System and method for determining parameters related to foam manufacturing - Patents.com

Abstract

A method is provided for determining machine parameters of a foam-making machine that includes a mix head configured to mix precursor reagents to form a reactive mixture, a plurality of inclined fall plates, a first inclined fall plate configured to receive the reactive mixture, each inclined fall plate having a vertically adjustable end, and a conveyor configured to receive the reactive mixture from the last inclined fall plate, the conveyor having an adjustable conveyor speed. The method includes executing software by a computer system that includes accessing a database for reading rise profiles for the reactive mixture of precursor reagents and calculating a vertical position of an end of each inclined fall plate and a conveyor speed that results in a predetermined predicted profile of the reactive mixture on the plurality of inclined fall plates.

Description

[Technical field]

[0001] Certain embodiments of the present invention relate to the field of polyurethane foams. More specifically, certain embodiments of the present invention relate to systems and methods for producing flexible polyurethane foams. [Background technology]

[0002] PU flexible slabstock foams have long been known from the prior art and are used worldwide, for example for the production of upholstered furniture and mattresses. In the production process, the liquid components are usually pumped to a mixing head, mixed and continuously dumped onto a conveyor belt. There, the reaction mixture starts to foam, i.e. expand. The driving forces for this are the formation of gaseous reaction products (e.g. CO2) as well as the evaporation of the physical blowing agent. To prevent the reaction mixture from flowing out to the sides, the conveyor belt is laterally restricted by side walls. Thus, in slabstock technology, the foam can rise freely in at least one direction (e.g. upwards). The pressure in the rising foam bubbles is usually approximately equal to atmospheric pressure. The reaction mixture expands vertically during its simultaneous horizontal movement on the conveyor belt and forms in a continuous process long blocks ("slabstock foam"), which are then cut according to specific lengths and transported to the reaction store. During the rise, the material solidifies due to the progressive cross-linking of the reactive components, thus a rigid but elastic flexible polyurethane foam is finally obtained. Just before the solidification of the material, cell openings still occur, associated with the loss of a small part of the cell gas and a slight retraction of the foam block, which is not yet solid. The process is relatively fast, often less than 2 minutes until solidification. As the foam expands on the flat conveyor belt, it grows upwards along the side walls. The friction of the side walls prevents the increasingly viscous foam mixture from growing at the edge of the block, rather than in the center. This results in a dome shape with a rounded top. The height of the foam block is therefore different in the center (higher) and at the edge (lower). For example, with a typical block height of 100 cm, the difference can easily be 5-10 cm.

[0003] In the early days of the polyurethane industry, large discontinuous boxes were filled with the reaction mixture and box foams were obtained after foaming. Today, due to its low efficiency, this technique is practically only used for test foaming and in laboratories. The terms continuous or discontinuous describe how the reaction mixture is mixed and dosed. In discontinuous production methods, the raw materials are mixed, stopped mixing, and then dosed. In continuous production methods, the operations are performed simultaneously (in parallel) without interruption, i.e., the raw materials are continuously fed into a mix head, mixed with a continuously rotating agitator, and continuously dosed, for example, on a conveyor belt. This application deals with the continuous production process of flexible slabstock polyurethane foam.

[0004] Attempts to continuously improve the production of flexible polyurethane slabstock foams, in particular to reduce the resulting cutting and waste rates, are ongoing. For this purpose, the formed rectangular cross-sections of the foam blocks and their optimal dimensions are important, for example, in order to be able to cut the rectangular mattress core from the foam block as efficiently as possible. A rounded top of the block increases the waste rate, since the rectangular mattress core cannot be cut from the top layer. An important step in creating a rectangular block cross-section was to expand the foam not only upwards, but also at least partially downwards. This has the advantage that the foaming mixture only has to rise a short distance to the side walls. In the case of a complete expansion downwards, there is not even a rise of the reaction mixture at the side walls. Instead, it flows downwards along the side walls. However, gravity acts here. This is technically realized in continuous slabstock plants by the so-called fall plate system. This was developed in particular by the company Laader Berg and was first implemented in the so-called MAXFOAM machine. Here, the reaction mixture is applied in a rising position onto the foil or coated paper. The paper moves at a constant speed, given by a conveyor belt, at the end of the machine. When the expansion of the reactive mixture begins, the fall plate ensures that the foam can expand downwards. The level of the upper edge of the reactive mixture remains constant or only rises slightly. The dimensions of the fall plate are fixed, but the height is adjustable. In this case, the fall plate is each connected at its end to the adjacent fall plate. The speed of the paper on which the reactive mixture is located can also be varied via the drive of the conveyor belt. When all parameters are set correctly, this technique continuously obtains foam blocks with an almost perfect rectangular shape. As a result, this technique is now widely used in the flexible polyurethane foam industry and is being adopted by other polyurethane machine manufacturers.

[0005] However, a common problem here is that the rise profile of the reaction mixture and the position on the production machine must now be aligned with each other. Graphically speaking, the rise profile of the foam must be mirrored downwards to give the correct setting of the fall plate. On the other hand, if the fall plate system and the rise profile are not aligned correctly, a wide variety of errors will occur with the produced foam block. These include the fall plate system being applied too early and then not working if the expansion occurs on a flat conveyor belt, or the foam block forming cracks because the foam has already solidified on the fall plate. For a detailed technical description of the process, see Gunter Oertel, Polyurethane Handbook (2nd edition, 1994, Carl Hanser Corporation).

[0006] Therefore, the synchronization of the rise profile with the machine settings is the main issue with regard to the current state of the technology. The gradient or rise profile is a property of the reaction mixture and depends on many factors. Among other things, it reflects the reactivity of the feedstock, the temperature of the feedstock but also the type and amount of catalyst selected. Different flexible slabstock foam formulations therefore have very different rise profiles. The rise profile is characterized by a record of the time-dependence of the height of the expanding foam mixture. When this is transferred to the machine, the time axis must be converted to distance on the machine (from the time of machine start-up or application of the reaction mixture). This can be done by accurately measuring / calculating the residence time of the reaction mixture after it has passed the mix head until it is above the paper. From there, the foam mixture moves at the conveyor belt speed. The foam rise profile can then be converted to a spatially resolved rise profile on the machine. Once this is done, the fall plate and belt speed can be adjusted to obtain the ideal desired gradient. If necessary, the formulation can also be adjusted so that the modified rise profile is preferably adapted to the machine conditions. One possibility for this is, for example, a modified catalyst concentration. Both the machine parameters and the formulation details can be varied as required.

[0007] For example, for prediction of the correct machine settings when using a new formulation, the rise profile of the formulation needs to be known. This is sometimes done by rough calculations that estimate the rise profile. A typical S-shaped rise profile is conventionally used, which is then adjusted using the defined activity parameters of the catalyst together with the concentrations and temperatures of the feedstocks. However, these rise profiles are only approximately calculated / estimated. This often results in deviations of the calculated rise profile from the actual one, which severely limits the predictability of the production process.

[0008] Furthermore, there are many special foam types for which the calculated rise profile obviously does not accurately represent the rise profile found in a continuously operating PU foam machine. In this case, inappropriate machine parameters are obtained, resulting in error patterns of foaming in industrial slabstock foam machines. Such non-optimized foaming processes in industrial plants, for example with a dosage of 250 kg / min and a minimum run time of a few minutes, are extremely costly and reduce the overall reliability of the simulation software.

[0009] In addition, there are problems with the first production of new foam formulations, especially those whose foaming behavior is little known. That is, to obtain the necessary, unknown, optimal machine settings for a new foam formulation, there are currently only two possible ways. In the first way, the foaming is tested in a large-scale production plant. This involves starting with already established or assumed settings and producing one or more test blocks. These are analyzed and the settings are modified. Improved conditions are then selected in the new foaming process. Thus, the optimized machine parameters are found in an iterative process. This process is time-consuming and expensive.

[0010] Furthermore, it is the opinion of many engineers that significant differences exist between small laboratory rise profiles and large scale manufacturing rise profiles, i.e., it is generally questioned to what extent discontinuous foam (laboratory foam) and continuous foam processes (industrial manufacturing) can be compared.

[0011] DE 10237005 A1 describes the measurement of rise height in continuous slabstock foam production. This is done by a sensor placed above the rising foam mixture. By knowing the rise behavior and the machine settings selected for the production process, it becomes possible to calculate the foam rise profile or to predict optimized machine parameters. This patent, with its complex and costly measurements of the foaming behavior in a real industrial production plant, clearly shows the industrial interest in obtaining meaningful rise profile data. However, the simple method of representative measurements upstream of laboratory rise profile data is not chosen here, instead on-site measurements in real production are chosen. This can be explained by the fact that the authors do not foresee significant rise profile data obtained from discontinuous laboratory foams.

[0012] Ultrasonic measurement sensors have been around for quite some time for measuring rise profiles in laboratories. The combination of sensor and foam software from Format Messtechnik ("FOAMAT") (Format Messtechnik GmbH, Im Schlehert 26, 76187 Karlsruhe, Germany) is particularly popular. The description uses rise profiles to determine creaming and rise times (e.g., to determine activity parameters of catalysts) or compares rise profiles with each other, but the use or export of the program to simulate the rise in a continuous foamer is neither disclosed nor anticipated (see, for example, https: / / www.format-messtechnik.de / foamat_d.htm#Steigh%C3%B6he%20und%20Steigprofil).

[0013] As the kinetics and reaction sequence of polyurethane reactions are of extreme interest for various applications, several attempts have also been made to calculate the reactions. This includes the rise profiles of PU flexible slabstock foam formulations. Examples of such calculations / simulations can be found, for example, in projects at the Fraunhofer Institute for Industrial Mathematics (see, for example, https: / / www.itwm.fraunhofer.de / de / abteilungen / sms / komplexe-fluide-und-mehrphasenstroemung / simulation-polyurethanschaum.html). However, the focus here is on the expansion of flexible polyurethane foams in closed moulds, not on freely rising flexible foams. But again, the use of simulated rather than actually measured rise profiles shows that the transfer of results from laboratory foaming to the manufacturing process (albeit in this case moulded foams) is difficult. In the flexible polyurethane foam industry, it is generally believed that laboratory measured reaction kinetic data (e.g. rise profiles) are not important for large scale industrial slabstock foam production. The background to this is the completely different mixing energies when mixing ingredients by hand in an open cup / container compared to a closed mixing chamber with a high performance agitator. The air input and therefore the nucleation efficiency are also significantly different here, which is manifested in a different cell structure.

[0014] Overall, it would be of considerable benefit to the slabstock industry to overcome the shortcomings of the state of the art as discussed above and provide accurate simulation and reliable prediction of the rise of the reaction mixture during slabstock production. [Prior art documents] [Patent documents]

[0015] [Patent Document 1] DE 10237005 A1 [Non-patent literature]

[0016] [Non-Patent Document 1] Gunter Oertel, Polyurethane Handbook (2nd edition, 1994, Carl Hanser Ltd.)

[0017] Summary of the Invention Various embodiments provide systems and methods for foam production and products provided by the methods described by the subject matter of the independent claims. Advantageous embodiments are described in the dependent claims. The embodiments of the invention can be freely combined with one another if they are not mutually exclusive.

[0018] In one aspect, the present invention relates to a method for determining machine parameters of a foam-making machine, the foam-making machine including a mix head configured to mix precursor reagents to form a reactive mixture, a plurality of inclined fall plates, a first inclined fall plate configured to receive the reactive mixture, each inclined fall plate having a vertically adjustable end, and a conveyor configured to receive the reactive mixture from the last inclined fall plate, the conveyor having an adjustable conveyor speed. The method includes executing software by a computer system, the computer system including at least one processor, the executing the software includes accessing a database for reading a rise profile for the reactive mixture of reagents, the rise profile including a height of the mixture as a function of time when the precursor reagents react to form foam, and calculating, based on the rise profile, a vertical position of an end of each inclined fall plate and a conveyor speed that results in a predetermined predicted profile of the reactive mixture on the plurality of inclined fall plates when the reactive mixture is conveyed along the plurality of inclined fall plates.

[0019] These features have the advantage of accurately calculating the machine parameters of the foam making machine to give a predetermined predicted profile of the reactive mixture on multiple inclined fall plates based on the rise profile accessed from the database by the software, thereby reducing production time and production waste associated with operating the foam making machine.

[0020] In one embodiment, the software includes or is part of artificial intelligence, machine learning software, neural networks, and may include and / or communicate with supervised or learning functions or tools.

[0021] In one embodiment, the method includes mixing precursor reagents in a container to form a second reactive mixture, the container being external to the foam block manufacturing machine; measuring a height of a top surface of the second reactive mixture as a function of time in the container to generate a rise profile; and storing the rise profile in a database.

[0022] Advantageously, by using rise profiles measured in a vessel outside the operation of the foam-making machine, or in other words, by using rise profiles obtained from the results of a discontinuous foaming process conducted in a laboratory, precise machine settings can be determined for a continuous foaming process in a large scale industrial environment, thereby reducing product waste and production times, particularly for reactive mixture reagents that are of unconventional types, ratios, or are relatively new for use in a continuous foaming process.

[0023] According to another embodiment, mixing the precursor reagents in the vessel to form the second reactive mixture and measuring the height of the top surface of the second reactive mixture in the vessel as a function of time to generate a rise profile are performed under environmental conditions that match the environmental conditions in which the foam-making machine is operated.

[0024] By replicating environmental conditions, these characteristics have the advantage that the rise profile as measured in a discontinuous laboratory foam manufacturing process (i.e., as measured in a vessel) more accurately represents the true rise profile as observed on a foam manufacturing machine in a continuous process of foam production.

[0025] In one embodiment, the method includes determining at least one additional parameter such as, but not limited to, machine parameters, reagent parameters, foam parameters, and / or environmental parameters (conditions), such as, for example, temperature, humidity, pressure, speed, vibration, odor, color, etc. This at least one additional parameter is written and stored in a database and / or calculated by the software in relation to and / or dependent on the respective rise profile.

[0026] In one adventurous embodiment, the method includes executing software, the software accessing a database for reading at least one additional parameter and a rise profile of the reactive mixture of reagents, the rise profile including the height of the mixture as a function of time as the precursor reagents react to form a foam, and calculating, based on the reading of the rise profile and the influence of the additional parameter, a vertical position of an end of each inclined fall plate and a conveyor speed that results in a predetermined predicted profile of the reactive mixture on the multiple inclined fall plates when the reactive mixture is conveyed along the multiple inclined fall plates.

[0027] These features have the advantage that the software accurately calculates the machine parameters of the foam making machine to give a predetermined predicted profile of the reactive mixture on a plurality of inclined fall plates under the defined additional parameters based on the rise profile accessed and adjusted by the at least one additional parameter, thereby reducing production time and production waste associated with the operation of the foam making machine.

[0028] In another embodiment, the method includes determining and / or measuring on-site an actual rise profile during foam production based on the vertical position of the end of each inclined fall plate and the conveyor speed, which results in a predetermined predicted profile of the reactive mixture on the multiple inclined fall plates, whereby the prediction was also based on the consideration and / or calculation of at least one additional parameter. Herein, the software includes instances or segments for evaluating, qualifying and / or quantifying the deviation and / or fit between the predicted rise profile and the on-site rise profile, and the associated rise profile for the reactive mixture of the agent in the database is adjusted, rated, and / or at least one control (e.g., adjustment or initialization) of the manufacturing machine and / or the manufacturing machine is generated or adjusted.

[0029] By "control" it is meant generating, outputting, receiving and / or communicating control data by machine processors, controller software, processors and / or actuation units and related methods.

[0030] The term "rated" means that the suitability or appropriateness of the read rise profile, for example under the influence of at least one additional or further parameter and / or under the influence of actual manufacturing conditions, is identified and / or defined by the software and / or stored in a database.

[0031] Determining the actual lift profile is preferably done by a non-contact sensor, for example but not limited to a laser scanning sensor, an ultrasonic sensor.

[0032] The expression "in situ rise profile" is intended to mean the true rise profile measured and observed on a foam making machine during the continuous process of foam production.

[0033] In one embodiment, the method includes determining additional parameters prior to and / or in parallel with reading the database rise profile, including but not limited to pre-production machine parameters, reagent parameters and / or environmental parameters / conditions, such as temperature, humidity, pressure, speed, vibration, odor, color of the surface and / or material.

[0034] In one adventurous embodiment and / or development, the method includes calculating at least one further machine or process parameter other than the vertical position of the end of each inclined fall plate and / or the conveyor speed based on the ascent profile, optionally under the influence of additional parameters. Without being limited thereto, such at least one further machine or process parameter is, but is not limited to, the state, speed, output, performance, etc. of actors, sensors, devices, units, etc., such as motors, valves, heaters, etc. According to another embodiment, the container is stationary.

[0035] In yet another embodiment, the movement of the mixture relative to the container only includes movement of a top surface of the mixture where the height of the top surface increases.

[0036] In one embodiment, the precursor reagents include at least one liquid polymer and at least one catalyst.

[0037] In another embodiment, the at least one liquid polymer comprises at least one liquid polyurethane.

[0038] According to yet another embodiment, the foam-making machine further includes a transport medium disposed between a bottom surface of the reactive mixture, the plurality of inclined fall plates, and a conveyor, the conveyor configured to pull the transport medium and the reactive mixture along the plurality of inclined fall plates at a conveyor speed for transporting the reactive mixture along the plurality of inclined fall plates.

[0039] According to one embodiment, the vessel includes a process liner, and the chemical composition of at least the surface of the transport medium of the foam manufacturing machine matches the chemical composition of at least the surface of the process liner used to generate the rise profiles stored in the database, the surface being in contact with the respective reactive mixture.

[0040] According to one embodiment, to ensure that the temperature of the reaction mixture matches the industrial conditions for large blocks, the vessel is made of a material with very low heat capacity and low thermal conductivity. Suitable materials may be, for example, rigid polyurethane foam or polystyrene foam.

[0041] By at least replicating the chemical composition of the liner (i.e., process liner and conveying medium) on the surface of the liner that comes into contact with each reactive mixture, these characteristics have the advantage that the rise profile measured in a discontinuous laboratory foam production process (i.e., as measured in a vessel) accurately represents the true rise profile observed on a foam making machine in a continuous process of foam production.

[0042] According to one embodiment, the transport medium is a sheet of paper.

[0043] According to another embodiment, the foam making machine includes a trough having a bottom surface including an input port configured to accept the reactive mixture from a mixhead and a side surface including a side lip through which the reactive mixture flows to a proximal end of a first inclined fall plate (i.e., the first inclined fall plate is configured to accept the reactive mixture from the trough), and the calculation is further based on one or more of: a vertical position of the side lip of the trough relative to a vertical position of the proximal end of the first inclined fall plate; and a size of the trough defined by the length between the bottom surface of the trough and the side lip of the trough.

[0044] In another embodiment, the predetermined predicted profile has a substantially flat upper surface having a slope angle of approximately arctan [(predetermined percentage of the foam height above the conveyor) / (horizontal length of the plurality of sloped fall plates)].

[0045] According to one embodiment, the predetermined percentage of the foam height above the conveyor is approximately 1 / 3 of the foam height above the conveyor.

[0046] These features have the advantage of further reducing unevenness in the top surface of the foam on the conveyor, resulting in a substantially flat (ie, non-dome shaped) top surface, thereby further reducing product waste.

[0047] According to further embodiments, the user is prompted to adjust one or more of the calculated vertical positions of the ends of each inclined fall plate and / or the conveyor speed to adjust the predicted profile of the reactive mixture on the conveyor belt to have a substantially flat upper surface.

[0048] These features have the advantage of automatically prompting the user to adjust certain machine parameters, in other words automatically warning the user that the form being produced does not have a substantially flat upper surface, so that the user may make adjustments without undue delay and without uncertainty as to which parameters to adjust.

[0049] In one embodiment, the computer system includes a network and a cloud server, the cloud server including at least one processor, a user having an account with the cloud server, the cloud server including a cloud database, and the method further includes authorizing, by the cloud server, the user's access to the cloud server based at least on a user profile stored in the cloud database, and executing, by the cloud server, software, wherein executing the software further includes automatically reading an elevation profile of the reactive mixture of precursor reagents from the cloud database based on the user profile.

[0050] These features have the advantage of offloading the execution of the software to a cloud server and automatically allowing the user to execute the software by the cloud server, including automatically reading a lift profile associated with the user based on a user profile stored in a cloud database, thereby effectively streamlining the method for determining machine parameters of a foam manufacturing machine (i.e., implementing the method via a centralized entity).

[0051] According to another embodiment, the user profile includes at least one purchasing information for a precursor reagent.

[0052] In yet another embodiment, the method further includes scanning a machine readable code associated with at least one of the precursor reagents upon delivery of the at least one of the precursor reagents to the user, The cloud server automatically retrieves the ascent profile from the cloud database based on the scanned machine readable code upon execution of the software.

[0053] These features have the advantage of efficiently obtaining a promotion profile associated with the user, in particular associated with the user based on purchase information.

[0054] In one embodiment, the foam making machine further includes at least one machine processor, controller software, and an actuation unit, and the method further includes outputting, by the processor, a calculated vertical position of an end of each inclined fall plate and a conveyor belt speed; executing, by the at least one machine processor, the controller software; receiving, by the at least one machine processor, the output calculated vertical position of an end of each inclined fall plate and a conveyor belt speed; and setting, by the actuation unit, parameters of the foam making machine for producing a foam block.

[0055] These features have the advantage of automating the setting of foam-making machine parameters, such as the vertical position of the ends of each inclined fall plate and the conveyor belt speed, which are determined by the software, to reduce human error in providing foam through the foam-making machine and to shorten production time.

[0056] The following embodiments of the invention are described in detail, by way of example only, with reference to the drawings in which: [Brief description of the drawings]

[0057] [Figure 1] FIG. 1 illustrates a foam-making machine according to one embodiment of the present disclosure. [Diagram 2] 1 is a flow diagram of a method for determining machine parameters of a foam manufacturing machine according to one embodiment of the present disclosure. [Diagram 3] FIG. 1 illustrates a predetermined predicted profile of a reactive mixture on a plurality of inclined fall plates having substantially flat inclined upper surfaces, according to one embodiment of the present disclosure. [Figure 4] FIG. 2 illustrates a foam-making machine according to another embodiment of the present disclosure. [Diagram 5] FIG. 1 illustrates a container according to one embodiment of the present disclosure. [Figure 6] FIG. 1 illustrates a computer system according to one embodiment of the present disclosure. [Figure 7] FIG. 1 shows the calculated and measured rise profile without creaming time for Formulation 1, according to one embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0058] The description of various embodiments of the present invention is presented for illustrative purposes and is not intended to be exhaustive or limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terms used in this specification are selected to conveniently explain the principles of the embodiments, practical applications or technical improvements to the technology found in the market, or to enable those skilled in the art to understand the embodiments disclosed in this specification.

[0059] The present disclosure relates to the field of PU flexible foam. This specification describes a process for improved prediction of parameters for industrial PU flexible slabstock foam production. Although there are significant differences between laboratory discontinuous flexible polyurethane foam production and large-scale continuous flexible polyurethane foam block production, it has been found that by using the conditions regulated in laboratory discontinuous foam production, accurate prediction of optimal machine parameters for continuous flexible slabstock foam production is possible by transferring laboratory slabstock data to simulation software.

[0060] Surprisingly, it has been found that accurate simulations of the rise behavior can be obtained and precisely fitted machine parameters can be derived by importing and using carefully and representatively measured rise profiles in the laboratory. In laboratory experiments under prescribed conditions, the rise profiles may be measured and uploaded into a simulation software for a slabstock foam manufacturing process to obtain accurate and reliable predictions. It has been found that accurate predictions for selecting optimized machine conditions can be derived by importing the precisely measured laboratory rise profiles into a simulation process for the manufacturing process. For large scale manufacturing, it is important to make the laboratory foaming as representative as possible. This includes not only bringing the raw materials to the temperatures used in the manufacturing trials, but also foaming into an insulated box / crate. The heat capacity and thermal conductivity of the box walls should be low. Suitable materials include rigid insulating polyurethane foam (PUR or PIR foam), or insulating foams such as polystyrene foam. Additionally, the same process liners used in large manufacturing plants may also be used in box foaming experiments to separate the box from the reaction mixture (also called the reactive mixture).

[0061] Surprisingly, the rise profiles of laboratory foaming experiments, which are carried out discontinuously on a much smaller scale than the production process, provide reliable predictions for setting machine parameters in simulation software for large-scale slabstock foam manufacturing processes.

[0062] As described further below, a process for improved prediction of parameters for industrial PU flexible slabstock foam production may include one or more of: (1) creating a PU flexible foam formulation; (2) measuring a time-resolved rise profile (also called a slump profile) in a laboratory (e.g., using laser or ultrasonic distance measurement and data recording); (3) maintaining and / or converting the data; (4) uploading the slump or rise profile data into production process simulation software; and (5) deriving production process parameters and simulating the production process.

[0063] In one embodiment, the measurement of the rise profile in the laboratory is carried out such that the same temperatures are chosen as in the industrial practice and the foam rise is carried out in an insulated box.

[0064] Optional preservation and / or transformation of the data includes processing the measured rise profile data and applying correction factors to correlate laboratory and machine conditions. In one embodiment, preparation of the rise profile data includes deleting data points before the start of foam rise and normalizing the rise profile to a % of maximum rise height (maximum rise height=100%).

[0065] The prepared rise profile data can be transferred to the simulation software in different databases or formats. The simulation software for the industrial foaming process uses the measured rise profile data to calculate the rise of the polyurethane foam during the industrial production of the polyurethane foam. Parameters related to the fall plate, as well as the output amount and the conveyor speed (e.g., conveyor belt speed) can then be derived.

[0066] As briefly described above, the present invention is in the technical field of polyurethane (PU) foam production, and more specifically, software configured to import a rise profile of precursor reagents including a catalyst that, when mixed together as liquids, form a flexible PU foam (e.g., a flexible PU foam block). The rise profile is generated by a profile measurement of the liquid mixture made in a laboratory as the liquid mixture reacts to form a foam. The software uses the imported rise profile to calculate machine parameters of a foam block making machine, such as, but not limited to, one or more of conveyor speed (e.g., conveyor belt speed), size of a mixing trough, and / or position of an inclined fall plate and position of a pivot point, such machine parameters being relevant for optimizing the profile of the foaming mixture on the conveyor system of the machine. Optimizing the profile of the foaming mixture on the conveyor belt system of the machine includes providing a substantially flat (i.e., substantially horizontal) profile of the foaming mixture on a series of inclined fall plates as the foaming mixture is conveyed on a conveyor, such as a conveyor belt, across the series of inclined fall plates. The substantially flat profile of the foaming mixture on a series of inclined fall plates results in foam blocks on the conveyor having essentially flat top surfaces, as opposed to the rounded or domed top surfaces of foam blocks produced by conventional systems and methods.

[0067] The present invention provides a solution to the current state of the art of using S-shaped rise profiles based on calculations of creaming point (in time) and total rise point (in time), such calculations being based on mixing reagents and then fitting an S-shaped curve between the creaming point and the total rise point. Such S-shaped fitted rise profiles are not a particularly accurate representation of the true rise profile and are particularly inaccurate when the foam generating liquid mixture and / or the components of the liquid mixture have non-standard or unusual densities, blow-off agents and / or ratios.

[0068] Embodiments of the present invention result in the production of flexible PU foam, such as flexible PU foam blocks or foams having any polygonal shape, with precisely predicted dimensions, thereby reducing material waste and processing time when providing foam that is cut into final or intermediate products with precise predetermined dimensions.

[0069] PU foam (polyurethane foam) and its manufacture are well known to those skilled in the art and do not require further explanation per se. Molded articles in the context of the present disclosure are molded bodies of different shapes. Preferred shapes in the context of the present embodiment are, for example, those of a sphere, a rectangular parallelepiped, a cylinder, etc. Thus, molded PU foam articles in the context of the present disclosure are molded bodies made of polyurethane foam. Particularly preferred shapes of hot-cure flexible PU foam articles in the context of the present disclosure are mattresses and / or cushions, and also foam blocks in general. Other flexible foam articles covered within the scope of the embodiments of the present disclosure include, but are not limited to, foams used in the manufacture or as accessories of shoes (e.g., pads and soles), sofas, bedding, bras, clothing (e.g., shoulder pads), air filters (e.g., filter foams), and vehicles (e.g., vehicle roofs / ceilings, dashboards, or laminates including foam layers used in the manufacture of foams used in seats and / or other automotive components).

[0070] The production of polyurethane foams is generally known per se. They are formed by the tried and tested reaction of at least one polyol component and at least one isocyanate component in the presence of at least one blowing agent (e.g., water) in a polyaddition reaction.

[0071] The polyurethane foam according to the embodiment of the present disclosure is a flexible polyurethane foam. The foam is made by a continuous process (also called a slabstock foaming process) using data (e.g., rise profile data) obtained from a discontinuous laboratory produced foam forming process. Flexible foams are typically used for comfort applications such as sofas, cushions or mattresses. Other technical applications of flexible foams include filter foams or flame laminated foams. Applications in the textile and clothing industry are also known (e.g., shoulder pads, bras).

[0072] Rigid polyurethane foams are used for insulation applications such as refrigerators or insulation plates. Rigid PU foams, which are non-elastic and usually have closed cells, are used for insulation purposes and are not the focus of the embodiments of this disclosure. Flexible PU foams are elastic and deformable and usually have open cells. As a result, air is more likely to escape when compressed.

[0073] There are a wide variety of flexible PU foams. For example, the skilled person is aware of ester foams (made from polyester polyols), flexible hot-cure PU foams and cold-cure PU foams, among others. Viscoelastic flexible PU foams are a relatively new type among hot-cure flexible PU foams. In the context of this disclosure, all flexible foam types are included. The important difference between hot-cure flexible PU foams and cold-cure PU foams lies in the different mechanical properties. In particular, it is possible to distinguish between flexible hot-cure PU foams and flexible cold-cure PU foams via the rebound resilience, also called ball rebound (BR) or elasticity. Methods for determining the rebound resilience are described, for example, in DIN EN ISO 8307:2008-03. There, a steel ball with a certain mass is dropped from a certain height onto the test specimen and the rebound height is measured in % of the drop height. The value for cold-cure flexible PU foams is preferably an area above 50%. Therefore, cold cure flexible PU foams are often also called HR foams (HR: high resilience). In contrast, hot cure flexible PU foams preferably have a resilience value of 1% to 50% or less. Thus, in the context of a preferred embodiment of the present invention, the hot cure flexible PU foam according to the present disclosure preferably has a resilience value determinable according to DIN EN ISO 8307:2008-03 of 1% to 50% or less.

[0074] A further mechanical criterion is the SAG, i.e. comfort factor. In this case, foam samples are compressed according to DIN EN ISO 2439 and the ratio of compressive stresses at 65% and 25% compression is measured. The cold-cure flexible PU foams here preferably have a SAG, i.e. comfort factor, greater than 2.5. The hot-cure flexible PU foams preferably have a value less than 2.5. Thus, in a preferred embodiment of the present invention, the hot-cure flexible PU foams according to the present disclosure have a SAG, i.e. comfort factor, determinable as described above, preferably less than 2.5.

[0075] The exact definition of the properties can also be taken, for example, from the data sheet "PUR-Kaltschaum" [Cold-cure PU foams], KAL20160323, last updated 23 March 2016, of the Fachverband Schaumkunststoffe und Polyurethane eV [Specialist Association for Foamed Plastics and Polyurethanes] (see, for example, https: / / www.fsk-vsv.de / wp-content / uploads / 2017 / 03 / Produktbeschreibung-PUR-Kaltschaum.pdf). This data sheet can also be ordered directly from Fachverband Schaumkunststoffe und Polyurethane eV (FSK), D-70435 Stuttgart, Stammheimerstr. 35.

[0076] The two names hot cure flexible PU foam and cold cure flexible PU foam are explained by the historical development of PU technology, and do not necessarily mean that different temperatures occur in the foaming process.

[0077] The different mechanical properties of hot-cure and cold-cure PU foams result from differences in the formulations for the production of the foam. For cold-cure flexible PU foams, mainly highly reactive polyols with primary OH groups and an average molar mass of more than 4000 g / mol are usually used. Sometimes, low molecular weight crosslinkers are also used, and it is also possible that the function of the crosslinker is assumed by isocyanates of high functionality. For hot-cure flexible PU foams, relatively mainly non-reactive polyols with secondary OH groups and an average molar mass of less than 4000 g / mol are usually used. Thus, for cold-cure flexible PU foams, the reaction of isocyanate groups with hydroxyl groups occurs as early and to a high extent as the expansion phase of the foam (CO2 formation from -NCO and H2O). This rapid polyurethane reaction, as a result of the viscosity increase, usually leads to a relatively high inherent stability of the foam during the foaming process. As a result, other foam stabilizers with different siloxane structures compared to hot-cure flexible PU foams are required. Cold-cure flexible PU foams are usually high-elasticity foams. Due to the high inherent stability, the cells are generally not fully opened at the end of the foaming operation, and the cell structure must be additionally opened by mechanical fracturing. In contrast, this is not usually necessary for hot-cure flexible PU foams. The rather large stabilization by the high molecular weight polyether siloxane structure is important here.

[0078] The open-cell hot-cure flexible PU foam preferably has a gas permeability (also called "porosity") in the range of 1 to 6.5 scfm. This is measured by applying a pressure differential and measuring the amount of air that flows according to ASTM D 3574 (2011-00). The method is described in more detail below (i.e., see subsection (f) discussed in Methods for Characterization of PU Foam Samples). Scfm (standard cubic feet per minute) is measured under standard conditions (23°C, 100 kPa).

[0079] Depending on the application, the hot cure flexible PU foam preferably has a strength of 8-80 kg / m 3 In particular, when such hot cure flexible PU foams are used as mattresses, mattress components and / or cushions, the foams are differentiated according to the local wants and needs, requirements and preferences of the consumers. The preferred hot cure flexible PU foams for mattress applications preferably have a foam density between 25 and 35 kg / m 3 The foam has a density of 0.01g / g.

[0080] A particular class of hot-cure flexible PU foams is that of viscoelastic PU foams. These are also known as "memory foams" and exhibit both low rebound resilience (preferably less than 10%) and slow recovery after compression (recovery time, preferably 2-10 seconds). Materials of this kind are well known in the prior art and are also highly valued, especially for their energy and sound absorption properties. Typical viscoelastic flexible foams usually have low porosity and high density (or high foam density (FD)) compared to other hot-cure flexible PU foams. The cushions are preferably designed to have a mass of 30-50 kg / m 3 and is therefore at the lower end of the density scale typical for viscoelastic foams, but viscoelastic PU foams for mattresses preferably have a foam density of 45 to 130 kg / m 3 It has a density in the range of

[0081] In hot-cure flexible flexible PU foams, the hard and soft segments are oriented relative to each other during the reaction and then spontaneously separate from each other to form morphologically distinct phases within the "bulk polymer". Such materials are also called "phase-separated" materials. The glass transition temperature in the case of viscoelastic foams is preferably between -20 and +15 °C. In contrast, the glass transition temperatures of other hot-cure flexible PU foams and cold-cure flexible PU foams are usually below -35 °C. Such "structural viscoelasticity" in the case of open-cell viscoelastic hot-cure flexible PU foams, which are essentially based on the glass transition temperature of the polymer, should be distinguished from the air pressure effect. In the latter case, the cell structure is relatively closed (low porosity). As a result of the low air permeability, the air flows back only gradually after compression, which results in a slow recovery.

[0082] Various hot-cure flexible PU foams are often classified not only by foam density but also by their compressive strength, also called load-bearing capacity for a particular application. For example, the compressive strength CLD (compression load deflection) at 40% according to DIN EN ISO 3386-1:2015-10 for hot-cure flexible PU foams is preferably in the range of 2.0-8.0 kPa, while viscoelastic polyurethane foams preferably have values ​​of 0.1-5.0 kPa, in particular 0.5-3.0 kPa.

[0083] Hot-cure flexible PU foams and their production are known per se. In a preferred embodiment of the present invention, the hot-cure flexible PU foam has a compressive strength CLD of 2.0 to 8.0 kPa at 40% compressive strength CLD according to DIN EN ISO 3386-1:2015-10 and / or a rebound resilience of 1 to 50%, measured according to DIN EN ISO 8307:2008-03, and / or a compressive strength of 8 to 80 kg / m 3and / or a porosity between 1 and 6 scfm, in particular between 1.5 and 4.5 scfm, more preferably between 1.75 and 4.25 scfm. Possible production methods are described, for example, in EP 2 481 770 A or EP 2 182 020 A. For the purposes of this disclosure, in a preferred embodiment of the present invention, the viscoelastic flexible PU foam has a glass transition temperature between −20° C. and +15° C., and / or a compressive strength CLD of 40% according to DIN EN ISO 3386-1:2015-10, a compressive strength CLD of 0.1 to 5.0 kPa, in particular between 0.5 and 2.5 kPa, and / or a rebound resilience of less than 10%, measured according to DIN EN ISO 8307:2008-03, and / or a porosity between 30 and 130 kg / m 3 and / or a porosity (after crushing the foam) of 1 to 6 scfm, in particular 1.5 to 4.5 scfm, more preferably 1.75 to 4.25 scfm. Possible manufacturing methods are described, for example, in WO 2013 / 131710. The glass transition temperature can be measured by dynamic mechanical analysis (DMA) (DIN 53513:1990-03) or differential scanning calorimetry (DSC) (ISO 11357-2:2013). Strictly speaking, it is the glass transition range that extends over a temperature range. The reported values ​​are therefore averages.

[0084] According to a preferred embodiment of the present invention, the molded hot cure flexible PU foam article (e.g., foam used as a mattress or mattress produced by the foam process of the present disclosure) has a height of at least 1 cm to no more than 50 cm, and a width of at least 20 cm to no more than 300 cm, and a length of at least 20 cm to no more than 300 cm. Preferred dimensions are, for example, a height in the range of 5 cm to 40 cm, a width in the range of 70 cm to 200 cm, and a length in the range of 150 cm to 220 cm. According to another preferred embodiment of the present invention, the molded PU foam article (e.g., a cushion) has a height of at least 1 cm to no more than 40 cm, and a width of at least 15 cm to no more than 200 cm, and a length of at least 15 cm to no more than 200 cm, and examples of preferred dimensions are a height in the range of 2 cm to 30 cm, a width in the range of 15 cm to 50 cm, and a length in the range of 15 cm to 50 cm.

[0085] In a further preferred embodiment of the present invention, the molded flexible PU foam article may also be a cold cure PU foam mattress, a viscoelastic flexible PU foam mattress, a hot cure flexible PU foam mattress, a PU gel foam mattress, a latex mattress, or a box spring mattress, each of which comprises at least a part made of hot cure flexible PU foam or cold cure flexible foam according to an embodiment of the present invention. These types of mattresses are known per se to those skilled in the art and are also sold under these names worldwide. Mattresses made only of hot cure flexible PU foam are usually referred to in the market simply as foam mattresses. The term mattress as used for the purposes of the present invention also encompasses the corresponding mattress coverings and underlays.

[0086] What provides a variety of flexible PU foams is that they are made by a continuous slabstock process. Discontinuous processes such as box foaming, or foaming into a mold (molded PU foam) are not the focus of the embodiments of the present disclosure. In the continuous manufacturing process of flexible PU foam, foam expansion is possible in a rectangular direction relative to the movement of the foam or reaction mixture. The gas pressure inside the expanding foam is therefore approximately equal to the gas pressure at which the rising foam is expanding. This is in contrast to molded foaming, where a significant overpressure is reached in the mold relative to the outside during foaming. The movement of the expanding foam is usually horizontal, forced by a conveyor (e.g., a conveyor belt). In some cases, vertical movement is also possible.

[0087] The production of the corresponding hot-cure flexible PU foams does not require further explanation in principle, but some preferred details of the production of PU foams used for the purposes of illustrating the embodiments of the invention are given below. The subject matter of the invention is described below by way of example, without intending the invention to be limited to these exemplary embodiments. Where ranges, general formulae or classes of compounds are specified below, these are intended to encompass not only the corresponding ranges or groups of compounds explicitly mentioned, but also all subranges and subgroups of compounds that can be obtained by removing individual values ​​(ranges) or compounds. Where documents are cited in the context of this specification, their entire contents are intended to form part of the disclosure of the invention, in particular with regard to the subject matter forming the context in which the documents are cited. Unless otherwise stated, percentages are figures in weight percent. When average values ​​are reported below, the values ​​are weight averages, unless otherwise stated. Where parameters determined by measurement are reported below, the measurements were carried out at a temperature of 23° C. and at a pressure of 100 kPa, unless otherwise stated.

[0088] For the purposes of the present invention, polyurethanes are all reaction products derived from suitable isocyanate-reactive molecules, including isocyanates, in particular polyisocyanates and polyisocyanurates, polyureas, as well as allophanates, biurets, uretdione, uretonine or carbodiimide-containing isocyanate or polyisocyanate reaction products. The skilled person who wishes to produce different flexible polyurethane foam types, for example hot-cure flexible PU foams, will clearly select the substances required for the respective purpose, such as isocyanates, polyols, stabilizers, surfactants, etc., in order to obtain the polyurethane type, in particular the polyurethane foam type, desired in each case. Further details of usable starting materials, catalysts as well as auxiliaries and additives can be found, for example, in Kunststoffhandbuch [Plastics Handbook], volume 7, Polyurethane [Polyurethane], Carl-Hanser Publishers, Munich, 1st edition 1966, 2nd edition 1983 and 3rd edition 1993. The following compounds, ingredients and additives are mentioned merely as examples and can be substituted and / or supplemented by other substances known to those skilled in the art.

[0089] The isocyanate component used is preferably one or more organic polyisocyanates having two or more isocyanate functional groups. The polyol component used is preferably one or more polyols having two or more isocyanate-reactive groups.

[0090] Suitable isocyanates as isocyanate components for the purposes of the present invention are all isocyanates containing at least two isocyanate groups. In general, it is possible to use all aliphatic, cycloaliphatic, arylaliphatic and preferably aromatic polyfunctional isocyanates known per se. The isocyanates are preferably used in the range of 60 to 350 mol%, more preferably in the range of 60 to 140 mol%, based on the total of the isocyanate consuming components.

[0091] Specific examples include alkylene diisocyanates having 4 to 12 carbon atoms in the alkylene group, such as dodecane 1,12-diisocyanate, 2-ethyltetramethylene 1,4-diisocyanate, 2-methylpentamethylene 1,5-diisocyanate, tetramethylene 1,4-diisocyanate, and preferably hexamethylene 1,6-diisocyanate (HMDI), cycloaliphatic diisocyanates such as cyclohexane 1,3- and 1,4-diisocyanate, and any mixtures of these isomers, 1-isocyanato-3,3,5-trimethyl-5-isocyanatomethylcyclohexane, and 1,6-diisocyanate. diisocyanates such as hexane (isophorone diisocyanate or IPDI for short), hexahydrotolylene 2,4- and 2,6-diisocyanate and the corresponding isomer mixtures, as well as preferably aromatic diisocyanates and polyisocyanates, such as tolylene 2,4- and 2,6-diisocyanate (TDI) and the corresponding isomer mixtures, mixtures of diphenylmethane 2,4'- and 2,2'-diisocyanate (MDI) and polyphenylpolymethylene polyisocyanate (crude MDI), and mixtures of crude MDI and tolylene diisocyanate (TDI). The organic diisocyanates and polyisocyanates can be used individually or in the form of their mixtures.

[0092] It is also possible to use isocyanates which have been modified by the incorporation of urethane, uretdione, isocyanurate, allophanate, and other groups, referred to as modified isocyanates.

[0093] Particularly suitable organic polyisocyanates which are particularly preferably used are therefore tolylene diisocyanate (tolylene 2,4- and 2,6-diisocyanate (TDI) in pure form or as an isomer mixture of various composition), diphenylmethane 4,4'-diisocyanate (MDI), the various isomers of "crude MDI" or "polymeric MDI" (containing the 4,4' isomer and the 2,4' and 2,2' isomers of MDI, as well as products with three or more rings), and also the two-ring products referred to as "pure MDI" and consisting mainly of a mixture of the 2,4' and 4,4' isomers, and prepolymers derived therefrom. Examples of particularly suitable isocyanates are detailed, for example, in EP 1 712 578, EP 1 161 474, WO 00 / 58383, U.S. Patent Application Publication No. 2007 / 0072951, EP 1 678 232, and WO 2005 / 085310, which are hereby incorporated by reference in their entirety.

[0094] Polyols suitable as polyol component for the purposes of the present invention are all organic substances having two or more isocyanate-reactive groups, preferably OH groups, and blends thereof. Preferred polyols are all polyether polyols and / or hydroxyl-containing aliphatic polycarbonates customarily used for producing polyurethane systems, in particular polyurethane foams, in particular polyether polycarbonate polyols and / or filled polyols (polymer polyols), such as SAN, PHD and PIPA polyols, which contain solid organic fillers in dispersed form up to a solids content of 40% or more, and / or autocatalytic polyols containing catalytically active functional groups, in particular amino groups and / or polyols of natural origin, known as "natural oil-based polyols" (NOPs). Polyols for hot-cure flexible PU foams preferably have a functionality of 1.8 to 8 and a number-average molecular weight in the range of 500 to 4000 g / mol. Polyols with OH values ​​in the range of 25 to 400 mg KOH / g are usually used. The number average molecular weight is usually determined by gel permeation chromatography (GPC), in particular using polypropylene glycol as reference material and tetrahydrofuran (THF) as eluent. The OH number can be determined in particular according to DIN standard DIN 53240:1971-12. Depending on the required properties of the obtained foam, it is possible to use suitable polyols, for example as described in US 2007 / 0072951, WO 2007 / 111828, US 2007 / 0238800, US 6359022 or WO 96 / 12759. Further polyols are known to those skilled in the art and can be found, for example, in EP 0 380 993 or US 3 346 557.

[0095] In a preferred embodiment of the invention, in particular for the production of flexible slabstock foams, polyether alcohols are used which preferably have more than 50%, more preferably more than 90%, of secondary hydroxyl groups, in particular those with propylene oxide blocks or random propylene oxide and ethylene oxide blocks at the chain ends, or those based only on propylene oxide blocks. Such polyether alcohols have a functionality preferably between 2 and 8, more preferably between 2 and 4, a number average molecular weight in the range of 500 to 4000 g / mol, preferably between 800 and 4000 g / mol, more preferably between 2500 and 4000 g / mol, and an OH number which is usually in the range of 20 to 100 mg KOH / g, preferably between 40 and 60 mg KOH / g.

[0096] In a further preferred embodiment of the present invention, difunctional and / or trifunctional polyether alcohols are further used, which preferably contain primary hydroxyl groups in an amount of more than 50%, more preferably more than 80%, in particular with ethylene oxide blocks at the chain ends. If the molar mass is at the same time more than 4000 g / mol, polyols for cold-cure flexible PU foams ("HR polyols") form part of this category. According to an embodiment of the present invention, in particular according to the necessary characteristics of this embodiment preferred for the production of hot-cure flexible PU foams as described above, it is preferred to use not only the polyether alcohols described herein, but also further polyether alcohols which have primary hydroxyl groups and are mainly based on ethylene oxide, in particular with a proportion of ethylene oxide blocks of more than 70%, preferably more than 90% ("hypersoft polyols"). All polyether alcohols described in the context of this preferred embodiment preferably have a functionality of 2 to 8, more preferably 2 to 5, a number average molecular weight in the range of 500 to 8000 g / mol, preferably 500 to 7000 g / mol, and an OH number usually in the range of 5 to 100 mg KOH / g, preferably 20 to 60 mg KOH / g. Polyols with primary OH functional groups are used herein in the case of the hot-cure flexible PU foams of the present invention in a preferred embodiment not alone, but rather in combination with polyols with secondary OH groups.

[0097] In a further preferred embodiment of the present invention, an autocatalytic polyol is used.

[0098] In a further preferred embodiment of the invention, in particular for the production of viscoelastic flexible PU foams, it is preferred to use a mixture of different, preferably two or three, multifunctional polyether alcohols. The polyol combinations used here usually consist of low molecular weight "crosslinker" polyols with high functionality, preferably with an OH value of 100 to 400 mg KOH / g, and / or conventional high molecular weight flexible slabstock foam polyols or HR polyols, and / or "hypersoft" polyether polyols with an OH value of 20 to 40 mg KOH / g, a high proportion of ethylene oxide and preferably cell opening properties. If HR polyols are also used in the viscoelastic foam formulation, their mass proportion in the polyol mixture is less than 50%.

[0099] Polyester polyols were the first polyols used in the early days of PU development and are produced by polycondensation of diacids with an excess of diols. Difunctional monomers are used to obtain linear polymers. The addition of small amounts of multifunctional starters with functionality greater than 2, such as trimethylolpropane and glycerin, can be used to produce polymers with average functionality greater than 2. The most used acids are adipic acid and phthalic acid. Adipic acid-based polyester polyols are used in applications where flexibility is desired, such as flexible polyurethane foams. Phthalic acid (or phthalic anhydride)-based polyols have rigid chains and are used in rigid foams and high performance coatings. For flexible PU foams, aliphatic polyester polyols are often used, usually based on adipic acid, diethylene glycol and trimethylolpropane or glycerin to induce high functionality. The average molecular weight is usually between 2000 and 3000 g / mol, with an OH value of 57 to 63 mg KOH / g.

[0100] In the polyester polyol manufacturing process, diols, triols, etc. are first heated to a temperature of 60-90°C. Dicarboxylic acids are then added and the removal of reaction water begins. The excess diol is calculated by the Flory equation to obtain the target molecular weight. Usually, the reaction is completed at temperatures up to 200°C. Nitrogen, carbon dioxide, or vacuum is used to remove the water to reach the desired conversion of 99.9%, and the resulting polyester should have an acid number less than 2. This conversion is necessary to minimize the presence of residual carboxylic acid end groups that can reduce reactivity. Polyesters are composed of all possible oligomers ranging from monomers to higher molecular weight species. Usually, aliphatic polyester polyols used for flexible polyurethanes are based on polyadipate diols such as ethylene glycol, diethylene glycol, propylene glycol, 1,4-butanediol, and 1,6-hexanediol. The growth of the diol chain increases the flexibility of the PU, as well as its hydrolytic stability, and decreases its polarity and glass transition temperature. Lightly branched poly(diethylene glycol adipate), mainly used to produce flexible foams, and a wide range of adipates made with two or more aliphatic diols. These are used to produce solid and microcellular elastomers, flexible coatings and adhesives. Relatively low-cost polyester polyols based on recovered materials from regeneration processes are also available. Mixed polyesters of adipic, glutaric and succinic acids are made using purified nylon waste acid. Compared to PU-based polyether polyols, PU-based polyesters are resistant to oils, greases, solvents and oxidation. They have favorable properties related to tensile and tear strength, flex fatigue, abrasion, adhesion and dimensional stability. On the other hand, PU-based esters are sensitive to hydrolysis and microbiological attack. The manufacturing process of flexible polyurethane foams based on polyester polyols follows the same principles as polyether polyol-based polyurethane flexible foams. Therefore, the machinery is also comparable. According to an embodiment of the present invention, a simulation of the manufacturing process can be derived from a laboratory rise profile in the same way as for flexible PU foams based on polyether polyols.Often, PU flexible foams based on polyester polyols are simply referred to as "polyester foams". It is also possible to combine polyether and polyester polyols in flexible PU foam formulations. Such foams are often referred to as "hybrid foams". All of these foams are within the scope of the present invention, as long as they are produced by a continuous manufacturing process.

[0101] In a further preferred embodiment of the present invention, recycled polyol is used. The recycled polyol is a polyol obtained from PU foam waste. It may be a production waste from hot-cure flexible PU foam production or from hot-cure flexible PU foam waste after use by the consumer (e.g. old mattresses). In both cases, the PU foam is liquefied by a chemical process. Various processes are useful here, for example glycolysis, hydrolysis or acidolysis. The resulting liquid recycled polyol can then be reused for the production of hot-cure flexible PU foam. However, such hot-cure flexible PU foam is often characterized by apparently detrimental mechanical properties, such as resistance to roll compression. One source of further information on the use of recycled polyol in hot-cure flexible PU foam is the following BMBF research report: https: / / www.cleaner-production.de / fileadmin / assets / bilder / BMBF-Projekte / 01RI05070-075_-_Abschlussbericht.pdf.

[0102] Further uses of recycled polyols in the context of the present invention correspond to preferred embodiments of the present invention per the items of the claimed subject matter.

[0103] The preferred ratio of isocyanate to polyol, expressed as a blend index, i.e. as the stoichiometric ratio of isocyanate groups to isocyanate-reactive groups (e.g. OH groups, NH groups) multiplied by 100, is in the range of 50 to 140, preferably 70 to 130, more preferably 85 to 125. An index of 100 represents a 1:1 molar ratio of reactive groups.

[0104] The flexible PU foams according to embodiments of the present invention can also be produced using a catalyst. The expression "catalyst" for the purposes of the present invention includes all compounds known from the prior art that are capable of catalyzing the isocyanate reaction and / or are used as catalysts, cocatalysts or activators in the production of polyisocyanate reaction products, in particular polyurethane foams.

[0105] Suitable catalysts are known and are in particular substances which catalyse the gelling reaction (isocyanate-polyol), the blowing reaction (isocyanate-water) and / or the dimerisation or trimerisation of isocyanates. Such catalysts are preferably nitrogen compounds, in particular amines and ammonium salts, and / or metal compounds.

[0106] Examples of nitrogen compounds suitable as catalysts for the purposes of the present invention are the amines, triethylamine, triethanolamine, diethanolamine, N,N-dimethylcyclohexylamine, N,N-dicyclohexylmethylamine, N,N-dimethylaminoethylamine, N,N,N',N'-tetramethylethane-1,2-diamine, N,N,N',N'-tetramethylpropane-1,3-diamine, N,N,N',N'-tetramethylbutane-1,4-diamine, N,N,N',N'-tetramethylhexane-1,6-diamine, N-[2-(dimethylamino)ethyl]-N,N',N'-trimethylethane-1,2-diamine, 2-[(2-(dimethylamino)ethyl)methylamino]ethanol, N',N'-dimethylpropane-1,3-diamine, N',N'-diethylpropane-1,3-diamine, 1-(2-aminoethyl)pyrrolidine, 1-(3-aminopropyl)pyrrolidine, 1-[3-(dimethylamino)propyl-(2-hydroxypropyl)amino]propan-2-ol, 2-[[3-(dimethylamino)propyl]methylamino]ethanol, 3-(2-dimethylamino)ethoxy)propylamine, N-[3-(dimethylamino)propyl]-N',N'-dimethylpropane-1,3-diamine, N'-[3-(dimethylamino)propyl]-N,N,N'-trimethylpropane-1,3-diamine, 1-[bis[3-(dimethylamino)propyl]amino]-2-propanol, N,N-bis[3-(dimethylamino)propyl]-N',N'-dimethylpropane-1,3-diamine, 1,4-diazabicyclo[2.2.2]octane, 1,4-diazabicyclo[2.2.2]octane-2-methanol, 1,2-dimethylimidazole, N-(2-hydroxypropyl)imidazole, 2-methyl-1-(2-methylpropyl)imidazole, N-(3-aminopropyl)imidazole, N-methylimidazole, 1-(3-aminopropyl)-2-methyl-1H-imidazole, N-ethylmorpholine, N-methylmorpholine, 2,2,4-trimethyl-2-silamorpholine, N-ethyl-2,2 -Dimethyl-2-silamorpholine, N-(2-aminoethyl)morpholine, N-(2-hydroxyethyl)morpholine, 2,2'-dimorpholinodiethyl ether, N,N'-dimethylpiperazine, N-(2-hydroxyethyl)piperazine, N-(2-aminoethyl)piperazine, N,N-dimethylbenzylamine, N,N-(dimethylamino)ethanol, N,N-(diethylamino)ethanol, 1-(2-hydroxyethyl)pyrrolidine, 3-dimethylamino-1-propanol, 1-(3-hydroxypropyl)pyrrolidine, 2-[2-(dimethylamino)ethoxy]ethanol, 2-[2-(diethylamino)ethoxy]ethanol, bis(2-dimethylaminoethyl)ether, 2-[[2-(2-(dimethylamino)ethoxy)ethyl]methylamino]ethanol, N-[2-[2-(dimethylamino)ethoxy]ethyl]-N-methyl Propane-1,3-diamine, 1,3,5-tris[3-(dimethylamino)propyl]hexahydro-1,3,5 triazine, 1,8-diazabicyclo[5.4.0]undec-7-ene, 1,5-diazabicyclo[4.3.0]non-5-ene, 1,5,7-triazabicyclo[4.4.0]dec-5-ene, N-methyl-1,5,7 triazabicyclo[4.4.0]dec-5-ene, 1,4,6 triazabicyclo[3.3.0]oct-4-ene, 1,1,3,3-tetramethylguanidine, 2-tertiary-butyl-1,1,3,3-tetramethylguanidine, guanidine, 1,1'-[(3-{bis[3-(dimethylamino)propyl]amino}propyl)imino]dipropan-2-ol, (3-aminopropyl)bis[3-(dimethylamino)propyl]amine, 3-(dimethylamino)propylurea, 1,3-bis[3-(dimethylamino)propyl]urea, 3-dimethylamino-N,N-dimethylpropanamide, 6-(dimethylamino)hexan-1-ol, and 2,4,6-tris[(dimethylamino)methyl]phenol.

[0107] Catalysts and / or mixtures of this kind are, for example, Jeffcat® ZF-10, Lupragen® DMEA, Lupragen® API, Toyocat® RX20 and Toyocat® RX21, DABCO® RP202, DABCO® RP204, DABCO® NE300, DABCO® NE310, DABCO® NE400, DABCO® NE500, DABCO® NE600, DABCO® NE650, DABCO® NE660, DABCO® NE700, DABCO® NE750, DABCO® NE760, DABCO® NE770, DABCO® NE780, DABCO® NE790, DABCO® NE800, DABCO® NE810, DABCO® NE820, DABCO® NE830, DABCO® NE840, DABCO® NE850, DABCO® NE860, DABCO® NE870, DABCO® NE880, DABCO® NE890, DABCO® NE900, DABCO® NE910, DABCO® NE920, DABCO® NE930, DABCO® NE940, DABCO® NE950, DABCO® NE960, DABCO® NE970, DABCO® NE980, DABCO® NE990, DABCO® NE100, DABCO® NE102, DABCO® NE104, DABCO® NE106, DABCO® NE108, DABCO® NE109, DABCO® NE101, DABCO® NE102, DABCO® NE103, DABCO® NE104, DABCO® and DABCO® NE2039, Niax® EF860, Niax® EF890, Niax® EF700, Niax® EF705, Niax® EF708, Niax® EF600, Niax® EF602, Kosmos® 54, Kosmos® EF, and Tegoamin® ZE1.

[0108] Metal compounds suitable as catalysts may be selected, for example, from the group consisting of metal-organic or organometallic compounds, metal-organic or organometallic salts, organometallic salts, inorganic metal salts, and from the group consisting of charged or uncharged metal-containing coordination compounds, in particular metal chelate complexes. The expression "metal-organic or organometallic compounds" in the context of the present invention particularly includes the use of metal compounds with direct carbon-metal bonds, also referred to herein as metal organyls (e.g. tin organyls) or organometallic compounds (e.g. organotin compounds). The expression "organometallic or metal-organic salts" in the context of the present invention particularly includes the use of metal-organic or organometallic compounds with salt properties, i.e. ionic compounds in which either the anion or the cation is essentially metal-organic (e.g. organotin oxides, organotin chlorides or organotin carboxylates). The expression "organometallic salt" in the context of embodiments of the present invention particularly includes the use of metal compounds that do not have a direct carbon-metal bond and are at the same time metal salts, either the anion or the cation being an organic compound (e.g., tin(II) carboxylate). The expression "inorganic metal salt" in the context of embodiments of the present invention particularly includes the use of metal compounds or metal salts, neither the anion nor the cation being an organic compound, such as metal chlorides (e.g., tin(II) chloride), pure metal oxides (e.g., tin oxide), or mixed metal oxides, i.e., multiple metals and / or metal silicates or aluminosilicates. The expression "coordination compounds" in the context of embodiments of the present invention particularly includes the use of metal compounds formed from one or more central particles and one or more ligands, the central particles being charged or uncharged metals (e.g., metal or tin-amine complexes). The expression "metal chelate complex" in the context of embodiments of the present invention specifically includes the use of metal coordination compounds having ligands that have at least two coordination or binding sites to the metal center (e.g., metal or tin-polyamine or metal or tin-polyether complexes).Suitable metal compounds as specifically defined above as catalysts in embodiments of the present invention may be selected from all metal compounds comprising, for example, lithium, sodium, potassium, magnesium, calcium, scandium, yttrium, titanium, zirconium, vanadium, niobium, chromium, molybdenum, tungsten, manganese, cobalt, nickel, copper, zinc, mercury, aluminium, gallium, indium, germanium, tin, lead and / or bismuth, in particular sodium, potassium, magnesium, calcium, titanium, zirconium, molybdenum, tungsten, zinc, aluminium, tin and / or bismuth, more preferably tin, bismuth, zinc and / or potassium.

[0109] Suitable metal-containing coordination compounds include any metal acetylacetonate, such as, for example, nickel(II) acetylacetonate, zinc(II) acetylacetonate, copper(II) acetylacetonate, molybdenum dioxoacetylacetonate, any iron acetylacetonate, any cobalt acetylacetonate, any zirconium acetylacetonate, any titanium acetylacetonate, any bismuth acetylacetonate, and any tin acetylacetonate. Particularly suitable metal-organic and organometallic salts, as defined above in particular as catalysts in the context of the present invention, are, for example, organotin, tin, zinc, bismuth and potassium salts, in particular the corresponding metal carboxylates, alkoxides, thiolates and mercaptoacetates, such as, for example, dibutyltin diacetate, dimethyltin dilaurate, dibutyltin dilaurate (DBTDL), dioctyltin dilaurate (DOTDL), dimethyltin dineodecanoate, dibutyltin dineodecanoate, dioctyltin dineodecanoate, dibutyltin dioleate, dibutyltin bis-n-lauryl mercaptide, dimethyltin bis-n-lauryl mercaptide, monomethyltin tris-2-ethylhexyl mercaptoacetate, dimethyltin bis-2-ethylhexyl mercaptoacetate, dibutyl ... dioctyltin bisisooctylmercaptoacetate, tin(II) acetate, tin(II) 2-ethylhexanoate (tin(II) octanoate), tin(II) isononanoate (tin(II) 3,5,5-trimethylhexanoate), tin(II) neodecanoate, tin(II) ricinoleate, zinc(II) acetate, zinc(II) 2-ethylhexanoate (zinc(II) octanoate), zinc(II) isononanoate ) (zinc(II) 3,5,5-trimethylhexanoate), zinc(II) neodecanoate, zinc(II) ricinoleate, bismuth acetate, bismuth 2-ethylhexanoate, bismuth octanoate, bismuth isononanoate, bismuth neodecanoate, potassium formate, potassium acetate, potassium 2-ethylhexanoate (potassium octanoate), potassium isononate, potassium neodecanoate, and / or potassium ricinoleate.Suitable metal catalysts are generally preferentially selected such that they are free of any inherent unpleasant odor, are substantially toxicologically unobjectionable, and impart the lowest possible levels of catalyst-induced emissions to the resulting polyurethane system, particularly polyurethane foam.

[0110] In addition to amines and metal compounds, it is also possible to use ammonium salts as catalysts, suitable examples being ammonium formate and / or ammonium acetate.

[0111] Suitable catalysts are described, for example, in DE 102007046860, EP 1985642, EP 1985644, EP 1977825, US 2008 / 0234402, EP 0656382 and US 2007 / 0282026, and in the patent documents cited therein.

[0112] The suitable amount of catalyst used depends on the type of catalyst, and is preferably in the range of 0.01 to 10.0 pphp, more preferably in the range of 0.02 to 5.00 pphp (=parts by weight per 100 parts by weight of polyol).

[0113] The optional additives used are all substances known in the prior art and used for the production of polyurethanes, in particular flexible PU foams, such as blowing agents, preferably water for the formation of CO2, and optionally further physical blowing agents, crosslinkers and chain extenders, stabilizers against oxidative degradation (called antioxidants), flame retardants, surfactants, biocides, cell refining additives, cell openers, solid fillers, antistatic additives, nucleating agents, thickeners, dyes, pigments, colour pastes, fragrances, emulsifiers, buffer substances and / or catalytically active substances, in particular those defined above.

[0114] Water is commonly used as a blowing agent in the production of flexible PU foams. It is preferable to use an amount of water such that the water concentration is 0.10 to 10.0 pphp (pphp = parts by weight per 100 parts by weight of polyol).

[0115] It is also possible to use suitable physical blowing agents, such as liquefied CO2 and volatile liquids, such as hydrocarbons with 3, 4 or 5 carbon atoms, preferably cyclopentane, isopentane and n-pentane, oxygen-containing compounds such as methyl formate, acetone and dimethoxymethane, or chlorinated hydrocarbons, preferably dichloromethane and 1,2-dichloroethane.

[0116] Apart from water and physical blowing agents, it is also possible to use other chemical blowing agents that react with isocyanates to generate gas, such as formic acid.

[0117] The optional crosslinker and optional chain extender are low molecular weight polyfunctional compounds that are reactive towards isocyanates. Suitable compounds are hydroxyl or amine terminated materials such as glycerol, neopentyl glycol, 2-methyl-1,3-propanediol, triethanolamine (TEOA), diethanolamine (DEOA), and trimethylolpropane. The concentration used is usually in the range of 0.1 to 5 parts per 100 parts polyol, but may deviate from this depending on the formulation.

[0118] Suitable optional stabilizers against oxidative degradation, so-called antioxidants, preferably include all commonly used free radical scavengers, peroxide scavengers, UV absorbers, light stabilizers, complexing agents for metal ion pollutants (metal deactivators). It is preferred to use compounds of the following classes of substances or compounds of the following classes of substances containing the following functional groups, the substituents on the respective parent molecules being preferably those bearing groups which are particularly reactive towards isocyanates, namely 2-(2'-hydroxyphenyl)benzotriazoles, 2-hydroxybenzophenones, benzoic acid and benzoates, phenols, especially those containing tertiary-butyl and / or methyl substituents on aromatic entities, benzofuranones, diarylamines, triazines, 2,2,6,6-tetramethylpiperidine, hydroxylamines, alkyl and aryl phosphites, sulfides, zinc carboxylates, diketones.

[0119] Suitable optional flame retardants in the context of the present embodiment are all substances that are considered suitable for this purpose by the prior art.Preferred flame retardants are, for example, liquid organic phosphorus compounds, such as halogen-free organic phosphates, for example, triethyl phosphate (TEP), halogenated phosphates, for example, tris(1-chloro-2-propyl)phosphate (TCPP) and tris(2-chloroethyl)phosphate (TCEP), and organic phosphonates, for example, dimethylmethane phosphonate (DMMP), dimethylpropane phosphonate (DMPP), or solids, for example, ammonium polyphosphate (APP) and red phosphorus.Suitable flame retardants also include halogenated compounds, for example, halogenated polyols, and solids, such as expandable graphite and melamine.

[0120] Due to the stabilization of the rising foam mixture and the influence on the foam properties of polyurethane foam, organomodified siloxanes are commonly used in the production of hot-cure flexible PU foams. Suitable (organically modified) siloxanes for this purpose are described by way of example in the following documents: EP 0839852, EP 1544235, DE 102004001408, EP 0839852, WO 2005 / 118668, US 20070072951, DE 2533074, EP 1537159, EP 533202, US 3933695, EP 0780414, DE 4239054, DE 4229402, EP 867465. These compounds may be prepared as described in the prior art. Suitable examples are described, for example, in US Pat. No. 4,147,847, EP Pat. No. 0,493,836, and US Pat. No. 4,855,379. Foam stabilizers for hot-cure flexible PU foams are characterized by large siloxane structures with more than 50 Si units and pendant polyethers. These foam stabilizers are also called polydialkylsiloxane-polyoxyalkylene copolymers. The structure of these compounds is preferred, for example, in which long-chain copolymers of ethylene oxide and propylene oxide are bonded to polydimethylsiloxane radicals. The bond between the polydialkylsiloxane and the polyether moiety may be via a Si-C bond or a Si-O-C bond. Structurally, the polyether or different polyethers may be bonded to the polydialkylsiloxane in terminal or lateral positions. The alkyl groups of the siloxane may be aliphatic, cycloaliphatic or aromatic. Methyl groups are quite particularly advantageous. The organomodified polydialkylsiloxanes may be linear or contain branches. Suitable stabilizers, in particular foam stabilizers, are described, inter alia, in US Patent Nos. 2,834,748, 2,917,480 and 3,629,308. The function of the foam stabilizer is to ensure the stability of the foaming reaction mixture.The contribution to foam stabilization correlates here with the siloxane chain length. Without foam stabilizers, collapse is observed and therefore no uniform foam is obtained. For some flexible PU foam types, which have high stability and therefore low tendency to collapse, it is also possible to use low molecular weight polyether siloxanes. These have siloxane chain lengths much shorter than 50. For example, for cold cure flexible PU foams or flexible foams based on polyester polyols, unmodified or modified short chain siloxanes are used. In contrast, when long chain and therefore powerful siloxane stabilizers are used, overstabilization and therefore shrinkage after foam production is observed in such foam types. The foam stabilizer may in principle be selected as desired in the context of the embodiments of the present invention.

[0121] The above compounds can be used, for example, with suitable solvents and / or further additives. As any solvent, it is possible to utilize all suitable substances known from the prior art. Depending on the application, it is possible to use aprotic non-polar, aprotic polar and protic solvents. Suitable aprotic non-polar solvents can be selected, for example, from the following classes of substances or classes of substances containing the following functional groups: aromatic hydrocarbons, aliphatic hydrocarbons (alkanes (paraffins) and olefins), carboxylic acid esters (e.g. isopropyl myristate, propylene glycol dioleate, decyl cocoate or other fatty acid esters) and polyesters, (poly)ethers, and / or halogenated hydrocarbons with low polarity. Suitable aprotic polar solvents can be selected, for example, from the following classes of substances or classes of substances containing the following functional groups: ketones, lactones, lactams, nitriles, carboxamides, sulfoxides, and / or sulfones. Suitable protic solvents can be selected, for example, from the following classes of substances or classes of substances containing the following functional groups: alcohols, polyols, (poly)alkylene glycols, amines, carboxylic acids, especially fatty acids, and / or primary and secondary amides. Solvents that are easily available in the foaming operation and do not adversely affect the foam properties are particularly preferred. For example, isocyanate-reactive compounds are suitable, since they are incorporated into the polymer matrix by reaction and do not produce any emissions in the foam.Examples are OH-functional compounds such as (poly)alkylene glycols, preferably monoethylene glycol (MEG or EG), diethylene glycol (DEG), triethylene glycol (TEG), 1,2-propylene glycol (PG), dipropylene glycol (DPG), trimethylene glycol (propane-1,3-diol, PDO), tetramethylene glycol (butanediol, BDO), butyl diglycol (BDG), neopentyl glycol, 2-methylpropane-1,3-diol (Ortegol CXT), and their higher homologues, such as polyethylene glycols (PEG) with an average molecular weight of 200 g / mol to 3000 g / mol. Particularly preferred OH-functional compounds further include polyethers having an average molecular weight of 200 g / mol to 4500 g / mol, in particular 400 g / mol to 2000 g / mol, among which preference is given to water-, allyl-, butyl- or nonyl-initiated polyethers, in particular those based on propylene oxide (PO) and / or ethylene oxide (EO) blocks.

[0122] In the production of flexible PU foams, it may be advantageous to prepare and / or use a composition comprising at least one polyol component, optionally at least one isocyanate component, and optionally one or more blowing agents, and to react this composition.

[0123] Flexible PU foams according to embodiments of the present invention can be produced by any continuous method well known to those skilled in the art, for example, by low-pressure or high-pressure foaming machines. The terms high-pressure or low-pressure refer to the pressure of the ingredients distributed to the mixhead. In high-pressure machines, pressures above 40 bar are used, and in low-pressure machines, pressures below 30 bar are used. To achieve these pressure ranges, different pumps and injection devices to the mixhead are utilized. Generally, the various liquid ingredient streams are pumped to the mixhead. In the mixhead, an agitator homogenizes the various ingredients, thus initiating the reaction. Also, gas can be added to the mixhead, for example, to assist in nucleation. The reaction mixture then leaves the mixhead and is either distributed directly onto a moving process liner, called liquid laydown technology, or fed into a trough where the already creaming reaction mixture then flows onto the process liner (trough or Maxfoam technology). The reaction mixture then expands vertically (if the main movement is horizontal). Here, foam expansion can occur in either the top or bottom direction, or both directions simultaneously. For foam expansion to the top, a flat horizontal conveyor is used. For foam expansion to the bottom, a fall plate system is used. The position of the fall plate resembles the foam's rise profile and needs to be precisely adjusted to avoid foam defects. This is the main problem to be solved by this invention. Once the foam reaches its full rise, blow-off is usually observed, and the foam changes from a closed-cell to an open-cell material. This is driven by the destabilization and rupture of membranes in the polyhedral structure. Cell opening is driven by phase separation processes in the material. The foam block settles slightly (settling) until the rapid viscosity increase due to the reaching of the gel point stabilizes the foam and turns it into a solid material that can no longer flow. The foam block is transported further in the tunnel to complete the chemical reaction. After a few meters, the tunnel ends and a saw cuts the continuously produced flexible foam into blocks. The length of these foam blocks is usually between 2 and 80 meters.The blocks are then transferred to a storage rack where the hot foam blocks are cooled and undergo the final hardening reaction. The temperature is usually as high as 140°C and the material has good insulating properties, over a period of 1-2 days. The foam blocks are then either transferred to a storage area or used directly in further manufacturing steps.

[0124] For the production of flexible PU foams it is possible to use any method known to a person skilled in the art, for example the foaming operation can be carried out either horizontally or vertically.

[0125] The compositions used according to the embodiments of the present invention can be used similarly with respect to liquid CO2 technology. Use in low and high pressure machines is possible. The raw material to be processed can be metered directly into the mixing chamber or can be mixed with one of the components entering the mixing chamber even before the mixing chamber. Mixing in the raw material tank is also possible.

[0126] Exemplary formulations for the production of hot cure flexible PU foam (flexible slabstock foam) as well as a comparison of the properties of flexible PU foam blocks produced by conventional processes and flexible PU foam blocks produced according to embodiments of the present disclosure are further described below in connection with Tables 1-3 and FIG. 7.

[0127] 1 illustrates a foam manufacturing machine 100 according to one embodiment of the present disclosure. The machine 100 includes a mix head 102, a plurality of inclined foam plates 104a, 104b, 104c, 104d, 104e, and a conveyor 106 configured to generate foam 137. The mix head 102 is configured to mix ingredients (e.g., precursor reagents) to form a reactive mixture 136. In one embodiment, the foam 137 is molded as a foam block 137, and in another embodiment, the foam block is a rectangular foam block.

[0128] In one embodiment, the precursor reagents are received by the mix head 102 via one or more delivery conduits, such as hoses 108. The conduits 108 may be connected to one or more storage vessels (not shown) that store the reagents under predetermined conditions, such as a predetermined pressure and / or temperature. The predetermined conditions may depend on the types and / or proportions of the reagents being mixed together and are commonly known to those of skill in the art.

[0129] In one embodiment, pour plate 110 receives mixed reagents (i.e., reactive mixture) from mix head 102. In one embodiment, mix head 102 is stationary as it dispenses reactive mixture 136 onto pour plate 110 via nozzles 103, where the reactive mixture spreads out to form a layer having a generally uniform height on pour plate 110. In another embodiment, mix head 102 is configured to move in lateral direction 112 as the reactive mixture is dispensed onto pour plate 110, thereby allowing the mixture to form a layer having a generally uniform height on pour plate 110.

[0130] In one embodiment, the transport medium 114 disposed on the pour plate 110 receives the mixed reagent from the mix head 102. In one embodiment, the transport medium 114 is a paper sheet, although the scope of the present invention encompasses other known media (e.g., impregnated paper, plastic, foil) that may be formed as a lamina or sheet used to receive the mixed reagent. The transport medium 114 is pulled across the pour plate 110, the inclined fall plate 104, and the conveyor 106 by the movement of the conveyor 106. For example, the manufacturing machine 100 may be initialized by feeding the transport medium 114 (e.g., a paper sheet) from the transport medium supply 116 across the pour plate 110 and the inclined fall plate 104 for attachment to the conveyor 106. In one embodiment, the conveyor 106 may be a conveyor belt configured to connect with the transport medium 114 either by frictional forces or mechanically (e.g., via surface protrusions (not shown) of the conveyor belt, such as hooks). The conveyor belt 106 may have an adjustable speed for pulling the transport medium 114 and the reactive mixture disposed on the transport medium 114 at an adjustable speed. In one embodiment, the conveyor belt 106 is disposed substantially horizontally as shown. As shown, the transport medium 114 is disposed between the bottom surface 135 of the reactive mixture 136 on the inclined fall plate 104 and the conveyor 106.

[0131] In one embodiment, the first inclined fall plate 104a is configured to receive the reactive mixture from the pour plate 110 as the transport medium 114 holding the reactive mixture is pulled across the fall plates 104 by the action (i.e., movement) of the conveyor 106. For ease of illustration, five inclined fall plates 104 are shown, although the scope of the present disclosure covers any number of inclined fall plates.

[0132] In one embodiment, each inclined fall plate 104 has two ends (i.e., a proximal end 118 and a distal end 120). Each end of each inclined fall plate 104 is vertically adjustable. In one embodiment, each end of each inclined fall plate 104 is configured to be removably attached to an inclined fall plate framework (not shown) to secure each end in a respective vertical position.

[0133] In another embodiment, each end 118, 120 is rotatably connected to a vertically adjustable pivot 122 to position each end at a respective vertical position. When the vertical positions of the two adjacent pivots 122 are selected, the vertical positions of the two ends 118, 120 of the inclined fall plate 104 that connect to the two adjacent pivots 122 are also determined, and thus the slope of the inclined fall plate is determined. For example, the vertical position of the first pivot 122a may be set so that the proximal end 118a of the first inclined fall plate 104a connected to the first pivot 122a is at the same height as the pour plate 110 (i.e., at the same vertical height of the pour plate 110). Then, the slope of the first inclined fall plate 104a may be determined by setting the vertical position of the second pivot 122b, taking into account the length of the first inclined fall plate 104a. The slope of the first fall plate is the rise / transition, which is the difference between the vertical positions of the first and second pivot axes divided by the square root of the length of the plate minus the square of the difference in the vertical positions of the first and second pivot axes.

[0134] Although the vertical position of first pivot axis 122a is shown to coincide with the vertical position of pour plate 110, the scope of the present invention includes a vertical position of first pivot axis 122a that is below the vertical position of pour plate 110, thereby forming a vertical gap (or drop) between proximal end 118a of first inclined fall plate 104a and pour plate 110.

[0135] In one embodiment, the machine 100 having n inclined fall plates has n pivots, with n=5 as shown. The scope of the present disclosure encompasses any number n of inclined fall plates 104 and pivots 122. In the embodiment as shown, the ends of adjacent inclined fall plates share a pivot (i.e., are connected to the same pivot). For example, the distal end 122a of the first inclined fall plate 104a and the proximal end 118b of the second inclined fall plate 104b are rotatably connected to a vertically adjustable second pivot 122b, such that there is no vertical gap between the distal end 122a of the first inclined fall plate 104a and the proximal end 118b of the second inclined fall plate.

[0136] However, the scope of the present disclosure encompasses an embodiment having n inclined fall plates and 2(n-1)+1 pivot axes. In this embodiment (not shown), the distal and proximal ends of each inclined fall plate are rotatably connected to two respective vertically adjustable pivot axes, such that a vertical gap between the distal and proximal ends of two adjacent inclined fall plates may be formed by adjusting the respective pivot axes connected to the distal and proximal ends of the two adjacent inclined fall plates to have different vertical positions.

[0137] As shown, in one embodiment, the conveyor 106 is configured to receive the reactive mixture from the final inclined fall plate 104e when the transport medium 114 holding the reactive mixture is pulled across the final inclined fall plate 104e and onto the conveyor 106 by the action (i.e., movement) of the conveyor 106.

[0138] 2 illustrates a method 200 for determining machine parameters of a foam making machine according to one embodiment of the present disclosure. The method covers machine parameters of foam making machine 100 and machine parameters of foam making machine 400. Foam making machine 400 is further described below in connection with FIG.

[0139] In step 202, two or more precursor reagents are mixed together to form a reactive mixture, also referred to as a lab-based reactive mixture. In one embodiment, two or more precursor reagents are mixed together in a container (FIG. 5) to form a reactive mixture. The container is external to the foam-making machine 100 and is not a component of the foam-making machine. In another embodiment, two or more precursor reagents are mixed together in a separate container, such as a paper cup or beaker, and then the mixed reagents are poured into the container (FIG. 5). In one embodiment, the precursor reagents include at least one liquid polymer and at least one catalyst. In another embodiment, the at least one liquid polymer includes at least one liquid polyurethane. In other embodiments, the precursor reagents include embodiments of the above combinations of reagents along with the flexible PU foam.

[0140] In step 204, the height of the top surface of the laboratory-based reactive mixture in the vessel is measured over time, and the height of the top surface as a function of time is defined as a rise profile. The rise profile may include pairs of height and time data, with any given pair of data including the measured height of the reactive mixture and the time at which the height was measured. In one embodiment, the time is measured relative to when the precursor reagents are mixed together. In another embodiment, the time is measured relative to when creaming first occurs.

[0141] In one embodiment, the rise profile is the height of the mixture measured in a laboratory as the precursor reagents react to form a foam. The height of the mixture is measured in a laboratory at different times after mixing the reagents together. The measurements are taken when the reactive mixture changes from a liquid mixture to a cloudy liquid mixture and foam, or in other words, when the mixture passes the creaming point and the blow-off point. The creaming time is the time it takes from the initial stage of mixing of the ingredients until the volume expansion of the reactive mixture begins due to the formation of gas that converts the liquid reaction mixture to foam. In other words, the creaming time is the length of time measured from the initial mixing of the precursor reagents to start the volume expansion. Creaming points, creaming times, and blow-off points are generally known to those skilled in the art and will not be described in further detail.

[0142] In one embodiment, the vessel is stationary; that is, in contrast to processing the reactive mixture through a foam-making machine, where the reactive mixture is transported through the machine via the action of a conveyor or other transport means, the reactive mixture is fed into a stationary vessel that is not a component of the foam-making machine, and the reactive mixture reacts to produce foam within the stationary vessel. In another embodiment, movement of the reactive mixture relative to the vessel includes only movement of the top surface of the mixture as the height of the top surface increases or expands upwardly when the mixture is converted into foam.

[0143] In one embodiment, a laser beam is used to measure the height of the top surface of a laboratory-based reactive mixture in a container at different times, however, the scope of this disclosure includes other conventionally known methods of measuring the surface of a liquid and / or foam mixture in a container as the top surface height increases.

[0144] In one embodiment, steps 202 and 204 comprise a discontinuous box foaming procedure (also called discontinuous container foaming procedure, e.g., performed in a container (FIG. 5)) for measuring the rise profile of the flexible foam formulation. The raw materials are stored in a climate cabinet at the temperature intended to be used in the actual slabstock foam production. In case of different temperatures of the various raw materials in the actual slabstock foam production, in the laboratory, the average temperature was used for the pretreatment of the raw materials. The raw materials were then weighed into paper cups. Only the TDI (i.e., tolylene diisocyanate) was left and added later just before the final mix. The amount of raw materials was calculated to completely fill the box after foaming. In addition to matching the temperature of the precursor reagents in the container to the temperature of the same precursor reagents in the foam making machine and / or matching the ambient temperature of the container to the ambient temperature in the foam making machine, other environmental conditions in the laboratory, represented by environmental parameters such as ambient pressure and ambient humidity, may also be adjusted or selected to match the corresponding environmental conditions in the respective foam making machine for which the machine parameters are to be determined. Matching the environmental conditions includes substantially matching one or more environmental parameters including one or more of the temperature of the precursor reagents (i.e., feedstocks), the ambient temperature, the ambient pressure, and / or the ambient humidity.

[0145] Mixing was done in a paper cup filled with the ingredients (TDI was added last, with the stirrer stopped). After mixing, the reaction mixture was poured into a box. The box is a square box made of insulating rigid polyurethane foam with a thickness of 1 cm. The rigid foam plates are glued together on the outside to form the box by adhesive tape.

[0146] Inside the box, a process liner (FIG. 5), used in large-scale continuous production of flexible slabstock foam, was used to separate the box from the liquid reaction mixture. That is, the process liner lines the inside of the box; in commercial foam-making machines, the process liner receives the reactive solution, slides over the fall plate, and may extend over the sidewall of the fall plate. The scope of the present invention covers process liners that are composed of any material that reduces friction between the wall of the box and the sidewall of the fall plate. The process liner can be, for example, paper, impregnated paper, PE-coated paper, and the like. Impregnated paper is a sheet that has liquid-retaining properties and is well known in the industry. It is usually made from wood pulp and natural cotton linters. Materials such as plastic or latex are used to percolate the paper rather than coat it to increase its tear resistance, wet strength, and oil resistance. Based on the type of resin, the impregnated paper market can be segmented into phenolic, melamine, and urea.

[0147] According to an embodiment, the process liner of the box (i.e., the container) is the same as the process liner of the foam making machine (referred to as the conveying medium 114) of the method 200 in order to obtain high accuracy between the rise profile measured from the discontinuous foam process in the laboratory container and the true rise profile of the continuous foam process of the foam making machine. Conventional laboratory boxes used to measure the properties of the reactive mixtures do not use industrial flexible foaming process liners. For example, in one embodiment, the chemical composition of at least the surface of the conveying medium 114 of the foam making machine is matched to the chemical composition of at least the surface of the process liner used to generate the rise profile stored in the database, the surface being the surface that contacts the respective reactive mixture. The scope of the present invention also covers process liners integrated into the side and / or bottom panels of the laboratory container, as well as side and / or bottom panels that are composed of a material or composition of materials that function as a process liner. For example, at least the surface of the side and / or bottom panels may be composed of a process liner material, such as plastic or latex (e.g., PE), and / or paper, impregnated paper. Impregnated paper is a sheet with excellent water absorption and liquid retention properties and is well known in the industry. It is usually made from wood pulp and natural cotton linters. Materials such as plastic or latex are used to percolate the paper rather than coat it to increase its tear resistance and wet strength.

[0148] The process liner was folded and stapled into the box. The process liner comprises a layer of tough, tear-resistant brown paper covered with a plastic film. The plastic film prevents penetration of liquid ingredients into the paper and can be made from a variety of thermoplastic polymers such as polyolefins (PE, PP) or polyester. The paper itself provides strength for the reaction mixture and transport of the formed foam block. The process liner may be used in commercial flexible foam slabstock production.

[0149] In one embodiment, the box has dimensions of 30 cm x 30 cm x 30 cm and is open at the top. On top of the box is a height measuring device that continuously records the height of the reaction mixture in the box. In this procedure, as the mixed ingredients are poured into the box, the height recording begins. The rise curve can be recorded and displayed.

[0150] In step 206, steps 202 and 204 are repeated to create two or more rise profiles for different combinations and / or different ratios of reactive reagents and / or under one or more different external conditions, such as different ambient temperatures and / or pressures. Each rise profile corresponds to a particular combination of reactive reagents that react with each other under a particular set of ambient environmental conditions. In one embodiment, steps 202 and 204 are performed under environmental conditions that match the environmental conditions in which the foam-making machine is operated. For example, ambient pressure, ambient temperature, ambient humidity and / or reactive reagent temperature are some of the environmental parameters that may be matched.

[0151] In step 208, one or more climb profiles are stored in a database.

[0152] In step 210, the database is accessed by a computer system 600 (FIG. 6) to read (also referred to as import) a ramp-up profile for a particular reactive mixture of a particular precursor reagent. In one embodiment, the computer system is a conventional computer system including at least one processor configured to execute software for reading the ramp-up profile. According to one embodiment, a user of the computer system may define the components and / or ratios of components of the reactive mixture, as well as other parameters that affect the reaction rate of the reactive mixture, such as the temperature and / or pressure at which the reaction occurs, and in response, the processor reads (or imports) a profile from the database that corresponds to the parameters defined by the user. In one embodiment, the processor, upon executing the software, queries the user for input parameters.

[0153] Alternatively, upon first execution of the software, the computer system may authenticate the user, and upon authentication, the processor reads (or imports) the lift profile from the database based on a user profile stored in the database. The user profile may include reagents or reactive mixtures previously used or purchased by the user. In one embodiment, the user indicates which lift profile to import from the lift profiles associated with the user and stored in the database.

[0154] In step 212, the vertical position of the end of each inclined fall plate (e.g., vertical position of the pivot axis) and the conveyor speed (e.g., conveyor belt speed) are calculated by the software executed by the computer system based on the imported rise profile, resulting in a predetermined predicted profile of the reactive mixture on the multiple inclined fall plates as the reactive mixture is conveyed along the multiple inclined fall plates. As described above in connection with FIG. 1, the reactive mixture may be conveyed along the multiple inclined fall plates as the conveying medium on which the reactive mixture is disposed is conveyed along the multiple inclined fall plates via the action of the conveyor that pulls the conveying medium across the pour plate and the inclined fall plates.

[0155] In one embodiment, the software includes an algorithm that selects a conveyor speed within the range of conventional conveyor belt speeds for the foam-making machine (e.g., a conveyor belt speed equal to the speed at which the reactive mixture is transported along both the pour plate and the inclined fall plate) and determines the vertical position of the end of each inclined fall plate (e.g., the vertical position of the pivot axis corresponding to the vertical position of the end of each fall plate) such that the change in height of the reactive mixture on any one particular inclined fall plate over the time interval that the reactive mixture is on the particular inclined fall plate is at least partially offset by the decrease in vertical height due to the slope of the particular inclined fall plate.

[0156] As an example, if the conveyor belt speed is Vx, where x is the horizontal direction, the velocity of the mixture on the inclined fall plate in the y direction is the slope of the inclined fall plate multiplied by Vx. In one embodiment, the algorithm selects the vertical position of the end of the inclined fall plate (i.e., selects the slope of the inclined fall plate) such that the product of the time interval the mixture is on the inclined fall plate and the velocity of the mixture on the inclined fall plate Vy is equal to the change in height of the reactive mixture during this time interval given by the rise profile. The time the mixture is on any particular inclined fall plate is the length of the fall plate divided by the velocity of the mixture on the fall plate (i.e., sqrt(Vx2+Vy2)). By equating the change in height of the reactive mixture during the time interval the reactive mixture is on each of the inclined fall plates to the change in vertical height between the end points of each of the respective inclined fall plates, a predetermined predicted profile may be obtained for the reactive mixture across all of the inclined fall plates. In the particular embodiment described above, the predetermined predicted profile has a substantially flat horizontal profile (i.e., a substantially flat horizontal upper surface).

[0157] However, in a preferred embodiment, the vertical position of the end of each inclined fall plate (e.g., vertical position of the pivot axis) and the conveyor speed (e.g., conveyor belt speed) are calculated by software executed by the computer system based on the imported rise profile, resulting in a predetermined predicted profile of the reactive mixture on a plurality of inclined fall plates having substantially flat inclined upper surfaces.

[0158] 3 illustrates a predetermined predicted profile 302 of a reactive mixture on a plurality of inclined fall plates 104 having a substantially flat inclined upper surface 304, according to one embodiment of the present disclosure. As illustrated, the substantially flat upper surface 304 of the reactive mixture on the plurality of inclined fall plates 104 is approximately equal to arctan[(height of the foam 137 above the conveyor h fx) / (horizontal length of multiple inclined fall plates d)]=arctan[(x·h f In a preferred embodiment, x is about 1 / 3, so x h f is equal to about 1 / 3 of the height of the foam 137 on the conveyor 106. The inventors have surprisingly discovered that using the imported rise profile to calculate the location of the vertical position of the end of the inclined fall plate and the conveyor speed results in a predicted rise profile with a positive slope angle (i.e., not zero), and more specifically, a foam 137 on the conveyor having a substantially flat (i.e., not domed) top surface 306 based on a positive slope angle on the reactive mixture 136 rising about 30% while being conveyed across the multiple inclined fall plates. Angle α is defined as the angle formed between a horizontal plane including a horizontal line 308 and the inclined top surface 304. A vertical plane including a vertical line 310 is defined as a vertical plane passing through the end portion 120e of the inclined fall plate 104e.

[0159] In one embodiment, the user selects the conveyor speed and / or the number of inclined fall plates 104 and / or the length of the inclined fall plates 104 and / or the position of the creaming line 132 (through adjustment of the length dimension of the pour plate 110 and / or the size of the trough 123 (e.g., trough volume) and / or the position of the trough side trough flip 130 relative to the trough bottom surface 126, as described in connection with FIG. 3 below) so that the reactive mixture rises approximately 30% as it is conveyed across the multiple inclined fall plates. The vertical position of the end of each inclined fall plate (e.g., vertical position of the pivot axis) given the conveyor speed selected as described above is calculated based on the imported rise profile by software executed by the computer system, resulting in a predetermined predicted profile of the reactive mixture on the multiple inclined fall plates having a substantially flat upper surface with an inclination angle α.

[0160] 4 illustrates a foam-making machine 400 according to another embodiment of the present disclosure. Reference numbers of the foam-making machine 400 that are the same as those of the foam-making machine 100 refer to similar components. As shown, the foam-making machine 400 does not include the pour plate 110 of the machine 100, but instead includes a trough 123. In this embodiment, the trough has a bottom surface 126 that includes an input port 127 configured to receive the reactive mixture from the mixhead through the mixhead and into the trough conduit 124 (MTT conduit 124). The trough also includes a side surface 128 and a side lip 130 through which the reactive mixture 136 flows onto the proximal end 118a of the first inclined fall plate 104a. That is, the first inclined fall plate is configured to receive the reactive mixture from the trough.

[0161] As shown, depending on the dimensions of the trough 123 (e.g., the volume of the trough), the flow rate of the mixture into the trough 123 through the input port 127, and the time it takes for the mixture to travel from the mixhead 102 to the trough 123 via the MTT conduit 124 (collectively the mixhead / trough parameters), the creaming line 132 will be located somewhere within the trough 123. In one embodiment, the mixhead / trough parameters are selected to provide a creaming line 132 located approximately ⅔ of the distance between the bottom surface 126 of the trough 123 and the top surface of the reactive mixture in the trough 123, which coincides with the lip 130 of the trough 123. Additionally, in another embodiment, the conveyor speed, as well as the number of inclined fall plates and / or the length of each inclined fall plate are selected, and in some embodiments, the mixhead / trough parameters are selected to provide a blow line 134 located somewhere above the conveyor, as shown. In order to obtain a foam 137 disposed on the conveyor 106 having a predicted profile with a substantially flat surface, or preferably a substantially flat inclined surface, it may be important to not only select the vertical position of each end of the inclined fall plates (or, in some embodiments, the vertical position of the pivot axis) and the conveyor speed based on the imported rise profile, but also to select one or more of the number of inclined fall plates and / or the length of each fall plate, the conveyor speed and / or the mixing head / trough parameters to provide a blow line 134 located somewhere above the conveyor 106 and a creaming point 132 located approximately 2 / 3 of the distance between the bottom surface 126 of the trough 123 and the top surface of the reactive mixture in the trough 123 (i.e., the vertical position of the lip 130).

[0162] Referring back to FIG. 2, step 212 may further include calculating, by software executed by the computer system, a vertical position of the end of each inclined fall plate and a conveyor belt speed based on the imported rise profile and further based on one or more of the vertical position of the lip 130 of the trough 123 relative to the vertical position of the proximal end 118a of the first inclined fall plate 104a and the size of the trough 123 defined by the length between the bottom surface 126 of the trough 123 and the lip 130 of the trough 123, which will result in a substantially horizontal or inclined predetermined predicted profile of the reactive mixture on the multiple inclined fall plates 104 when the reactive mixture is transported along the multiple inclined fall plates 104.

[0163] In optional step 214, the user is prompted to adjust one or more of the vertical positions of the end portions 118, 120 of the inclined fall plate 104, or the vertical position of the pivot axis 122 (corresponding to the vertical positions of the respective end portions 118, 120 of the inclined fall plate 104), and / or the conveyor speed initially determined or selected by the software to adjust the predicted profile of the reactive mixture on the inclined fall plate 104 and / or the conveyor 106. For example, if the machine settings initially determined by the software do not result in the machine 100,400 producing a foam 137 having a substantially flat top surface above the conveyor 106, or if the user wishes to adjust the predicted profile of the mixture to have a profile that does not have a substantially flat top surface above the inclined fall plate in order to achieve a substantially flat top surface of the foam 137 above the conveyor 106, the user may input or otherwise change one or more of the vertical positions of the end portions 118,120 of the inclined fall plate 104, or the vertical position of the pivot 122 (corresponding to the vertical positions of the respective end portions 118,120 of the inclined fall plate 104), and / or the conveyor speed initially selected / determined by the software. Upon accepting the user input, the software calculates a new predicted profile of the reactive mixture above the inclined fall plate 104 based on the imported rise profile and the user input.

[0164] In another embodiment of the present disclosure, the computer system 600 (FIG. 6) further includes a network and a cloud server, the cloud server including at least one processor and a cloud database. In one embodiment, the processor running the software is a component of the cloud server. A user may have an account with the cloud server.

[0165] In optional step 216, a user of the computer system logs into the cloud server, and in response, the cloud server grants the user access to the cloud server based at least on the user profile stored in the cloud database, and the cloud server executes the software.

[0166] In optional step 218, the processor of the cloud server automatically reads (or imports) the rise profile of the precursor reagent reactive mixture from the cloud database, for example, based on a user profile stored in the cloud database. In one embodiment, the user profile includes at least one purchase information of the precursor reagent of the reactive mixture.

[0167] In optional step 220, user purchase information for the one or more precursor reagents is obtained by scanning a machine readable code associated with at least one of the precursor reagents upon delivery of the one or more precursor reagents to the user. In one embodiment, referring back to optional step 218, the processor of the cloud server automatically reads (or imports) an elevation profile of the reactive mixture of precursor reagents from the cloud database based on the machine readable code scanned in optional step 220.

[0168] According to a further embodiment of the present disclosure, the foam making machine 100,400 further includes a machine control unit 138 (see FIG. 4). The machine control unit 138 includes at least one machine processor 140, controller software 142, a memory 144 configured to store the controller software 142, and an actuator unit 146 including one or more actuators (not shown) for controlling settings of the foam making machine 100,400. For example, the one or more actuators may control (e.g., adjust or initialize) one or more of the vertical position of each end of the inclined fall plate, the flow rate of the mixture from the mix head 102 to the pour plate 110 or trough 123, and the speed of the conveyor 106. The actuators are commonly known and may include pneumatic or electrical control elements that adjust the position and speed of the components of the machine 100,400.

[0169] 2, the method 200 may optionally include step 222. In optional step 222, the processor outputs the calculated vertical position of the end of each inclined fall plate and the conveyor belt speed, the at least one machine processor 140 executes the controller software 142, the at least one machine processor 140 receives the calculated and output vertical position of the end of each inclined fall plate and the conveyor belt speed, and the actuation unit 146 sets parameters of the foam making machine 100,400 for making foam blocks. Setting the parameters includes both initially setting the parameters of the machine 100,400 and adjusting the parameters of the machine 100,400 to have different values.

[0170] FIG. 5 shows a container 500 according to one embodiment of the present disclosure. The container 500 has four side walls 502 and a bottom 504. The side walls 502 and bottom 504 are covered by a process liner 506 as described above. Although the container as shown is shaped as a box, the scope of the present invention includes any polygonal container, preferably without a top or lid. The characteristics of the container 500 have been described above. For example, the container 500 may be an insulated box, or other polygonal shaped container. In one embodiment, the side walls 502 and / or bottom 504 are made of rigid foam insulation plate and may have a thickness of, for example, 1 cm. In another embodiment, the process liner 506 is integrated into the side walls 502 and / or bottom 504.

[0171] 6 illustrates a computer system 600 according to one embodiment of the present disclosure. The computer system 600 includes at least one processor 602 and a database 604. In another embodiment, the computer system 600 further includes a network 606, a cloud server 608. The cloud server 608 may also include a cloud database 610. In one embodiment, the cloud server optionally includes at least one processor 602.

[0172] A computer system, such as computer system 600, typically includes a variety of computer system readable media. Such media may be any available media that can be accessed by the computer system and includes both volatile and nonvolatile media, removable and non-removable media.

[0173] For purposes of the description of embodiments of the present disclosure, the reactive mixture 136 (FIGS. 1, 3, and 4) is continuously transformed from a liquid state to a solid state via chemical reactions as it is conveyed along the fall plate and conveyor, and thus reactive mixture refers to the mixture produced after the initial mixing of the precursor reagents up to the blow-off point (also called the blow-off line). The mixture between these points has at least partially developed into a foam, but for purposes of the present disclosure, the term foam refers to foam 137 that is on the conveyor after the blow-off line. Foam 137 is also called slabstock foam.

[0174] Properties of flexible PU foam blocks made by conventional and innovative processes according to embodiments of the present disclosure. [Table 1] 1) Polyol 1: VORANOL® CP3322 available from Dow Chemical, a glycerol-based polyether polyol with an OH number of 48 mg KOH / g and predominantly secondary OH groups, average molar mass=3500 g / mol. 2) KOSMOS® T9 available from Evonik Industries: a tin(II) salt of 2-ethylhexanoic acid. 3) DABCO® 33LV: Diazabicyclooctane 33% dissolved in dipropylene glycol, available from Evonik Operations. A standard amine catalyst for producing polyurethane foams. 4) Foam stabilizer TEGOSTAB® BF2370 available from Evonik Operations. 5) Tolylene diisocyanate TDI80 (80% 2,4 isomer, 20% 2,6 isomer), from Covestro, 3 mPa·s, 48% NCO, functionality 2.

[0175] Methods for characterization of PU foam samples: The produced flexible PU foams may be evaluated according to the following physical properties a) to g): a) Rise time: the time between the end of mixing of the reactive components and the blow-off of the polyurethane foam. Rise time can also be measured from the first moment of volume expansion (end of creaming time). The scope of the embodiments herein covers rise times measured from the initial mixing of the reactive components as well as rise times measured from the creaming time.

[0176] b) Maximum Rise Height: The maximum height of the free rise foam. Foam height is reported in centimeters (cm).

[0177] c) Settling of the foam at the end of the rising phase (=fallback): Settling is determined from the difference in foam height directly after blow-off and 3 minutes after foam blow-off. The foam height is measured at the maximum in the middle of the foam pile by means of a needle fixed on a centimeter scale. Here, negative values ​​represent settling of the foam after blow-off and positive values ​​represent correspondingly further rise of the foam.

[0178] d) Number of bubbles per cm (bubble count): This is determined visually on a cut surface (measured in accordance with DIN EN 15702).

[0179] e) Foam Density (FD): Determined by measuring the core density as described in ASTM D 3574-11 under test A. Foam density is kg / m 3 In the case of full-scale industrial blocks, it is common to measure foam density in three locations (top-middle-bottom) since density usually shows a gradient within the foam block. Therefore, the density spread across the block is an important quality criterion. In the case of laboratory box foaming, the exact center of the test block is used to measure foam density.

[0180] f) Porosity determined by the flow method: In the air flow method according to ASTM D 3574 (2011-00), the volume of air flowing through a defined foam specimen in a specific period of time upon application of a pressure difference is determined. For this purpose, three specimens with dimensions of 5 cm x 5 cm x 2.5 cm were cut from each of the finished foams transversely to the direction of foam rise and inserted successively into an analytical instrument built for this method. The construction of this instrument is described in ASTM D 3574 (2011-00). The analytical instrument creates a pressure difference of 125 Pa between the interior of the instrument and the surrounding atmosphere by drawing enough air through the specimen to keep the difference constant. The air flow through the specimen is therefore a measure of the porosity of the foam. Values ​​ranging from 0 to 6.5 scfm (standard cubic feet per minute) are measured, with lower values ​​in the interval characterizing closed foams and higher values ​​characterizing open foams.

[0181] g) Foam hardness was determined by cutting a 10 cm cube from the foam sample and performing a compression experiment according to DIN EN ISO 3386-1:2015-10. The pressure value at 40% compression was taken as CLD40 (kPa). For full-scale industrial blocks it is common to measure foam hardness in three positions (top-middle-bottom) since the hardness usually shows a gradient within the foam block. The hardness spread over the whole block is therefore an important quality criterion. For laboratory box foaming, the exact center of the test block is used to measure the foam hardness.

[0182] h) Creaming time: The time between the end of mixing of the reactants and the beginning of the volume expansion of the reaction mixture.

[0183] For completeness, the measurement principle of DIN EN ISO 16000-9:2008-04 is also explained below.

[0184] 400 g of polyol was used in each box foam run and other formulation ingredients were recalculated accordingly, e.g., 1.00 part of the ingredient shown for 1.00 g of this material per 100 g of polyol.

[0185] The foaming was carried out by so-called manual mixing. Formulation 1 shown in Table 1 was used. All raw materials were preconditioned to the temperature relevant for the actual production. In this example, 21°C was used. A paper cup was filled with the polyol, the respective amine catalyst mixture, the tin catalyst tin(II) 2-ethylhexanoate, water and foam stabilizer and mixed with a disk stirrer at 1000 rpm for 60 seconds. After the first stirring, the isocyanate (TDI) was added to the reaction mixture, stirred at 2500 rpm for 7 seconds and then immediately transferred to a box lined with a process liner (base area 30 cm x 30 cm and height 30 cm). The box is made from a rigid foam insulation plate 1 cm thick. The process liner was the same as that used in the subsequent industrial tests (Olmo paper by Mondi).

[0186] After injection, the foam was allowed to rise in the foaming box. In the ideal case, the foam was blown off when it reached the maximum rise height and then fell back slightly. The foam height was recorded during the foam rise by an ultrasonic height measuring device. To evaluate the properties of the obtained foam, the characteristic parameters of rise time, rise height and foam fallback (=settling) after the end of the rise phase were determined.

[0187] Results of discontinuous foaming Rise time including creaming time: 100 seconds Creaming time: 14 seconds Rise time without creaming: 86 seconds Maximum foam height: 30.51cm Settling: 0.12cm Number of bubbles per cm: 11 Foam density: 25.5kg / m 3 Air permeability: 3.1scfm Hardness, CLD40: 4.1kPa

[0188] The recorded rise time, including creaming time, was 100 s (86 s without creaming time), and the time-resolved foam height data was exported at intervals from 1 s to 300 s. The absolute heights were then recalculated to relative heights by dividing by the maximum height. The rise profile with relative heights was exported to the simulation software.

[0189] Data processing and development of optimized machine settings Industrial tests were then planned on an FB-20 5-section fall plate foam machine manufactured by LaaderBerg Aps, 6013 Langrabben 14, Ålesund, Norway. The machine was used without a flat top processing unit. The machine uses a trough and five fall plates. In these tests, three blocks were produced in subsequent runs. The blocks are produced from the same formulation (i.e., Formulation 1 as shown above). Various processing conditions were adjusted between runs.

[0190] The machine has the following overall dimensions and certain settings: Trough volume: 80 L (for all trials) Height of trough above conveyor: 66 cm (2 / 3 of block height for all trials) Fall plate 1 length: 175cm Fall plate 2 length: 60cm Fall plate 3 length: 120cm Fall plate 4 length: 120cm Fall plate 5 length: 85cm

[0191] The total length of the entire fall plate system is 5.60 m. Standard process liners (OLMO paper by Mondi Coatings GmbH, Marxergasse 4A, 1030 Vienna, Austria) were used to cover the conveyor and the sides. The temperature of all raw materials was 21 °C. All additional parameters like gas injection (for nucleation) in the mix head or pump settings were kept constant during the test. The target block height directly at the end of the production tunnel was 1.00 m. The width of the conveyor was 2.10 m, allowing to cut mattresses of 2.00 m length after cooling and hardening.

[0192] The total length of the entire fall plate system is 5.60 m. Standard process liners (OLMO paper by Mondi Coatings GmbH, Marxergasse 4A, 1030 Vienna, Austria) were used to cover the conveyor and the sides. The temperature of all raw materials was 21 °C. All additional parameters like gas injection (for nucleation) in the mix head or pump settings were kept constant during the test. The target block height directly at the end of the production tunnel was 1.00 m. The width of the conveyor was 2.10 m, allowing to cut mattresses of 2.00 m length after cooling and hardening.

[0193] For the tests, machine parameters were determined (i.e., optimized) based on a) calculated rise profiles, b) experimental rise profiles generated in discontinuous box foam tests, and c) parameters empirically established over the years by flexible foam manufacturers. Scenarios a) and c) represent the conventional procedure, while b) represents the inventive procedure according to an embodiment of the present disclosure.

[0194] For the simulation of the correct machine parameters, the rise profile was loaded into the software, which converts the time-resolved expansion curve of the rise profile into a distance-resolved expansion curve of the fall plate system and the top of the subsequent conveyor system. An expansion of 2 / 3 at the bottom and 1 / 3 at the top was considered ideal. Furthermore, by choosing different conveyor speeds, the blow-off position was placed about 0.5 m after the end of the last fall plate. The power coefficient was selected to result in a foam height of about 1.00 m after expansion. The calculation of the rise profile for scenario a) was done by assuming that the foam expansion always follows an S-curve: a slow start when the reaction mixture is cold - a fast expansion when the reaction mixture warms up - a final speed drop when a particular ingredient becomes low in concentration and the increase in viscosity reduces its reactivity. The S-curve was symmetrical with respect to a gradient reversal point located exactly in the middle. To determine the rise time, a set of parameters was developed that shows the influence of various individual ingredients on the rise time. These parameters were determined in foaming tests, by the variation of the focus of the ingredients, and by plotting the rise time in a double logarithmic diagram against the concentration. The slope defines a parameter and is used in the exponential function to calculate the ingredient contribution to the rise time. By summing the contribution of the various ingredients, the rise time could be calculated. The following times were calculated: Rise time including creaming time: 110 seconds Creaming time: 11 seconds Rise time without creaming: 99 seconds

[0195] The rise time including the creaming time was used as the total rise time. A symmetrical S-curve appeared between the start point of foam expansion (after the creaming time) and the total rise (or blow-off) point. To facilitate data processing, the S-curve was cut into 10 sections. Calculation of such S-curve rise profiles is known in the art. However, differences between such calculated rise profiles and the actually measured rise profiles can be observed.

[0196] For example, Figure 7 shows the calculated rise profile 702 and the measured rise profile 704 (i.e., rise curves) for Formulation 1. To better compare the curves, the creaming time is shortened, which means that the swelling of the reaction mixture starts from zero. However, it should be noted that the creaming times are also slightly different.

[0197] While both curves appear similar, the time of full rise without creaming differs by more than 10 seconds, and the heights at various times vary to such an extent that they require different settings of the fall plate height (i.e., at various times, the fall plate height set according to the measured rise profile deviates significantly from the fall plate height set according to the calculated rise profile). Lists a) and b) below give the machine parameters derived from the two rise profiles (i.e., calculated and measured conventionally according to an embodiment of the present disclosure) that place the full rise / blow-off position 0.5 m after the fall plate system, make the top surface of the foam look like a smooth line, and provide a 1.00 m high block. List c) gives the conventional empirical machine parameters used by a foam making machine to produce a foam according to Formulation 1.

[0198] a) Calculated machine parameters for the climb profile: Power factor: 1.30 Polyol output: 130kg / min Conveyor speed: 4.05m / min Trough height above conveyor: 66cm above conveyor baseline Height end of fall plate 1: 37 cm above conveyor baseline Height end of fall plate 2: 27 cm above the conveyor baseline Height end of fall plate 3: 8cm above conveyor baseline Height end of fall plate 4: 2 cm above the conveyor baseline Height of fall plate 5 end: conveyor height b) Measured machine parameters of the climb profile: Power factor: 1.45 Polyol output: 145kg / min Conveyor speed: 4.55m / min Trough height above conveyor: 66cm above conveyor baseline Height end of fall plate 1: 49 cm above conveyor baseline Height end of fall plate 2: 40 cm above the conveyor baseline Height end of fall plate 3: 21 cm above the conveyor baseline Height end of fall plate 4: 7 cm above the conveyor baseline Height of fall plate 5 end: conveyor height c) Experimental machine parameters used by the foam manufacturer to produce foam according to Formulation 1: Power factor: 1.55 Polyol output: 155kg / min Conveyor speed: 4.75m / min Trough height above conveyor: 66cm above conveyor baseline Height end of fall plate 1: 46 cm above conveyor baseline Height end of fall plate 2: 39 cm above the conveyor baseline Height end of fall plate 3: 24 cm above the conveyor baseline Height end of fall plate 4: 7 cm above the conveyor baseline Height of fall plate 5 end: conveyor height

[0199] Industrial Test Results Industrial testing was performed by using an FB20 foaming machine in a subsequent run to produce a 15 m long foam block using the conditions in a), followed by a 15 m long foam block using the machine parameters in scenario b) and finally (for comparison) a 30 m long foam block using the standard empirical settings of the machine.

[0200] During the run the following observations were made: [Table 2]

[0201] The foam blocks were transferred to a curing rack and kept there for 3 days. Afterwards, cross sections were cut from the center of the blocks. These cross sections (each 15 cm thick) were transferred to the laboratory for further evaluation. The following properties were obtained: [Table 3]

[0202] Upon inspection, most of the blocks are free of defects overall. Only the blocks in scenario a) show the beginning of splits in the bottom area of ​​the sides, which is related to premature blow-off on the conveyor. This directly points to a mismatch of the foam expansion curve with the selected machine settings. The shape of the blocks is optimal for scenario b), where the height of the center and sides of the blocks in the vertical direction is the same. In scenario a), we observed that the blocks were 1.5 cm higher at the sides compared to the center. In scenario c), it was the opposite with blocks that were higher in the center (1 cm higher). Naturally, the ideal blocks are rectangular with the same height in the center and on the sides to minimize scrap formation during cutting of the foam blocks into mattresses and other consumer goods.

[0203] Moreover, by using the machine parameters generated on the basis of the measured rise profile, a significantly more uniform density distribution could be obtained over the block cross section. The density deviation is even slightly better than the values ​​obtained using the empirical parameters of the foam production machine. The spread of low density in the block is important, since density specifications are often part of the supply contracts for flexible PU foams. The maximum deviations allowed are often in the range of 10%. Clearly, the parameters obtained with the help of the measured rise profile allow the reaction mixture to expand smoothly, resulting in a uniform density distribution. The calculated rise results in the highest density spread.

[0204] The same trend is seen for hardness, but the difference is small. The number of bubbles is the same.

[0205] Overall, the results of the industrial testing using the exemplary reactive mixture (i.e., Formulation 1) demonstrate the advantageous use of rise profile data obtained from discontinuous box foam testing by simulation software for predicting continuous flexible foam machine parameters and settings in optimizing the manufacturing process. By importing measured rise profile data from coordinated box foaming experiments, constant and consistent foam quality is obtained in continuous flexible foam production.

[0206] Aspects of the present disclosure are described herein with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer readable program instructions.

[0207] Embodiments of the present disclosure may be systems, methods, products, and / or computer program products. The computer program product may include computer-readable storage medium(s) having computer-readable program instructions for causing a processor to perform aspects of the present invention.

[0208] A computer-readable storage medium may be a tangible device that can hold and store instructions for use by an instruction execution device. A computer-readable storage medium may be, for example, but not limited to, an electronic storage device, a magnetic storage device, an optical storage device, an electromagnetic storage device, a semiconductor storage device, or any suitable combination thereof. A non-exhaustive list of specific examples of computer-readable storage media includes portable computer diskettes, hard disks, random access memories (RAMs), read-only memories (ROMs), erasable programmable read-only memories (EPROMs or flash memories), static random access memories (SRAMs), portable compact disk read-only memories (CD-ROMs), digital versatile disks (DVDs), memory sticks, floppy disks, mechanically encoded devices such as punch cards or ridge structures in grooves with instructions recorded thereon, and any suitable combinations of the above. As used herein, a computer-readable storage medium should not be construed as being a transitory signal per se, such as radio waves or other freely propagating electromagnetic waves, electromagnetic waves propagating through a waveguide or other transmission medium (e.g., light pulses passing through a fiber optic cable), or electrical signals transmitted over wires.

[0209] Although the present description and examples describe a method, software, and / or machine having an inclined fall plate, which may be controlled and adjustable as described herein, the method, software, and / or machine may also be adapted with respect to flat foam making machines and / or methods without such a fall plate, having vertically increasing foam formation, whereby the embodiments, details, examples, and any aspects described herein shall apply accordingly as far as practicable. As an example of a similar method, the following shall apply:

[0210] 1. A method for determining machine parameters of a foam-making machine, the foam-making machine including a mixhead configured to mix precursor reagents to form a reactive mixture, whereby the first segment and / or conveyor is configured to receive the reactive mixture, and the conveyor, e.g., the first conveyor, has an adjustable conveyor speed. 2. The method, comprising: executing software by a computer system, the computer system including at least one processor, the executing the software including: accessing a database for reading a rise profile for the reactive mixture of precursor reagents, the rise profile including height of the mixture as a function of time when the precursor reagents react to form foam, and calculating, based on the rise profile, a conveyor speed that will result in a predetermined predicted profile of the reactive mixture on the conveyor if the reactive mixture is conveyed along it.

[0211] In one preferred embodiment, based on the rise profile, machine parameters are further calculated that will result in a predetermined predicted profile of the reactive mixture on the conveyor when the reactive mixture is conveyed along it.

Claims

1. A method for determining the mechanical parameters of a foam manufacturing machine (100, 400), wherein the foam manufacturing machine comprises: a mixing head (102) configured to mix precursor reagents for forming a reactive mixture (136); a plurality of inclined fall plates (104), wherein the first inclined fall plate is configured to receive the reactive mixture, and each inclined fall plate has vertically adjustable ends (118, 120); and a conveyor (106) configured to receive the reactive mixture from the last inclined fall plate, wherein the conveyor has an adjustable conveyor speed, and the method is A step of executing software by a computer system (600), wherein the computer system includes at least one processor (602), and the step of executing the software includes, A step of accessing a database (604) for reading the rise profile of the precursor reagent with respect to the reactive mixture, wherein the rise profile includes the height of the mixture as a function of time when the precursor reagent reacts to form a form (137), A step of calculating the vertical position of the end of each inclined fall plate and the conveyor speed, which, based on the upward profile, yield a predetermined predicted profile of the reactive mixture on the plurality of inclined fall plates when the reactive mixture is conveyed along the plurality of inclined fall plates. Methods that include...

2. The method described above is The step of mixing the precursor reagent in a container (500) to form a second reactive mixture, wherein the container is located outside the foam manufacturing machine, The steps include measuring the height of the upper surface of the second reactive mixture as a function of time in the container in order to generate the rising profile, The steps include storing the aforementioned rise profile in the database and The method according to claim 1, further comprising:

3. The method of claim 2, wherein the steps of mixing the precursor reagent in the container to form the second reactive mixture and measuring the height of the top surface of the second reactive mixture in the container as a function of time to generate the rising profile are performed under environmental conditions that are consistent with the environmental conditions for operating the foam manufacturing machine, and the consistency of environmental conditions means consistency of at least one environmental parameter.

4. The method according to claim 2, wherein the container is fixed.

5. The method according to claim 2, wherein the movement of the mixture in relation to the container includes only the movement of the upper surface of the mixture when the height of the upper surface increases.

6. The method according to claim 1, wherein the precursor reagent comprises at least one liquid polymer and at least one catalyst.

7. The method according to claim 6, wherein the at least one liquid polymer comprises at least one liquid polyurethane.

8. The method according to claim 2, wherein the foam manufacturing machine further comprises a transport medium (114) disposed between the bottom surface (135) of the reactive mixture, the plurality of inclined fall plates, and the conveyor, and the conveyor is configured to pull the transport medium and the reactive mixture along the plurality of inclined fall plates at the conveyor speed for transporting the reactive mixture along the plurality of inclined fall plates.

9. The method according to claim 8, wherein the container includes a process liner (506), the chemical composition of at least the surface of the transport medium of the foam manufacturing machine matches the chemical composition of at least the surface of the process liner used to generate the rise profile stored in the database, and the surface is in contact with the respective reactive mixture.

10. The method according to claim 8, wherein the transport medium is a paper sheet.

11. The method according to claim 1, wherein the foam manufacturing machine includes a trough (123), the trough having a bottom surface (126) including an input port (127) configured to receive the reactive mixture from the mixing head, and a side surface (128) including a side lip (130) through which the reactive mixture flows to the proximal end of the first inclined fall plate, and the calculation further depends on one or more of the vertical position of the side lip of the trough relative to the vertical position of the proximal end of the first inclined fall plate, and the size of the trough, defined by the length between the bottom surface of the trough and the side lip of the trough.

12. The method according to claim 1, wherein the predetermined prediction profile has a substantially flat top surface (304), and the substantially flat top surface has an inclination angle of approximately arctan [(a predetermined ratio of the height of the form on the conveyor) / (the horizontal length of the plurality of inclined fall plates)].

13. The method according to claim 12, wherein the predetermined ratio of the height of the form on the conveyor is approximately 1 / 3 of the height of the form on the conveyor.

14. The method described above is The method according to claim 1, further comprising the step of prompting the user to adjust one or more of the calculated vertical positions of the ends of each inclined fall plate and / or the conveyor speed in order to adjust the predicted profile of the reactive mixture on the conveyor belt to have a substantially flat top surface (306).

15. The computer system comprises a network (606) and a cloud server (608), the cloud server comprises at least one processor, the user has an account with the cloud server, the cloud server includes a cloud database (610), and the method is The steps include: authorizing the user's access to the cloud server based at least on the user profile stored in the cloud database; A step of executing the software on the cloud server, the step of executing the software further includes a step of automatically reading the rise profile of the reactive mixture of precursor reagents from the cloud database based on the user profile. The method according to claim 1, further comprising:

16. The method according to claim 15, wherein the user profile includes at least one purchase information for the precursor reagent.

17. The method described above is The method according to claim 15, further comprising the step of scanning a machine-readable code associated with the at least one of the precursor reagents when delivering the at least one of the precursor reagents to the user, wherein the step of automatically reading the rise profile from the cloud database includes the step of automatically reading the rise profile from the cloud database based on the scanned machine-readable code.

18. The foam manufacturing machine further includes at least one machine processor (140), controller software (142), and an operating unit (146), and the method is The processor outputs the calculated vertical position of the end of each inclined fall plate and the conveyor belt speed. The steps include: executing the controller software using at least one machine processor; The steps include receiving the output and calculated vertical position of the end of each inclined fall plate and the conveyor belt speed by at least one machine processor, The operation unit enables the setting of the parameters of the foam manufacturing machine for manufacturing the foam. The method according to claim 1, further comprising:

19. A computer-readable medium for storing instructions, wherein, when executed by a computer, the instructions cause the computer to carry out the method according to any one of claims 1 to 18.

Images