CN114591483A - Polyurethane foam and method of forming same - Google Patents

Polyurethane foam and method of forming same Download PDF

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Publication number
CN114591483A
CN114591483A CN202011432120.0A CN202011432120A CN114591483A CN 114591483 A CN114591483 A CN 114591483A CN 202011432120 A CN202011432120 A CN 202011432120A CN 114591483 A CN114591483 A CN 114591483A
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Prior art keywords
polyurethane foam
polyol component
material mixture
original
total weight
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CN202011432120.0A
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Chinese (zh)
Inventor
孙文君
董玥
周静
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Saint Gobain Performance Plastics Corp
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Saint Gobain Performance Plastics Corp
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Priority to CN202011432120.0A priority Critical patent/CN114591483A/en
Priority to PCT/US2021/072658 priority patent/WO2022126066A1/en
Publication of CN114591483A publication Critical patent/CN114591483A/en
Pending legal-status Critical Current

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    • 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
    • C08G18/4009—Two or more macromolecular compounds not provided for in one single group of groups C08G18/42 - C08G18/64
    • 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
    • C08G18/30—Low-molecular-weight compounds
    • C08G18/32—Polyhydroxy compounds; Polyamines; Hydroxyamines
    • C08G18/3203—Polyhydroxy compounds
    • C08G18/3206—Polyhydroxy compounds aliphatic
    • 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
    • C08G18/30—Low-molecular-weight compounds
    • C08G18/32—Polyhydroxy compounds; Polyamines; Hydroxyamines
    • C08G18/3271—Hydroxyamines
    • C08G18/3275—Hydroxyamines containing two 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
    • C08G18/40—High-molecular-weight compounds
    • C08G18/48—Polyethers
    • C08G18/4825—Polyethers containing two 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
    • C08G18/40—High-molecular-weight compounds
    • C08G18/48—Polyethers
    • C08G18/4829—Polyethers containing 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
    • 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
    • C08G18/6681—Compounds of group C08G18/48 or C08G18/52 with compounds of group C08G18/32 or polyamines of C08G18/38 with compounds of group C08G18/32 or C08G18/3271 and/or polyamines of C08G18/38
    • C08G18/6688—Compounds of group C08G18/48 or C08G18/52 with compounds of group C08G18/32 or polyamines of C08G18/38 with compounds of group C08G18/32 or C08G18/3271 and/or polyamines of C08G18/38 with compounds of group C08G18/3271
    • 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
    • C08G18/70—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the isocyanates or isothiocyanates used
    • C08G18/72—Polyisocyanates or polyisothiocyanates
    • C08G18/74—Polyisocyanates or polyisothiocyanates cyclic
    • C08G18/76—Polyisocyanates or polyisothiocyanates cyclic aromatic
    • C08G18/7657—Polyisocyanates or polyisothiocyanates cyclic aromatic containing two or more aromatic rings
    • C08G18/7664—Polyisocyanates or polyisothiocyanates cyclic aromatic containing two or more aromatic rings containing alkylene polyphenyl 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
    • C08G2101/00—Manufacture of cellular products
    • 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

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  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Polyurethanes Or Polyureas (AREA)

Abstract

The present application relates to polyurethane foams and methods of forming the same. A polyurethane foam may include a first polyol component, a second polyol component, and a third polyol component. The first polyol component may include a polyol having an OH number of at least about 35KOH mg/g and not greater than about 70KOH mg/g, the second polyol component may include a polyol having an OH number of at least about 100KOH mg/g and not greater than about 180KOH mg/g, and the third polyol component may include a polyol having an OH number of at least about 300KOH mg/g and not greater than about 350KOH mg/g. The polyurethane foam may have a glass transition temperature of at least about-10 ℃ and not greater than about 35 ℃.

Description

Polyurethane foam and method of forming same
Technical Field
The present disclosure relates to a polyurethane foam and a method of forming the same, and more particularly, to a polyurethane foam having properties and a method of forming the same.
Background
Polyurethane foams are widely used in the construction, transportation and electronics fields. However, such polyurethane foams often contain special characteristics that make them susceptible to certain safety issues. For example, such polyurethane foams are often prone to rapid combustion due to their inherent chemical properties (i.e., -NH-COO-groups "of the polyurethane foam resulting in decomposition temperatures lower than many other polymers) and physical properties (i.e., the low density of the polyurethane results in severe dripping during combustion). Accordingly, there is a need for polyurethane foam formulations with improved safety characteristics.
Disclosure of Invention
According to a first aspect, a polyurethane foam may include a first polyol component, a second polyol component, and a third polyol component. The first polyol component may include a polyol having an OH number of at least about 35KOH mg/g and not greater than about 70KOH mg/g, the second polyol component may include a polyol having an OH number of at least about 100KOH mg/g and not greater than about 180KOH mg/g, and the third polyol component may include a polyol having an OH number of at least about 300KOH mg/g and not greater than about 350KOH mg/g. The polyurethane foam may have a glass transition temperature of at least about-10 ℃ and no greater than about 35 ℃.
According to another aspect, a polyurethane foam may include a first polyol component, a second polyol component, and a third polyol component. The first polyol component may include a polyol having an OH number of at least about 35KOH mg/g and not greater than about 70KOH mg/g, the second polyol component may include a polyol having an OH number of at least about 100KOH mg/g and not greater than about 180KOH mg/g, and the third polyol component may include a polyol having an OH number of at least about 300KOH mg/g and not greater than about 350KOH mg/g. The polyurethane foam may have a tan delta of at least about 0.75.
According to yet another aspect, a method of forming a polyurethane foam may comprise: providing a raw material mixture; and forming the raw material mixture into a polyurethane foam. The virgin material mixture may include a virgin first polyol component, a virgin second polyol component, and a virgin third polyol component. The original first polyol component may include a polyol having an OH number of at least about 35KOH mg/g and not greater than about 70KOH mg/g, the original second polyol component may include a polyol having an OH number of at least about 100KOH mg/g and not greater than about 180KOH mg/g, and the original third polyol component may include a polyol having an OH number of at least about 300KOH mg/g and not greater than about 350KOH mg/g. The polyurethane foam may have a glass transition temperature of at least about-10 ℃ and no greater than about 35 ℃.
According to yet another aspect, a method of forming a polyurethane foam may comprise: providing a raw material mixture; and forming the raw material mixture into a polyurethane foam. The virgin material mixture may include a virgin first polyol component, a virgin second polyol component, and a virgin third polyol component. The original first polyol component may include a polyol having an OH number of at least about 35KOH mg/g and not greater than about 70KOH mg/g, the original second polyol component may include a polyol having an OH number of at least about 100KOH mg/g and not greater than about 180KOH mg/g, and the original third polyol component may include a polyol having an OH number of at least about 300KOH mg/g and not greater than about 350KOH mg/g. The polyurethane foam may have a tan delta of at least about 0.75.
Drawings
The embodiments are shown by way of example and are not limited by the accompanying figures.
Fig. 1 includes a diagram illustrating a polyurethane foam forming method 100 according to embodiments described herein.
Skilled artisans appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale.
Detailed Description
The following discussion will focus on specific implementations and examples of the present teachings. The detailed description is provided to aid in the description of certain embodiments and should not be construed to limit the scope or applicability of the disclosure or teachings. It is to be understood that other embodiments may be used based on the disclosure and teachings provided herein.
The terms "consisting of," "comprising," "including," "having," or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited to only those features but may include other features not expressly listed or inherent to such method, article, or apparatus. In addition, "or" refers to an inclusive "or" rather than an exclusive "or" unless explicitly stated otherwise. For example, any of the following conditions a or B may be satisfied: a is true (or present) and B is false (or not present), a is false (or not present) and B is true (or present), and both a and B are true (or present).
Also, the use of "a" or "an" is used to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. Unless clearly indicated otherwise, such description should be understood to include one, at least one, or the singular also includes the plural, or vice versa. For example, when a single item is described herein, more than one item may be used in place of a single item. Similarly, where more than one item is described herein, a single item may be substituted for more than one item.
Embodiments described herein relate generally to a polyurethane foam and a method of forming the same.
For purposes of illustration, fig. 1 includes a diagram illustrating a polyurethane foam-forming method 100 according to particular embodiments described herein. The polyurethane forming method 100 may include a first step 110 of providing a raw material mixture and a second step 120 of forming the raw material mixture into a polyurethane foam.
Referring to the first step 110, according to certain embodiments, the original material mixture may include an original first polyol component, an original second polyol component, and an original third polyol component.
According to certain embodiments, the starting material mixture may include a particular content of the starting first polyol component. For example, the starting material mixture can include an original first polyol component content of at least about 7 wt% based on the total weight of the starting material mixture, such as at least about 8 wt%, or at least about 9 wt%, or even at least about 10 wt% based on the total weight of the starting material mixture. According to still other embodiments, the starting material mixture may include an original first polyol component content of not greater than about 15 wt.%, such as not greater than about 14 wt.%, or not greater than about 13 wt.%, or not greater than about 12 wt.%, or even not greater than about 11 wt.%, based on the total weight of the starting material mixture. It will be appreciated that the amount of the original first polyol component present in the original material mixture can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the original first polyol component may be present in the original material mixture in an amount ranging between any of the minimum and maximum values noted above.
According to still further embodiments, the original first polyol component may have a particular OH number. For example, the original first polyol component may have an OH number of at least about 35KOH mg/g, such as at least about 38KOH mg/g, or at least about 40KOH mg/g, or at least about 43KOH mg/g, or at least about 45KOH mg/g, or even at least about 48KOH mg/g. According to other embodiments, the original first polyol component may have an OH number of not greater than about 70KOH mg/g, such as not greater than about 67KOH mg/g, or not greater than about 65KOH mg/g, or not greater than about 62KOH mg/g, or even not greater than about 60KOH mg/g. It will be appreciated that the OH value of the original first polyol component can be within a range between any of the minimum and maximum values noted above. It should be further understood that the OH value of the original first polyol component can be any value between any of the minimum and maximum values noted above.
According to other embodiments, the virgin first polyol component may include a polyether polyol, a polyester polyol, a polymer polyol, a bio-based polyol, or a combination thereof.
According to still further embodiments, the original first polyol component may have a particular functionality. For example, the original first polyol component may have a functionality of 2 or 3.
According to other embodiments, the original first polyol component may have a particular molecular mass. For example, the original first polyol component may have a molecular mass of at least about 2000g/mol, such as at least about 2100g/mol, or at least about 2200g/mol, or at least about 2300g/mol, or at least about 2400g/mol, or at least about 2500g/mol, or at least about 2600g/mol, or at least about 2700g/mol, or at least about 2800g/mol, or even at least about 2900. According to other embodiments, the pristine first polyol component may have a molecular mass of no greater than about 4000g/mol, such as no greater than about 3900g/mol, or no greater than about 3800g/mol, or no greater than about 3700g/mol, or no greater than about 3600g/mol, or no greater than about 3500g/mol, or no greater than about 3400g/mol, or no greater than about 3300g/mol, or no greater than about 3200g/mol, or even no greater than about 3100 g/mol. It will be appreciated that the molecular mass of the original first polyol component can be within a range between any of the minimum and maximum values noted above. It should be further understood that the molecular mass of the original first polyol component may be any value between any of the minimum and maximum values noted above.
According to further embodiments, the virgin first polyol component may have a specific viscosity as measured according to ASTM D4878-15 (Standard test methods for polyurethane virgin materials: determination of polyol viscosity). For example, the original first polyol component may have a viscosity of at least about 400PA ·, such as at least about 410PA ·, or at least about 420PA ·, or at least about 430PA ·, or at least about 440PA ·, or at least about 450PA ·, or at least about 460PA ·, or at least about 470PA ·, or even at least about 480PA ·. According to other embodiments, the original first polyol component may have a viscosity of not greater than about 600PA ·, such as not greater than about 590PA ·, or not greater than about 580PA ·, or not greater than about 570PA ·, or not greater than about 560PA ·, or not greater than about 550PA ·, or not greater than about 530PA ·, or not greater than about 520PA ·, or not greater than about 510PA ·, or even not greater than about 500PA ·. It will be appreciated that the viscosity of the original first polyol component can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the viscosity of the original first polyol component can be any value between any of the minimum and maximum values noted above.
According to certain embodiments, the starting material mixture may include a specific content of the starting second polyol component. For example, the starting material mixture can include a raw second polyol component content of at least about 15 wt%, such as at least about 16 wt%, or at least about 17 wt%, or at least about 18 wt%, or at least about 19 wt%, or at least about 20 wt%, or at least about 21 wt%, or even at least about 22 wt%, based on the total weight of the starting material mixture. According to other embodiments, the starting material mixture may include a raw second polyol component content of not greater than about 30 wt.%, such as not greater than about 29 wt.%, or not greater than about 28 wt.%, or not greater than about 27 wt.%, or even not greater than about 26 wt.%, based on the total weight of the starting material mixture. It will be appreciated that the amount of the original second polyol component present in the original material mixture can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the content of the virgin second polyol component in the virgin material mixture can be any value between any of the minimum and maximum values noted above.
According to still further embodiments, the original second polyol component may have a particular OH value. For example, the original second polyol component may have an OH number of at least about 500KOH mg/g, such as at least about 600KOH mg/g, or at least about 700KOH mg/g, or at least about 800KOH mg/g, or even at least about 900KOH mg/g. According to other embodiments, the raw second polyol component may have an OH number of not greater than about 1500KOH mg/g, such as not greater than about 1400KOH mg/g, or not greater than about 1300KOH mg/g, or not greater than about 1200KOH mg/g, or even not greater than about 1100KOH mg/g. It will be appreciated that the OH value of the original second polyol component can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the OH value of the original second polyol component can be any value between any minimum and maximum values noted above.
According to other embodiments, the original second polyol component may have a particular functionality. For example, the original second polyol component may have a functionality of 2 or 3.
According to other embodiments, the original second polyol component may have a particular molecular mass as measured according to Gel Permeation Chromatography (GPC). For example, the original second polyol component may have a molecular mass of at least about 500g/mol, such as at least about 550g/mol, or at least about 600g/mol, or at least about 650g/mol, or at least about 700g/mol, or at least about 750g/mol, or at least about 800g/mol, or even at least about 850 g/mol. According to other embodiments, the original second polyol component may have a molecular mass of not greater than about 1500g/mol, such as not greater than about 1450g/mol, or not greater than about 1400g/mol, or not greater than about 1350g/mol, or not greater than about 1300g/mol, or not greater than about 1250g/mol, or not greater than about 1200g/mol, or even not greater than about 1150 g/mol. It will be appreciated that the molecular mass of the original second polyol component can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the molecular mass of the original second polyol component can be any value between any of the minimum and maximum values noted above.
According to further embodiments, the virgin second polyol component may have a specific viscosity as measured according to ASTM D4878-15 (Standard test methods for polyurethane virgin materials: determination of polyol viscosity). For example, the original second polyol component may have a viscosity of at least about 130PA ·, such as at least about 135PA ·, or at least about 140PA ·, or at least about 145PA ·, or at least about 150PA ·, or at least about 155PA ·, or at least about 160PA ·, or at least about 165PA ·, or even at least about 170PA ·. According to other embodiments, the original second polyol component may have a viscosity of not greater than about 270PA ·, such as not greater than about 265PA ·, or not greater than about 260PA ·, or not greater than about 255PA ·, or not greater than about 250PA ·, or not greater than about 245PA ·, or not greater than about 240PA ·, or not greater than about 235PA ·, or not greater than about 230PA ·, or even not greater than about 225PA ·. It will be appreciated that the viscosity of the original second polyol component can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the viscosity of the original second polyol component can be any value between any of the minimum and maximum values noted above.
According to certain embodiments, the starting material mixture may include a specific content of the starting third polyol component. For example, the starting material mixture may include an original third polyol component content of at least about 10 wt%, such as at least about 10.5 wt%, or at least about 11 wt%, or at least about 11.5 wt%, or at least about 12 wt%, or at least about 12.5 wt%, or at least about 13 wt%, or at least about 13.5 wt%, or even at least about 14 wt%, based on the total weight of the starting material mixture. According to other embodiments, the starting material mixture may include an original third polyol component content of not greater than about 20 wt%, such as not greater than about 19.5 wt%, or not greater than about 19 wt%, or not greater than about 18.5 wt%, or not greater than about 18 wt%, or not greater than about 17.5 wt%, or not greater than about 17 wt%, or not greater than about 16.5 wt%, or even not greater than about 16 wt%, based on the total weight of the starting material mixture. It will be appreciated that the amount of the original third polyol component present in the original material mixture can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the original third polyol component can be present in the original material mixture at any value between any minimum and maximum values noted above.
According to still further embodiments, the original third polyol component may have a particular OH value. For example, the original third polyol component may have an OH number of at least about 200KOH mg/g, such as at least about 220KOH mg/g, or at least about 240KOH mg/g, or at least about 260KOH mg/g, or even at least about 280KOH mg/g. According to other embodiments, the original third polyol component may have an OH number of not greater than about 330KOH mg/g, such as not greater than about 310KOH mg/g, or not greater than about 290KOH mg/g, or even not greater than about 280KOH mg/g. It will be appreciated that the OH value of the original third polyol component can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the OH value of the original third polyol component can be any value between any of the minimum and maximum values noted above.
According to still further embodiments, the original third polyol component may have a particular functionality. For example, the original third polyol component may have a functionality of 3.
According to other embodiments, the original third polyol component may have a particular molecular mass. For example, the original third polyol component may have a molecular mass of at least about 250g/mol, such as at least about 260g/mol, or at least about 270g/mol, or at least about 280g/mol, or at least about 290g/mol, or at least about 300g/mol, or at least about 310g/mol, or at least about 320g/mol, or at least about 330g/mol, or at least about 340g/mol, or at least about 350g/mol, or at least about 360g/mol, or at least about 370g/mol, or at least about 380g/mol, or at least about 390g/mol, or even at least about 400 g/mol. According to other embodiments, the original third polyol component may have a molecular mass of not greater than about 750g/mol, such as not greater than about 740g/mol, not greater than about 730g/mol, or not greater than about 720g/mol, or not greater than about 710g/mol, or not greater than about 700g/mol, or even not greater than about 690 g/mol. It will be appreciated that the molecular mass of the original third polyol component can be within a range between any of the minimum and maximum values noted above. It should be further understood that the molecular mass of the original third polyol component can be any value between any of the minimum and maximum values noted above.
According to further embodiments, the virgin third polyol component may have a specific viscosity as measured according to ASTM D4878-15 (Standard test methods for polyurethane virgin materials: determination of polyol viscosity). For example, the original third polyol component may have a viscosity of at least about 230 PAs, such as at least about 235 PAs, or at least about 240 PAs, or at least about 245 PAs, or at least about 250 PAs, or at least about 255 PAs, or at least about 260 PAs, or at least about 265 PAs, or even at least about 270 PAs. According to other embodiments, the original third polyol component may have a viscosity of no greater than about 370PA ­ s, such as no greater than about 365PA ­ s, or no greater than about 360PA ­ s, or no greater than about 355PA ­ s, or no greater than about 350PA ­ s, or no greater than about 345PA ­ s, or no greater than about 340PA ­ s, or no greater than about 335PA ­ s, or no greater than about 330PA ­ s, or even no greater than about 325PA ­ s. It will be appreciated that the viscosity of the original third polyol component can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the viscosity of the original third polyol component can be any value between any of the minimum and maximum values noted above.
According to other embodiments, the starting material mixture may further comprise a starting fourth polyol component.
According to certain embodiments, the starting material mixture may include a specified content of a starting fourth polyol component. For example, the starting material mixture may include an original fourth polyol component content of at least about 0.1 wt%, such as at least about 0.5 wt%, or at least about 1.0 wt%, or at least about 1.5 wt%, or at least about 2.0 wt%, or at least about 2.5 wt%, or at least about 3.0 wt%, or at least about 3.5 wt%, or at least about 4.0 wt%, or at least about 4.5 wt%, or even at least about 5.0 wt%, based on the total weight of the starting material mixture. According to other embodiments, the starting material mixture may include an original fourth polyol component content of not greater than about 10 wt%, such as not greater than about 9.5 wt%, or not greater than about 9.0 wt%, or not greater than about 8.5 wt%, or not greater than about 8.0 wt%, or not greater than about 7.5 wt%, or not greater than about 7.0 wt%, or even not greater than about 6.5 wt%, based on the total weight of the starting material mixture. It will be appreciated that the amount of the original fourth polyol component present in the original material mixture can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the original fourth polyol component may be present in the original material mixture at any value between any minimum and maximum values noted above.
According to still further embodiments, the original fourth polyol component may have a particular OH value. For example, the original fourth polyol component may have an OH number of at least about 28KOH mg/g, such as at least about 28.5KOH mg/g, or at least about 29.0KOH mg/g, or at least about 29.5KOH mg/g, or even at least about 30.0KOH mg/g. According to other embodiments, the raw fourth polyol component may have an OH number of not greater than about 32.0KOH mg/g, such as not greater than about 31.5KOH mg/g, or not greater than about 31.0KOH mg/g, or even not greater than about 31.5KOH mg/g. It will be appreciated that the OH value of the original fourth polyol component can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the OH value of the original fourth polyol component can be any value between any of the minimum and maximum values noted above.
According to still further embodiments, the original fourth polyol component may have a particular functionality. For example, the original fourth polyol component may have a functionality of no greater than 5, such as no greater than 4, or no greater than 3, or even 2.
According to other embodiments, the original fourth polyol component may have a particular molecular mass. For example, the original fourth polyol component may have a molecular mass of at least about 4500g/mol, such as at least about 5000 g/mol. According to other embodiments, the original fourth polyol component may have a molecular mass of not greater than about 6500g/mol, such as not greater than about 7000 g/mol. It will be appreciated that the molecular mass of the original fourth polyol component may be within a range between any of the minimum and maximum values noted above. It should be further understood that the molecular mass of the original fourth polyol component may be any value between any of the minimum and maximum values noted above.
According to further embodiments, the virgin fourth polyol component may have a specific viscosity as measured according to ASTM D4878-15 (Standard test methods for polyurethane virgin materials: determination of polyol viscosity). For example, the original fourth polyol component may have a viscosity of at least about 4500PA ·, such as at least about 4600PA ·, or at least about 4700PA ·, or at least about 4800PA ·, or even at least about 4900PA ·. According to other embodiments, the original fourth polyol component may have a viscosity of no greater than about 5500 PA-s, such as no greater than about 5400 PA-s, or no greater than about 5300 PA-s, or no greater than about 5200 PA-s, or even no greater than about 5100 PA-s. It will be appreciated that the viscosity of the original fourth polyol component can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the viscosity of the original fourth polyol component can be any value between any of the minimum and maximum values noted above.
According to other embodiments, the starting material mixture may further comprise a starting first surfactant component.
According to other embodiments, the initial first surfactant component may be a silicone surfactant.
According to certain embodiments, the raw material mixture may comprise a specific content of a raw first surfactant component. For example, the starting material mixture may comprise an original first surfactant component content of at least about 2 wt%, such as at least about 2.1 wt%, or at least about 2.2 wt%, or at least about 2.3 wt%, or at least about 2.4 wt%, or at least about 2.5 wt%, or even at least about 2.6 wt%, based on the total weight of the starting material mixture. According to other embodiments, the starting material mixture may include an original first surfactant component content of not greater than about 6.0 wt%, such as not greater than about 5.9 wt%, or not greater than about 5.8 wt%, or not greater than about 5.7 wt%, or not greater than about 5.6 wt%, or not greater than about 5.5 wt%, or not greater than about 5.4 wt%, or not greater than about 5.3 wt%, or even not greater than about 5.2 wt%, based on the total weight of the starting material mixture. It will be appreciated that the amount of the initial first surfactant component in the initial material mixture can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the original first surfactant component can be present in the original material mixture at any value between any minimum and maximum value noted above.
According to other embodiments, the starting material mixture may further comprise a starting second surfactant component.
According to other embodiments, the primary second surfactant component may be a silicone surfactant.
According to certain embodiments, the raw material mixture may comprise a specific amount of a raw secondary surfactant component. For example, the starting material mixture may comprise an original second surfactant component content of at least about 2 wt%, such as at least about 2.1 wt%, or at least about 2.2 wt%, or at least about 2.3 wt%, or at least about 2.4 wt%, or at least about 2.5 wt%, or even at least about 2.6 wt%, based on the total weight of the starting material mixture. According to other embodiments, the starting material mixture may include an original secondary surfactant component content of no greater than about 6.0 wt.%, such as no greater than about 5.9 wt.%, or no greater than about 5.8 wt.%, or no greater than about 5.7 wt.%, or no greater than about 5.6 wt.%, or no greater than about 5.5 wt.%, or no greater than about 5.4 wt.%, or no greater than about 5.3 wt.%, or even no greater than about 5.2 wt.%, based on the total weight of the starting material mixture. It will be appreciated that the amount of the initial second surfactant component in the initial material mixture can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the amount of the primary second surfactant component present in the primary material mixture can be any amount between any of the minimum and maximum values noted above.
According to further embodiments, the starting material mixture may further comprise a starting first catalyst component.
According to other embodiments, the original first catalyst component may comprise a metal catalyst comprising a metal component such as tin, copper, lead, zinc, cobalt, or nickel, and an amine catalyst such as a tertiary amine or quaternary ammonium salt.
According to certain embodiments, the raw material mixture may comprise a specific content of the raw first catalyst component. For example, the starting material mixture may comprise an original first catalyst component content of at least about 0.1 wt%, such as at least about 0.2 wt%, or at least about 0.3 wt%, or even at least about 0.4 wt%, based on the total weight of the starting material mixture. According to other embodiments, the starting material mixture may include an original first catalyst component content of not greater than about 1.0 wt%, such as not greater than about 0.9 wt%, or not greater than about 0.8 wt%, or not greater than about 0.7 wt%, or even not greater than about 0.6 wt%, based on the total weight of the starting material mixture. It will be appreciated that the amount of the original first catalyst component in the original material mixture can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the original first catalyst component may be present in the original material mixture in an amount ranging between any of the minimum and maximum values noted above.
According to further embodiments, the raw material mixture may further comprise a raw second catalyst component.
According to other embodiments, the original second catalyst component may comprise a metal catalyst comprising a metal component such as tin, copper, lead, zinc, cobalt, or nickel, and an amine catalyst such as a tertiary amine or quaternary ammonium salt.
According to certain embodiments, the raw material mixture may comprise a specific content of the raw second catalyst component. For example, the starting material mixture can comprise an original second catalyst component content of at least about 0.1 wt%, such as at least about 0.2 wt%, or at least about 0.3 wt%, or even at least about 0.4 wt%, based on the total weight of the starting material mixture. According to other embodiments, the starting material mixture may include an original first catalyst component content of not greater than about 1.0 wt%, such as not greater than about 0.9 wt%, or not greater than about 0.8 wt%, or not greater than about 0.7 wt%, or even not greater than about 0.6 wt%, based on the total weight of the starting material mixture. It will be appreciated that the amount of the original second catalyst component in the original material mixture can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the amount of the original second catalyst component present in the original material mixture can be any value between any of the minimum and maximum values noted above.
According to other embodiments, the starting material mixture may further comprise a starting chain extender component.
According to other embodiments, the original chain extender component may comprise a compound having at least two isocyanate-reactive groups, such as diethylene glycol, butanediol, dipropylene glycol, or diethanolamine.
According to certain embodiments, the raw material mixture may include a specific content of the raw chain extender component. For example, the starting material mixture may comprise an original chain extender component content of at least about 0.1 wt%, such as at least about 0.25 wt%, or at least about 0.5 wt%, or at least about 0.75 wt%, or at least about 1.0 wt%, or at least about 1.25 wt%, or even at least about 1.5 wt%, based on the total weight of the starting material mixture. According to still some embodiments, the starting material mixture may include an original chain extender component content of not greater than about 5 wt%, such as not greater than about 4.75 wt%, or not greater than about 4.5 wt%, or not greater than about 4.25 wt%, or not greater than about 4.0 wt%, or not greater than about 3.75 wt%, or not greater than about 3.5 wt%, or not greater than about 3.25 wt%, or not greater than about 3.0 wt%, or not greater than about 2.75 wt%, or not greater than about 2.5 wt%, or not greater than about 2.25 wt%, or even not greater than about 2.0 wt%, based on the total weight of the starting material mixture. It will be appreciated that the original chain extender component content of the original material mixture can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the original chain extender component content of the original material mixture can be any value between any of the minimum and maximum values noted above.
According to further embodiments, the starting material mixture may further comprise a starting isocyanate component.
According to other embodiments, the original isocyanate component may comprise monomeric diphenylmethane diisocyanate (MDI), modified MDI, polymeric MDI, and combinations thereof.
According to certain embodiments, the raw material mixture may comprise a specific content of the raw isocyanate component. For example, the starting material mixture may comprise an original isocyanate component content of at least about 22 wt%, such as at least about 23 wt%, or at least about 24 wt%, or at least about 25 wt%, or at least about 26 wt%, or at least about 27 wt%, or even at least about 28 wt%, based on the total weight of the starting material mixture. According to still other embodiments, the starting material mixture may include a starting isocyanate component content of not greater than about 35 wt.%, such as not greater than about 34 wt.%, or not greater than about 33 wt.%, or not greater than about 32 wt.%, or not greater than about 31 wt.%, or even not greater than about 30 wt.%, based on the total weight of the starting material mixture. It will be appreciated that the amount of the original isocyanate component in the original material mixture can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the amount of the original isocyanate component in the original material mixture can be any value between any minimum and maximum value noted above.
According to further embodiments, the raw material mixture may further comprise a raw pigment component.
According to other embodiments, the primary pigment component may comprise a carbon dispersion in a polyol.
According to certain embodiments, the raw material mixture may comprise a specific content of the raw pigment component. For example, the starting material mixture may comprise an original pigment component content of at least about 0.1 wt%, such as at least about 0.25 wt%, or at least about 0.5 wt%, or at least about 0.75 wt%, or at least about 1.0 wt%, or at least about 1.25 wt%, or even at least about 1.5 wt%, based on the total weight of the starting material mixture. According to still some embodiments, the starting material mixture may include an original pigment component content of not greater than about 5 wt%, such as not greater than about 4.75 wt%, or not greater than about 4.5 wt%, or not greater than about 4.25 wt%, or not greater than about 4.0 wt%, or not greater than about 3.75 wt%, or not greater than about 3.5 wt%, or not greater than about 3.25 wt%, or not greater than about 3.0 wt%, or not greater than about 2.75 wt%, or not greater than about 2.5 wt%, or not greater than about 2.25 wt%, or even not greater than about 2.0 wt%, based on the total weight of the starting material mixture. It will be appreciated that the content of the original pigment component in the original material mixture can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the content of the original pigment component in the original material mixture can be any value between any minimum and maximum value noted above.
According to further embodiments, the starting material mixture may further comprise a starting thixotropic agent component.
According to other embodiments, the original thixotropic agent component may comprise an aerosol, bentonite, a polyuria compound, or combinations thereof.
According to certain embodiments, the virgin material mixture may include a particular level of virgin thixotropic agent component. For example, the starting material mixture may include an original thixotropic agent component content of at least about 0.1 wt%, such as at least about 0.25 wt%, or at least about 0.5 wt%, or at least about 0.75 wt%, or at least about 1.0 wt%, or at least about 1.25 wt%, or even at least about 1.5 wt%, based on the total weight of the starting material mixture. According to other embodiments, the starting material mixture may include an original thixotropic agent component content of no greater than about 4 wt.%, such as no greater than about 3.75 wt.%, or no greater than about 3.5 wt.%, or no greater than about 3.25 wt.%, or no greater than about 3.0 wt.%, or no greater than about 2.75 wt.%, or no greater than about 2.5 wt.%, or no greater than about 2.25 wt.%, or even no greater than about 2.0 wt.%, based on the total weight of the starting material mixture. It should be appreciated that the amount of the original thixotropic agent component in the original material mixture may be within a range between any of the minimum and maximum values noted above. It should be further appreciated that the amount of the original thixotropic agent component in the original material mixture can be any amount between any minimum and maximum values noted above.
According to still further embodiments, the virgin material mixture may further comprise virgin filler. According to certain embodiments, the primary filler may comprise aluminum hydroxide, kaolin clay, talc, calcium carbonate, titanium dioxide, clay, zinc oxide, and the like.
According to still further embodiments, the virgin material mixture may further comprise a particular content of virgin filler. For example, the raw material mixture may comprise an original filler content of at least about 0.1 wt%, such as at least about 0.25 wt%, or at least about 0.5 wt%, or at least about 0.75 wt%, or at least about 1.0 wt%, or at least about 1.25 wt%, or even at least about 1.5 wt%, based on the total weight of the raw material mixture. According to still further embodiments, the starting material mixture may include an original filler content of not greater than about 25 wt%, such as not greater than about 24 wt%, or not greater than about 23 wt%, or not greater than about 22 wt%, or not greater than about 21 wt%, or not greater than about 20 wt%, or not greater than about 19 wt%, or not greater than about 18 wt%, or even not greater than about 17 wt%, based on the total weight of the starting material mixture. It will be appreciated that the amount of the starting filler in the starting material mixture can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the amount of virgin filler in the virgin material mixture can be any value between any of the minimum and maximum values noted above.
According to still other embodiments, forming the raw material mixture into a polyurethane foam may include foaming the raw material mixture to form a foam mixture. According to other embodiments, forming the starting material mixture into a polyurethane foam may further include curing the foam material mixture to form a polyurethane foam.
Referring now to polyurethane foams formed in accordance with embodiments described herein, the polyurethane foams may include a first polyol component, a second polyol component, and a third polyol component.
According to still other embodiments, the polyurethane foam may have a specific glass transition temperature as measured by Dynamic Mechanical Analysis (DMA). For example, the polyurethane foam may have a glass transition temperature of at least about-10 ℃, such as at least about-9 ℃, or at least about-8 ℃, or at least about-7 ℃, or at least about-6 ℃, or at least about-5 ℃, or at least about-4 ℃, or at least about-3 ℃, or at least about-2 ℃, or at least about-1 ℃, or at least about 0 ℃, or at least about-1 ℃, or at least about 2 ℃, or at least about 3 ℃, or even at least about 4 ℃. According to other embodiments, the polyurethane foam may have a glass transition temperature of not greater than about 35 ℃, such as not greater than about 34 ℃, or not greater than about 33 ℃, or not greater than about 32 ℃, or not greater than about 31 ℃, or not greater than about 30 ℃, or not greater than about 29 ℃, or not greater than about 28 ℃, or not greater than about 27 ℃, or not greater than about 26 ℃, or even not greater than about 25 ℃. It will be appreciated that the glass transition temperature of the polyurethane foam can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the glass transition temperature of the polyurethane foam can be any value between any minimum and maximum values noted above.
According to still other embodiments, the polyurethane foam may have a specific tan δ as measured by Dynamic Mechanical Analysis (DMA). For example, the polyurethane foam may have a tan δ of at least about 0.75, such as at least about 0.8, or at least about 0.85, or at least about 0.9, or at least about 0.95, or even at least about 1.0. It is to be understood that the tan delta of the polyurethane foam can be within a range between any of the values noted above. It should be further understood that the tan delta of the polyurethane foam can be any value between any of the minimum and maximum values noted above.
According to other embodiments, the polyurethane foam may have a specific tan δ as measured according to ASTM # D3574. For example, the polyurethane foam may have at least about 50kg/m3Such as at least about 100kg/m3The density of (c). According to other embodiments, the polyurethane foam may have a density of no greater than about 500kg/m3Such as not greater than about 450kg/m3The density of (c). It will be appreciated that the density of the polyurethane foam can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the polyurethane foam can have a density between any of the minimum and maximum values noted aboveAny value.
According to certain embodiments, the polyurethane foam may include a specific content of the first polyol component. For example, the polyurethane foam may comprise a first polyol component content of at least about 7 wt.%, such as at least about 8 wt.%, or at least about 9 wt.%, or at least about 10 wt.%, or even at least about 11 wt.%, based on the total weight of the polyurethane foam. According to still some embodiments, the polyurethane foam may include a first polyol component content of no greater than about 15 wt.%, such as no greater than about 14 wt.%, or no greater than about 8 wt.%, or even no greater than about 13 wt.%, based on the total weight of the polyurethane foam. It will be appreciated that the amount of the first polyol component in the polyurethane foam can be within a range between any of the minimum and maximum values noted above. It will be further understood that the amount of the first polyol component in the polyurethane foam can be any value between any of the minimum and maximum values noted above.
According to still further embodiments, the first polyol component may have a particular OH number. For example, the first polyol component may have an OH number of at least about 35KOH mg/g, such as at least about 38KOH mg/g, or at least about 40KOH mg/g, or at least about 43KOH mg/g, or at least about 45KOH mg/g, or even at least about 48KOH mg/g. According to other embodiments, the first polyol component may have an OH number of not greater than about 70KOH mg/g, such as not greater than about 67KOH mg/g, or not greater than about 65KOH mg/g, or not greater than about 62KOH mg/g, or even not greater than about 60KOH mg/g. It will be appreciated that the OH number of the first polyol component can be within a range between any of the minimum and maximum values noted above. It will be further understood that the OH number of the first polyol component can be any value between any minimum and maximum value noted above.
According to other embodiments, the first polyol component may include a polyether polyol, a polyester polyol, a polymer polyol, a bio-based polyol, or a combination thereof.
According to still further embodiments, the first polyol component may have a particular functionality. For example, the original first polyol component may have a functionality of 2 or 3.
According to other embodiments, the first polyol component may have a particular molecular mass. For example, the first polyol component may have a molecular mass of at least about 2000g/mol, such as at least about 2100g/mol, or at least about 2200g/mol, or at least about 2300g/mol, or at least about 2400g/mol, or at least about 2500g/mol, or at least about 2600g/mol, or at least about 2700g/mol, or at least about 2800g/mol, or even at least about 2900. According to other embodiments, the first polyol component may have a molecular mass of no greater than about 4000g/mol, such as no greater than about 3900g/mol, or no greater than about 3800g/mol, or no greater than about 3700g/mol, or no greater than about 3600g/mol, or no greater than about 3500g/mol, or no greater than about 3400g/mol, or no greater than about 3300g/mol, or no greater than about 3200g/mol, or even no greater than about 3100 g/mol. It will be appreciated that the molecular mass of the first polyol component can be within a range between any of the minimum and maximum values noted above. It will be further understood that the molecular mass of the first polyol component can be any value between any of the minimum and maximum values noted above.
According to further embodiments, the first polyol component may have a specific viscosity as measured according to ASTM D4878-15 (Standard test methods for polyurethane virgin materials: determination of polyol viscosity). For example, the first polyol component may have a viscosity of at least about 400PA × s, such as at least about 405PA × s, or at least about 410PA × s, or at least about 415PA × s, or at least about 420PA × s, or at least about 425PA × s, or at least about 430PA × s, or at least about 435PA × s, or at least about 440PA × s, or at least about 445PA × s, or at least about 450PA × s, or at least about 455PA × s, or at least about 460PA × s, or at least about 465PA × s, or at least about 470PA × s, or at least about 475PA × s, or at least about 480PA × s, or at least about PA 485PA × s, or even at least about 490PA × s. According to other embodiments, the first polyol component may have a viscosity of no greater than about 800PA ·, such as no greater than about 750PA ·, or no greater than about 700PA ·, or no greater than about 650PA ·, or no greater than about 600PA ·, or no greater than about 550PA ·, or no greater than about 545PA ·, or no greater than about 540PA ·, or no greater than about 535PA ·, or no greater than about 530PA ·, or no greater than about 525PA ·, or no greater than about 520PA ·, or no greater than about 515PA ·, or no greater than about 510PA ·, or even no greater than about 505PA ·. It will be appreciated that the viscosity of the first polyol component can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the viscosity of the first polyol component can be any value between any minimum and maximum values noted above.
According to certain embodiments, the polyurethane foam may include a specific content of the second polyol component. For example, the polyurethane foam may include a second polyol component content of at least about 15 wt.%, such as at least about 16 wt.%, or at least about 17 wt.%, or at least about 18 wt.%, or at least about 19 wt.%, or at least about 20 wt.%, or at least about 21 wt.%, or even at least about 22 wt.%, based on the total weight of the starting material mixture. According to still other embodiments, the polyurethane foam may include a second polyol component content of not greater than about 30 wt.%, such as not greater than about 29 wt.%, or not greater than about 28 wt.%, or not greater than about 27 wt.%, or even not greater than about 26 wt.%, based on the total weight of the polyurethane foam. It will be appreciated that the amount of the second polyol component in the polyurethane foam can be within a range between any of the minimum and maximum values noted above. It will be further understood that the amount of the second polyol component in the polyurethane foam can be any value between any of the minimum and maximum values noted above.
According to still other embodiments, the second polyol component may have a particular OH number. For example, the second polyol component may have an OH number of at least about 500KOH mg/g, such as at least about 600KOH mg/g, or at least about 700KOH mg/g, or at least about 800KOH mg/g, or even at least about 900KOH mg/g. According to other embodiments, the second polyol component may have an OH number of not greater than about 1500KOH mg/g, such as not greater than about 1400KOH mg/g, or not greater than about 1300KOH mg/g, or not greater than about 1200KOH mg/g, or even not greater than about 1100KOH mg/g. It will be appreciated that the OH value of the second polyol component can be within a range between any of the minimum and maximum values noted above. It will be further understood that the OH number of the second polyol component can be any value between any minimum and maximum value noted above.
According to other embodiments, the second polyol component may have a particular functionality. For example, the second polyol component may have a functionality of 2 or 3.
According to other embodiments, the second polyol component may have a particular molecular mass as measured according to Gel Permeation Chromatography (GPC). For example, the second polyol component may have a molecular mass of at least about 500g/mol, such as at least about 550g/mol, or at least about 600g/mol, or at least about 650g/mol, or at least about 700g/mol, or at least about 750g/mol, or at least about 800g/mol, or even at least about 850 g/mol. According to other embodiments, the second polyol component may have a molecular mass of not greater than about 1500g/mol, such as not greater than about 1450g/mol, or not greater than about 1400g/mol, or not greater than about 1350g/mol, or not greater than about 1300g/mol, or not greater than about 1250g/mol, or not greater than about 1200g/mol, or even not greater than about 1150 g/mol. It will be appreciated that the molecular mass of the second polyol component can be within a range between any of the minimum and maximum values noted above. It will be further understood that the molecular mass of the second polyol component can be any value between any of the minimum and maximum values noted above.
According to further embodiments, the second polyol component may have a specific viscosity as measured according to ASTM D4878-15 (Standard test methods for polyurethane virgin materials: determination of polyol viscosity). For example, the second polyol component may have a viscosity of at least about 130PA ·, such as at least about 135PA ·, or at least about 140PA ·, or at least about 145PA ·, or at least about 150PA ·, or at least about 155PA ·, or at least about 160PA ·, or at least about 165PA ·, or even at least about 170PA ·. According to other embodiments, the second polyol component may have a viscosity of not greater than about 270PA ·, such as not greater than about 265PA ·, or not greater than about 260PA ·, or not greater than about 255PA ·, or not greater than about 250PA ·, or not greater than about 245PA ·, or not greater than about 240PA ·, or not greater than about 235PA ·, or not greater than about 230PA ·, or even not greater than about 225PA ·. It will be appreciated that the viscosity of the second polyol component can be within a range between any of the minimum and maximum values noted above. It will be further understood that the viscosity of the second polyol component can be any value between any of the minimum and maximum values noted above.
According to certain embodiments, the polyurethane foam may comprise a specific content of the third polyol component at least about 10 wt.%, such as at least about 10.5 wt.%, or at least about 11 wt.%, or at least about 11.5 wt.%, or at least about 12 wt.%, or at least about 12.5 wt.%, or at least about 13 wt.%, or at least about 13.5 wt.%, or even at least about 14 wt.%, based on the total weight of the starting material mixture. According to other embodiments, the polyurethane foam may include a third polyol component content of not greater than about 20 wt.%, such as not greater than about 19.5 wt.%, or not greater than about 19 wt.%, or not greater than about 18.5 wt.%, or not greater than about 18 wt.%, or not greater than about 17.5 wt.%, or not greater than about 17 wt.%, or not greater than about 16.5 wt.%, or even not greater than about 16 wt.%, based on the total weight of the polyurethane foam. It will be appreciated that the amount of third polyol component in the polyurethane foam can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the third polyol component may be present in the polyurethane foam at any value between any minimum and maximum values noted above.
According to still other embodiments, the third polyol component may have a particular OH number. For example, the third polyol component may have an OH number of at least about 200KOH mg/g, such as at least about 220KOH mg/g, or at least about 240KOH mg/g, or at least about 260KOH mg/g, or even at least about 280KOH mg/g. According to other embodiments, the third polyol component may have an OH number of not greater than about 330KOH mg/g, such as not greater than about 310KOH mg/g, or not greater than about 290KOH mg/g, or even not greater than about 280KOH mg/g. It will be appreciated that the OH value of the third polyol component can be within a range between any of the minimum and maximum values noted above. It should be further understood that the OH number of the third polyol component can be any value between any minimum and maximum value noted above.
According to still further embodiments, the third polyol component may have a particular functionality. For example, the third polyol component may have a functionality of 3.
According to other embodiments, the third polyol component may have a particular molecular mass. For example, the third polyol component may have a molecular mass of at least about 250g/mol, such as at least about 260g/mol, or at least about 270g/mol, or at least about 280g/mol, or at least about 290g/mol, or at least about 300g/mol, or at least about 310g/mol, or at least about 320g/mol, or at least about 330g/mol, or at least about 340g/mol, or at least about 350g/mol, or at least about 360g/mol, or at least about 370g/mol, or at least about 380g/mol, or at least about 390g/mol, or even at least about 400 g/mol. According to other embodiments, the third polyol component may have a molecular mass of not greater than about 750g/mol, such as not greater than about 740g/mol, not greater than about 730g/mol, or not greater than about 720g/mol, or not greater than about 710g/mol, or not greater than about 700g/mol, or even not greater than about 690 g/mol. It will be appreciated that the molecular mass of the third polyol component can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the molecular mass of the third polyol component can be any value between any minimum and maximum value noted above.
According to further embodiments, the third polyol component may have a specific viscosity as measured according to ASTM D4878-15 (Standard test methods for polyurethane virgin materials: determination of polyol viscosity). For example, the third polyol component may have a viscosity of at least about 230PA ·, such as at least about 235PA ·, or at least about 240PA ·, or at least about 245PA ·, or at least about 250PA ·, or at least about 255PA ·, or at least about 260PA ·, or at least about 265PA ·, or even at least about 270PA ·. According to other embodiments, the third polyol component may have a viscosity of no greater than about 370PA ­ s, such as no greater than about 365PA ­ s, or no greater than about 360PA ­ s, or no greater than about 355PA ­ s, or no greater than about 350PA ­ s, or no greater than about 345PA ­ s, or no greater than about 340PA ­ s, or no greater than about 335PA ­ s, or no greater than about 330PA ­ s, or even no greater than about 325PA ­ s. It will be appreciated that the viscosity of the third polyol component can be within a range between any of the minimum and maximum values noted above. It should be further understood that the viscosity of the third polyol component may be any value between any of the minimum and maximum values noted above.
According to other embodiments, the polyurethane foam may further comprise a fourth polyol component.
According to certain embodiments, the polyurethane foam may include a specific content of the fourth polyol component. For example, the polyurethane foam may include a fourth polyol component content of at least about 0.1 wt.%, such as at least about 0.5 wt.%, or at least about 1.0 wt.%, or at least about 1.5 wt.%, or at least about 2.0 wt.%, or at least about 2.5 wt.%, or at least about 3.0 wt.%, or at least about 3.5 wt.%, or at least about 4.0 wt.%, or at least about 4.5 wt.%, or even at least about 5.0 wt.%, based on the total weight of the polyurethane foam. According to other embodiments, the polyurethane foam may include a fourth polyol component content of not greater than about 10 wt.%, such as not greater than about 9.5 wt.%, or not greater than about 9.0 wt.%, or not greater than about 8.5 wt.%, or not greater than about 8.0 wt.%, or not greater than about 7.5 wt.%, or not greater than about 7.0 wt.%, or even not greater than about 6.5 wt.%, based on the total weight of the polyurethane foam. It will be appreciated that the amount of the fourth polyol component in the polyurethane foam can be within a range between any of the minimum and maximum values noted above. It will be further understood that the amount of the fourth polyol component in the polyurethane foam can be any value between any of the minimum and maximum values noted above.
According to still further embodiments, the fourth polyol component may have a particular OH number. For example, the fourth polyol component may have an OH number of at least about 28KOH mg/g, such as at least about 28.5KOH mg/g, or at least about 29.0KOH mg/g, or at least about 29.5KOH mg/g, or even at least about 30.0KOH mg/g. According to other embodiments, the fourth polyol component may have an OH number of not greater than about 32.0KOH mg/g, such as not greater than about 31.5KOH mg/g, or not greater than about 31.0KOH mg/g, or even not greater than about 31.5KOH mg/g. It will be appreciated that the OH value of the fourth polyol component can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the OH number of the fourth polyol component can be any value between any minimum and maximum value noted above.
According to still further embodiments, the fourth polyol component may have a particular functionality. For example, the original phosphorus polyol component may have a functionality of no greater than 5, such as no greater than 4, or no greater than 3, or no greater than 2, or even 1.
According to other embodiments, the fourth polyol component may have a particular molecular mass. For example, the fourth polyol component may have a molecular mass of at least about 4500g/mol, such as at least about 5000 g/mol. According to other embodiments, the fourth polyol component may have a molecular mass of not greater than about 6500g/mol, such as not greater than about 7000 g/mol. It will be appreciated that the molecular mass of the fourth polyol component can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the molecular mass of the fourth polyol component can be any value between any of the minimum and maximum values noted above.
According to other embodiments, the fourth polyol component may have a specific viscosity as measured according to ASTM D4878-15 (Standard test method for polyurethane virgin materials: determination of polyol viscosity). For example, the fourth polyol component may have a viscosity of at least about 4500PA ×, such as at least about 4600PA ×, or at least about 4700PA ×, or at least about 4800PA ×, or even at least about 4900PA ×.s. According to other embodiments, the fourth polyol component may have a viscosity of no greater than about 5500 PA-s, such as no greater than about 5400 PA-s, or no greater than about 5300 PA-s, or no greater than about 5200 PA-s, or even no greater than about 5100 PA-s. It will be appreciated that the viscosity of the fourth polyol component can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the viscosity of the fourth polyol component can be any value between any minimum and maximum value noted above.
According to other embodiments, the polyurethane foam may further comprise a first surfactant component.
According to other embodiments, the first surfactant component may be a silicone surfactant.
According to certain embodiments, the polyurethane foam may comprise a specific level of the first surfactant component. For example, the polyurethane foam may comprise a first surfactant component content of at least about 2 wt.%, such as at least about 2.1 wt.%, or at least about 2.2 wt.%, or at least about 2.3 wt.%, or at least about 2.4 wt.%, or at least about 2.5 wt.%, or even at least about 2.6 wt.%, based on the total weight of the starting material mixture. According to still some embodiments, the polyurethane foam may include a first surfactant component content of no greater than about 6.0 wt.%, such as no greater than about 5.9 wt.%, or no greater than about 5.8 wt.%, or no greater than about 5.7 wt.%, or no greater than about 5.6 wt.%, or no greater than about 5.5 wt.%, or no greater than about 5.4 wt.%, or no greater than about 5.3 wt.%, or even no greater than about 5.2 wt.%, based on the total weight of the polyurethane foam. It will be appreciated that the amount of the first surfactant component in the polyurethane foam can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the amount of the first surfactant component in the polyurethane foam can be any amount between any minimum and maximum values noted above.
According to other embodiments, the polyurethane foam may further comprise a second surfactant component.
According to other embodiments, the second surfactant component may be a silicone surfactant.
According to certain embodiments, the polyurethane foam may comprise a specific level of the second surfactant component. For example, the polyurethane foam may comprise a second surfactant component content of at least about 0.1 wt.%, such as at least about 0.2 wt.%, or at least about 0.3 wt.%, or at least about 0.4 wt.%, or at least about 0.5 wt.%, or even at least about 0.6 wt.%, based on the total weight of the polyurethane foam. According to still some embodiments, the polyurethane foam may include a second surfactant component content of not greater than about 6.0 wt.%, such as not greater than about 5.9 wt.%, or not greater than about 5.8 wt.%, or not greater than about 5.7 wt.%, or not greater than about 5.6 wt.%, or not greater than about 5.5 wt.%, or not greater than about 5.4 wt.%, or not greater than about 5.3 wt.%, or even not greater than about 5.2 wt.%, based on the total weight of the polyurethane foam. It will be appreciated that the amount of the second surfactant component in the polyurethane foam can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the amount of the second surfactant component in the polyurethane foam can be any amount between any minimum and maximum values noted above.
According to other embodiments, the polyurethane foam may further comprise a first catalyst component.
According to other embodiments, the first catalyst component may comprise a metal catalyst comprising a metal component such as tin, copper, lead, zinc, cobalt, or nickel, and an amine catalyst such as a tertiary amine or quaternary ammonium salt.
According to certain embodiments, the polyurethane foam may comprise a specific amount of the first catalyst component. For example, the polyurethane foam may comprise a first catalyst component content of at least about 0.1 wt.%, such as at least about 0.2 wt.%, or at least about 0.3 wt.%, or even at least about 0.4 wt.%, based on the total weight of the starting material mixture. According to other embodiments, the starting material mixture may include an original first catalyst component content of not greater than about 1.0 wt%, such as not greater than about 0.9 wt%, or not greater than about 0.8 wt%, or not greater than about 0.7 wt%, or even not greater than about 0.6 wt%, based on the total weight of the starting material mixture. It will be appreciated that the amount of the first catalyst component in the polyurethane foam can be within a range between any of the minimum and maximum values noted above. It will be further understood that the amount of the first catalyst component in the polyurethane foam can be any value between any of the minimum and maximum values noted above.
According to other embodiments, the polyurethane foam may further comprise a second catalyst component.
According to other embodiments, the second catalyst component may comprise a metal catalyst comprising a metal component such as tin, copper, lead, zinc, cobalt, or nickel, and an amine catalyst such as a tertiary amine or quaternary ammonium salt.
According to certain embodiments, the polyurethane foam may comprise a specific content of the second catalyst component. For example, the polyurethane foam may comprise a second catalyst component content of at least about 0.1 wt.%, such as at least about 0.2 wt.%, or at least about 0.3 wt.%, or even at least about 0.4 wt.%, based on the total weight of the starting material mixture. According to other embodiments, the starting material mixture may include an original first catalyst component content of not greater than about 1.0 wt%, such as not greater than about 0.9 wt%, or not greater than about 0.8 wt%, or not greater than about 0.7 wt%, or even not greater than about 0.6 wt%, based on the total weight of the starting material mixture. It will be appreciated that the amount of the second catalyst component in the polyurethane foam can be within a range between any of the minimum and maximum values noted above. It will be further understood that the amount of the second catalyst component in the polyurethane foam can be any value between any of the minimum and maximum values noted above.
According to other embodiments, the polyurethane foam may further comprise a chain extender component.
According to other embodiments, the chain extender component may comprise a compound having at least two isocyanate-reactive groups, such as diethylene glycol, triethylene glycol, dipropylene glycol, or tripropylene glycol.
According to certain embodiments, the polyurethane foam may include a specific content of the chain extender component. For example, the polyurethane foam may comprise a chain extender component content of at least about 0.1 wt.%, such as at least about 0.25 wt.%, or at least about 0.5 wt.%, or at least about 0.75 wt.%, or at least about 1.0 wt.%, or at least about 1.25 wt.%, or even at least about 1.5 wt.%, based on the total weight of the polyurethane foam. According to still some embodiments, the polyurethane foam may include a chain extender component content of not greater than about 5 wt.%, such as not greater than about 4.75 wt.%, or not greater than about 4.5 wt.%, or not greater than about 4.25 wt.%, or not greater than about 4.0 wt.%, or not greater than about 3.75 wt.%, or not greater than about 3.5 wt.%, or not greater than about 3.25 wt.%, or not greater than about 3.0 wt.%, or not greater than about 2.75 wt.%, or not greater than about 2.5 wt.%, or not greater than about 2.25 wt.%, or even not greater than about 2.0 wt.%, based on the total weight of the polyurethane foam. It will be appreciated that the amount of the chain extender component in the polyurethane foam can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the amount of the chain extender component in the polyurethane foam can be any value between any minimum and maximum value noted above.
According to other embodiments, the polyurethane foam may further comprise an isocyanate component.
According to other embodiments, the isocyanate component may comprise monomeric diphenylmethane diisocyanate (MDI), modified MDI, polymeric MDI, and combinations thereof.
According to certain embodiments, the polyurethane foam may include a specific content of the isocyanate component. For example, the polyurethane foam may comprise an isocyanate component content of at least about 22 wt.%, such as at least about 23 wt.%, or at least about 24 wt.%, or at least about 25 wt.%, or at least about 26 wt.%, or at least about 27 wt.%, or even at least about 28 wt.%, based on the total weight of the starting material mixture. According to still some embodiments, the polyurethane foam may include an isocyanate component content of not greater than about 35 wt.%, such as not greater than about 34 wt.%, or not greater than about 33 wt.%, or not greater than about 32 wt.%, or not greater than about 31 wt.%, or even not greater than about 30 wt.%, based on the total weight of the polyurethane foam. It will be appreciated that the isocyanate component content of the polyurethane foam can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the isocyanate component may be present in the polyurethane foam at any value between any minimum and maximum value noted above.
According to other embodiments, the polyurethane foam may further comprise a pigment component.
According to other embodiments, the pigment component may comprise a carbon dispersion in a polyol.
According to certain embodiments, the polyurethane foam may comprise a specific content of a pigment component. For example, the polyurethane foam may comprise a pigment component content of at least about 0.1 wt.%, such as at least about 0.25 wt.%, or at least about 0.5 wt.%, or at least about 0.75 wt.%, or at least about 1.0 wt.%, or at least about 1.25 wt.%, or even at least about 1.5 wt.%, based on the total weight of the polyurethane foam. According to still some embodiments, the polyurethane foam may include a pigment component content of not greater than about 5 wt.%, such as not greater than about 4.75 wt.%, or not greater than about 4.5 wt.%, or not greater than about 4.25 wt.%, or not greater than about 4.0 wt.%, or not greater than about 3.75 wt.%, or not greater than about 3.5 wt.%, or not greater than about 3.25 wt.%, or not greater than about 3.0 wt.%, or not greater than about 2.75 wt.%, or not greater than about 2.5 wt.%, or not greater than about 2.25 wt.%, or even not greater than about 2.0 wt.%, based on the total weight of the polyurethane foam. It will be appreciated that the amount of the pigment component in the polyurethane foam can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the amount of the pigment component in the polyurethane foam can be any amount between any minimum and maximum values noted above.
According to other embodiments, the polyurethane foam may further comprise a thixotropic agent component.
According to other embodiments, the thixotropic agent component may comprise an aerosol, bentonite, a polyuria compound, or combinations thereof.
According to certain embodiments, the polyurethane foam may include a specific content of a thixotropic agent component. For example, the polyurethane foam may comprise a thixotropic agent component content of at least about 0.1 wt.%, such as at least about 0.25 wt.%, or at least about 0.5 wt.%, or at least about 0.75 wt.%, or at least about 1.0 wt.%, or at least about 1.25 wt.%, or even at least about 1.5 wt.%, based on the total weight of the polyurethane foam. According to other embodiments, the polyurethane foam may include a thixotropic agent component content of no greater than about 4 wt.%, such as no greater than about 3.75 wt.%, or no greater than about 3.5 wt.%, or no greater than about 3.25 wt.%, or no greater than about 3.0 wt.%, or no greater than about 2.75 wt.%, or no greater than about 2.5 wt.%, or no greater than about 2.25 wt.%, or even no greater than about 2.0 wt.%, based on the total weight of the polyurethane foam. It will be appreciated that the amount of thixotropic agent component in the polyurethane foam can be within a range between any minimum and maximum values noted above. It will be further appreciated that the amount of the thixotropic agent component in the polyurethane foam can be any amount between any minimum and maximum amount noted above.
According to other embodiments, the polyurethane foam may further comprise a filler. According to certain embodiments, the filler may comprise aluminum hydroxide, kaolin, talc, calcium carbonate, titanium dioxide, clay, zinc oxide, and the like.
According to still other embodiments, the polyurethane foam may further comprise a specific content of filler. For example, the polyurethane foam may comprise a filler content of at least about 0.1 wt.%, such as at least about 0.25 wt.%, or at least about 0.5 wt.%, or at least about 0.75 wt.%, or at least about 1.0 wt.%, or at least about 1.25 wt.%, or even at least about 1.5 wt.%, based on the total weight of the polyurethane foam. According to still some embodiments, the polyurethane foam may include a filler content of not greater than about 25 wt.%, such as not greater than about 24 wt.%, or not greater than about 23 wt.%, or not greater than about 22 wt.%, or not greater than about 21 wt.%, or not greater than about 20 wt.%, or not greater than about 19 wt.%, or not greater than about 18 wt.%, or even not greater than about 17 wt.%, based on the total weight of the polyurethane foam. It will be appreciated that the filler content of the polyurethane foam can be within a range between any of the minimum and maximum values noted above. It will be further understood that the filler content of the polyurethane foam can be any value between any minimum and maximum values noted above.
According to still other embodiments, the polyurethane foam may have a particular thickness. For example, the polyurethane foam may have a thickness of at least about 0.1mm, such as at least about 0.15mm, or at least about 0.2mm, or at least about 0.25mm, or at least about 0.3mm, or even at least about 0.35 mm. According to other embodiments, the polyurethane foam may have a thickness of no greater than about 15mm, such as no greater than about 14.5mm, or no greater than about 14.0mm, or no greater than about 13.5mm, or no greater than about 13.0mm, or no greater than about 12.5mm, or no greater than about 12.0mm, or no greater than about 11.5mm, or no greater than about 11.0mm, or no greater than about 10.5mm, or no greater than about 10.0mm, or no greater than about 9.5mm, or no greater than about 9.0mm, or no greater than about 8.5mm, or no greater than about 8.0mm, or no greater than about 7.5mm, or no greater than about 7.0mm, or no greater than about 6.5mm, or no greater than about 6.0mm, or no greater than about 5.5mm, or no greater than about 5.0mm, or no greater than about 4.5mm, or no greater than about 4.0mm, or no greater than about 3.5mm, or no greater than about 3.0mm, or no greater than about 2.5mm, or no greater than about 1.0mm, or even 1 mm. It will be appreciated that the thickness of the polyurethane foam can be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the thickness of the polyurethane foam can be any value between any minimum and maximum values noted above.
Referring now to specific uses of polyurethane foams formed in accordance with embodiments described herein, particular embodiments may include cell compression pads that may include polyurethane foams. It should be understood that the polyurethane foam of the cell compression mat may be formed according to any of the embodiments described herein. It should be further understood that the polyurethane foam of the cell compression pad may comprise any of the components described with reference to any of the embodiments described herein. It should be further understood that the polyurethane foam of the battery compression pad may include any of the characteristics described with reference to the embodiments described herein.
Many different aspects and embodiments are possible. Some of these aspects and embodiments are described herein. After reading this description, those skilled in the art will appreciate that those aspects and embodiments are illustrative only and do not limit the scope of the present invention. Embodiments may be in accordance with any one or more of the embodiments listed below.
Example 1. a polyurethane foam comprising: a first polyol component comprising a polyol having an OH number of at least about 35KOH mg/g and not greater than about 70KOH mg/g; a second polyol component comprising a polyol having an OH number of at least about 100KOH mg/g and not greater than about 180KOH mg/g; and a third polyol component comprising a polyol having an OH number of at least about 300KOH mg/g and not greater than about 350KOH mg/g, wherein the polyurethane foam has a glass transition temperature of at least about-10 ℃ and not greater than about 35 ℃.
Example 2. a polyurethane foam comprising: a first polyol component comprising a polyether polyol having an OH value of at least about 50KOH mg/g and not greater than about 60KOH mg/g; a second polyol component comprising a polyol having an OH number of at least about 100KOH mg/g and not greater than about 180KOH mg/g; and a third polyol component comprising a polyol having an OH number of at least about 300KOH mg/g and not greater than about 350KOH mg/g, wherein the polyurethane foam has a tan delta of at least about 0.75.
Embodiment 3. the polyurethane foam of embodiment 2, wherein the polyurethane foam has a glass transition temperature of at least about-10 ℃ and no greater than about 35 ℃.
Embodiment 4. the polyurethane foam of embodiment 1, wherein the polyurethane foam has a tan delta of at least about 0.75.
Embodiment 5. the polyurethane foam of any one of embodiments 1, 2, 3, and 4, wherein the polyurethane foam comprises no greater than about 500kg/m3The density of (2).
Embodiment 6 the polyurethane foam of any one of embodiments 1, 2, 3, and 4, wherein the polyurethane foam comprises at least about 50kg/m3The density of (c).
Embodiment 7. the polyurethane foam of any of embodiments 1, 2, 3, and 4, wherein the first polyol component comprises a viscosity of at least about 450PA @.
Embodiment 8 the polyurethane foam of any one of embodiments 1, 2, 3, and 4, wherein the first polyol component comprises a viscosity of not greater than about 550PA s.
Embodiment 9 the polyurethane foam of any of embodiments 1, 2, 3, and 4, wherein the first polyol component comprises at least about 2000g mol-1Molecular mass of (2).
Embodiment 10 the polyurethane foam of any of embodiments 1, 2, 3, and 4, wherein the first polyol component comprises not greater than about 4000g mol-1Molecular mass of (2).
Embodiment 11 the polyurethane foam of any of embodiments 1, 2, 3, and 4, wherein the first polyol component comprises a functionality of at least about 2 or 3.
Embodiment 12 the polyurethane foam of any one of embodiments 1, 2, 3, and 4, wherein the polyurethane foam comprises a first polyol component content of at least about 7 wt% based on the total weight of the polyurethane foam.
Embodiment 13 the polyurethane foam of any one of embodiments 1, 2, 3, and 4, wherein the polyurethane foam comprises a first polyol component content of not greater than about 15 wt% based on the total weight of the polyurethane foam.
Embodiment 14 the polyurethane foam of any one of embodiments 1, 2, 3, and 4, wherein the second polyol component comprises a viscosity of at least about 130PA @.
Embodiment 15 the polyurethane foam of any one of embodiments 1, 2, 3, and 4, wherein the second polyol component comprises a viscosity of not greater than about 270PA s.
Embodiment 16 the polyurethane foam of any of embodiments 1, 2, 3, and 4, wherein the second polyol component comprises at least about 500g mol-1Molecular mass of (2).
Embodiment 17 the polyurethane foam of any of embodiments 1, 2, 3, and 4, wherein the second polyol component comprises not greater than about 1500g x mol-1Molecular mass of (2).
Embodiment 18 the polyurethane foam of any of embodiments 1, 2, 3, and 4, wherein the second polyol component comprises a functionality of 2 or 3.
Embodiment 19 the polyurethane foam of any one of embodiments 1, 2, 3, and 4, wherein the polyurethane foam comprises a second polyol component content of at least about 15 wt% based on the total weight of the polyurethane foam.
Embodiment 20 the polyurethane foam of any one of embodiments 1, 2, 3, and 4, wherein the polyurethane foam includes a second polyol component content of not greater than about 30 wt% based on the total weight of the polyurethane foam.
Embodiment 21 the polyurethane foam of any one of embodiments 1, 2, 3, and 4, wherein the third polyol component comprises a viscosity of at least about 230PA @.
Embodiment 22 the polyurethane foam of any one of embodiments 1, 2, 3, and 4, wherein the third polyol component comprises a viscosity of not greater than about 370PA s.
Embodiment 23. the polyurethane foam of any of embodiments 1, 2, 3, and 4, wherein theThe third polyol component comprises at least about 150g mol-1Molecular mass of (2).
Embodiment 24 the polyurethane foam of any one of embodiments 1, 2, 3, and 4, wherein the third polyol component comprises not greater than about 400g x mol-1Molecular mass of (2).
Embodiment 25 the polyurethane foam of any one of embodiments 1, 2, 3, and 4, wherein the third polyol component comprises a functionality of 3.
Embodiment 26 the polyurethane foam of any one of embodiments 1, 2, 3, and 4, wherein the polyurethane foam comprises a third polyol component content of at least about 10 weight percent based on the total weight of the polyurethane foam.
Embodiment 27 the polyurethane foam of any one of embodiments 1, 2, 3, and 4, wherein the polyurethane foam comprises a third polyol component content of not greater than about 20 wt% based on the total weight of the polyurethane foam.
Embodiment 28 the polyurethane foam of embodiment 1 wherein the polyurethane foam further comprises a fourth polyol component having an OH number of at least about 28KOH mg/g and not greater than about 32KOH mg/g.
Embodiment 29 the polyurethane foam of embodiment 28, wherein the fourth polyol component comprises a viscosity of at least about 4500 PA-s.
Embodiment 30 the polyurethane foam of embodiment 28, wherein the fourth polyol component comprises a viscosity of no greater than about 5500 PA-s.
Embodiment 31 the polyurethane foam of embodiment 28, wherein the fourth polyol component comprises at least about 4500g x mol-1The molecular mass of (2).
Embodiment 32 the polyurethane foam of embodiment 28, wherein the fourth polyol component comprises not greater than about 7000g x mol-1Molecular mass of (2).
Embodiment 33 the polyurethane foam of embodiment 28, wherein the polyurethane foam includes a fourth polyol component content of at least about 0.1 wt% based on the total weight of the polyurethane foam.
Embodiment 34 the polyurethane foam of embodiment 28, wherein the polyurethane foam includes a fourth polyol component content of no greater than about 10 wt% based on the total weight of the polyurethane foam.
Embodiment 35 the polyurethane foam of any of embodiments 1, 2, 3, and 4, wherein the polyurethane foam further comprises a first surfactant.
Embodiment 36 the polyurethane foam of embodiment 35, wherein the first surfactant is a silicone surfactant.
Embodiment 37. the polyurethane foam of embodiment 35, wherein the polyurethane foam comprises a first surfactant content of at least about 2 weight percent of the total weight of the polyurethane foam.
Embodiment 38 the polyurethane foam of embodiment 35, wherein the polyurethane foam comprises a first surfactant content of not greater than about 6 wt% based on the total weight of the polyurethane foam.
Embodiment 39 the polyurethane foam of any of embodiments 1, 2, 3, and 4, wherein the polyurethane foam further comprises a second surfactant.
Embodiment 40 the polyurethane foam of embodiment 39, wherein the second surfactant is a silicone surfactant.
Embodiment 41 the polyurethane foam of embodiment 39, wherein the polyurethane foam comprises a second surfactant content of at least about 0.1 wt% based on the total weight of the polyurethane foam.
Embodiment 42 the polyurethane foam of embodiment 39, wherein the polyurethane foam comprises a second surfactant content of not greater than about 6 wt% based on the total weight of the polyurethane foam.
Embodiment 43 the polyurethane foam of any one of embodiments 1, 2, 3, and 4, wherein the polyurethane foam further comprises a first catalyst.
Embodiment 44 the polyurethane foam of embodiment 43, wherein the first catalyst is a nickel catalyst.
Embodiment 45 the polyurethane foam of embodiment 43, wherein the polyurethane foam comprises a first catalyst content of at least about 0.1 wt% based on the total weight of the polyurethane foam.
Embodiment 46 the polyurethane foam of embodiment 43, wherein the polyurethane foam comprises a first catalyst content of not greater than about 1.0 wt% based on the total weight of the polyurethane foam.
Embodiment 47 the polyurethane foam of any one of embodiments 1, 2, 3, and 4, wherein the polyurethane foam further comprises a second catalyst.
Embodiment 48 the polyurethane foam of any one of embodiments 1, 2, 3, and 4, wherein the polyurethane foam further comprises a chain extender.
Embodiment 49. the polyurethane foam of embodiment 47, wherein the chain extender is diethylene glycol, tetramethylene glycol, dipropylene glycol, or diethanolamine.
Embodiment 50 the polyurethane foam of embodiment 47, wherein the polyurethane foam comprises a chain extender content of at least about 0.1 weight percent based on the total weight of the polyurethane foam.
Embodiment 51. the polyurethane foam of embodiment 47, wherein the polyurethane foam comprises a chain extender content of no greater than about 5 wt.% based on the total weight of the polyurethane foam.
Embodiment 52 the polyurethane foam of any one of embodiments 1, 2, 3, and 4, wherein the polyurethane foam comprises an isocyanate.
Embodiment 53 the polyurethane foam of embodiment 52, wherein the polyurethane foam comprises an isocyanate content of at least about 22 weight percent based on the total weight of the polyurethane foam.
Embodiment 54 the polyurethane foam of embodiment 52, wherein the polyurethane foam comprises an isocyanate content of no greater than about 35 wt% based on the total weight of the polyurethane foam.
Embodiment 55. a method of forming a polyurethane foam, wherein the method comprises: providing a starting material mixture comprising: a virgin first polyol component comprising a polyol having an OH value of at least about 35KOH mg/g and not greater than about 70KOH mg/g, a virgin second polyol component comprising a polyol having an OH value of at least about 100KOH mg/g and not greater than about 180KOH mg/g, and a virgin third polyol component comprising a polyol having an OH value of at least about 300KOH mg/g and not greater than about 350KOH mg/g; and forming the starting material mixture into a polyurethane foam, wherein the polyurethane foam has a glass transition temperature of at least about 0 ℃ and not greater than about 35 ℃.
Embodiment 56. a method of forming a polyurethane foam, wherein the method comprises: providing a starting material mixture comprising: a virgin first polyol component comprising a polyol having an OH value of at least about 35KOH mg/g and not greater than about 70KOH mg/g, a virgin second polyol component comprising a polyol having an OH value of at least about 100KOH mg/g and not greater than about 180KOH mg/g, and a virgin third polyol component comprising a polyol having an OH value of at least about 300KOH mg/g and not greater than about 350KOH mg/g; and forming the starting material mixture into a polyurethane foam, wherein the polyurethane foam has a tan delta of at least about 0.75.
Embodiment 57 the polyurethane foam of embodiment 56, wherein the polyurethane foam has a glass transition temperature of at least about-10 ℃ and not greater than about 35 ℃.
Embodiment 58. the polyurethane foam of embodiment 55, wherein the polyurethane foam has a tan delta of at least about 0.75.
Embodiment 59. the method of any one of embodiments 55, 56, 57, and 58, wherein the polyurethane foam comprises no greater than about 500kg/m3The density of (2).
Embodiment 60. the method of any one of embodiments 55, 56, 57, and 58, wherein the original first polyol component comprises a viscosity of at least about 400PA @.
Embodiment 61. the method of any one of embodiments 55, 56, 57, and 58, wherein the original first polyol component comprises a viscosity of not greater than about 800PA s.
Embodiment 62. the method of any one of embodiments 55, 56, 57, and 58, wherein the original first polyol component comprises at least about 2000 g-mol-1Molecular mass of (2).
Embodiment 63. the method of any one of embodiments 55, 56, 57, and 58, wherein the original first polyol component comprises not greater than about 4000g mol-1Molecular mass of (2).
Embodiment 64. the method of any one of embodiments 55, 56, 57, and 58, wherein the original first polyol component comprises a functionality of 2 or 3.
Embodiment 65. the method of any one of embodiments 55, 56, 57, and 58, wherein the starting material mixture comprises a first polyol component content of at least about 7 wt% based on the total weight of the starting material mixture.
Embodiment 66. the method of any one of embodiments 55, 56, 57, and 58, wherein the starting material mixture comprises an original first polyol component content of not greater than about 15 wt% for the total weight of the starting material mixture.
Embodiment 67. the method of any one of embodiments 55, 56, 57, and 58, wherein the original second polyol component comprises a viscosity of at least about 130PA @.
Embodiment 68. the method of any one of embodiments 55, 56, 57, and 58, wherein the original second polyol component comprises a viscosity of not greater than about 270PA s.
Embodiment 69. the method of any one of embodiments 55, 56, 57, and 58, wherein the original second polyol component comprises at least about 500 g-mol-1Molecular mass of (2).
Embodiment 70. the method according to any of embodiments 55, 56, 57 and 58Wherein the original second polyol component comprises no more than about 1500g mol-1Molecular mass of (2).
Embodiment 71. the method of any one of embodiments 55, 56, 57, and 58, wherein the original second polyol component comprises a functionality of 2 or 3.
Embodiment 72 the method of any one of embodiments 55, 56, 57, and 58, wherein the starting material mixture comprises a raw second polyol component content of at least about 15 weight percent based on the total weight of the starting material mixture.
Embodiment 73. the method of any one of embodiments 55, 56, 57, and 58, wherein the starting material mixture comprises a raw second polyol component content of not greater than about 30 wt% for the total weight of the starting material mixture.
Embodiment 74. the method of any of embodiments 55, 56, 57, and 58 wherein the original third polyol component comprises a viscosity of at least about 230PA ×.s.
Embodiment 75. the method of any one of embodiments 55, 56, 57, and 58, wherein the original third polyol component comprises a viscosity of not greater than about 370PA @.
Embodiment 76. the method of any of embodiments 55, 56, 57, and 58, wherein the original third polyol component comprises at least about 250 g-mol-1Molecular mass of (2).
Embodiment 77. the method of any one of embodiments 55, 56, 57, and 58 wherein the original third polyol component comprises no more than about 750g/mol-1Molecular mass of (2).
Embodiment 78 the method of any one of embodiments 55, 56, 57, and 58, wherein the third polyol component comprises a functionality of 3.
Embodiment 79. the method of any one of embodiments 55, 56, 57, and 58, wherein the starting material mixture comprises an original third polyol component content of at least about 10 weight percent based on the total weight of the starting material mixture.
Embodiment 80. the method of any one of embodiments 55, 56, 57, and 58, wherein the starting material mixture comprises an original third polyol component content of not greater than about 20 wt% for the total weight of the starting material mixture.
Embodiment 81. the method of any one of embodiments 55, 56, 57, and 58, wherein the starting material mixture further comprises a raw fourth polyol component having an OH number of at least about 28KOH mg/g and not greater than about 32KOH mg/g.
Embodiment 82. the method of embodiment 81, wherein the original fourth polyol component comprises a viscosity of at least about 4500 PA-s.
Embodiment 83. the method of embodiment 81, wherein the original fourth polyol component comprises a viscosity of not greater than about 5500 PA-s.
Embodiment 84. the method of embodiment 81 wherein the original fourth polyol component comprises at least about 4500g mol-1The molecular mass of (2).
Embodiment 85. the method of embodiment 81, wherein the original fourth polyol component comprises not greater than about 7000g x mol-1Molecular mass of (2).
Embodiment 86. the method of embodiment 81, wherein the starting material mixture comprises a raw fourth polyol component content of at least about 0.1 wt% based on the total weight of the starting material mixture.
Embodiment 87 the method of embodiment 81, wherein the starting material mixture comprises a raw fourth polyol component content of not greater than about 10 wt% for the total weight of the starting material mixture.
Embodiment 88 the method of any one of embodiments 55, 56, 57, and 58, wherein the virgin material mixture further comprises virgin first surfactant.
Embodiment 89 the method of embodiment 88, wherein the pristine first surfactant is a silicone surfactant.
Embodiment 90 the method of embodiment 88, wherein the starting material mixture comprises an original first surfactant content of at least about 2 wt% based on the total weight of the starting material mixture.
Embodiment 91 the method of embodiment 88, wherein the starting material mixture comprises an original first surfactant content of not greater than about 6 wt% for the total weight of the starting material mixture.
Embodiment 92 the method of any one of embodiments 55, 56, 57, and 58, wherein the virgin material mixture further comprises a virgin secondary surfactant.
Embodiment 93 the method of embodiment 92, wherein the pristine second surfactant is a silicone surfactant.
Embodiment 94 the method of embodiment 92, wherein the starting material mixture comprises a starting secondary surfactant content of at least about 0.1 wt% based on the total weight of the starting material mixture.
Embodiment 95 the method of embodiment 92, wherein the starting material mixture comprises a starting secondary surfactant content of no greater than about 6 wt% based on the total weight of the starting material mixture.
Embodiment 96. the method of any one of embodiments 55, 56, 57, and 58, wherein the starting material mixture further comprises a starting first catalyst.
Embodiment 97 the method of embodiment 96, wherein the original first catalyst is a nickel catalyst.
Embodiment 98. the method of embodiment 96, wherein the raw material mixture comprises an original first catalyst content of at least about 0.1 wt% based on the total weight of the raw material mixture.
Embodiment 99 the method of embodiment 96, wherein the raw material mixture comprises an original first catalyst content of not greater than about 1.0 wt% for the total weight of the raw material mixture.
Embodiment 100. the method of any one of embodiments 55, 56, 57, and 58, wherein the raw material mixture further comprises a raw second catalyst.
Embodiment 101. the method of embodiment 100, wherein the original second catalyst is a nickel catalyst.
Embodiment 102 the method of embodiment 100, wherein the raw material mixture comprises an original second catalyst content of at least about 0.1 wt% based on the total weight of the raw material mixture.
Embodiment 103 the method of embodiment 100, wherein the raw material mixture comprises a raw second catalyst content of not greater than about 1.0 wt% based on the total weight of the raw material mixture.
Embodiment 104. the method of any one of embodiments 55, 56, 57, and 58, wherein the raw material mixture further comprises a raw chain extender.
Embodiment 105. the method of embodiment 104, wherein the original chain extender is diethylene glycol, tetramethylene glycol, dipropylene glycol, or diethanolamine.
Embodiment 106 the method of embodiment 104, wherein the starting material mixture comprises an original chain extender content of at least about 0.1 wt% based on the total weight of the starting material mixture.
Embodiment 107. the method of embodiment 104, wherein the starting material mixture comprises a starting chain extender content of not greater than about 5 wt% based on the total weight of the starting material mixture.
Embodiment 108. the method of any of embodiments 55, 56, 57, and 58, wherein the raw material mixture comprises raw isocyanates.
Embodiment 109 the method of embodiment 108, wherein the starting material mixture comprises a starting isocyanate content of at least about 22 wt% based on the total weight of the starting material mixture.
Embodiment 110 the method of embodiment 108, wherein the starting material mixture comprises a starting isocyanate content of not greater than about 35 wt% based on the total weight of the starting material mixture.
Examples of the invention
The concepts described herein will be further described in the following examples, which do not limit the scope of the invention described in the claims.
Example 1
Sample polyurethane foams S1-S3 were formed according to the examples described herein. Table 1 below summarizes the composition of sample polyurethane foams S1-S3.
TABLE 1 sample foam composition
Figure BDA0002820960490000361
Comparative sample polyurethane foams CS1-CS3 were formed for comparison with the examples described herein. Table 2 below summarizes the composition of comparative sample polyurethane foams CS1-CS 3.
TABLE 2 comparative sample foam composition
Figure BDA0002820960490000371
Sample and comparative polyurethane foams were formed by mixing all liquid components (including first polyol, second polyol, third polyol, fourth polyol, surfactant, catalyst, pigment, chain extender) until the liquid phase was homogeneous. Then, any filler is added to the liquid mixture. The combined mixture is then mixed until it reaches a homogeneous composition. Finally, an isocyanate is added to the combined mixture. The final mixture was cured in an oven above 170 ℃ for a few minutes.
It is noted that not all of the activities in the general descriptions or examples above are required, that a portion of a specific activity may not be required, and that one or more further activities may be performed in addition to those described. Further, the order in which activities are listed are not necessarily the order in which they are performed.
Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. The benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced, however, are not to be construed as a critical, required, or essential feature or feature of any or all the claims.
The description and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The description and drawings are not intended to serve as an exhaustive or comprehensive description of all the elements and features of apparatus and systems that utilize the structures or methods described herein. Separate embodiments may also be provided in combination in a single embodiment, and conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any sub-combination. Further, reference to a value being expressed as a range includes each and every value within that range. Many other embodiments will be apparent to the skilled person only after reading this description. Other embodiments may be utilized and derived from the disclosure, such that structural substitutions, logical substitutions, or other changes may be made without departing from the scope of the disclosure. The present disclosure is, therefore, to be considered as illustrative and not restrictive.

Claims (110)

1. A polyurethane foam comprising:
a first polyol component comprising a polyol having an OH value of at least about 35KOHmg/g and not greater than about 70KOH mg/g,
a second polyol component comprising a polyol having an OH value of at least about 100KOHmg/g and not greater than about 180KOH mg/g, and
a third polyol component comprising a polyol having an OH value of at least about 300KOHmg/g and not greater than about 350KOH mg/g,
wherein the polyurethane foam has a glass transition temperature of at least about-10 ℃ and not greater than about 35 ℃.
2. A polyurethane foam comprising:
a first polyol component comprising a polyether polyol having an OH value of at least about 50KOHmg/g and not greater than about 60KOH mg/g,
a second polyol component comprising a polyol having an OH value of at least about 100KOHmg/g and not greater than about 180KOH mg/g, and
a third polyol component comprising a polyol having an OH value of at least about 300KOHmg/g and not greater than about 350KOH mg/g,
wherein the polyurethane foam has a tan delta of at least about 0.75.
3. The polyurethane foam of claim 2, wherein the polyurethane foam has a glass transition temperature of at least about-10 ℃ and not greater than about 35 ℃.
4. The polyurethane foam of claim 1, wherein the polyurethane foam has a tan delta of at least about 0.75.
5. The polyurethane foam according to any one of claims 1, 2, 3, and 4, wherein the polyurethane foam comprises no greater than about 500kg/m3The density of (c).
6. The polyurethane foam according to any one of claims 1, 2, 3, and 4, wherein the polyurethane foam comprises at least about 50kg/m3The density of (c).
7. The polyurethane foam according to any of claims 1, 2, 3, and 4, wherein the first polyol component comprises a viscosity of at least about 130 PA-s.
8. The polyurethane foam according to any of claims 1, 2, 3, and 4, wherein the first polyol component comprises a viscosity of not greater than about 270 PA-s.
9. The polyurethane foam of any of claims 1, 2, 3, and 4Wherein the first polyol component comprises at least about 2000g mol-1Molecular mass of (2).
10. The polyurethane foam according to any of claims 1, 2, 3, and 4, wherein the first polyol component comprises not greater than about 4000g mol-1Molecular mass of (2).
11. The polyurethane foam according to any of claims 1, 2, 3, and 4, wherein the first polyol component comprises a functionality of at least about 2 or 3.
12. The polyurethane foam according to any one of claims 1, 2, 3, and 4, wherein the polyurethane foam comprises a first polyol component content of at least about 7 wt% based on the total weight of the polyurethane foam.
13. The polyurethane foam according to any one of claims 1, 2, 3, and 4, wherein the polyurethane foam comprises a first polyol component content of not greater than about 15 wt% based on the total weight of the polyurethane foam.
14. The polyurethane foam according to any one of claims 1, 2, 3, and 4, wherein the second polyol component comprises a viscosity of at least about 130 PA-s.
15. The polyurethane foam according to any of claims 1, 2, 3, and 4, wherein the second polyol component comprises a viscosity of not greater than about 270 PA-s.
16. The polyurethane foam according to any of claims 1, 2, 3, and 4, wherein the second polyol component comprises at least about 500g mol-1Molecular mass of (2).
17. The polyurethane foam according to any one of claims 1, 2, 3, and 4, wherein the second polyol component comprises no greater than about1500g*mol-1Molecular mass of (2).
18. The polyurethane foam according to any of claims 1, 2, 3, and 4, wherein the second polyol component comprises a functionality of 2 or 3.
19. The polyurethane foam according to any one of claims 1, 2, 3, and 4, wherein the polyurethane foam comprises a second polyol component content of at least about 15 wt% based on the total weight of the polyurethane foam.
20. The polyurethane foam according to any one of claims 1, 2, 3, and 4, wherein the polyurethane foam comprises a second polyol component content of not greater than about 30 wt% based on the total weight of the polyurethane foam.
21. The polyurethane foam according to any of claims 1, 2, 3, and 4, wherein the third polyol component comprises a viscosity of at least about 230 PA-s.
22. The polyurethane foam according to any of claims 1, 2, 3, and 4, wherein the third polyol component comprises a viscosity of not greater than about 370 PA-s.
23. The polyurethane foam according to any of claims 1, 2, 3, and 4, wherein the third polyol component comprises at least about 150g mol-1Molecular mass of (2).
24. The polyurethane foam according to any of claims 1, 2, 3, and 4, wherein the third polyol component comprises not greater than about 400g mol-1Molecular mass of (2).
25. The polyurethane foam according to any of claims 1, 2, 3, and 4, wherein the third polyol component comprises a functionality of 3.
26. The polyurethane foam according to any one of claims 1, 2, 3, and 4, wherein the polyurethane foam comprises a third polyol component content of at least about 10 wt% based on the total weight of the polyurethane foam.
27. The polyurethane foam according to any one of claims 1, 2, 3, and 4, wherein the polyurethane foam comprises a third polyol component content of not greater than about 20 wt% based on the total weight of the polyurethane foam.
28. The polyurethane foam of claim 1, wherein the polyurethane foam further comprises a fourth polyol component having an OH number of at least about 28KOH mg/g and not greater than about 32KOH mg/g.
29. The polyurethane foam according to claim 28, wherein the fourth polyol component comprises a viscosity of at least about 4500 PA-s.
30. The polyurethane foam according to claim 28, wherein the fourth polyol component comprises a viscosity of not greater than about 5500 PA-s.
31. The polyurethane foam of claim 28 wherein the fourth polyol component comprises at least about 4500g mol-1Molecular mass of (2).
32. The polyurethane foam of claim 28 wherein the fourth polyol component comprises no greater than about 7000g mol-1Molecular mass of (2).
33. The polyurethane foam of claim 28, wherein the polyurethane foam comprises a fourth polyol component content of at least about 0.1 wt% based on the total weight of the polyurethane foam.
34. The polyurethane foam of claim 28, wherein the polyurethane foam comprises a fourth polyol component content of not greater than about 10 wt% based on the total weight of the polyurethane foam.
35. The polyurethane foam according to any one of claims 1, 2, 3, and 4, wherein the polyurethane foam further comprises a first surfactant.
36. The polyurethane foam of claim 35, wherein the first surfactant is a silicone surfactant.
37. The polyurethane foam of claim 35, wherein the polyurethane foam comprises a first surfactant content of at least about 2 wt% based on the total weight of the polyurethane foam.
38. The polyurethane foam of claim 35, wherein the polyurethane foam comprises a first surfactant content of not greater than about 6 wt% based on the total weight of the polyurethane foam.
39. The polyurethane foam according to any one of claims 1, 2, 3, and 4, wherein the polyurethane foam further comprises a second surfactant.
40. The polyurethane foam according to claim 39, wherein the second surfactant is a silicone surfactant.
41. The polyurethane foam of claim 39, wherein the polyurethane foam comprises a second surfactant content of at least about 0.1 wt% based on the total weight of the polyurethane foam.
42. The polyurethane foam of claim 39, wherein the polyurethane foam comprises a second surfactant content of not greater than about 6 wt% based on the total weight of the polyurethane foam.
43. The polyurethane foam according to any one of claims 1, 2, 3, and 4, wherein the polyurethane foam further comprises a first catalyst.
44. The polyurethane foam according to claim 43, wherein the first catalyst is a nickel catalyst.
45. The polyurethane foam of claim 43, wherein the polyurethane foam comprises a first catalyst content of at least about 0.1 weight percent based on the total weight of the polyurethane foam.
46. The polyurethane foam of claim 43, wherein the polyurethane foam comprises a first catalyst content of not greater than about 1.0 wt% based on the total weight of the polyurethane foam.
47. The polyurethane foam according to any one of claims 1, 2, 3, and 4, wherein the polyurethane foam further comprises a second catalyst.
48. The polyurethane foam of any of claims 1, 2, 3, and 4, wherein the polyurethane foam further comprises a chain extender.
49. The polyurethane foam of claim 47, wherein the chain extender is diethylene glycol, tetramethylene glycol, dipropylene glycol, or diethanolamine.
50. The polyurethane foam of claim 47, wherein the polyurethane foam comprises a chain extender content of at least about 0.1 weight percent of the total weight of the polyurethane foam.
51. The polyurethane foam of claim 47, wherein the polyurethane foam comprises a chain extender content of not greater than about 5 wt.% based on the total weight of the polyurethane foam.
52. The polyurethane foam according to any one of claims 1, 2, 3, and 4, wherein the polyurethane foam comprises an isocyanate.
53. The polyurethane foam according to claim 52, wherein the polyurethane foam comprises an isocyanate content of at least about 22 wt% based on the total weight of the polyurethane foam.
54. The polyurethane foam according to claim 52, wherein the polyurethane foam comprises an isocyanate content of not greater than about 35% by weight based on the total weight of the polyurethane foam.
55. A method of forming a polyurethane foam, wherein the method comprises:
providing a starting material mixture comprising:
an original first polyol component comprising a polyol having an OH number of at least about 35KOH mg/g and not greater than about 70KOH mg/g,
a virgin second polyol component comprising a polyol having an OH number of at least about 100KOH mg/g and not greater than about 180KOH mg/g, and
a virgin third polyol component comprising a polyol having an OH number of at least about 300KOH mg/g and not greater than about 350KOH mg/g, and
forming the raw material mixture into a polyurethane foam,
wherein the polyurethane foam has a glass transition temperature of at least about-10 ℃ and not greater than about 35 ℃.
56. A method of forming a polyurethane foam, wherein the method comprises:
providing a starting material mixture comprising:
an original first polyol component comprising a polyol having an OH number of at least about 35KOH mg/g and not greater than about 70KOH mg/g,
a virgin second polyol component comprising a polyol having an OH number of at least about 100KOH mg/g and not greater than about 180KOH mg/g, and
a virgin third polyol component comprising a polyol having an OH number of at least about 300KOH mg/g and not greater than about 350KOH mg/g, and
forming the raw material mixture into a polyurethane foam,
wherein the polyurethane foam has a tan delta of at least about 0.75.
57. The polyurethane foam of claim 56, wherein the polyurethane foam has a glass transition temperature of at least about-10 ℃ and not greater than about 35 ℃.
58. The polyurethane foam according to claim 55, wherein the polyurethane foam has a tan δ of at least about 0.75.
59. The method of any one of claims 55, 56, 57, and 58, wherein the polyurethane foam comprises no greater than about 500kg/m3The density of (c).
60. The method according to any one of claims 55, 56, 57, and 58, wherein the original first polyol component comprises a viscosity of at least about 450 PA-s.
61. The method according to any one of claims 55, 56, 57, and 58, wherein the original first polyol component comprises a viscosity of not greater than about 550 PA-s.
62. The method according to any one of claims 55, 56, 57, and 58, wherein the original first polyol component comprises at least about 2000g mol-1Molecular mass of (2).
63. The method according to any one of claims 55, 56, 57, and 58, wherein the original first polyol component comprises not greater than about 4000g mol-1Molecular mass of (2).
64. The method of any one of claims 55, 56, 57, and 58 wherein the original first polyol component comprises a functionality of 3.
65. The method of any one of claims 55, 56, 57, and 58, wherein the starting material mixture comprises an original first polyol component content of at least about 7 wt% for the total weight of the starting material mixture.
66. The method of any one of claims 55, 56, 57, and 58, wherein the starting material mixture comprises an original first polyol component content of not greater than about 15 wt% for the total weight of the starting material mixture.
67. The method according to any one of claims 55, 56, 57, and 58, wherein the original second polyol component comprises a viscosity of at least about 130 PA-s.
68. The method according to any one of claims 55, 56, 57, and 58, wherein the original second polyol component comprises a viscosity of not greater than about 270 PA-s.
69. The method according to any one of claims 55, 56, 57, and 58, wherein the original second polyol component comprises at least about 500g mol-1Molecular mass of (2).
70. The method according to any one of claims 55, 56, 57, and 58, wherein the original second polyol component comprises not greater than about 1500 g-mol-1Molecular mass of (2).
71. The method of any one of claims 55, 56, 57, and 58, wherein the original second polyol component comprises a functionality of 2 or 3.
72. The method of any one of claims 55, 56, 57, and 58, wherein the starting material mixture comprises a starting second polyol component content of at least about 15 wt% based on the total weight of the starting material mixture.
73. The method of any one of claims 55, 56, 57, and 58, wherein the starting material mixture comprises a starting second polyol component content of not greater than about 30 wt% for the total weight of the starting material mixture.
74. A method according to any one of claims 55, 56, 57, and 58, wherein the original third polyol component comprises a viscosity of at least about 230PA s.
75. The method according to any one of claims 55, 56, 57, and 58, wherein the original third polyol component comprises a viscosity of not greater than about 370 PA-s.
76. The method according to any one of claims 55, 56, 57, and 58, wherein the original third polyol component comprises at least about 250 g-mol-1Molecular mass of (2).
77. The method according to any one of claims 55, 56, 57, and 58, wherein the original third polyol component comprises not greater than about 750g mol-1Molecular mass of (2).
78. The method of any one of claims 55, 56, 57, and 58, wherein the original third polyol component comprises a functionality of 3.
79. The method of any one of claims 55, 56, 57, and 58, wherein the starting material mixture comprises an original third polyol component content of at least about 10 wt% based on the total weight of the starting material mixture.
80. The method of any one of claims 55, 56, 57, and 58, wherein the starting material mixture comprises an original third polyol component content of not greater than about 20 wt% for the total weight of the starting material mixture.
81. The method of any one of claims 55, 56, 57, and 58, wherein the starting material mixture further comprises a starting fourth polyol component having an OH number of at least about 28KOH mg/g and not greater than about 32KOH mg/g.
82. The method of claim 81 wherein the original fourth polyol component comprises a viscosity of at least about 4500PA s.
83. A method in accordance with claim 81 wherein the original fourth polyol component comprises a viscosity of not greater than about 5500PA s.
84. The method of claim 81 wherein the original fourth polyol component comprises at least about 4500g mol-1Molecular mass of (2).
85. The method of claim 81 wherein the original fourth polyol component comprises no greater than about 7000g mol-1Molecular mass of (2).
86. The method of claim 81, wherein the starting material mixture comprises a starting fourth polyol component content of at least about 0.1 wt% based on the total weight of the starting material mixture.
87. The method of claim 81, wherein the starting material mixture comprises a starting fourth polyol component content of not greater than about 10 wt% for the total weight of the starting material mixture.
88. The method of any one of claims 55, 56, 57, and 58, wherein the virgin material mixture further comprises virgin first surfactant.
89. The method according to claim 88, wherein the pristine first surfactant is a silicone surfactant.
90. The method of claim 88, wherein the starting material mixture comprises a starting first surfactant content of at least about 2 weight percent based on the total weight of the starting material mixture.
91. The method of claim 88, wherein the starting material mixture comprises a starting first surfactant content of not greater than about 6 wt% for the total weight of the starting material mixture.
92. The method of any one of claims 55, 56, 57, and 58, wherein the virgin material mixture further comprises virgin secondary surfactant.
93. The method of claim 92, wherein the pristine second surfactant is a silicone surfactant.
94. The method of claim 92, wherein the starting material mixture comprises a starting secondary surfactant content of at least about 0.1 wt% based on the total weight of the starting material mixture.
95. The method of claim 92, wherein the starting material mixture comprises a starting secondary surfactant content of not greater than about 6 wt% for the total weight of the starting material mixture.
96. The method of any one of claims 55, 56, 57, and 58, wherein the starting material mixture further comprises a starting first catalyst.
97. The method of claim 96, wherein the original first catalyst is a nickel catalyst.
98. The method of claim 96, wherein the starting material mixture comprises an original first catalyst content of at least about 0.1 weight percent based on the total weight of the starting material mixture.
99. The method of claim 96, wherein the starting material mixture comprises an original first catalyst content of not greater than about 1.0 wt% for the total weight of the starting material mixture.
100. The method of any one of claims 55, 56, 57, and 58, wherein the raw material mixture further comprises a raw second catalyst.
101. The method of claim 100, wherein the original second catalyst is a nickel catalyst.
102. The method of claim 100, wherein the raw material mixture comprises a raw second catalyst content of at least about 0.1 wt% based on the total weight of the raw material mixture.
103. The method of claim 100, wherein the raw material mixture comprises a raw second catalyst content of not greater than about 1.0 wt% for the total weight of the raw material mixture.
104. The method of any one of claims 55, 56, 57, and 58, wherein the virgin material mixture comprises virgin chain extenders.
105. The method of claim 104, wherein the original chain extender is diethylene glycol, tetramethylene glycol, dipropylene glycol, or diethanolamine.
106. The method of claim 104, wherein the starting material mixture comprises a starting chain extender content of at least about 0.1 weight percent based on the total weight of the starting material mixture.
107. The method of claim 104, wherein the starting material mixture comprises a starting chain extender content of not greater than about 5 wt% based on the total weight of the starting material mixture.
108. The method of any one of claims 55, 56, 57, and 58, wherein the starting material mixture comprises a starting isocyanate.
109. The method of claim 108, wherein the starting material mixture comprises a starting isocyanate content of at least about 22 weight percent based on the total weight of the starting material mixture.
110. The method of claim 108, wherein the raw material mixture comprises a raw isocyanate content of not greater than about 35% by weight, based on the total weight of the raw material mixture.
CN202011432120.0A 2020-12-07 2020-12-07 Polyurethane foam and method of forming same Pending CN114591483A (en)

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