WO2022126066A1 - Mousse de polyuréthane et ses procédés de formation - Google Patents

Mousse de polyuréthane et ses procédés de formation Download PDF

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Publication number
WO2022126066A1
WO2022126066A1 PCT/US2021/072658 US2021072658W WO2022126066A1 WO 2022126066 A1 WO2022126066 A1 WO 2022126066A1 US 2021072658 W US2021072658 W US 2021072658W WO 2022126066 A1 WO2022126066 A1 WO 2022126066A1
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WIPO (PCT)
Prior art keywords
polyurethane foam
polyol component
raw
koh
material mixture
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PCT/US2021/072658
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English (en)
Inventor
Wenjun Sun
Yue DONG
Jing Zhou
Original Assignee
Saint-Gobain Performance Plastics Corporation
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Publication of WO2022126066A1 publication Critical patent/WO2022126066A1/fr

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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

Definitions

  • the present disclosure relates to a polyurethane foam and methods of forming the same, more particularly, the present disclosure related to a polyurethane foam having performance and methods of forming the same.
  • Polyurethane foams are widely used in applications of construction, transportation, and electronics. However, such polyurethanes foams often include specific characteristics that make them prone specific safety issues. For example, such polyurethane foams are generally prone to rapid fire growth due to their inherent chemical properties (i.e., the “-NH- COO- groups” of the polyurethane foam cause lower decomposition temperature than many other polymers) and physical properties (i.e., low density of the polyurethane causes severe dripping during combustion and porous structure promotes oxygen and heat transfer). Accordingly, polyurethane foams formulations with improved safety characteristics are desired.
  • 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 35 KOH mg/g and not greater than about 70 KOH mg/g
  • the second polyol component may include a polyol having an OH number of at least about 100 KOH mg/g and not greater than about 180 KOH mg/g
  • the third polyol component may include a polyol having an OH number of at least about 300 KOH mg/g and not greater than about 350 KOH mg/g.
  • the polyurethane foam may have a glass transition temperature of at least about -10 °C and not greater than about 35 °C.
  • 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 35 KOH mg/g and not greater than about 70 KOH mg/g
  • the second polyol component may include a polyol having an OH number of at least about 100 KOH mg/g and not greater than about 180 KOH mg/g
  • the third polyol component may include a polyol having an OH number of at least about 300 KOH mg/g and not greater than about 350 KOH mg/g.
  • the polyurethane foam may have a land of at least about 0.75.
  • a method of forming a polyurethane foam may include providing a raw material mixture and forming the raw material mixture into a polyurethane foam.
  • the raw material mixture may include a raw first polyol component, a raw second polyol component, and a raw third polyol component.
  • the raw first polyol component may include a polyol having an OH number of at least about 35 KOH mg/g and not greater than about 70 KOH mg/g
  • the raw second polyol component may include a polyol having an OH number of at least about 100 KOH mg/g and not greater than about 180 KOH mg/g
  • the raw third polyol component may include a polyol having an OH number of at least about 300 KOH mg/g and not greater than about 350 KOH mg/g.
  • the polyurethane foam may have a glass transition temperature of at least about -100 °C and not greater than about 35 °C.
  • a method of forming a polyurethane foam may include providing a raw material mixture and forming the raw material mixture into a polyurethane foam.
  • the raw material mixture may include a raw first polyol component, a raw second polyol component, and a raw third polyol component.
  • the raw first polyol component may include a polyol having an OH number of at least about 35 KOH mg/g and not greater than about 70 KOH mg/g
  • the raw second polyol component may include a polyol having an OH number of at least about 100 KOH mg/g and not greater than about 180 KOH mg/g
  • the raw third polyol component may include a polyol having an OH number of at least about 300 KOH mg/g and not greater than about 350 KOH mg/g.
  • the polyurethane foam may have a land of at least about 0.75.
  • FIG. 1 includes a diagram showing a polyurethane foam forming method 100 according to embodiments described herein.
  • Embodiments described herein are generally directed to a polyurethane foam and methods of forming the same.
  • FIG. 1 includes a diagram showing 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.
  • the raw material mixture may include a raw first polyol component, a raw second polyol component, and a raw third polyol component.
  • the raw material mixture may include a content of the raw first polyol component of not greater than about 15 wt.% for a total weight of the raw material mixture, 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.%. It will be appreciated that the content of the raw first polyol component in the raw material mixture may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the content of the raw first polyol component in the raw material mixture may be any value between any of the minimum and maximum values noted above.
  • the raw first polyol component may have a particular OH number.
  • the raw first polyol component may have an OH number of at least about 35 KOH mg/g, such as, at least about 38 KOH mg/g or at least about 40 KOH mg/g or at least about 43 KOH mg/g or at least about 45 KOH mg/g or even at least about 48 KOH mg/g.
  • the raw first polyol component may have an OH number of not greater than about 70 KOH mg/g, such as, not greater than about 67 KOH mg/g or not greater than about 65 KOH mg/g or not greater than about 62 KOH mg/g or even not greater than about 60 KOH mg/g.
  • the OH number of the raw first polyol component may 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 raw first polyol component may be any value between any of the minimum and maximum values noted above.
  • the raw first polyol component may include polyether polyols, polyester polyols, polymer polyols, bio-based polyols or combinations thereof.
  • the raw first polyol component may have a particular functionality.
  • the raw first polyol component may have a functionality of 2 or 3.
  • the raw first polyol component may have a particular molecular mass.
  • the raw first polyol component may have a molecular mass of at least about 2000 g/mol, such as, at least about 2100 g/mol or at least about 2200 g/mol or at least about 2300 g/mol or at least about 2400 g/mol or at least about 2500 g/mol or at least about 2600 g/mol or at least about 2700 g/mol or at least about 2800 g/mol or even at least about 2900.
  • the raw first polyol component may have a particular viscosity as measured according to ASTM D4878 - 15 (Standard Test Methods for Polyurethane Raw Materials: Determination of Viscosity of Polyols).
  • the raw first polyol component may have a viscosity of at least about 400 PA*s, such as, at least about 410 PA*s or at least about 420 PA*s or at least about 430 PA*s or at least about 440 PA*s or at least about 450 PA*s or at least about 460 PA*s or at least about 470 PA*s or even at least about 480 PA*s.
  • the raw first polyol component may have a viscosity of not greater than about 600 PA*s, such as, not greater than about 590 PA*s or not greater than about 580 PA*s or not greater than about 570 PA*s or not greater than about 560 PA*s or not greater than about 550 PA*s or not greater than about 530 PA*s or not greater than about 520 PA*s or not greater than about 510 PA*s or even not greater than about 500 PA*s. It will be appreciated that the viscosity of the raw first polyol component may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the viscosity of the raw first polyol component may be any value between any of the minimum and maximum values noted above.
  • the raw material mixture may include a particular content of raw second polyol component.
  • the raw material mixture may include a content of the raw second polyol component of at least about 15 wt.% for a total weight of the raw material mixture, 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.%.
  • the raw material mixture may include a content of the raw second polyol component of not greater than about 30 wt.% for a total weight of the raw material mixture, 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.%. It will be appreciated that the content of the raw second polyol component in the raw material mixture may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the content of the raw second polyol component in the raw material mixture may be any value between any of the minimum and maximum values noted above.
  • the raw second polyol component may have a particular OH number.
  • the raw second polyol component may have an OH number of at least about 500 KOH mg/g, such as, at least about 600 KOH mg/g or at least about 700 KOH mg/g or at least about 800 KOH mg/g or even at least about 900 KOH mg/g.
  • the raw second polyol component may have an OH number of not greater than about 1500 KOH mg/g, such as, not greater than about 1400 KOH mg/g or not greater than about 1300 KOH mg/g or not greater than about 1200 KOH mg/g or even not greater than about 1100 KOH mg/g.
  • the OH number of the raw second polyol component may 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 raw second polyol component may be any value between any of the minimum and maximum values noted above.
  • the raw second polyol component may have a particular functionality.
  • the raw second polyol component may have a functionality of 2 or 3.
  • the raw second polyol component may have a particular molecular mass as measure according to Gel Permeation Chromatography (GPC).
  • GPC Gel Permeation Chromatography
  • the raw second polyol component may have a molecular mass of at least about 500 g/mol, such as, at least about 550 g/mol or at least about 600 g/mol or at least about 650 g/mol or at least about 700 g/mol or at least about 750 g/mol or at least about 800 g/mol or even at least about 850 g/mol.
  • the raw second polyol component may have a molecular mass of not greater than about 1500 g/mol, such as, not greater than about 1450 g/mol or not greater than about 1400 g/mol or not greater than about 1350 g/mol or not greater than about 1300 g/mol or not greater than about 1250 g/mol or not greater than about 1200 g/mol or even not greater than about 1150 g/mol. It will be appreciated that the molecular mass of the raw second polyol component may 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 raw second polyol component may be any value between any of the minimum and maximum values noted above.
  • the raw second polyol component may have a particular viscosity as measured according to ASTM D4878 - 15 (Standard Test Methods for Polyurethane Raw Materials: Determination of Viscosity of Polyols).
  • the raw second polyol component may have a viscosity of at least about 130 PA*s, such as, at least about 135 PA*s or at least about 140 PA*s or at least about 145 PA*s or at least about 150 PA*s or at least about 155 PA*s or at least about 160 PA*s or at least about 165 PA*s or even at least about 170 PA*s.
  • the raw second polyol component may have a viscosity of not greater than about 270 PA*s, such as, not greater than about 265 PA*s or not greater than about 260 PA*s or not greater than about 255 PA*s or not greater than about 250 PA*s or not greater than about 245 PA*s or not greater than about 240 PA*s or not greater than about 235 PA*s or not greater than about 230 PA*s or even not greater than about 225 PA*s. It will be appreciated that the viscosity of the raw second polyol component may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the viscosity of the raw second polyol component may be any value between any of the minimum and maximum values noted above.
  • the raw material mixture may include a particular content of raw third polyol component.
  • the raw material mixture may include a content of the raw third polyol component of at least about 10 wt.% for a total weight of the raw material mixture, 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.%.
  • the raw material mixture may include a content of the raw third polyol component of not greater than about 20 wt.% for a total weight of the raw material mixture, 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.% even not greater than about 16 wt.%.
  • the content of the raw third polyol component in the raw material mixture may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the content of the raw third polyol component in the raw material mixture may be any value between any of the minimum and maximum values noted above.
  • the raw third polyol component may have a particular OH number.
  • the raw third polyol component may have an OH number of at least about 200 KOH mg/g, such as, at least about 220 KOH mg/g or at least about 240 KOH mg/g or at least about 260 KOH mg/g or even at least about 280 KOH mg/g.
  • the raw third polyol component may have an OH number of not greater than about 330 KOH mg/g, such as, not greater than about 310 KOH mg/g or not greater than about 290 KOH mg/g or not greater than about 280 KOH mg/g.
  • the raw third polyol component may have a particular molecular mass.
  • the raw third polyol component may have a molecular mass of at least about 250 g/mol, such as, at least about 260 g/mol or at least about 270 g/mol or at least about 280 g/mol or at least about 290 g/mol or at least about 300 g/mol or at least about 310 g/mol or at least about 320 g/mol or at least about 330 g/mol or at least about 340 g/mol or at least about 350 g/mol or at least about 360 g/mol or at least about 370 g/mol or at least about 380 g/mol or at least about 390 g/mol or even at least about 400 g/mol.
  • the raw third polyol component may have a molecular mass of not greater than about 750 g/mol, such as, not greater than about 740 g/mol or not greater than about 730 g/mol or not greater than about 720 g/mol or not greater than about 710 g/mol or not greater than about 700 g/mol or even not greater than about 690 g/mol. It will be appreciated that the molecular mass of the raw third polyol component may 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 raw third polyol component may be any value between any of the minimum and maximum values noted above.
  • the raw third polyol component may have a particular viscosity as measured according to ASTM D4878 - 15 (Standard Test Methods for Polyurethane Raw Materials: Determination of Viscosity of Polyols).
  • the raw third polyol component may have a viscosity of at least about 230 PA*s, such as, at least about 235 PA*s or at least about 240 PA*s or at least about 245 PA*s or at least about 250 PA*s or at least about 255 PA*s or at least about 260 PA*s or at least about 265 PA*s or even at least about 270 PA*s.
  • the raw third polyol component may have a viscosity of not greater than about 370 PA*s, such as, not greater than about 365 PA*s or not greater than about 360 PA*s or not greater than about 355 PA*s or not greater than about 350 PA*s or not greater than about 345 PA*s or not greater than about 340 PA*s or not greater than about 335 PA*s or not greater than about 330 PA*s or even not greater than about 325 PA*s. It will be appreciated that the viscosity of the raw third polyol component may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the viscosity of the raw third polyol component may be any value between any of the minimum and maximum values noted above.
  • the raw material mixture may include a particular content of raw fourth polyol component.
  • the raw material mixture may include a content of the raw fourth polyol component of at least about 0.1 wt.% for a total weight of the raw material mixture, 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.%.
  • the raw material mixture may include a content of the raw fourth polyol component of not greater than about 10 wt.% for a total weight of the raw material mixture, 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 8.5 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.%.
  • the content of the raw fourth polyol component in the raw material mixture may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the content of the raw fourth polyol component in the raw material mixture may be any value between any of the minimum and maximum values noted above.
  • the raw fourth polyol component may have a particular OH number.
  • the raw fourth polyol component may have an OH number of at least about 28 KOH mg/g, such as, at least about 28.5 KOH mg/g or at least about 29.0 KOH mg/g or at least about 29.5 KOH mg/g or even at least about 30.0 KOH mg/g.
  • the raw fourth polyol component may have an OH number of not greater than about 32.0 KOH mg/g, such as, not greater than about 31.5 KOH mg/g or not greater than about 31.0 KOH mg/g or not greater than about 31.5 KOH mg/g.
  • the OH number of the raw fourth polyol component may 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 raw fourth polyol component may be any value between any of the minimum and maximum values noted above.
  • the raw fourth polyol component may have a particular functionality.
  • the raw fourth polyol component may have a functionality of not greater than 5, such as, not greater than 4 or not greater than 3 or even 2.
  • the raw fourth polyol component may have a particular molecular mass.
  • the raw fourth polyol component may have a molecular mass of at least about 4500 g/mol, such as, at least about 5000 g/mol.
  • the raw fourth polyol component may have a molecular mass of not greater than about 6500 g/mol, such as, not greater than about 7000 g/mol. It will be appreciated that the molecular mass of the raw fourth polyol component may 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 raw fourth polyol component may be any value between any of the minimum and maximum values noted above.
  • the raw fourth polyol component may have a particular viscosity as measured according to ASTM D4878 - 15 (Standard Test Methods for Polyurethane Raw Materials: Determination of Viscosity of Polyols).
  • the raw fourth polyol component may have a viscosity of at least about 4500 PA*s, such as, at least about 4600 PA*s or at least about 4700 PA*s or at least about 4800 PA*s or even at least about 4900 PA*s.
  • the raw fourth polyol component may have a viscosity of not greater than about 5500 PA*s, such as, not greater than about 5400 PA*s or not greater than about 5300 PA*s or not greater than about 5200 PA*s or even not greater than about 5100 PA*s. It will be appreciated that the viscosity of the raw fourth polyol component may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the viscosity of the raw fourth polyol component may be any value between any of the minimum and maximum values noted above.
  • the raw material mixture may further include a raw first surfactant component.
  • the raw first surfactant component may be a silicone surfactant.
  • the raw material mixture may include a particular content of the raw first surfactant component.
  • the raw material mixture may include a content of the raw first surfactant component of at least about 2 wt.% for a total weight of the raw material mixture, 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.%.
  • the raw material mixture may include a content of the raw first surfactant component of not greater than about 6.0 wt.% for a total weight of the raw material mixture, 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.%.
  • the content of the raw first surfactant component in the raw material mixture may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the content of raw first surfactant component in the raw material mixture may be any value between any of the minimum and maximum values noted above.
  • the raw material mixture may further include a raw second surfactant component.
  • the raw second surfactant component may be a silicone surfactant.
  • the raw material mixture may include a particular content of the raw second surfactant component.
  • the raw material mixture may include a content of the raw second surfactant component of at least about 2 wt.% for a total weight of the raw material mixture, 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.%.
  • the raw material mixture may include a content of the raw second surfactant component of not greater than about 6.0 wt.% for a total weight of the raw material mixture, 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.%.
  • the content of the raw second surfactant component in the raw material mixture may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the content of raw second surfactant component in the raw material mixture may be any value between any of the minimum and maximum values noted above.
  • the raw material mixture may further include a raw first catalyst component.
  • the raw first catalyst component may include metal catalysts containing metal component such as tin, cooper, lead, zinc, cobalt, or nickel, and amine catalysts such as tertiary amine or quaternary ammonium salt.
  • metal catalysts containing metal component such as tin, cooper, lead, zinc, cobalt, or nickel
  • amine catalysts such as tertiary amine or quaternary ammonium salt.
  • the raw material mixture may include a particular content of raw first catalyst component.
  • the raw material mixture may include a content of the raw first catalyst component of at least about 0.1 wt.% for a total weight of the raw material mixture, such as, at least about 0.2 wt.% or at least about 0.3 wt.% or even at least about 0.4 wt.%.
  • the raw material mixture may include a content of the raw first catalyst component of not greater than about 1.0 wt.% for a total weight of the raw material mixture, 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.%. It will be appreciated that the content of the raw first catalyst component in the raw material mixture may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the content of the raw first catalyst component in the raw material mixture may be any value between any of the minimum and maximum values noted above.
  • the raw material mixture may further include a raw second catalyst component.
  • the raw second catalyst component may include metal catalysts containing metal component such as tin, cooper, lead, zinc, cobalt, or nickel, and amine catalysts such as tertiary amine or quaternary ammonium salt.
  • metal catalysts containing metal component such as tin, cooper, lead, zinc, cobalt, or nickel
  • amine catalysts such as tertiary amine or quaternary ammonium salt.
  • the raw material mixture may include a particular content of raw second catalyst component.
  • the raw material mixture may include a content of the raw second catalyst component of at least about 0.1 wt.% for a total weight of the raw material mixture, such as, at least about 0.2 wt.% or at least about 0.3 wt.% or even at least about 0.4 wt.%.
  • the raw material mixture may include a content of the raw first catalyst component of not greater than about 1.0 wt.% for a total weight of the raw material mixture, 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.%. It will be appreciated that the content of the raw second catalyst component in the raw material mixture may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the content of the raw second catalyst component in the raw material mixture may be any value between any of the minimum and maximum values noted above.
  • the raw material mixture may further include a raw chain extender component.
  • the raw chain extender component may include compounds with at least two isocyanate reactive groups such as diethylene glycol, tetramethylene glycol, dipropylene glycol, or diethanolamine.
  • the raw material mixture may include a particular content of raw chain extender component.
  • the raw material mixture may include a content of the raw chain extender component of at least about 0.1 wt.% for a total weight of the raw material mixture, 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.%.
  • the raw material mixture may include a content of the raw chain extender component of not greater than about 5 wt.% for a total weight of the raw material mixture, 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.%.
  • the content of the raw chain extender component in the raw material mixture may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the content of the raw chain extender component in the raw material mixture may be any value between any of the minimum and maximum values noted above.
  • the raw material mixture may further include a raw isocyanate component.
  • the raw isocyanate component may include monomeric methylenediphenyl diisocyanate (MDI), modified MDI, polymeric MDI and combinations thereof.
  • the raw material mixture may include a particular content of raw isocyanate component.
  • the raw material mixture may include a content of the raw isocyanate component of at least about 22 wt.% for a total weight of the raw material mixture, 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.%.
  • the raw material mixture may include a content of the raw isocyanate component of not greater than about 35 wt.% for a total weight of the raw material mixture, 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.%. It will be appreciated that the content of the raw isocyanate component in the raw material mixture may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the content of the raw isocyanate component in the raw material mixture may be any value between any of the minimum and maximum values noted above.
  • the raw material mixture may further include a raw pigment component.
  • the raw pigment component may include carbon dispersions in polyols.
  • the raw material mixture may include a particular content of raw pigment component.
  • the raw material mixture may include a content of the raw pigment component of at least about 0.1 wt.% for a total weight of the raw material mixture, 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.%.
  • the raw material mixture may include a content of the raw pigment component of not greater than about 5 wt.% for a total weight of the raw material mixture, 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.%.
  • the content of the raw pigment component in the raw material mixture may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the content of the raw pigment component in the raw material mixture may be any value between any of the minimum and maximum values noted above.
  • the raw material mixture may further include a raw thixotropic agent component.
  • the raw thixotropic agent component may include aerosol, bentonite, polyuria compounds or combinations thereof.
  • the raw material mixture may include a particular content of raw thixotropic agent component.
  • the raw material mixture may include a content of the raw thixotropic agent component of at least about 0.1 wt.% for a total weight of the raw material mixture, 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.%.
  • the raw material mixture may include a content of the raw thixotropic agent component of not greater than about 4 wt.% for a total weight of the raw material mixture, such as, 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.%.
  • the content of the raw thixotropic agent component in the raw material mixture may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the content of the raw thixotropic agent component in the raw material mixture may be any value between any of the minimum and maximum values noted above.
  • the raw material mixture may further include a raw filler.
  • the raw may include aluminum hydroxide, kaolin, talc, calcium carbonate, titanium dioxide, clay and zinc oxide, etc.
  • the raw material mixture may include a content of the raw filler of not greater than about 25 wt.% for a total weight of the raw material mixture, 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.%.
  • the content of the raw filler in the raw material mixture may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the content of the raw filler in the raw material mixture may be any value between any of the minimum and maximum values noted above.
  • forming the raw material mixture into a polyurethane foam may include foaming the raw material mixture to form a foamed material mixture. According to still other embodiments, forming the raw material mixture into a polyurethane foam may further include curing the foamed material mixture to form the polyurethane foam.
  • the polyurethane foam may include a first polyol component, a second polyol component, and a third polyol component.
  • the polyurethane foam may have a particular glass transition temperature as measured with Dynamic Mechanical Analysis (DMA) .
  • DMA Dynamic Mechanical Analysis
  • the polyurethane foam may have a glass transition temperature of at least about -10 °C, such as, at least about -9 °C or at least about -8 °C or at least about -7 °C or at least about - 6 °C or at least about -5 °C or at least about -4 °C or at least about -3 °C or at least about -2 °C or at least about -1 °C or at least about 0 °C or at least about 1 °C or at least about 2 °C or at least about 3 °C or even at least about 4 °C.
  • the polyurethane foam may have a glass transition temperature of not greater than about 35 °C, such as, not greater than about 34 °C or not greater than about 33 °C or not greater than about 32 °C or not greater than about 31 °C or not greater than about 30 °C or not greater than about 29 °C or not greater than about 28 °C or not greater than about 27 °C or not greater than about 26 °C or even not greater than about 25 °C. It will be appreciated that the glass transition temperature of the polyurethane foam may 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 may be any value between any of the minimum and maximum values noted above.
  • the polyurethane foam may have a particular land as measured with Dynamic Mechanical Analysis (DMA).
  • DMA Dynamic Mechanical Analysis
  • the polyurethane foam may have a land 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.
  • the land of the polyurethane foam may be within a range between any of the values noted above. It will be further appreciated that the land of the polyurethane foam may be any value between any of the minimum and maximum values noted above.
  • the polyurethane foam may have a particular density as measured according to ASTM # D3574.
  • the polyurethane foam may have a density of at least about 50 kg/m , such as, at least about 100 kg/m .
  • the polyurethane foam may have a density of not greater than about 500 kg/m , such as, not greater than about 450 kg/m . It will be appreciated that the density of the polyurethane foam may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the density of the polyurethane foam may be any value between any of the minimum and maximum values noted above.
  • the polyurethane foam may include a particular content of first polyol component.
  • the polyurethane foam may include a content of the first polyol component of at least about 7 wt.% for a total weight of the polyurethane foam, 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.%.
  • the polyurethane foam may include a content of the first polyol component of not greater than about 15 wt.% for a total weight of the polyurethane foam, such as, not greater than about 14 wt.% or not greater than about 8 wt.% or even not greater than about 13 wt.%. It will be appreciated that the content of the first polyol component in the polyurethane foam may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the content of the first polyol component in the polyurethane foam may be any value between any of the minimum and maximum values noted above.
  • the first polyol component may have a particular OH number.
  • the first polyol component may have an OH number of at least about 35 KOH mg/g, such as, at least about 38 KOH mg/g or at least about 40 KOH mg/g or at least about 43 KOH mg/g or at least about 45 KOH mg/g or even at least about 48 KOH mg/g.
  • the first polyol component may have an OH number of not greater than about 70 KOH mg/g, such as, not greater than about 67 KOH mg/g or not greater than about 65 KOH mg/g or not greater than about 62 KOH mg/g or even not greater than about 60 KOH mg/g.
  • the OH number of the first polyol component may 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 first polyol component may be any value between any of the minimum and maximum values noted above.
  • the first polyol component may include polyether polyols, polyester polyols, polymer polyols, bio-based polyols or combinations thereof.
  • the first polyol component may have a particular functionality.
  • the raw first polyol component may have a functionality of 2 or 3.
  • the first polyol component may have a particular molecular mass.
  • the first polyol component may have a molecular mass of at least about 2000 g/mol, such as, at least about 2100 g/mol or at least about 2200 g/mol or at least about 2300 g/mol or at least about 2400 g/mol or at least about 2500 g/mol or at least about 2600 g/mol or at least about 2700 g/mol or at least about 2800 g/mol or even at least about 2900.
  • the first polyol component may have a molecular mass of not greater than about 4000 g/mol, such as, not greater than about 3900 g/mol or not greater than about 3800 g/mol or not greater than about 3700 g/mol or not greater than about 3600 g/mol or not greater than about 3500 g/mol or not greater than about 3400 g/mol or not greater than about 3300 g/mol or not greater than about 3200 g/mol or even not greater than about 3100 g/mol. It will be appreciated that the molecular mass of the first polyol component may 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 first polyol component may be any value between any of the minimum and maximum values noted above.
  • the first polyol component may have a particular viscosity as measured according to ASTM D4878 - 15 (Standard Test Methods for Polyurethane Raw Materials: Determination of Viscosity of Polyols).
  • the first polyol component may have a viscosity of at least about 400 PA*s, such as, at least about 405 PA*s or at least about 410 PA*s or at least about 415 PA*s or at least about 420 PA*s or at least about 425 PA*s or at least about 430 PA*s or at least about 435 PA*s or at least about 440 PA*s or at least about 445 PA*s or at least about 450 PA*s or at least about 455 PA*s or at least about 460 PA*s or at least about 465 PA*s or at least about 470 PA*s or at least about 475 PA*s or at least about 480 PA*s or at least about485 PA*s or even at least about 490 PA*s.
  • PA*s such as, at least about 405 PA*s or at least about 410 PA*s or at least about 415 PA*s or at least about 420 PA*s or at least about 425 PA*s or at least about 430 PA*s or at least about
  • the first polyol component may have a viscosity of not greater than about 800 PA*s, such as, not greater than about 750 PA*s or not greater than about 700 PA*s or not greater than about 650 PA*s or not greater than about 600 PA*s or not greater than about 550 PA*s or not greater than about 545 PA*s or not greater than about 540 PA*s or not greater than about 535 PA*s or not greater than about 530 PA*s or not greater than about 525 PA*s or not greater than about 520 PA*s or not greater than about 515 PA*s or not greater than about 510 PA*s or even not greater than about 505 PA*s.
  • PA*s such as, not greater than about 750 PA*s or not greater than about 700 PA*s or not greater than about 650 PA*s or not greater than about 600 PA*s or not greater than about 550 PA*s or not greater than about 545 PA*s or not greater than about 540 PA*s or not greater than about 535 PA*s or not greater
  • the viscosity of the first polyol component may 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 may be any value between any of the minimum and maximum values noted above.
  • the polyurethane foam may include a particular content of second polyol component.
  • the polyurethane foam may include a content of the second polyol component of at least about 15 wt.% for a total weight of the raw material mixture, 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.%.
  • the polyurethane foam may include a content of the second polyol component of not greater than about 30 wt.% for a total weight of the polyurethane foam, 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.%. It will be appreciated that the content of the second polyol component in the polyurethane foam may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the content of the second polyol component in the polyurethane foam may be any value between any of the minimum and maximum values noted above.
  • the second polyol component may have a particular OH number.
  • the second polyol component may have an OH number of at least about 500 KOH mg/g, such as, at least about 600 KOH mg/g or at least about 700 KOH mg/g or at least about 800 KOH mg/g or even at least about 900 KOH mg/g.
  • the second polyol component may have an OH number of not greater than about 1500 KOH mg/g, such as, not greater than about 1400 KOH mg/g or not greater than about 1300 KOH mg/g or not greater than about 1200 KOH mg/g or even not greater than about 1100 KOH mg/g.
  • the OH number of the second polyol component may 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 second polyol component may be any value between any of the minimum and maximum values noted above.
  • the second polyol component may have a particular functionality.
  • the second polyol component may have a functionality of 2 or 3.
  • the second polyol component may have a particular molecular mass as measure according to Gel Permeation Chromatography (GPC).
  • GPC Gel Permeation Chromatography
  • the second polyol component may have a molecular mass of at least about 500 g/mol, such as, at least about 550 g/mol or at least about 600 g/mol or at least about 650 g/mol or at least about 700 g/mol or at least about 750 g/mol or at least about 800 g/mol or even at least about 850 g/mol.
  • the second polyol component may have a molecular mass of not greater than about 1500 g/mol, such as, not greater than about 1450 g/mol or not greater than about 1400 g/mol or not greater than about 1350 g/mol or not greater than about 1300 g/mol or not greater than about 1250 g/mol or not greater than about 1200 g/mol or even not greater than about 1150 g/mol. It will be appreciated that the molecular mass of the second polyol component may 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 second polyol component may be any value between any of the minimum and maximum values noted above.
  • the second polyol component may have a particular viscosity as measured according to ASTM D4878 - 15 (Standard Test Methods for Polyurethane Raw Materials: Determination of Viscosity of Polyols).
  • the second polyol component may have a viscosity of at least about 130 PA*s, such as, at least about 135 PA*s or at least about 140 PA*s or at least about 145 PA*s or at least about 150 PA*s or at least about 155 PA*s or at least about 160 PA*s or at least about 165 PA*s or even at least about 170 PA*s.
  • the second polyol component may have a viscosity of not greater than about 270 PA*s, such as, not greater than about 265 PA*s or not greater than about 260 PA*s or not greater than about 255 PA*s or not greater than about 250 PA*s or not greater than about 245 PA*s or not greater than about 240 PA*s or not greater than about 235 PA*s or not greater than about 230 PA*s or even not greater than about 225 PA*s. It will be appreciated that the viscosity of the second polyol component may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the viscosity of the second polyol component may be any value between any of the minimum and maximum values noted above.
  • the polyurethane foam may include a particular content third polyol component of at least about 10 wt.% for a total weight of the raw material mixture, 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.%.
  • a particular content third polyol component of at least about 10 wt.% for a total weight of the raw material mixture, 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.%.
  • the polyurethane foam may include a content of the third polyol component of not greater than about 20 wt.% for a total weight of the polyurethane foam, 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.% even not greater than about 16 wt.%.
  • the content of the third polyol component in the polyurethane foam may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the content of the third polyol component in the polyurethane foam may be any value between any of the minimum and maximum values noted above.
  • the third polyol component may have a particular OH number.
  • the third polyol component may have an OH number of at least about 200 KOH mg/g, such as, at least about 220 KOH mg/g or at least about 240 KOH mg/g or at least about 260 KOH mg/g or even at least about 280 KOH mg/g.
  • the third polyol component may have an OH number of not greater than about 330 KOH mg/g, such as, not greater than about 310 KOH mg/g or not greater than about 290 KOH mg/g or not greater than about 280 KOH mg/g.
  • the OH number of the third polyol component may 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 third polyol component may be any value between any of the minimum and maximum values noted above.
  • the third polyol component may have a particular functionality.
  • the third polyol component may have a functionality of 3.
  • the third polyol component may have a particular molecular mass.
  • the third polyol component may have a molecular mass of at least about 250 g/mol, such as, at least about 260 g/mol or at least about 270 g/mol or at least about 280 g/mol or at least about 290 g/mol or at least about 300 g/mol or at least about 310 g/mol or at least about 320 g/mol or at least about 330 g/mol or at least about 340 g/mol or at least about 350 g/mol or at least about 360 g/mol or at least about 370 g/mol or at least about 380 g/mol or at least about 390 g/mol or even at least about 400 g/mol.
  • the third polyol component may have a molecular mass of not greater than about 750 g/mol, such as, not greater than about 740 g/mol or not greater than about 730 g/mol or not greater than about 720 g/mol or not greater than about 710 g/mol or not greater than about 700 g/mol or even not greater than about 690 g/mol. It will be appreciated that the molecular mass of the third polyol component may 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 may be any value between any of the minimum and maximum values noted above.
  • the third polyol component may have a particular viscosity as measured according to ASTM D4878 -15 (Standard Test Methods for Polyurethane Raw Materials: Determination of Viscosity of Polyols).
  • the third polyol component may have a viscosity of at least about 230 PA*s, such as, at least about 235 PA*s or at least about 240 PA*s or at least about 245 PA*s or at least about 250 PA*s or at least about 255 PA*s or at least about 260 PA*s or at least about 265 PA*s or even at least about 270 PA*s.
  • the third polyol component may have a viscosity of not greater than about 370 PA*s, such as, not greater than about 365 PA*s or not greater than about 360 PA*s or not greater than about 355 PA*s or not greater than about 350 PA*s or not greater than about 345 PA*s or not greater than about 340 PA*s or not greater than about 335 PA*s or not greater than about 330 PA*s or even not greater than about 325 PA*s. It will be appreciated that the viscosity of the third polyol component may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the viscosity of the third polyol component may be any value between any of the minimum and maximum values noted above.
  • the polyurethane foam may further include a fourth polyol component.
  • the polyurethane foam may include a particular content of fourth polyol component.
  • the polyurethane foam may include a content of the fourth polyol component of at least about 0.1 wt.% for a total weight of the polyurethane foam, 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.%.
  • the polyurethane foam may include a content of the fourth polyol component of not greater than about 10 wt.% for a total weight of the polyurethane foam, 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 8.5 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.%.
  • the content of the fourth polyol component in the polyurethane foam may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the content of the fourth polyol component in the polyurethane foam may be any value between any of the minimum and maximum values noted above.
  • the fourth polyol component may have a particular OH number.
  • the fourth polyol component may have an OH number of at least about 28 KOH mg/g, such as, at least about 28.5 KOH mg/g or at least about 29.0 KOH mg/g or at least about 29.5 KOH mg/g or even at least about 30.0 KOH mg/g.
  • the fourth polyol component may have an OH number of not greater than about 32.0 KOH mg/g, such as, not greater than about 31.5 KOH mg/g or not greater than about 31.0 KOH mg/g or not greater than about 31.5 KOH mg/g.
  • the OH number of the fourth polyol component may 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 may be any value between any of the minimum and maximum values noted above.
  • the fourth polyol component may have a particular functionality.
  • the raw phosphorous polyol component may have a functionality of not greater than 5, such as, not greater than 4 or not greater than 3 or not greater than 2 or even 1.
  • the fourth polyol component may have a particular molecular mass.
  • the fourth polyol component may have a molecular mass of at least about 4500 g/mol, such as, at least about 5000 g/mol.
  • the fourth polyol component may have a molecular mass of not greater than about 6500 g/mol, such as, not greater than about 7000 g/mol. It will be appreciated that the molecular mass of the fourth polyol component may 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 may be any value between any of the minimum and maximum values noted above.
  • the fourth polyol component may have a particular viscosity as measured according to ASTM D4878 -15 (Standard Test Methods for Polyurethane Raw Materials: Determination of Viscosity of Polyols).
  • the fourth polyol component may have a viscosity of at least about 4500 PA*s, such as, at least about 4600 PA*s or at least about 4700 PA*s or at least about 4800 PA*s or even at least about 4900 PA*s.
  • the fourth polyol component may have a viscosity of not greater than about 5500 PA*s, such as, not greater than about 5400 PA*s or not greater than about 5300 PA*s or not greater than about 5200 PA*s or even not greater than about 5100 PA*s. It will be appreciated that the viscosity of the fourth polyol component may 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 may be any value between any of the minimum and maximum values noted above.
  • the polyurethane foam may further include a first surfactant component.
  • the first surfactant component may be a silicone surfactant.
  • the polyurethane foam may include a particular content of the first surfactant component.
  • the polyurethane foam may include a content of the first surfactant component of at least about 2 wt.% for a total weight of the raw material mixture, 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.%.
  • the polyurethane foam may include a content of the first surfactant component of not greater than about 6.0 wt.% for a total weight of the polyurethane foam, 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.%.
  • the content of the first surfactant component in the polyurethane foam may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the content of first surfactant component in the polyurethane foam may be any value between any of the minimum and maximum values noted above.
  • the polyurethane foam may further include a second surfactant component.
  • the second surfactant component may be a silicone surfactant.
  • the polyurethane foam may include a particular content of the second surfactant component.
  • the polyurethane foam may include a content of the second surfactant component of at least about 0.1 wt.% for a total weight of the polyurethane foam, 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.%.
  • the polyurethane foam may include a content of the second surfactant component of not greater than about 6.0 wt.% for a total weight of the polyurethane foam, 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.%.
  • the content of the second surfactant component in the polyurethane foam may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the content of second surfactant component in the polyurethane foam may be any value between any of the minimum and maximum values noted above.
  • the polyurethane foam may further include a first catalyst component.
  • the first catalyst component may include metal catalysts containing metal component such as tin, cooper, lead, zinc, cobalt, or nickel, and amine catalysts such as tertiary amine or quaternary ammonium salt.
  • the polyurethane foam may include a particular content of first catalyst component.
  • the polyurethane foam may include a content of the first catalyst component of at least about 0.1 wt.% for a total weight of the raw material mixture, such as, at least about 0.2 wt.% or at least about 0.3 wt.% or even at least about 0.4 wt.%.
  • the raw material mixture may include a content of the raw first catalyst component of not greater than about 1.0 wt.% for a total weight of the raw material mixture, 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.%.
  • the content of the first catalyst component in the polyurethane foam may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the content of the first catalyst component in the polyurethane foam may be any value between any of the minimum and maximum values noted above.
  • the polyurethane foam may further include a second catalyst component.
  • the second catalyst component may include metal catalysts containing metal component such as tin, cooper, lead, zinc, cobalt, or nickel, and amine catalysts such as tertiary amine or quaternary ammonium salt.
  • the polyurethane foam may include a particular content of second catalyst component.
  • the polyurethane foam may include a content of the second catalyst component of at least about 0.1 wt.% for a total weight of the raw material mixture, such as, at least about 0.2 wt.% or at least about 0.3 wt.% or even at least about 0.4 wt.%.
  • the raw material mixture may include a content of the raw first catalyst component of not greater than about 1.0 wt.% for a total weight of the raw material mixture, 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.%.
  • the content of the second catalyst component in the polyurethane foam may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the content of the second catalyst component in the polyurethane foam may be any value between any of the minimum and maximum values noted above.
  • the polyurethane foam may further include a chain extender component.
  • the chain extender component may include compounds with at least two isocyanate reactive groups such as diethylene glycol, triethylene glycol, dipropylene glycol, or tri propylene glycol.
  • the polyurethane foam may include a particular content of chain extender component.
  • the polyurethane foam may include a content of the chain extender component of at least about 0.1 wt.% for a total weight of the polyurethane foam, 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.%.
  • the polyurethane foam may include a content of the chain extender component of not greater than about 5 wt.% for a total weight of the polyurethane foam, 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.%.
  • the content of the chain extender component in the polyurethane foam may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the content of the chain extender component in the polyurethane foam may be any value between any of the minimum and maximum values noted above.
  • the polyurethane foam may further include an isocyanate component.
  • the isocyanate component may include monomeric methylenediphenyl diisocyanate (MDI), modified MDI, polymeric MDI and combinations thereof.
  • MDI monomeric methylenediphenyl diisocyanate
  • modified MDI polymeric MDI and combinations thereof.
  • the polyurethane foam may include a particular content of isocyanate component.
  • the polyurethane foam may include a content of the isocyanate component of at least about 22 wt.% for a total weight of the raw material mixture, 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.%.
  • the polyurethane foam may include a content of the isocyanate component of not greater than about 35 wt.% for a total weight of the polyurethane foam, 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.%. It will be appreciated that the content of the isocyanate component in the polyurethane foam may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the content of the isocyanate component in the polyurethane foam may be any value between any of the minimum and maximum values noted above.
  • the polyurethane foam may further include a pigment component.
  • the pigment component may include carbon dispersions in polyols.
  • the polyurethane foam may include a particular content of pigment component.
  • the polyurethane foam may include a content of the pigment component of at least about 0.1 wt.% for a total weight of the polyurethane foam, 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.%.
  • the polyurethane foam may include a content of the pigment component of not greater than about 5 wt.% for a total weight of the polyurethane foam, 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.%.
  • the content of the pigment component in the polyurethane foam may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the content of the pigment component in the polyurethane foam may be any value between any of the minimum and maximum values noted above.
  • the polyurethane foam may further include a thixotropic agent component.
  • the thixotropic agent component may include aerosol, bentonite, polyuria compounds or combinations thereof.
  • the polyurethane foam may include a particular content of thixotropic agent component.
  • the polyurethane foam may include a content of the thixotropic agent component of at least about 0.1 wt.% for a total weight of the polyurethane foam, 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.%.
  • the polyurethane foam may include a content of the thixotropic agent component of not greater than about 4 wt.% for a total weight of the polyurethane foam, such as, 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.%.
  • the content of the thixotropic agent component in the polyurethane foam may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the content of the thixotropic agent component in the polyurethane foam may be any value between any of the minimum and maximum values noted above.
  • the polyurethane foam may further include a particular content of filler.
  • the polyurethane foam may include a content of the filler of at least about 0.1 wt.% for a total weight of the polyurethane foam, 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.%.
  • the polyurethane foam may include a content of the filler of not greater than about 25 wt.% for a total weight of the polyurethane foam, 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.%.
  • the content of the filler in the polyurethane foam may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the content of the filler in the polyurethane foam may be any value between any of the minimum and maximum values noted above.
  • the polyurethane foam may have a particular thickness.
  • the polyurethane foam may have a thickness of at least about 0.1 mm, such as, at least about 0.15 mm or at least about 0.2 mm or at least about 0.25 mm or at least about 0.3 mm or even at least about 0.35 mm.
  • the polyurethane foam may have a thickness of not greater than about 15 mm, such as, not greater than about 14.5 mm or not greater than about 14.0 mm or not greater than about 13.5 mm or not greater than about 13.0 mm or not greater than about 12.5 mm or not greater than about 12.0 mm or not greater than about 11.5 mm or not greater than about 11.0 mm or not greater than about 10.5 mm or not greater than about 10.0 mm or not greater than about 9.5 mm or not greater than about 9.0 mm or not greater than about 8.5 mm or not greater than about 8.0 mm or not greater than about 7.5 mm or not greater than about 7.0 mm or not greater than about 6.5 mm or not greater than about 6.0 mm or not greater than about 5.5 mm or not greater than about 5.0 mm or not greater than about 4.5 mm or not greater than about 4.0 mm or not greater than about 3.5 mm or not greater than about 3.0 mm or not greater than about 2.5 mm or not
  • a particular embodiment may include a battery compression pad that may include a polyurethane foam.
  • the polyurethane foam of the battery compression pad may be formed according to any of the embodiments described herein.
  • the polyurethane foam of the batter compression pad may include any of the components described in reference to any of the embodiments described herein.
  • the polyurethane foam of the battery compression pad may include any of the characteristics described in reference to embodiments described herein.
  • Embodiment 1 A polyurethane foam comprising: a first polyol component comprising a polyol having an OH number of at least about 35 KOH mg/g and not greater than about 70 KOH mg/g, a second polyol component comprising a polyol having an OH number of at least about 100 KOH mg/g and not greater than about 180 KOH mg/g, and a third polyol component comprising a polyol having an OH number of at least about 300 KOH mg/g and not greater than about 350 KOH mg/g, wherein the polyurethane foam has a glass transition temperature of at least about -10 °C and not greater than about 35 °C.
  • a polyurethane foam comprising: a first polyol component comprising a polyether polyol having an OH number of at least about 50 KOH mg/g and not greater than about 60 KOH mg/g, a second polyol component comprising a polyol having an OH number of at least about 100 KOH mg/g and not greater than about 180 KOH mg/g, and a third polyol component comprising a polyol having an OH number of at least about 300 KOH mg/g and not greater than about 350 KOH mg/g, wherein the polyurethane foam has a land 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 °C and not greater than about 35 °C.
  • Embodiment 4 The polyurethane foam of embodiment 1, wherein the polyurethane foam has a tan 6 of at least about 0.75.
  • Embodiment 5 The polyurethane foam of any one of embodiments 1, 2, 3, and 4,
  • polyurethane foam comprises a density of at least about 50 kg/m .
  • Embodiment 7 The polyurethane foam of any one of embodiments 1, 2, 3, and 4, wherein the first polyol component comprises a viscosity of at least about 450 PA*s.
  • Embodiment 9 The polyurethane foam of any one of embodiments 1, 2, 3, and 4, wherein the first polyol component comprises a molecular mass of at least about 2000 g*mol i
  • Embodiment 10 The polyurethane foam of any one of embodiments 1, 2, 3, and 4, wherein the first polyol component comprises a molecular mass of not greater than about 4000 g*mol’ 1 .
  • Embodiment 11 The polyurethane foam of any one of embodiments 1, 2, 3, and 4, wherein the first polyol component comprises a functionality of 2 or 3.
  • Embodiment 12 The polyurethane foam of any one of embodiments 1, 2, 3, and 4, wherein the polyurethane foam comprises first polyol component content of at least about 7 wt.% for a 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.% for a 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 130 PA*s.
  • 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 270 PA*s.
  • Embodiment 16 The polyurethane foam of any one of embodiments 1, 2, 3, and 4, wherein the second polyol component comprises a molecular mass of at least about 500 g*mol -1 .
  • Embodiment 17 The polyurethane foam of any one of embodiments 1, 2, 3, and 4, wherein the second polyol component comprises a molecular mass of not greater than about 1500 g*moF 1 .
  • Embodiment 18 The polyurethane foam of any one 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 second polyol component content of at least about 15 wt.% for a 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 comprises a second polyol component content of not greater than about 30 wt.% for a total weight of the polyurethane foam.
  • 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 370 PA*s.
  • Embodiment 23 The polyurethane foam of any one of embodiments 1, 2, 3, and 4, wherein the third polyol component comprises a molecular mass of at least about 150 g*moF i
  • Embodiment 24 The polyurethane foam of any one of embodiments 1, 2, 3, and 4, wherein the third polyol component comprises a molecular mass of not greater than about 400 g*mol’ 1 .
  • 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 third polyol component content of at least about 10 wt.% for a 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.% for a total weight of the polyurethane foam.
  • Embodiment 28 The polyurethane foam of embodiment 1, wherein the polyurethane foam further comprises a fourth polyol component have an OH number of at least about 28 KOH mg/g and not greater than about 32 KOH 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 not greater than about 5500 PA*s.
  • Embodiment 31 The polyurethane foam of embodiment 28, wherein the fourth polyol component comprises a molecular mass of at least about 4500 g*mol’ 1 .
  • Embodiment 32 The polyurethane foam of embodiment 28, wherein the fourth polyol component comprises a molecular mass of not greater than about 7000 g*mol’ 1 .
  • Embodiment 33 The polyurethane foam of embodiment 28, wherein the polyurethane foam comprises a fourth polyol component content of at least about 0.1 wt.% for a total weight of the polyurethane foam.
  • Embodiment 34 The polyurethane foam of embodiment 28, wherein the polyurethane foam comprises a fourth polyol component content of not greater than about 10 wt.% for a total weight of the polyurethane foam.
  • Embodiment 35 The polyurethane foam of any one 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 wt.% for a 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.% for a total weight of the polyurethane foam.
  • Embodiment 39 The polyurethane foam of any one 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.% for a 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.% for a 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.% for a 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.% for a 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 51 The polyurethane foam of embodiment 47, wherein the polyurethane foam comprises a chain extender content of not greater than about 5 wt.% for a 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 isocyanate.
  • Embodiment 53 The polyurethane foam of embodiment 52, wherein the polyurethane foam comprises a isocyanate content of at least about 22 wt.% for a total weight of the polyurethane foam.
  • Embodiment 54 The polyurethane foam of embodiment 52, wherein the polyurethane foam comprises an isocyanate content of not greater than about 35 wt.% for a total weight of the polyurethane foam.
  • Embodiment 56 A method of forming a polyurethane foam, wherein the method comprises: providing a raw material mixture comprising: a raw first polyol component comprising a polyol having an OH number of at least about 35 KOH mg/g and not greater than about 70 KOH mg/g, a raw second polyol component comprising a polyol having an OH number of at least about 100 KOH mg/g and not greater than about 180 KOH mg/g, and a raw third polyol component comprising a polyol having an OH number of at least about 300 KOH mg/g and not greater than about 350 KOH mg/g, and forming the raw material mixture into a polyurethane foam, wherein the polyurethane foam has a land of at least about 0.75.
  • Embodiment 57 The method of embodiment 56, wherein the polyurethane foam has a glass transition temperature of at least about -10 °C and not greater than about 35 °C.
  • Embodiment 58 The method of embodiment 55, wherein the polyurethane foam has a tand of at least about 0.75.
  • Embodiment 59 The method of any one of embodiments 55, 56, 57, and 58, wherein Q the polyurethane foam comprises a density of not greater than about 500 kg/m .
  • Embodiment 61 The method of any one of embodiments 55, 56, 57, and 58, wherein the raw first polyol component comprises a viscosity of not greater than about 800 PA*s.
  • Embodiment 62 The method of any one of embodiments 55, 56, 57, and 58, wherein the raw first polyol component comprises a molecular mass of at least about 2000 g*mol’ 1 .
  • Embodiment 63 The method of any one of embodiments 55, 56, 57, and 58, wherein the raw first polyol component comprises a molecular mass of not greater than about 4000 g*mol -1 .
  • Embodiment 64 The method of any one of embodiments 55, 56, 57, and 58, wherein the raw 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 raw material mixture comprises first polyol component content of at least about 7 wt.% for a total weight of the raw material mixture.
  • Embodiment 66 The method of any one of embodiments 55, 56, 57, and 58, wherein the raw material mixture comprises a raw first polyol component content of not greater than about 15 wt.% for a total weight of the raw material mixture.
  • Embodiment 67 The method of any one of embodiments 55, 56, 57, and 58, wherein the raw second polyol component comprises a viscosity of at least about 130 PA*s.
  • Embodiment 68 The method of any one of embodiments 55, 56, 57, and 58, wherein the raw second polyol component comprises a viscosity of not greater than about 270 PA*s.
  • Embodiment 69 The method of any one of embodiments 55, 56, 57, and 58, wherein the raw second polyol component comprises a molecular mass of at least about 500 g*mol’ 1 .
  • Embodiment 70 The method of any one of embodiments 55, 56, 57, and 58, wherein the raw second polyol component comprises a molecular mass of not greater than about 1500 g*mol' 1 .
  • Embodiment 71 The method of any one of embodiments 55, 56, 57, and 58, wherein the raw 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 raw material mixture comprises raw second polyol component content of at least about 15 wt.% for a total weight of the raw material mixture.
  • Embodiment 73 The method of any one of embodiments 55, 56, 57, and 58, wherein the raw material mixture comprises a raw second polyol component content of not greater than about 30 wt.% for a total weight of the raw material mixture.
  • Embodiment 74 The method of any one of embodiments 55, 56, 57, and 58, wherein the raw third polyol component comprises a viscosity of at least about 230 PA*s.
  • Embodiment 75 The method of any one of embodiments 55, 56, 57, and 58, wherein the raw third polyol component comprises a viscosity of not greater than about 370 PA*s.
  • Embodiment 76 The method of any one of embodiments 55, 56, 57, and 58, wherein the raw third polyol component comprises a molecular mass of at least about 250 g*mol -1 .
  • Embodiment 77 The method of any one of embodiments 55, 56, 57, and 58, wherein the raw third polyol component comprises a molecular mass of not greater than about 750 g*mol -1 .
  • 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 raw material mixture comprises a raw third polyol component content of at least about 10 wt.% for a total weight of the raw material mixture.
  • Embodiment 80 The method of any one of embodiments 55, 56, 57, and 58, wherein the raw material mixture comprises a raw third polyol component content of not greater than about 20 wt.% for a total weight of the raw material mixture.
  • Embodiment 81 The method of any one of embodiments 55, 56, 57, and 58, wherein the raw material mixture further comprises a raw fourth polyol component have an OH number of at least about 28 KOH mg/g and not greater than about 32 KOH mg/g.
  • Embodiment 82 The method of embodiment 81, wherein the raw fourth polyol component comprises a viscosity of at least about 4500 PA*s.
  • Embodiment 83 The method of embodiment 81, wherein the raw fourth polyol component comprises a viscosity of not greater than about 5500 PA*s.
  • Embodiment 84 The method of embodiment 81, wherein the raw fourth polyol component comprises a molecular mass of at least about 4500 g*mol’ 1 .
  • Embodiment 85 The method of embodiment 81, wherein the raw fourth polyol component comprises a molecular mass of not greater than about 7000 g*mol’ 1 .
  • Embodiment 86 The method of embodiment 81, wherein the raw material mixture comprises a raw fourth polyol component content of at least about 0.1 wt.% for a total weight of the raw material mixture.
  • Embodiment 87 The method of embodiment 81, wherein the raw material mixture comprises a raw fourth polyol component content of not greater than about 10 wt.% for a total weight of the raw material mixture.
  • Embodiment 88 The method of any one of embodiments 55, 56, 57, and 58, wherein the raw material mixture further comprises a raw first surfactant.
  • Embodiment 89 The method of embodiment 88, wherein the raw first surfactant is a silicone surfactant.
  • Embodiment 90 The method of embodiment 88, wherein the raw material mixture comprises a raw first surfactant content of at least about 2 wt.% for a total weight of the raw material mixture.
  • Embodiment 91 The method of embodiment 88, wherein the raw material mixture comprises a raw first surfactant content of not greater than about 6 wt.% for a total weight of the raw material mixture.
  • Embodiment 92 The method of any one of embodiments 55, 56, 57, and 58, wherein the raw material mixture further comprises a raw second surfactant.
  • Embodiment 93 The method of embodiment 92, wherein the raw second surfactant is a silicone surfactant.
  • Embodiment 94 The method of embodiment 92, wherein the raw material mixture comprises a raw second surfactant content of at least about 0.1 wt.% for a total weight of the raw material mixture.
  • Embodiment 95 The method of embodiment 92, wherein the raw material mixture comprises a raw second surfactant content of not greater than about 6 wt.% for a total weight of the raw material mixture.
  • Embodiment 96 The method of any one of embodiments 55, 56, 57, and 58, wherein the raw material mixture further comprises a raw first catalyst.
  • Embodiment 97 The method of embodiment 96, wherein the raw first catalyst is a nickel catalyst.
  • Embodiment 98 The method of embodiment 96, wherein the raw material mixture comprises a raw first catalyst content of at least about 0.1 wt.% for a total weight of the raw material mixture.
  • Embodiment 99 The method of embodiment 96, wherein the raw material mixture comprises a raw first catalyst content of not greater than about 1.0 wt.% for a 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 raw second catalyst is a nickel catalyst.
  • Embodiment 102 The method of embodiment 100, wherein the raw material mixture comprises a raw second catalyst content of at least about 0.1 wt.% for a 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.% for a 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 raw chain extender is diethylene glycol, tetramethylene glycol, dipropylene glycol, or diethanolamine.
  • Embodiment 106 The method of embodiment 104, wherein the raw material mixture comprises a raw chain extender content of at least about 0.1 wt.% for a total weight of the raw material mixture.
  • Embodiment 107 The method of embodiment 104, wherein the raw material mixture comprises a raw chain extender content of not greater than about 5 wt.% for a total weight of the raw material mixture.
  • Embodiment 108 The method of any one of embodiments 55, 56, 57, and 58, wherein the raw material mixture comprises raw isocyanate.
  • Embodiment 109 The method of embodiment 108, wherein the raw material mixture comprises a raw isocyanate content of at least about 22 wt.% for a total weight of the raw material mixture.
  • Embodiment 110 The method of embodiment 108, wherein the raw material mixture comprises a raw isocyanate content of not greater than about 35 wt.% for a total weight of the raw material mixture.
  • Sample polyurethane foams S1-S3 were formed according to embodiments described herein.
  • the compositions of sample polyurethane foams S1-S3 are summarized in Table 1 below.
  • Comparative sample polyurethane foams CS1-CS3 were formed for comparison to embodiments described herein.
  • the compositions of comparative sample polyurethane foams CS1-CS3 are summarized in Table 2 below. Table 2 - Comparative Sample Foam Composition
  • sample polyurethane foams and the comparative sample polyurethane foams were formed by mixing all the liquid components (including the first polyol, second polyol, third polyol, fourth polyol, surfactant, catalyst, pigment, chain extender) until the liquid phase is homogeneous. Then, any fillers were added to the liquid mixture. The combined mixture was then mixed until it reached a homogeneous composition. Finally, the isocyanate was added to the combined mixture. The final mixture was cured in an over at 170 °C oven for several minutes.

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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

La présente invention concerne une mousse de polyuréthane qui peut comprendre un premier constituant polyol, un deuxième constituant polyol et un troisième constituant polyol. Le premier constituant polyol peut comprendre un polyol ayant un indice d'OH d'au moins environ 35 mg de KOH/g et inférieur ou égal à environ 70 mg de KOH/g, le deuxième constituant polyol peut comprendre un polyol ayant un indice d'OH d'au moins environ 100 mg de KOH/g et inférieur ou égal à environ 180 mg de KOH/g et le troisième constituant polyol peut comprendre un polyol ayant un indice d'OH d'au moins environ 300 mg de KOH/g et inférieur ou égal à environ 350 mg de KOH/g. La mousse de polyuréthane peut présenter une température de transition vitreuse d'au moins environ -10 °C et inférieure ou égale à environ 35 °C.
PCT/US2021/072658 2020-12-07 2021-12-01 Mousse de polyuréthane et ses procédés de formation WO2022126066A1 (fr)

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5900442A (en) * 1995-05-12 1999-05-04 Imperial Chemical Industries Plc Flexible polyurethane foams
US20090264547A1 (en) * 2008-02-27 2009-10-22 Bayer Materialscience Ag Visco-elastic polyurethane foam with castor oil
US20110034575A1 (en) * 2007-12-20 2011-02-10 Bayer Materialscience Ag Visco-elastic polyurethane foam
US20110190408A1 (en) * 2007-08-27 2011-08-04 Dow Global Technologies Inc. Catalysis of natural oil based flexible polyurethane foams with bismuth compounds
US20190322914A1 (en) * 2016-12-23 2019-10-24 Sika Technology Ag Two component polyurethane composition

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5900442A (en) * 1995-05-12 1999-05-04 Imperial Chemical Industries Plc Flexible polyurethane foams
US20110190408A1 (en) * 2007-08-27 2011-08-04 Dow Global Technologies Inc. Catalysis of natural oil based flexible polyurethane foams with bismuth compounds
US20110034575A1 (en) * 2007-12-20 2011-02-10 Bayer Materialscience Ag Visco-elastic polyurethane foam
US20090264547A1 (en) * 2008-02-27 2009-10-22 Bayer Materialscience Ag Visco-elastic polyurethane foam with castor oil
US20190322914A1 (en) * 2016-12-23 2019-10-24 Sika Technology Ag Two component polyurethane composition

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