Process for producing a low density free-rise polyurethane foam
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examples 1-2
[0125]In these Examples, foam samples were produced pursuant to the formulations provided in Table 1 (all parts are parts by weight). The methodology used in each Example was as follows.
[0126]A resin mixture was produced by mixing all ingredients except the isocyanate in a 1 L mixing vessel for a period of approximately 10 seconds at 3000 rpm. Next, the isocyanate was added to the mixing vessel and the contexts were mixed for a further 5 seconds. The contents of the mixing vessel were transferred to an open (15″×12″×12″) and allowed to free rise. box The resulting foam was allowed to cure for at least 24 hours prior to testing.
[0127]Table 2 reports observations during production of the foam samples and properties of the resulting foams. These observations and properties illustrate that a good quality slab foam having very low density can be made using a high primary hydroxyl content polyol (normally used to produce molded foam) in the absence of added auxiliary blowing agents while ...
example 3
[0128]The methodology of Examples 1 was repeated using the formulation provided in Table 3 (all parts are parts by weight).
[0129]Table 4 reports observations during production of the foam samples and properties of the resulting foam. The positive results seen in Example 1 were also seen in Example 2 even when a mixture of polyols (i.e., a high primary hydroxyl content polyol and a high secondary hydroxyl content polyol) was used with a reactive (non-fugitive) catalyst system.
example 4
[0130]The methodology of Examples 1-2 was repeated using the formulation provided in Table 5 (all parts are parts by weight).
[0131]Table 6 reports observations during production of the foam samples and properties of the resulting foam. The positive results seen in Example 1 (re. low density) were also seen in Example 3 even when a mixture of polyols (i.e., a high primary hydroxyl content polyol and a high secondary hydroxyl content polyol), a mixture of isocyanates (i.e., TDI and MDI), a different surfactant and a different combination of catalysts.
[0132]While this invention has been described with reference to illustrative embodiments and examples, the description is not intended to be construed in a limiting sense. Thus, various modifications of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to this description. It is therefore contemplated that the appended claims will cover any such modif...
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Abstract
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