 35% 2,6 TDI are particularly preferable.
8 In place of pure isocyanates or blended with these, so-called modified isocyanates are frequently used. These modified isocyanates may be formed for example through incorporation of groups into the polyisocyanates. Examples of such groups are urethane, allophanate, carbodiimide, uretoneimine, isocyanurate, urea and biuret groups.
Particular preference is given to polyisocyanates modified with urethane groups, these polyisocyanates being typically prepared by reacting the isocyanates with a deficiency of compounds having two or more isocyanate-reactive hydrogen atoms. Compounds formed therefrom are frequently referred to as NCO prepolymers. The compounds used and having two or more isocyanate-reactive hydrogen atoms are preferably polymeric compounds having isocyanate-reactive groups (b) and/or chain-extending and/or crosslinking agents (c).
Particular preference is likewise given to carbodiimide- or uretoneimine-containing polyisocyanates, which are formed by specific catalyzed reaction of isocyanates with themselves. Mixtures of TDI
and MDI can also be used.
Polymeric compounds having isocyanate-reactive groups (b) have a number average molecular weight of at least 450 g/mol and more preferably in the range from 460 to 12 000 g/mol and have two or more isocyanate-reactive hydrogen atoms per molecule. Polymeric compounds having isocyanate-reactive groups (b) preferably include polyester alcohols and/or polyether alcohols having a functionality of 2 to 8, especially of 2 to 6 and preferably 2 to 4 and an average equivalent molecular weight in the range from 400 to 3000 g/mol and preferably in the range from 1000 to 2500 g/mol. Polyether alcohols are used in particular.
Polyether alcohols are obtainable by known methods, usually via catalytic addition of alkylene oxides, especially ethylene oxide and/or propylene oxide, onto H-functional starter substances, or via condensation of tetrahydrofuran. When alkylene oxides are used, the products are also known as polyalkylene oxide polyols. Useful H-functional starter substances include especially polyfunctional alcohols and/or amines. Preference is given to using water, dihydric alcohols, for
Particular preference is given to polyisocyanates modified with urethane groups, these polyisocyanates being typically prepared by reacting the isocyanates with a deficiency of compounds having two or more isocyanate-reactive hydrogen atoms. Compounds formed therefrom are frequently referred to as NCO prepolymers. The compounds used and having two or more isocyanate-reactive hydrogen atoms are preferably polymeric compounds having isocyanate-reactive groups (b) and/or chain-extending and/or crosslinking agents (c).
Particular preference is likewise given to carbodiimide- or uretoneimine-containing polyisocyanates, which are formed by specific catalyzed reaction of isocyanates with themselves. Mixtures of TDI
and MDI can also be used.
Polymeric compounds having isocyanate-reactive groups (b) have a number average molecular weight of at least 450 g/mol and more preferably in the range from 460 to 12 000 g/mol and have two or more isocyanate-reactive hydrogen atoms per molecule. Polymeric compounds having isocyanate-reactive groups (b) preferably include polyester alcohols and/or polyether alcohols having a functionality of 2 to 8, especially of 2 to 6 and preferably 2 to 4 and an average equivalent molecular weight in the range from 400 to 3000 g/mol and preferably in the range from 1000 to 2500 g/mol. Polyether alcohols are used in particular.
Polyether alcohols are obtainable by known methods, usually via catalytic addition of alkylene oxides, especially ethylene oxide and/or propylene oxide, onto H-functional starter substances, or via condensation of tetrahydrofuran. When alkylene oxides are used, the products are also known as polyalkylene oxide polyols. Useful H-functional starter substances include especially polyfunctional alcohols and/or amines. Preference is given to using water, dihydric alcohols, for
9 example ethylene glycol, propylene glycol, or butane diols, trihydric alcohols, for example glycerol or trimethylolpropane, and also more highly hydric alcohols, such as pentaerythritol, sugar alcohols, for example sucrose, glucose or sorbitol. Preferable amines are aliphatic amines having up to 10 carbon atoms, for example ethylenediamine, diethylenetriamine, propylenediamine, and also amino alcohols, such as ethanolamine or diethanolamine. The alkylene oxides used are preferably ethylene oxide and/or propylene oxide, while polyether alcohols used for preparing flexible polyurethane foams frequently have an ethylene oxide block added at the chain end. Useful catalysts for the addition reaction of alkylene oxides include especially basic compounds in that potassium hydroxide is industrially the most important one. When the level of unsaturated constituents in the polyether alcohols is to be low, di- or multi metal cyanide compounds, so-called DMC catalysts, can also be used as catalysts. Viscoelastic flexible polyurethane foams are produced using especially two- and/or three-functional polyalkylene oxide polyols.
Useful compounds having two or more active hydrogen atoms further include polyester polyols obtainable for example from organic dicarboxylic acids having 2 to 12 carbon atoms, preferably aliphatic dicarboxylic acids having 8 to 12 carbon atoms, and polyhydric alcohols, preferably diols, having 2 to 12 carbon atoms and preferably 2 to 6 carbon atoms. Useful dicarboxylic acids include for example succinic acid, glutaric acid, adipic acid, suberic acid, azelaic acid, sebacic acid, decanedicarboxylic acid, maleic acid, fumaric acid, phthalic acid, isophthalic acid, terephthalic acid and the isomeric naphthalene dicarboxylic acids. Use of adipic acid is preferable. The dicarboxylic acids can be used not only individually but also mixed with one another.
Instead of the free dicarboxylic acids it is also possible to use the corresponding dicarboxylic acid derivatives, for example dicarboxylic esters of alcohols having 1 to 4 carbon atoms or dicarboxylic anhydrides.
Examples of alcohols having two or more hydroxyl groups and especially diols are: ethanediol, diethylene glycol, 1,2-propanediol, 1,3-propanediol, dipropylene glycol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,10-decanediol, glycerol and trimethylolpropane.
Preference is given to using ethanediol, diethylene glycol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol or mixtures of two or more thereof, especially mixtures of 1,4-butanediol, 1,5-pentanediol and 1,6-hexanediol. It is further possible to use polyester polyols formed from lactones, e.g., E-caprolactone, or hydroxy carboxylic acids, e.g., 0)-hydroxycaproic acid and hydroxybenzoic acids. The use of dipropylene glycol is preferred.
5 The polymeric compounds having isocyanate-reactive groups (b) comprise (b1) 10 to 40 wt% of at least one polyalkylene oxide having a hydroxyl number of 90 to 300 mg KOH/g, based on a 3 to 6-functional starter molecule and a propylene oxide fraction, based on the alkylene oxide content, of 80 to 100 wt%, (b2) 5 to 20 wt% of at least one polyalkylene oxide having a hydroxyl number of 10 to 60 mg KOH/g, based on a 2 to 4-functional starter molecule and a propylene oxide fraction,
Useful compounds having two or more active hydrogen atoms further include polyester polyols obtainable for example from organic dicarboxylic acids having 2 to 12 carbon atoms, preferably aliphatic dicarboxylic acids having 8 to 12 carbon atoms, and polyhydric alcohols, preferably diols, having 2 to 12 carbon atoms and preferably 2 to 6 carbon atoms. Useful dicarboxylic acids include for example succinic acid, glutaric acid, adipic acid, suberic acid, azelaic acid, sebacic acid, decanedicarboxylic acid, maleic acid, fumaric acid, phthalic acid, isophthalic acid, terephthalic acid and the isomeric naphthalene dicarboxylic acids. Use of adipic acid is preferable. The dicarboxylic acids can be used not only individually but also mixed with one another.
Instead of the free dicarboxylic acids it is also possible to use the corresponding dicarboxylic acid derivatives, for example dicarboxylic esters of alcohols having 1 to 4 carbon atoms or dicarboxylic anhydrides.
Examples of alcohols having two or more hydroxyl groups and especially diols are: ethanediol, diethylene glycol, 1,2-propanediol, 1,3-propanediol, dipropylene glycol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,10-decanediol, glycerol and trimethylolpropane.
Preference is given to using ethanediol, diethylene glycol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol or mixtures of two or more thereof, especially mixtures of 1,4-butanediol, 1,5-pentanediol and 1,6-hexanediol. It is further possible to use polyester polyols formed from lactones, e.g., E-caprolactone, or hydroxy carboxylic acids, e.g., 0)-hydroxycaproic acid and hydroxybenzoic acids. The use of dipropylene glycol is preferred.
5 The polymeric compounds having isocyanate-reactive groups (b) comprise (b1) 10 to 40 wt% of at least one polyalkylene oxide having a hydroxyl number of 90 to 300 mg KOH/g, based on a 3 to 6-functional starter molecule and a propylene oxide fraction, based on the alkylene oxide content, of 80 to 100 wt%, (b2) 5 to 20 wt% of at least one polyalkylene oxide having a hydroxyl number of 10 to 60 mg KOH/g, based on a 2 to 4-functional starter molecule and a propylene oxide fraction,
10 based on the alkylene oxide content, of 80 to 100 wt%, (b3) 10 to 50 wt%
of at least one polyalkylene oxide having a hydroxyl number of 10 to 55 mg KOH/g, based on a 2 to 4-functional starter molecule and an ethylene oxide fraction, based on the alkylene oxide content, of 70 to 100 wt%, and (b4) 0 to 20 wt%, preferably 1-20 wt% of at least one polyalkylene oxide having a hydroxyl number of 50 to 200 mg KOH/g, preferably 56-200 mg KOH/g, based on a 2-functional starter molecule and an ethylene oxide fraction, based on the alkylene oxide content, of 80 to 100 wt%, all based on the total weight of polymeric compounds having isocyanate-reactive groups (b).
It is preferable to use exclusively polyether polyols as polymeric compounds having isocyanate-reactive groups (b). It is essential here for the purposes of the present invention that the polymeric compounds having isocyanate-reactive groups (b) comprise the polyetherols (b1) to (b4) at not less than 80 wt%, preferably not less than 85 wt%, more preferably not less than 90 wt% and especially not less than 95 wt%, all based on the total weight of the polymer compounds having isocyanate-reactive groups (b). In an especially preferred embodiment of the present invention, the polymeric compounds having isocyanate-reactive groups (b), in addition to the polyetherols (b1) to (b4) do not contain any further polymeric compounds having isocyanate-reactive groups.
It is particularly preferable for the polyetherols of the present invention, aside from the starter, to include essentially exclusively ethylene oxide and propylene oxide units. Here "essentially" is to be
of at least one polyalkylene oxide having a hydroxyl number of 10 to 55 mg KOH/g, based on a 2 to 4-functional starter molecule and an ethylene oxide fraction, based on the alkylene oxide content, of 70 to 100 wt%, and (b4) 0 to 20 wt%, preferably 1-20 wt% of at least one polyalkylene oxide having a hydroxyl number of 50 to 200 mg KOH/g, preferably 56-200 mg KOH/g, based on a 2-functional starter molecule and an ethylene oxide fraction, based on the alkylene oxide content, of 80 to 100 wt%, all based on the total weight of polymeric compounds having isocyanate-reactive groups (b).
It is preferable to use exclusively polyether polyols as polymeric compounds having isocyanate-reactive groups (b). It is essential here for the purposes of the present invention that the polymeric compounds having isocyanate-reactive groups (b) comprise the polyetherols (b1) to (b4) at not less than 80 wt%, preferably not less than 85 wt%, more preferably not less than 90 wt% and especially not less than 95 wt%, all based on the total weight of the polymer compounds having isocyanate-reactive groups (b). In an especially preferred embodiment of the present invention, the polymeric compounds having isocyanate-reactive groups (b), in addition to the polyetherols (b1) to (b4) do not contain any further polymeric compounds having isocyanate-reactive groups.
It is particularly preferable for the polyetherols of the present invention, aside from the starter, to include essentially exclusively ethylene oxide and propylene oxide units. Here "essentially" is to be
11 understood as meaning that small amounts of other alkylene oxide units are not disadvantageous.
The fraction of alkylene oxide units other than ethylene oxide or propylene oxide units is preferably less than 5 wt%, more preferably less than 1 wt% and especially 0 wt%, all based on the total weight of alkylene oxide units.
The chain-extending agents and/or crosslinking agents (c) used are substances having a molecular weight of below 400 g/mol and preferably in the range from 60 to 350 g/mol, chain extenders having 2 isocyanate-reactive hydrogen atoms and crosslinkers having 3 or more isocyanate-reactive hydrogen atoms. These can be used individually or in the form of mixtures. Preference is given to using diols and/or triols having molecular weights less than 400, more preferably in the range from 60 to 300 and especially in the range from 60 to 150. Possibilities are for example, aliphatic, cycloaliphatic and/or aromatic diols, and also diols having aromatic structures, with 2 to 14 and preferably 2 to 10 carbon atoms, such as ethylene glycol, 1,3-propanediol, 1,10-decanediol, o-dihydroxycyclohexane, m-dihydroxycyclohexane, p-dihydroxycyclohexane, diethylene glycol, dipropylene glycol and preferably 1,4-butanediol, 1,6-hexanediol and bis(2-hydroxyethyl)hydroquinone, triols, such as 1,2,4-trihydroxycyclohexane, 1,3,5-trihydroxycyclohexane, glycerol and trimethylolpropane, and low molecular weight hydroxyl-containing polyalkylene oxides based on ethylene oxide and/or 1,2-propylene oxide and the aforementioned diols and/or triols as starter molecules. Particular preference for use as chain extenders (d) is given to monoethylene glycol, 1,4-butanediol and/or glycerol.
When chain-extending agents, crosslinking agents or mixtures thereof are used, the amounts in which they are used are advantageously in the range from 0.1 to 20 wt%, preferably in the range from 0.5 to 10 wt% and especially in the range from 0.8 to 5 wt%, based on the weight of components (b) and (c).
In addition to polymeric compounds having isocyanate-reactive groups, it is optionally also possible to use one or more compounds having just one isocyanate-reactive group (d).
These compounds are for example monoamines, monothiols and/or monoalcohols, for example based on polyethers, =
The fraction of alkylene oxide units other than ethylene oxide or propylene oxide units is preferably less than 5 wt%, more preferably less than 1 wt% and especially 0 wt%, all based on the total weight of alkylene oxide units.
The chain-extending agents and/or crosslinking agents (c) used are substances having a molecular weight of below 400 g/mol and preferably in the range from 60 to 350 g/mol, chain extenders having 2 isocyanate-reactive hydrogen atoms and crosslinkers having 3 or more isocyanate-reactive hydrogen atoms. These can be used individually or in the form of mixtures. Preference is given to using diols and/or triols having molecular weights less than 400, more preferably in the range from 60 to 300 and especially in the range from 60 to 150. Possibilities are for example, aliphatic, cycloaliphatic and/or aromatic diols, and also diols having aromatic structures, with 2 to 14 and preferably 2 to 10 carbon atoms, such as ethylene glycol, 1,3-propanediol, 1,10-decanediol, o-dihydroxycyclohexane, m-dihydroxycyclohexane, p-dihydroxycyclohexane, diethylene glycol, dipropylene glycol and preferably 1,4-butanediol, 1,6-hexanediol and bis(2-hydroxyethyl)hydroquinone, triols, such as 1,2,4-trihydroxycyclohexane, 1,3,5-trihydroxycyclohexane, glycerol and trimethylolpropane, and low molecular weight hydroxyl-containing polyalkylene oxides based on ethylene oxide and/or 1,2-propylene oxide and the aforementioned diols and/or triols as starter molecules. Particular preference for use as chain extenders (d) is given to monoethylene glycol, 1,4-butanediol and/or glycerol.
When chain-extending agents, crosslinking agents or mixtures thereof are used, the amounts in which they are used are advantageously in the range from 0.1 to 20 wt%, preferably in the range from 0.5 to 10 wt% and especially in the range from 0.8 to 5 wt%, based on the weight of components (b) and (c).
In addition to polymeric compounds having isocyanate-reactive groups, it is optionally also possible to use one or more compounds having just one isocyanate-reactive group (d).
These compounds are for example monoamines, monothiols and/or monoalcohols, for example based on polyethers, =
12 polyesters or polyether-polyesters. Monoalcohols used for example are more preferably polyether monools obtained on the basis of monofunctional starter molecules, for example ethylene glycol monomethyl ether. These are obtainable similarly to the polyetherols described above via polymerization of alkylene oxide onto the starter molecule. Polyether monools preferably have a high proportion of primary OH groups. It is particularly preferable to prepare polyether monools using ethylene oxide as sole alkylene oxide. Preferable monools further include compounds having an aromatic group. The number average molecular weight of compounds having one isocyanate-reactive group is preferably in the range from 50 to 1000 g/mol, more preferably in the range from 80 to 300 g/mol and especially in the range from 100 to 200 g/mol. When compounds having one isocyanate-reactive group (d) are used, they are preferably used in a proportion of 0.1 to 5 wt% and more preferably 0.5 to 4.5 wt%, based on the total weight of polymeric compounds having isocyanate-reactive groups (b) and compounds having just one isocyanate-reactive group (d).
Useful catalysts (e) for preparing the viscoelastic polyurethane foams are preferably compounds which greatly speed the reaction of the hydroxyl-containing compounds of components (b), (c) and optionally (d) with the polyisocyanates (a) and/or the reaction of isocyanates with water. Examples are amidines, such as 2,3-dimethy1-3,4,5,6-tetrahydropyrimidine, tertiary amines, such as triethylamine, tributylamine, dimethylbenzylamine, N-methylmorpholine, N-ethylmorpholine, N-cyclohexylmorpholine, N,N,N',N'-tetramethylethylenediamine, N,N,N',N'-tetramethylbutanediamine, N,N,N',N'-tetramethylhexanediamine, pentamethyldiethylenetriamine, tetramethyldiaminoethyl ether, bis(dimethylaminopropyl)urea, dimethylpiperazine, 1,2-dimethylimidazole, 1-azabicyclo-(3,3,0)-octane and preferably 1,4-diazabicyclo-(2,2,2)-octane and alkanolamine compounds, such as triethanolamine, triisopropanolamine, N-methyldiethanolamine, N-ethyldiethanolamine and dimethylethanolamine. Similarly suitable are organic metal compounds, preferably organic tin compounds, such as tin(II) salts of organic carboxylic acids, e.g., tin(II) acetate, tin(II) octoate, tin(II) ethylhexanoate and tin(II) laurate, and the dialkyltin(IV) salts of organic carboxylic acids, for example dibutyltin diacetate, dibutyltin dilaurate, dibutyltin maleate and dioctyltin diacetate, and also bismuth carboxylates, such as bismuth(111) neodecanoate, bismuth 2-ethylhexanoate and bismuth octanoate, or mixtures thereof. The organic metal compounds can be used alone or
Useful catalysts (e) for preparing the viscoelastic polyurethane foams are preferably compounds which greatly speed the reaction of the hydroxyl-containing compounds of components (b), (c) and optionally (d) with the polyisocyanates (a) and/or the reaction of isocyanates with water. Examples are amidines, such as 2,3-dimethy1-3,4,5,6-tetrahydropyrimidine, tertiary amines, such as triethylamine, tributylamine, dimethylbenzylamine, N-methylmorpholine, N-ethylmorpholine, N-cyclohexylmorpholine, N,N,N',N'-tetramethylethylenediamine, N,N,N',N'-tetramethylbutanediamine, N,N,N',N'-tetramethylhexanediamine, pentamethyldiethylenetriamine, tetramethyldiaminoethyl ether, bis(dimethylaminopropyl)urea, dimethylpiperazine, 1,2-dimethylimidazole, 1-azabicyclo-(3,3,0)-octane and preferably 1,4-diazabicyclo-(2,2,2)-octane and alkanolamine compounds, such as triethanolamine, triisopropanolamine, N-methyldiethanolamine, N-ethyldiethanolamine and dimethylethanolamine. Similarly suitable are organic metal compounds, preferably organic tin compounds, such as tin(II) salts of organic carboxylic acids, e.g., tin(II) acetate, tin(II) octoate, tin(II) ethylhexanoate and tin(II) laurate, and the dialkyltin(IV) salts of organic carboxylic acids, for example dibutyltin diacetate, dibutyltin dilaurate, dibutyltin maleate and dioctyltin diacetate, and also bismuth carboxylates, such as bismuth(111) neodecanoate, bismuth 2-ethylhexanoate and bismuth octanoate, or mixtures thereof. The organic metal compounds can be used alone or
13 preferably in combination with strong basic amines. When component (b) is an ester, it is preferable to use exclusively amine catalysts.
Preference is given to using from 0.001 to 5 wt% and especially from 0.05 to 2 wt% of catalyst or catalyst combination, based on the weight of component (b).
Polyurethane foams are further produced in the presence of one or more blowing agents (f). By way of blowing agents (f) it is possible to use chemically acting blowing agent and/or physically acting compounds. Chemical blowing agents are compounds which react with isocyanate to form gaseous products, for example water or formic acid. Physical blowing agents are compounds that have been dissolved or emulsified in the reactants of polyurethane synthesis and vaporize under the conditions of polyurethane formation. Examples are hydrocarbons, halogenated hydrocarbons and other compounds, for example perfluorinated alkanes, such as perfluorohexane, chlorofluorocarbons, and ethers, esters, ketones and/or acetals, for example (cyclo)aliphatic hydrocarbons having 4 to 8 carbon atoms, hydrofluorocarbons, such as Solkanes 365 mfc, or gases, such as carbon dioxide. In one preferable embodiment, the blowing agent used is a mixture of these blowing agents, comprising water and more preferably exclusively water.
The level of physical blowing agents (f), if present, in a preferable embodiment is in the range between 1 and 20 wt% and especially 5 and 20 wt%, the amount of water is preferably in the range between 0.5 and 8 wt% and more preferably between 0.8 and 6 wt% and especially between 1 and 5 wt%, all based on the total weight of components (a) to (g).
Useful auxiliaries and/or addition agents (g) include for example surface-active substances, foam stabilizers, cell regulators, external and internal release agents, fillers, pigments, dyes, flame retardants, antistats, hydrolysis control agents and also fungistats and bacteriostats.
Preference is given to using from 0.001 to 5 wt% and especially from 0.05 to 2 wt% of catalyst or catalyst combination, based on the weight of component (b).
Polyurethane foams are further produced in the presence of one or more blowing agents (f). By way of blowing agents (f) it is possible to use chemically acting blowing agent and/or physically acting compounds. Chemical blowing agents are compounds which react with isocyanate to form gaseous products, for example water or formic acid. Physical blowing agents are compounds that have been dissolved or emulsified in the reactants of polyurethane synthesis and vaporize under the conditions of polyurethane formation. Examples are hydrocarbons, halogenated hydrocarbons and other compounds, for example perfluorinated alkanes, such as perfluorohexane, chlorofluorocarbons, and ethers, esters, ketones and/or acetals, for example (cyclo)aliphatic hydrocarbons having 4 to 8 carbon atoms, hydrofluorocarbons, such as Solkanes 365 mfc, or gases, such as carbon dioxide. In one preferable embodiment, the blowing agent used is a mixture of these blowing agents, comprising water and more preferably exclusively water.
The level of physical blowing agents (f), if present, in a preferable embodiment is in the range between 1 and 20 wt% and especially 5 and 20 wt%, the amount of water is preferably in the range between 0.5 and 8 wt% and more preferably between 0.8 and 6 wt% and especially between 1 and 5 wt%, all based on the total weight of components (a) to (g).
Useful auxiliaries and/or addition agents (g) include for example surface-active substances, foam stabilizers, cell regulators, external and internal release agents, fillers, pigments, dyes, flame retardants, antistats, hydrolysis control agents and also fungistats and bacteriostats.
14 Further particulars about the starting materials used appear for example in Kunststoffhandbuch, volume 7, Polyurethanes, edited by Gunter Oertel, Carl-Hanser-Verlag, Munich, 3rd edition 1993, chapter 5, Flexible polyurethane foams.
having isocyanate-reactive groups (b), the optionally used chain-extending and/or crosslinking agents (c), the optionally used compounds having just one isocyanate-reactive group with a hydroxyl number of 100 to 500 mg KOH/g (d), the catalysts (e), the blowing agents (f), and also the optionally used auxiliaries and/or addition agents (g) are typically mixed to form a so-called polyol To produce the viscoelastic polyurethane foams of the present invention, the polyisocyanate prepolymers are reacted with the polymeric compounds having isocyanate-reactive groups in the presence of the recited blowing agents, catalysts and auxiliary and/or addition agents (polyol The polyurethane foams of the present invention are preferably produced by the one-shot process, for example using the high-pressure or low-pressure technique. The foams are obtainable in open or closed metallic molds or via the continuous application of the reaction mixture to belt lines or in troughs to produce foam blocks.
It is particularly advantageous to proceed via the so-called two-component process wherein, as mentioned above, a polyol component is produced and foamed with polyisocyanate a). The components are preferably mixed at a temperature in the range between 15 and 120 C and =
preferably 20 to 80 C and introduced into the mold or onto the belt line. The temperature in the mold is usually in the range between 15 and 120 C and preferably between 30 and 80 C.
The density of the viscoelastic flexible polyurethane foam of the present invention is less than 5 150 g/I, preferably in the range from 20 to 100 WI, more preferably in the range from 30 to 80 g/I
and especially in the range from 40 to 60 g/I.
Flexible polyurethane foams of the present invention are preferably used for insulating and damping elements, especially in vehicle building, for example as carpetback coating, for 10 upholstered, sitting or lying furniture, for mattresses or cushions, for example in the orthopedic and/or medical sector, or for shoe inlay soles. A further field of use is that of automotive safety parts, supporting areas, armrests and similar parts in the furniture sector and in automotive engineering. Viscoelastic components are further used for acoustical insulation and absorption. It is particularly preferably to use the flexible polyurethane foams of the present invention for mattresses
having isocyanate-reactive groups (b), the optionally used chain-extending and/or crosslinking agents (c), the optionally used compounds having just one isocyanate-reactive group with a hydroxyl number of 100 to 500 mg KOH/g (d), the catalysts (e), the blowing agents (f), and also the optionally used auxiliaries and/or addition agents (g) are typically mixed to form a so-called polyol To produce the viscoelastic polyurethane foams of the present invention, the polyisocyanate prepolymers are reacted with the polymeric compounds having isocyanate-reactive groups in the presence of the recited blowing agents, catalysts and auxiliary and/or addition agents (polyol The polyurethane foams of the present invention are preferably produced by the one-shot process, for example using the high-pressure or low-pressure technique. The foams are obtainable in open or closed metallic molds or via the continuous application of the reaction mixture to belt lines or in troughs to produce foam blocks.
It is particularly advantageous to proceed via the so-called two-component process wherein, as mentioned above, a polyol component is produced and foamed with polyisocyanate a). The components are preferably mixed at a temperature in the range between 15 and 120 C and =
preferably 20 to 80 C and introduced into the mold or onto the belt line. The temperature in the mold is usually in the range between 15 and 120 C and preferably between 30 and 80 C.
The density of the viscoelastic flexible polyurethane foam of the present invention is less than 5 150 g/I, preferably in the range from 20 to 100 WI, more preferably in the range from 30 to 80 g/I
and especially in the range from 40 to 60 g/I.
Flexible polyurethane foams of the present invention are preferably used for insulating and damping elements, especially in vehicle building, for example as carpetback coating, for 10 upholstered, sitting or lying furniture, for mattresses or cushions, for example in the orthopedic and/or medical sector, or for shoe inlay soles. A further field of use is that of automotive safety parts, supporting areas, armrests and similar parts in the furniture sector and in automotive engineering. Viscoelastic components are further used for acoustical insulation and absorption. It is particularly preferably to use the flexible polyurethane foams of the present invention for mattresses
15 and cushions.
The viscoelastic polyurethane foams of the present invention are characterized by excellent mechanical properties, especially outstanding values for tensile strength and elongation at break.
The viscoelastic polyurethane foams of the present invention at the same time have outstanding air flow values of above 1 dm3/s. The viscoelastic polyurethane foams of the present invention are washable and can be washed and dried in commercial domestic washing machines using customary washing powders at temperatures up to 60 C without destruction and without significant impairment, especially of viscoelastic properties and mechanical properties, such as tensile strength and elongation at break.
The examples which follow illustrate the invention.
Examples 1 and 2
The viscoelastic polyurethane foams of the present invention are characterized by excellent mechanical properties, especially outstanding values for tensile strength and elongation at break.
The viscoelastic polyurethane foams of the present invention at the same time have outstanding air flow values of above 1 dm3/s. The viscoelastic polyurethane foams of the present invention are washable and can be washed and dried in commercial domestic washing machines using customary washing powders at temperatures up to 60 C without destruction and without significant impairment, especially of viscoelastic properties and mechanical properties, such as tensile strength and elongation at break.
The examples which follow illustrate the invention.
Examples 1 and 2
16 The polyols, catalysts and addition agents reported in table 1 were mixed together to form a polyol component, the reported amounts being parts by weight. The polyol component was mixed with an MDI isocyanate mixture (diphenylmethane diisocyanate mixture) at the reported index in a Puromat equipped with MKA 10-2/16 mixing head at about 150 bar, and the mixture was introduced into a closeable metal mold having the dimensions 40x40x10 cm, where it cured to the flexible foam in the closed mold. The metal mold has a temperature of 60 C, the demolding time was 6 minutes.
The mechanical properties of the foams are reported in the tables.
polyol 1 polyether alcohol based on trimethylolpropane and propylene oxide, hydroxyl number 160 mg KOH/g polyol 2 polyether alcohol based on glycerol, propylene oxide and ethylene oxide, hydroxyl number 170 mg KOH/g and a proportion of propylene oxide, based on the total weight of ethylene oxide and propylene oxide, of about 95 wt%
polyol 3 polyether alcohol based on glycerol and propylene oxide, hydroxyl number 42 mg KOH/g polyol 4 polyether alcohol based on glycerol, ethylene oxide and propylene oxide, hydroxyl number 42 mg KOH/g and a proportion of ethylene oxide, based on the total weight of ethylene oxide and propylene oxide, of about 74 wt%
polyol 5 polyether alcohol based on ethylene glycol as starter and ethylene oxide, hydroxyl number 188 mg KOH/g monool monool, hydroxyl number 406 mg KOH/g crosslinker glycerol, hydroxyl number 1825 mg KOH/g stabilizer 1 DabcoO DC 198 Air Products catalyst 2 JeffcatO ZF10 ¨ incorporable amine catalyst from Huntsman catalyst 3 VP9357 ¨ incorporable amine catalyst from BASF SE
catalyst 4 Dabco NE 1070 ¨ incorporable amine catalyst from Air Products Is 1 MDI mixture from BASF SE, NCO content 32.8%, comprising 2,4'-MDI, 4,4'-MDI and higher-nuclear homologs of MDI
detergent: commercially available Persil laundry detergent from Henkel
The mechanical properties of the foams are reported in the tables.
polyol 1 polyether alcohol based on trimethylolpropane and propylene oxide, hydroxyl number 160 mg KOH/g polyol 2 polyether alcohol based on glycerol, propylene oxide and ethylene oxide, hydroxyl number 170 mg KOH/g and a proportion of propylene oxide, based on the total weight of ethylene oxide and propylene oxide, of about 95 wt%
polyol 3 polyether alcohol based on glycerol and propylene oxide, hydroxyl number 42 mg KOH/g polyol 4 polyether alcohol based on glycerol, ethylene oxide and propylene oxide, hydroxyl number 42 mg KOH/g and a proportion of ethylene oxide, based on the total weight of ethylene oxide and propylene oxide, of about 74 wt%
polyol 5 polyether alcohol based on ethylene glycol as starter and ethylene oxide, hydroxyl number 188 mg KOH/g monool monool, hydroxyl number 406 mg KOH/g crosslinker glycerol, hydroxyl number 1825 mg KOH/g stabilizer 1 DabcoO DC 198 Air Products catalyst 2 JeffcatO ZF10 ¨ incorporable amine catalyst from Huntsman catalyst 3 VP9357 ¨ incorporable amine catalyst from BASF SE
catalyst 4 Dabco NE 1070 ¨ incorporable amine catalyst from Air Products Is 1 MDI mixture from BASF SE, NCO content 32.8%, comprising 2,4'-MDI, 4,4'-MDI and higher-nuclear homologs of MDI
detergent: commercially available Persil laundry detergent from Henkel
17 Table 1 Example 1 2 polyol 1 34.3 polyol 2 28 polyol 3 15 15.3 polyol 4 40 31 polyol 5 20 monool 4 crosslinker 1 stabilizer 1 1.0 1.5 catalyst 2 0.2 0.2 catalyst 3 2 1 catalyst 4 1 water 1.5 3.0 !so 1 100 100 index 100 80 ,
18 Table 2 Example 1 2 tan delta (max) at C 20 25 tan delta at 20 C 0.68 0.61 overall density kg/m3 78 48 compressive strength 40% 3.3 1.0 [kPa]
tensile strength [kPa] 190 136 elongation at break [%] 173 201 CS (22h/70 C/50%) [%] 2.3 4.6 CS (22h/70 C/90%) [%] 3.2 7.7 hysteresis [%] 41 57 resilience [%] 6 11 air flow value [dm3/s] 1.7 2.0 =
tensile strength [kPa] 190 136 elongation at break [%] 173 201 CS (22h/70 C/50%) [%] 2.3 4.6 CS (22h/70 C/90%) [%] 3.2 7.7 hysteresis [%] 41 57 resilience [%] 6 11 air flow value [dm3/s] 1.7 2.0 =
19 Table 3 Example 1 lb 1 c ld washed at C - 40, once 60, once washed at C + Persil - 60, once overall density kg/m3 78 76 78 78 compressive strength 40% 3.3 3.0 3.4 3.5 [kPa]
tensile strength [kPa] 190 177 171 192 elongation at break [%] 173 181 186 188 CS (22h/70 C/50%) [%] 2.3 2.2 1.9 1.9 CS (22h/70 C/90%) [%] 3.2 3.3 7.6 8.5 hysteresis [%] 41 42 46 45 resilience [%] 6 5 4 6 air flow value [dm3/s] 1.7 1.7 1.4 1.5 = CA 02857609 2014-05-30 Table 4 Example 2 2b 2c 2d 2e washed at C - 40, once 60, once washed at C + Persil - 60, once 40, five x overall density kg/m3 48 45 44 44 45 compressive strength 40% 1.0 1.2 1.3 1.4 1.5 [kPa]
tensile strength [kPa] 136 160 170 163 146 elongation at break [%] 201 187 187 186 174 CS (22h/70 C/50%) [%] 4.6 4.8 4.7 4.9 5.4 CS (22h/70 C/90%) [%] 7.7 7.0 6.4 9.3 5.1 hysteresis [%1 57 62 63 65 66 resilience [%] 11 12 12 12 12 air flow value [dm3/s] 2.0 2.4 2.3 2.2 2.3 Overall density was determined according to DIN EN ISO 845, compressive strength and hysteresis according to DIN EN ISO 3386, tensile strength according to DIN EN
ISO 1798, 5 elongation at break according to DIN EN ISO 1798, compression set (CS) according to DIN EN ISO 1856, resilience according to DIN EN ISO 8307 and air flow value according to DIN EN ISO 7231.
In a washing test, a pillow was weighed and measured out beforehand and washed inside a pillow 10 casing in a commercially available washing machine (Bomann 9110) in the heavy duty cycle at 40 C or 60 C.
Depending on the test, Persil from Henkel was included in the wash (1 cup).
The program includes a spin at 1000 rpm. The still residually moist pillow was then weighed and measured and 15 thereafter dried either at room temperature or at 60 C in a circulating air oven to constant weight and then tested. In test 2e, the pillow was washed altogether five times and dried again.
The pillows as dried are visually impeccable, have an intact skin structure and no cracks or visible defects.
Table 5: Swelling behavior and water imbibition using test 2d as an example:
Before washing After spinning After drying length 100% 108% 99%
width 100% 109% 100%
height 100% 109% 98%
weight 100% 165% 97%
visual assessment impeccable impeccable impeccable The weight increase of 65% shows that the foam is hydrophilic. Nonetheless, it only swells by about 9% and is readily dryable. After drying the foam has the same geometry and the same mechanical and especially viscoelastic properties.
tensile strength [kPa] 190 177 171 192 elongation at break [%] 173 181 186 188 CS (22h/70 C/50%) [%] 2.3 2.2 1.9 1.9 CS (22h/70 C/90%) [%] 3.2 3.3 7.6 8.5 hysteresis [%] 41 42 46 45 resilience [%] 6 5 4 6 air flow value [dm3/s] 1.7 1.7 1.4 1.5 = CA 02857609 2014-05-30 Table 4 Example 2 2b 2c 2d 2e washed at C - 40, once 60, once washed at C + Persil - 60, once 40, five x overall density kg/m3 48 45 44 44 45 compressive strength 40% 1.0 1.2 1.3 1.4 1.5 [kPa]
tensile strength [kPa] 136 160 170 163 146 elongation at break [%] 201 187 187 186 174 CS (22h/70 C/50%) [%] 4.6 4.8 4.7 4.9 5.4 CS (22h/70 C/90%) [%] 7.7 7.0 6.4 9.3 5.1 hysteresis [%1 57 62 63 65 66 resilience [%] 11 12 12 12 12 air flow value [dm3/s] 2.0 2.4 2.3 2.2 2.3 Overall density was determined according to DIN EN ISO 845, compressive strength and hysteresis according to DIN EN ISO 3386, tensile strength according to DIN EN
ISO 1798, 5 elongation at break according to DIN EN ISO 1798, compression set (CS) according to DIN EN ISO 1856, resilience according to DIN EN ISO 8307 and air flow value according to DIN EN ISO 7231.
In a washing test, a pillow was weighed and measured out beforehand and washed inside a pillow 10 casing in a commercially available washing machine (Bomann 9110) in the heavy duty cycle at 40 C or 60 C.
Depending on the test, Persil from Henkel was included in the wash (1 cup).
The program includes a spin at 1000 rpm. The still residually moist pillow was then weighed and measured and 15 thereafter dried either at room temperature or at 60 C in a circulating air oven to constant weight and then tested. In test 2e, the pillow was washed altogether five times and dried again.
The pillows as dried are visually impeccable, have an intact skin structure and no cracks or visible defects.
Table 5: Swelling behavior and water imbibition using test 2d as an example:
Before washing After spinning After drying length 100% 108% 99%
width 100% 109% 100%
height 100% 109% 98%
weight 100% 165% 97%
visual assessment impeccable impeccable impeccable The weight increase of 65% shows that the foam is hydrophilic. Nonetheless, it only swells by about 9% and is readily dryable. After drying the foam has the same geometry and the same mechanical and especially viscoelastic properties.
Claims (15)
1. A process for producing viscoelastic flexible polyurethane foams having an air flow value of at least 1 dm3/s, which comprises a) polyisocyanate being mixed with b) polymeric compounds having isocyanate-reactive groups, c) optionally chain-extending and/or crosslinking agents, d) optionally compounds having one isocyanate-reactive group with a hydroxyl number of 100 to 500 mg KOH/g, e) catalyst, blowing agent, and also optionally 9) addition agents to form a reaction mixture and convert it into flexible polyurethane foam, wherein the polymeric compounds having isocyanate-reactive groups (b) comprise b1) 10 to 40 wt% of at least one polyalkylene oxide having a hydroxyl number of 90 to 300 mg KOH/g, based on a 3 to 6-functional starter molecule and a propylene oxide fraction, based on the alkylene oxide content, of 80 to 100 wt%, b2) 5 to 20 wt% of at least one polyalkylene oxide having a hydroxyl number of 10 to 60 mg KOH/g, based on a 2 to 4-functional starter molecule and a propylene oxide fraction, based on the alkylene oxide content, of 80 to 100 wt%, b3) 10 to 50 wt% of at least one polyalkylene oxide having a hydroxyl number of to 55 mg KOH/g, based on a 2 to 4-functional starter molecule and an ethylene oxide fraction, based on the alkylene oxide content, of 70 to 100 wt%, and b4) 0 to 20 wt% of at least one polyalkylene oxide having a hydroxyl number of 50 to 200 mg KOH/g, based on a 2-functional starter molecule and an ethylene oxide fraction, based on the alkylene oxide content, of 80 to 100 wt%, and wherein the fraction of compounds b1) to b4), based on the total weight of polymeric compounds having isocyanate-reactive groups (b), is at least 80 wt%.
2. The process according to claim 1, wherein the fraction of compounds having one isocyanate-reactive group (d) is from 0.1 to 5 wt%, based on the total weight of polymeric compounds having isocyanate-reactive groups (b) and compounds having one isocyanate-reactive group (d).
3. The process according to claim 1 or 2, wherein the fraction of compounds b1) to b4), based on the total weight of polymeric compounds having isocyanate-reactive groups (b), is at least 95 wt%.
4. The process according to any one of claims 1 to 3, wherein the tensile strength of viscoelastic polyurethane foam is at least 100 kPa.
5. The process according to any one of claims 1 to 4, wherein the absolute maximum of the loss modulus lies in the temperature range from 15 to 30°C.
6. The process according to any one of claims 1 to 5, wherein polyisocyanate (a) comprises diphenylmethane diisocyanate.
7. The process according to any one of claims 1 to 6, wherein polyisocyanate (a) comprises toluene diisocyanate.
8. The process according to any one of claims 1 to 7, wherein polyisocyanate (a) comprises isocyanate prepolymers.
9. The process according to any one of claims 1 to 8, wherein said blowing agent (c) comprises water.
10. The process according to claim 9, wherein the fraction of water, based on the total weight of components (a) to (f), is from 1 to 5 wt%.
11. The process according to any one of claims 1 to 10, wherein the step of curing the reaction mixture to the polyurethane foam takes place in a mold.
12. The process according to any one of claims 1 to 11, wherein the reaction mixture is foamed free-risen.
13. The process according to any one of claims 1 to 11, wherein the reaction mixture is foamed in a closed mold.
14. A viscoelastic flexible polyurethane foam obtainable according to any one of claims 1 to 13.
15. The use of a viscoelastic polyurethane foam according to claim 14 in vehicle interiors or for mattresses and cushions.
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EP11191757.1A EP2599810A1 (en) | 2011-12-02 | 2011-12-02 | Washable visco-elastic soft polyurethane foams |
PCT/EP2012/073671 WO2013079461A1 (en) | 2011-12-02 | 2012-11-27 | Washable viscoelastic flexible polyurethane foams |
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DK (1) | DK2785775T3 (en) |
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WO2016160874A2 (en) * | 2015-03-31 | 2016-10-06 | Dow Global Technologies Llc | Polyether polyol compositions |
CN106243304A (en) | 2015-06-11 | 2016-12-21 | 科思创聚合物(中国)有限公司 | Viscoelasticity reticulated polyurethane foam and preparation method thereof |
EP3133097B1 (en) * | 2015-08-17 | 2022-10-05 | Evonik Operations GmbH | Polyurethane flexible foams with increased hardness |
WO2017104600A1 (en) * | 2015-12-16 | 2017-06-22 | 株式会社ブリヂストン | Soft polyurethane foam and seat pad |
WO2017194340A1 (en) * | 2016-05-12 | 2017-11-16 | Basf Se | Tack-free polyurethane flexible foam |
ES2880289T3 (en) * | 2017-01-17 | 2021-11-24 | Dow Global Technologies Llc | Polyol blends useful for the production of memory foam |
WO2018169833A1 (en) * | 2017-03-15 | 2018-09-20 | Covestro Llc | Viscoelastic polyurethane foams with reduced temperature sensitivity |
CA3064515A1 (en) * | 2017-06-27 | 2019-01-03 | Basf Se | Flexible polyurethane foams having improved air permeability |
JP2021532236A (en) * | 2018-07-25 | 2021-11-25 | ビーエイエスエフ・ソシエタス・エウロパエアBasf Se | Silicone-free foam stabilizer for producing polyurethane foam |
CN112752780B (en) * | 2018-10-08 | 2023-03-31 | 陶氏环球技术有限责任公司 | Formulated polyol compositions |
CN110577625B (en) * | 2019-09-30 | 2021-09-07 | 长华化学科技股份有限公司 | Breathable slow-rebound polyurethane foam plastic and preparation method and application thereof |
BR112022013087A2 (en) * | 2020-01-06 | 2022-09-06 | Dow Global Technologies Llc | POLYURETHANE FOAM, AND, PROCESS FOR PRODUCING A POLYURETHANE FOAM |
CN112142942A (en) * | 2020-09-24 | 2020-12-29 | 南通馨宇诺家居用品有限公司 | Washable antibacterial mildew-proof memory foam and application thereof |
CN114262421A (en) * | 2021-12-27 | 2022-04-01 | 武汉长嘉新材料有限公司 | Polyurethane polymer, preparation method and application |
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DE3942330A1 (en) | 1989-12-21 | 1991-06-27 | Basf Ag | METHOD FOR THE PRODUCTION OF FLEXIBLE POLYURETHANE SOFT FOAMS WITH VISCOELASTIC, BODY SOUND ABSORBING PROPERTIES AND POLYOXYALKYLENE-POLYOL BLENDS TO BE USED THEREFOR |
DE19744747A1 (en) | 1997-10-10 | 1999-04-15 | Basf Ag | Process for the production of flexible polyurethane foams |
DE19924804C5 (en) * | 1999-05-29 | 2009-02-12 | Basf Se | Process for the production of sound-absorbing polyurethane foams having an adhesive surface |
US6391935B1 (en) | 2000-01-31 | 2002-05-21 | Bayer Antwerp, N.V. | Viscoelastic polyurethane foams |
EP1456269B1 (en) | 2001-11-29 | 2016-07-20 | Huntsman International Llc | Viscoelastic polyurethanes |
US20040266900A1 (en) | 2003-06-26 | 2004-12-30 | Raymond Neff | Viscoelastic polyurethane foam |
DE10352100A1 (en) | 2003-11-04 | 2005-06-02 | Basf Ag | Polyurethane foams containing acrylate polyols |
DE102005058090A1 (en) | 2005-12-05 | 2007-06-06 | Basf Ag | Process for the production of viscoelastic flexible polyurethane foams |
JP2009524718A (en) | 2006-01-27 | 2009-07-02 | ビーエーエスエフ ソシエタス・ヨーロピア | Method for producing viscoelastic and soft open-cell polyurethane foam |
WO2007144272A1 (en) | 2006-06-14 | 2007-12-21 | Basf Se | Open-cell viscoelastic flexible polyurethane foams |
US20070299153A1 (en) | 2006-06-23 | 2007-12-27 | Hager Stanley L | Viscoelastic foams with slower recovery and improved tear |
WO2009032894A1 (en) | 2007-09-07 | 2009-03-12 | Dow Global Technologies Inc. | Use of natural oil based compounds of low functionality to enhance foams |
DE102007061883A1 (en) | 2007-12-20 | 2009-06-25 | Bayer Materialscience Ag | Viscoelastic polyurethane foam |
EP2247667B1 (en) | 2008-02-27 | 2016-02-10 | Covestro Deutschland AG | Viscoelastic polyurethane foam containing castor oil |
EP2159240A2 (en) * | 2008-09-01 | 2010-03-03 | Basf Se | Plastic mouldable polyurethane foams |
EP2350157B1 (en) * | 2008-10-24 | 2013-03-20 | Basf Se | Method for producing viscoelastic polyurethane flexible foams |
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DK2785775T3 (en) | 2016-01-04 |
WO2013079461A1 (en) | 2013-06-06 |
EP2599810A1 (en) | 2013-06-05 |
MX2014006522A (en) | 2014-09-01 |
CN104093773A (en) | 2014-10-08 |
MX339744B (en) | 2016-06-08 |
PL2785775T3 (en) | 2016-03-31 |
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