System and method for automatically setting parameters for foam manufacturing - Patents.com

Abstract

A method is provided for setting machine parameters of a foam-making machine including an intermediate transport unit configured to receive a reactive mixture, a plurality of drop plates having vertically adjustable ends configured to receive the reactive mixture from the intermediate transport unit, and a conveyor configured to receive the reactive mixture from the drop plates. The method includes executing software by a computer system, where executing the software includes importing characteristics of the foam-making machine and a rise profile for the reactive mixture, and iteratively determining process and machine parameters including a flow rate of the reactive mixture, a conveyor speed, dimensions of the intermediate transport unit, and a vertical position for an end of each drop plate that results in a predefined predicted profile of the reactive mixture on the plurality of drop 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 normally liquid components are 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 inside the cells of the rising foam is usually approximately equal to atmospheric pressure. The reactive mixture expands vertically during its simultaneous horizontal movement on the conveyor belt and forms long blocks ("slabstock foams") in a continuous process, which are then cut according to specific lengths and transported to the reaction store. During the rise, the progressive cross-linking of the reactive components solidifies the material, so that a rigid but elastic flexible polyurethane foam is finally obtained. Just before the solidification of the material, cell opening still occurs, associated with a small loss of the bubble gas and a slight retreat of the not yet solid foam block. The process is relatively fast, often taking less than 2 minutes to solidify. As the foam expands on the flat conveyor belt, it grows upwards along the side walls. The friction on the side walls prevents the increasingly viscous foam mixture from growing at the edge of the block instead of in the center. This results in a dome shape with a rounded top. The height of the foam block is therefore different at 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 in test foaming and 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] There has been no lack of attempts to continuously improve the production of flexible polyurethane slabstock foams, in particular to reduce the resulting cutting and waste rates. For this purpose, the formed rectangular cross-sections of the foam blocks and their optimal dimensioning are important, for example, to be able to cut rectangular mattress cores from the foam blocks as efficiently as possible. A rounded block top increases the waste rate, since the rectangular mattress core cannot be cut from the top layer. An important step in creating rectangular block cross-sections was to expand the foam not only upwards, but also at least partially downwards. This has the advantage that the foaming mixture has to rise a shorter 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, the reaction mixture flows downwards along the side walls. However, gravity helps here. This is technically realized in continuous slabstock plants by the so-called falling 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 starts, the drop 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 drop plate are fixed, but the height is adjustable. In this case, each drop plate is connected at the end to the adjacent drop 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 geometric 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 reactive mixture and the position on the production machine must match each other. Diagrammatically 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 do not match correctly, a wide variety of errors will occur with the generated 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 formation of cracks in the foam block because the foam has already solidified on the fall plate. For a more detailed technical description of the process, see Gunter Oertel (2 nd For example, see Polyurethane Handbook, by Carl Hanser Pub. Inc., 1994 edition.

[0006] Therefore, the synchronization of the rise profile and the machine settings is a major issue with 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 raw materials, the temperature of the raw materials, 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 the record of the time dependence of the height of the expanding foam mixture.

[0007] Two points in the rise profile are of particular importance: the moment when the mixture starts to expand (location of the creaming point) and the moment when it stops expanding (location of the full rise point) (due to cell opening and gas blow-off). Creaming and blow-off are well-defined phenomena occurring during the expansion phase of flexible polyurethane foams. Both are characterized by abrupt events that can also be detected visually: the raw mixture becomes milky and opaque due to creaming and starts to rise. At the blow-off cells at the surface of the foam burst, gas is released and the foam surface sinks a little. The rise profile is obtained by recording the height of the reacting mixture in a time-resolved manner. Both phenomena can be detected in this curve by a change in the slope: for creaming, the differential quotient changes from 0 to positive values; for blow-off, the differential quotient changes from positive values ​​to 0 or even negative values. Both phenomena can be precisely localized in the rise profile curve, so called creaming or blow-off points. The blow-off point is also called the full rise point, since it represents the maximum height of the foam during expansion. When the formulation is transferred to a continuous industrial production machine for flexible polyurethane foam ("slabstock technology"), both phenomena can be seen as well, but this occurs in a layer in the reaction mixture perpendicular to the foam block movement. The foam production is usually observed from a top-down view, so the term "line" is usually used. This is a line on the foam surface across the width of the conveyor belt. In this case, a creaming line or blow-off line (also "blow line") is visible. Thus, the expressions creaming line or blow-off line / full rise line refer to the creaming or blow-off that occurs in flexible foam slabstock production, and the terms creaming point or blow-off point both refer to the rise profile curve.

[0008] Both points can be obtained directly from the rise profile. If the rise profile is to be transferred to the machine, the time axis must be converted to distance on the machine (from the start of the machine or from the time of application of the reactive mixture). This can be done by precisely measuring / calculating the residence time of the reactive mixture through the mix head and onto the paper. From there, the foaming mixture moves at the conveyor belt speed. The foam rise profile can then be converted to a spatially resolved rise profile on the machine. The position of the creaming point and / or the position of the full rise point are also transferred in this way to special positions on the machine. These positions are compared to the optimum positions. Once this is done, the drop plate and belt speeds can be adjusted to obtain the ideal desired gradient. If necessary, the formulation can also be adjusted so that the modified rise profile better fits the machine conditions. One possibility for this is, for example, a modified catalyst concentration. If necessary, both the machine parameters and the formulation details can also be changed.

[0009] 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 general S-shaped rise profile is traditionally used, which is then adjusted using defined activity parameters for the catalyst together with the raw material concentrations and temperatures. However, these rise profiles are only approximately calculated / estimated. This often results in deviations of the calculated rise profile from the actual one, severely limiting the predictability of the production process.

[0010] Furthermore, there are also many special foam types where 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 a non-optimized foaming process in an industrial plant, for example with a dosage of 250 kg / min and a minimum run time of a few minutes, is very cost intensive and overall reduces the reliability of the simulation software.

[0011] In addition, there are problems especially with the first production of new foam formulations whose foaming behavior is little known. That is, there are currently only two possible methods to obtain the necessary, as yet unknown, optimal machine settings for a new foam formulation. In the first method, the foaming can be tested in a large-scale production plant. This involves starting from already established or assumed settings and generating 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.

[0012] Furthermore, it is the opinion of many engineers that significant differences exist between laboratory and production rise profiles, i.e., it is generally questioned to what extent discontinuous foam processes (laboratory foaming) and continuous foam processes (industrial production) can be compared.

[0013] 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 is possible to calculate the foam rise profile or predict optimized machine parameters. This patent, with its complex and cost-intensive measurements of the foaming behavior in real industrial production plants, clearly shows the industrial interest in obtaining meaningful rise profile data. However, the simpler method of representative measurements upstream of laboratory rise profile data is not chosen here, but instead in situ measurements in real production. This can be explained by the fact that the authors do not foresee meaningful rise profile data obtained from discontinuous laboratory foams.

[0014] Ultrasonic measurement sensors have existed for some time for measuring rise profiles in laboratories. The combination of sensors and foam software from Format Messtechnik ("FOAMAT" (Format Messtechnik GmbH, Im Schlehert 26, 76187 Karlsruhe, Germany) is particularly popular. Descriptions use rise profiles to determine rise times or compare rise profiles with each other (e.g. to determine activity parameters for catalysts), but the use or export of programs to simulate rise in continuous foamers is neither disclosed nor anticipated (see, for example, www.format-messtechnik.de / foamat_d.htm#Steigh%C3%B6he%20und%20Steigprofil).

[0015] As the kinetics and reaction sequence of the polyurethane reaction are of great 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 foam in a closed mold, and not on a freely rising flexible foam. But again, the use of simulated rather than actually measured rise profiles demonstrates the difficulty of transferring the results from laboratory foaming to the production process (albeit in this case molded foam). In the flexible polyurethane foam industry, laboratory measured kinetic data (such as rise profiles) are generally considered not important for large-scale industrial slabstock foam production. The background to this is the completely different mixing energies when mixing raw materials by hand in an open cup / vessel compared to a closed mixing chamber with a high performance stirrer. The air input and therefore the nucleation efficiency are also significantly different here, which manifests itself in a different bubble structure.

[0016] Overall, it would be of considerable benefit to the slabstock industry to overcome the shortcomings of the prior art as discussed above and to provide proper simulation and reliable prediction of the rise of the reaction mixture during slabstock production. [Prior art documents] [Patent documents]

[0017] [Patent Document 1] DE 10237005 A1

[0018] Summary of the Invention Various embodiments provide systems and methods for foam production and products provided by the methods as described in the subject matter of the independent claims. Advantageous embodiments are set forth in the dependent claims. The embodiments of the invention can be freely combined with one another if they are not mutually exclusive.

[0019] In one aspect, the invention relates to a method for automatically setting machine parameters of a foam-making machine, the foam-making machine including a mixhead configured to mix precursor reagents to form a reactive mixture, an intermediate transport unit configured to receive the reactive mixture from the mixhead, a plurality of fall plates, a proximal end of a first fall plate configured to receive the reactive mixture from the intermediate transport unit, each fall plate having a vertically adjustable end, and a conveyor configured to receive the reactive mixture from a last fall plate, the reactive mixture forming foam on the conveyor. The method includes executing software by a computer system, the computer system including at least one processor, and executing the software includes importing characteristics of the foam-making machine from a database, the characteristics being: At least one dimension of the intermediate transport unit, a range of conveyor speeds, a number of drop plates, and a range of vertical positions for the vertically adjustable ends of the drop plates. and importing a rise profile for a reactive mixture of precursor reagents from a database, the rise profile preferably including the height of the mixture as a function of time as the precursor reagents react; determining a location of a creaming point and / or a location of a full rise point; determining a conveyor speed from a range of conveyor speeds based on a rise profile; determining a location of a creaming line and / or a location of a full rise line based on the rise profile and the determined conveyor speed; comparing the location of the creaming line and / or the location of the full rise line towards an optimum value; and determining: the determined conveyor speed, the determined position of the creaming line, the determined position of the full rise line, and / or the predefined target height h of the foam f , preferably at a predetermined density of foam on the conveyor. determining a value for a flow rate of the reactive mixture to the first drop plate and at least one dimension of the intermediate transport unit based on at least one of the above; Iteratively repeating the determination to provide a final flow rate, a final value for at least one dimension of the intermediate transport unit, a final conveyor speed, and a final position of the creaming line, and / or a final position of the complete rise line; determining a vertical position for an end of each drop plate based on the rise profile and the final conveyor speed, which results in a predefined predicted profile of the reactive mixture on the multiple drop plates as the reactive mixture is transported along the multiple drop plates by a conveyor moving at the final conveyor speed; and storing at least one of the final flow rate, the final value for at least one dimension of the intermediate transport unit, the final conveyor speed, and the vertical position for the end of each drop plate in a database. Includes.

[0020] These features have the advantage of automatically setting the machine parameters of the foam making machine and resulting in a predefined, predicted profile of the reactive mixture on multiple inclined drop plates, thereby reducing production time and production waste associated with operating the foam making machine.

[0021] According to one embodiment, the method includes determining values ​​for a flow rate of the reactive mixture to the first drop plate and at least one dimension of the intermediate transport unit based on at least one of the determined conveyor speed, the determined position of the creaming line, the determined position of the full rise line and / or a predefined target height hf of the foam, and a determination of a predetermined density of the foam on the conveyor.

[0022] According to one preferred embodiment, the method includes determining values ​​for a flow rate of the reactive mixture to the first drop plate and at least one dimension of the intermediate transport unit based on the determined conveyor speed, the determined position of the creaming line, the determined position of the full rise line and / or a predefined target height hf of the foam, and a predefined density of the foam on the conveyor.

[0023] According to one embodiment, the intermediate transport unit includes a trough having a lip and a volume and configured to receive the reactive mixture from the mixhead, the proximal end of the first drop plate is configured to receive the reactive mixture from the lip of the trough, and at least one dimension of the trough includes at least one of a trough height, a trough width, and a trough length, the trough height being the distance between a bottom of the trough and the lip.

[0024] According to another embodiment, the intermediate transport unit comprises a pour plate configured to receive the reactive mixture from a mix head, the position of the mix head being adjustable to deposit the reactive mixture at a laydown position on the pour plate, a proximal end of the first drop plate being configured to receive the reactive mixture from an end of the pour plate distal to the laydown position, and at least one dimension of the pour plate including a distance between the laydown position on the pour plate and the proximal end of the first drop plate.

[0025] These features have the advantage of providing an intermediate conveying unit with adjustable dimensions to enable rapid and automatic adjustment of the position of the creaming line and / or the position of the full rise line of the reactive mixture during the process of determining the final settings for the machine parameters.

[0026] According to yet another embodiment, the method further comprises: determining whether the vertical distance between the lip of the trough and the conveyor is greater than or equal to a predefined target height h of the foam; f This involves adjusting the position of the trough so that it is approximately 2 / 3 of the original height.

[0027] In another embodiment, the method further comprises: adjusting the vertical distance between the pour plate and the conveyor to a predefined target height h of the foam. f This involves adjusting the position of the pouring plate so that it is approximately 2 / 3 of the way there.

[0028] In one embodiment, the location of the creaming line is located at a distance of about ⅓ the height of the trough below the lip.

[0029] In another embodiment, determining a value for at least one dimension of the pouring plate includes selecting a distance between a laydown position on the pouring plate and a proximal end of the first fall plate such that the position of the creaming line is located approximately 15 cm in front of the proximal end of the first fall plate.

[0030] According to another embodiment, the predefined distance of the location of the full rise line is in the range of 0.2m to 1.2m, preferably 0.3 to 0.8m, more preferably 0.4m to 0.7m after the distal end of the last drop board.

[0031] In one embodiment, the steps of determining and adjusting to provide a final flow rate, a final value for at least one dimension of the intermediate transport unit, and a final conveyor speed are repeated (i.e., iterated) once, twice, or several times until the values ​​converge to a constant.

[0032] In a further embodiment, the sensor for determining the rise profile is an ultrasonic measurement sensor and / or a 3D laser scanner and is configured to communicate data with the running software and / or at least one processor of the computer system. The sensor can be configured to communicate data directly or indirectly with the running software. Indirect communication can include processing and / or at least temporary storage of the measurement data and / or conversion data.

[0033] In a further embodiment, the method includes determining the height and / or height gradient by the sensor of at least two defined test areas or test passages of the rise profile and / or foam surface, either in the laboratory or in the field at the production machine and production process, respectively. These distinct areas may be expected areas or passages of creaming lines, expected first maximum height of the formed foam, boundary areas along sidewalls, and / or other characteristic areas or passages.

[0034] These features have the advantage that they provide a fast process for setting the machine parameters of a foam-making machine, i.e., only one or two iterations are required for the solution to converge, since the method is robust to most, but not all, reactive mixtures.

[0035] In another embodiment, the predefined predicted profile has a substantially flat upper surface, the substantially flat upper surface having a slope angle of about arctan [(predefined percentage of the foam height above the conveyor) / (horizontal length of the plurality of sloped drop plates)]. In a further embodiment, the predefined percentage of the foam height above the conveyor is about ⅓ of the foam height above the conveyor.

[0036] These features have the advantage, for example, of providing a foam block with improved density distribution and hardness uniformity, as well as providing a foam block with a substantially horizontal, flat upper surface, thereby reducing material waste.

[0037] In another embodiment, the machine further includes a machine control unit including at least one machine processor, controller software executable by the processor, and an actuator unit including one or more actuators for controlling settings of the foam making machine. The method further includes executing the controller software by the at least one machine processor, where executing the controller software includes receiving data including at least one of a final value for at least one dimension of the intermediate transport unit, a final conveyor speed, a final flow rate, and a determined vertical position for an end of each drop plate, generating a control signal based on the received data, and sending the control signal to the actuator unit to automatically control settings of the foam making machine.

[0038] These features have the advantage of automatically controlling the settings of the foam making machine via actuators, thereby reducing direct physical user interaction with the machine and therefore reducing the risk of human (operator) error and increasing the efficiency and productivity of foam production.

[0039] The following embodiments of the invention are described in more detail, by way of example only, with reference to the drawings, in which: [Brief description of the drawings]

[0040] [Figure 1] FIG. 1 illustrates a foam-making machine according to one embodiment of the present disclosure. [Diagram 2] 1 is a flow chart 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 predefined predicted profile of a reactive mixture on multiple inclined drop 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. 2 illustrates a receptacle 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 calculated and measured rise profiles without creaming time for reactive mixture of Formulation 1, according to one embodiment of the present disclosure. [Figure 8] 1 is a flowchart of a method for setting machine parameters of a foam manufacturing machine according to one embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0041] 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 terminology used in this specification is selected to best 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.

[0042] 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 adjusted 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.

[0043] Surprisingly, it has been found that accurate simulations of the rise behavior can be obtained and precisely adapted machine parameters can be derived by importing and using rise profiles that have been carefully and representatively measured in the laboratory. To obtain precise and reliable predictions, the rise profiles can be measured in laboratory experiments under defined conditions and uploaded into a simulation software for the slabstock foam manufacturing process. It has been found that by importing the precisely measured laboratory rise profiles into a simulation process for the manufacturing process, precise predictions can be derived for selecting optimized machine conditions. For large scale manufacturing, it is important to make the laboratory foam as representative as possible. This includes not only bringing the raw materials to the temperatures that will be used in the manufacturing trials, but also foaming them into an insulated box / crate. The heat capacity and thermal conductivity of the box walls must be small. Suitable materials include rigid insulating polyurethane foams (PUR or PIR foams) or insulating foams such as polystyrene foams. Additionally, the same process liners that are used in large manufacturing plants can also be used in box foaming experiments to separate the box from the reaction mixture (also called reactive mixture).

[0044] Surprisingly, the rise profiles of laboratory foam experiments, which are performed 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.

[0045] A process for improved prediction of parameters for industrial PU flexible slabstock foam production, as further described below, can include one or more of the following: (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 manufacturing process simulation software, and (5) deriving manufacturing process parameters and simulating the manufacturing process.

[0046] In one embodiment, laboratory rise profile measurements are performed such that the same temperature as in industrial practice is chosen and the foam rise is carried out in an insulated box.

[0047] Optional retention and / or transformation of the data includes processing of the measured rise profile data and application of correction factors to correlate laboratory and machine conditions. In one embodiment, preparation of the rise profile data includes removing data points before the start of foam rise and normalizing the rise profile to a % of maximum rise height (maximum rise height=100%). Creaming time (time before expansion begins) can be provided for further processing as well as full rise time (when expansion stops).

[0048] The transfer of the prepared rise profile data, as well as the transfer when creaming and full rise times are taken into account, to the simulation software can be done in different database or table 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. Then, the parameters related to the drop plate, as well as the output amount and the conveyor speed (e.g., conveyor belt speed) can be derived.

[0049] As briefly described above, the present invention is in the field of polyurethane (PU) foam manufacturing, 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 profile measurements 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 manufacturing machine, such as, but not limited to, conveyor speed (e.g., conveyor belt speed), mixing trough size, and / or one or more of inclined drop plate position and pivot point position, 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 drop plates as the foaming mixture is transported across the series of inclined drop plates on a conveyor, such as a conveyor belt. The substantially flat profile of the foaming mixture on a series of inclined drop 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.

[0050] Embodiments of the present invention provide a solution to the problem of the current prior art of using an S-shaped rise profile based on calculations of creaming point (in time) and full rise point (in time), where such calculations are based on mixing reagents and then fitting an S-shaped curve between the creaming point and the full rise point. Such S-shaped fitted rise profiles are not particularly accurate representations of the true rise profile and are particularly inaccurate when the liquid mixture and / or the components of the foam-generating liquid mixture have non-standard or unusual densities, blow-off agents, and / or ratios.

[0051] Embodiments of the present invention result in the production of flexible PU foams, such as flexible PU foam blocks or foams having any polygonal shape, with more accurately predicted dimensions, thereby reducing material waste and processing time in providing foam that is cut into final or intermediate products with precise predetermined dimensions.

[0052] PU foam (polyurethane foam) and its manufacture are well known to those skilled in the art and do not require further elucidation 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 geometric shapes such as, for example, spheres, cuboids, cylinders, etc. Molded PU foam articles in the context of the present disclosure are therefore molded bodies made of polyurethane foam. Particularly preferred shapes of thermoset 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 by the scope of the present disclosure embodiments 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).

[0053] 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.

[0054] 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 manufacturing foam forming process. Flexible foams are typically used for comfort applications such as sofas, cushions, or mattresses. Other technical applications for flexible foams include filter foams or flame laminated foams. Applications in the textile and clothing industries are also known (e.g., shoulder pads, bras).

[0055] Rigid polyurethane foams are used for insulation applications such as refrigerators or insulation boards. 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.

[0056] A wide variety of flexible PU foams exists. 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 key 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 resilience. Methods for determining the rebound resilience are described, for example, in DIN EN ISO 8307:2008-03. Here, 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 in question for cold-cure flexible PU foams is preferably in the region of >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 rebound 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 rebound value, determinable according to DIN EN ISO 8307:2008-03, of 1% to 50% or less.

[0057] A further mechanical criterion is the SAG or 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. Cold-cure flexible PU foams here preferably have a SAG or comfort factor >2.5. Hot-cure flexible PU foams preferably have a value <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 or comfort factor, determinable as described above, preferably <2.5.

[0058] The exact definition of the properties can also be taken, for example, from the data sheet "PUR-Kaltschaum" [Cold-Cure PU Foam] from Fachverband Schaumkunststoffe und Polyurethane eV [Specialist Association Foamed Plastics and Polyurethanes], Reference KAL20160323, last updated 23.03.2016 (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), postal address: Stammheimerstr. 35, D-70435 Stuttgart.

[0059] 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.

[0060] The different mechanical properties of hot-cure and cold-cure PU foams result from differences in the formulations for the production of the foams. For cold-cure flexible PU foams, highly reactive polyols with mainly primary OH groups and an average molar mass >4000 g / mol are usually used. Optionally, low molecular weight crosslinkers are also used, and it is also possible that the function of the crosslinker is assumed by a more functional isocyanate. For hot-cure flexible PU foams, relatively mainly non-reactive polyols with secondary OH groups and an average molar mass <4000 g / mol are usually used. Thus, for cold-cure flexible PU foams, the reaction of the isocyanate groups with the hydroxyl groups occurs as early and to a higher extent as the expansion phase of the foam (CO2 formation from -NCO and H2O). This rapid polyurethane reaction usually results in a relatively high inherent stability of the foam during the foaming process as a result of the viscosity increase. As a result, other foam stabilizers with a different siloxane structure 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 further opened by mechanical disruption. In contrast, for thermoset flexible PU foams this is usually not necessary. The rather large stabilization by the high molecular weight polyether siloxane structure is important here.

[0061] The open-cell thermoset 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 volume of air that flows according to ASTM D 3574 (2011-00). This method is elucidated in more detail below (i.e., see subsection (f) described in Methods for Characterizing PU Foam Samples). scfm (standard cubic feet per minute) is measured under standard conditions (23°C, 100 kPa).

[0062] Depending on the application, the thermoset flexible PU foam is preferably 8-80 kg / m 3In particular, when such thermoset flexible PU foams are used as mattresses, mattress components, and / or cushions, said foams are differentiated according to the local wants and needs, requirements, and preferences of the consumers. The preferred thermoset flexible PU foams for mattress applications preferably have a foam density of 25-30 kg / m 3 The foam has a density of 0.01g / g.

[0063] A particular class of thermoset flexible PU foams is that of viscoelastic PU foams. These are also known as "memory foams" and exhibit both low rebound resilience (preferably <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 a low porosity and high density (or high foam density (FD)) compared to other thermoset flexible PU foams. The cushions have a mass of preferably 30-50 kg / m 3 and thus at the lower end of the density scale typical for viscoelastic foams, whereas viscoelastic PU foams for mattresses preferably have a foam density of 45-130 kg / m 3 It has a density in the range of

[0064] In thermoset 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 -20 to +15 °C. In contrast, the glass transition temperatures of other thermoset flexible PU foams and cold-cure flexible PU foams are usually below -35 °C. Such "structural viscoelasticity" in the case of viscoelastic thermoset flexible PU foams, which are essentially open-celled 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, resulting in a slow recovery.

[0065] The various thermoset 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 (compressive load deflection) at 40% according to DIN EN ISO 3386-1:2015-10 for thermoset 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.

[0066] The hot-cured flexible PU foams and their production are known per se. In a preferred embodiment of the present invention, the hot-cured flexible PU foam has a 40% compressive strength CLD of 2.0 to 8.0 kPa 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 3 and / or a porosity of 1-6 scfm, in particular 1.5-4.5 scfm, more preferably 1.75-4.25 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 invention, the viscoelastic flexible PU foam has a glass transition temperature of -20°C to +15°C, and / or a 40% compressive strength CLD of 0.1 to 5.0 kPa, in particular 0.5 to 2.5 kPa, according to DIN EN ISO 3386-1:2015-10, and / or a rebound resilience of <10%, measured according to DIN EN ISO 8307:2008-03, of 30 to 130 kg / m 3and / 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.

[0067] According to a preferred embodiment of the present invention, the molded thermoset flexible PU foam article (e.g., a mattress or foam used as a 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.

[0068] 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 containing at least a portion 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 worldwide under these names. Mattresses made only of hot-cure flexible PU foam are usually simply called foam mattresses in the market. The term mattress as used for the purposes of the present invention also encompasses the corresponding mattress coverings and underlays.

[0069] What is provided is that the various flexible PU foams 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, the foam expansion is possible in a rectangular direction relative to the movement of the foam or reaction mixture. The gas pressure in 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.

[0070] The production of the corresponding thermoset 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 embodiments of the invention are given below. The subject matter of the invention is illustrated by way of examples below, 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. Percentages are weight percent figures, unless otherwise stated. Where average values ​​are reported below, the values ​​in question are weight averages, unless otherwise stated. Where parameters determined by measurement are reported below, the measurements have been carried out at a temperature of 23° C. and at a pressure of 100 kPa, unless otherwise stated.

[0071] For the purposes of the present invention, polyurethanes are all reaction products derived from suitable isocyanate-reactive molecules, including isocyanates, especially polyisocyanates, and polyisocyanurates, polyureas, as well as allophanates, biurets, uretdione, uretonimine, or carbodiimide-containing isocyanate or polyisocyanate reaction products. It will be clear to the skilled person who intends to produce different flexible polyurethane foam types, for example hot-cured flexible PU foams, to appropriately select the substances required for each respective purpose, such as isocyanates, polyols, stabilizers, surfactants, etc., to obtain the polyurethane type, especially 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 [Polyurethanes], Carl-Hanser-Verlag 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.

[0072] 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.

[0073] 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.

[0074] Specific examples are alkylene diisocyanates having 4 to 12 carbon atoms in the alkylene radical, such as dodecane 1,12-diisocyanate, 2-ethyltetramethylene 1,4-diisocyanate, 2-methylpentamethylene 1,5-diisocyanate, tetramethylene 1,4-diisocyanate, 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-isocyanat-methyl-2-isocyanate ... Examples of suitable isocyanates include ethylcyclohexane (isophorone diisocyanate or IPDI for short), hexahydrotolylene 2,4- and 2,6-diisocyanate and the corresponding isomer mixtures, 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.

[0075] 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.

[0076] 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 of MDI as well as the 2,4' and 2,2' isomers and products with three or more rings), and the two-ring products, referred to as "pure MDI" and consisting mainly of the 2,4' and 4,4' isomer mixtures, 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 entireties.

[0077] Suitable polyols 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 thermosetting 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 typically used. The number average molecular weight is typically 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.

[0078] In a preferred embodiment of the invention, especially for the production of flexible slabstock foams, polyether alcohols are used which preferably have secondary hydroxyl groups in an amount of more than 50%, more preferably more than 90%, 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 preferably have a number average molecular weight in the range of 500 to 4000 g / mol, preferably 800 to 4000 g / mol, more preferably 2500 to 4000 g / mol, and a functionality of 2 to 8, more preferably 2 to 4, typically with an OH value in the range of 20 to 100 mg KOH / g, preferably 40 to 60 mg KOH / g.

[0079] In a further preferred embodiment of the present invention, di- and / or trifunctional polyether alcohols containing primary hydroxyl groups, preferably in an amount of more than 50%, more preferably more than 80%, are additionally used, in particular those having ethylene oxide blocks at the chain ends. Polyols for cold-cure flexible PU foams ("HR polyols") form part of this category, provided that the molar mass is at the same time >4000 g / mol. According to an embodiment of the present invention, and in particular according to the necessary properties of this embodiment which is preferred for the production of hot-cure flexible PU foams as described above, it is preferred to use not only the polyether alcohols described hereinabove, but also further polyether alcohols which have primary hydroxyl groups and which are mainly based on ethylene oxide, in particular with a proportion of ethylene oxide blocks of >70%, preferably >90% ("hypersoft polyols"). All polyether alcohols described in the context of this preferred embodiment preferably have a number-average molecular weight in the range of 500 to 8000 g / mol, preferably 500 to 7000 g / mol, and a functionality of 2 to 8, more preferably 2 to 5, typically with an OH value in the range of 5 to 100 mg KOH / g, preferably 20 to 60 mg KOH / g. Polyols with primary OH functional groups are in a preferred embodiment not used alone in the case of the hot-cure flexible PU foams of the present invention, but rather in combination with polyols with secondary OH groups.

[0080] In a further preferred embodiment of the present invention, an autocatalytic polyol is used.

[0081] In a further preferred embodiment of the invention, in particular for the production of viscoelastic flexible PU foams, it is preferred to use mixtures of different, preferably two or three, multifunctional polyether alcohols. The polyol combinations used here typically consist of low molecular weight "crosslinker" polyols with high functionality, preferably with an OH value of 100-400 mg KOH / g, and / or conventional high molecular weight flexible slabstock foam polyols or HR polyols, and / or "hypersoft" polyether polyols, preferably with an OH value of 20-40 mg KOH / g, with a high proportion of ethylene oxide and cell opening properties. If HR polyols are also used in the viscoelastic foam formulation, their mass proportion in the polyol mixture is <50%.

[0082] Polyester polyols were the first polyols used in the early days of PU development and are produced by polycondensation of diacids with excess diols. Difunctional monomers are used to obtain linear polymers. Small amounts of multifunctional initiators with functionality greater than 2, such as trimethylolpropane and glycerin, can be added 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, typically based on adipic acid, diethylene glycol, and trimethylolpropane or glycerin, to induce higher functionality. The average molecular weight is typically 2000-3000 g / mol, with an OH value of 57-63 mg KOH / g.

[0083] In the polyester polyol manufacturing process, diols, triols, etc. are first heated to a temperature of 60-90°C. Then, dicarboxylic acid is added and removal of reaction water begins. Excess diol is calculated by Flory's equation to obtain the target molecular weight. Usually, the reaction is completed at a temperature of up to 200°C. Nitrogen, carbon dioxide, or vacuum is used to remove water to reach the desired conversion of 99.9%, and the resulting polyester should have an acid number of 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. Diol chain growth increases the flexibility of the PU, increases its hydrolytic stability, and decreases its polarity and glass transition temperature. Lightly branched poly(diethylene glycol adipate), primarily used to make flexible foams, and a wide range of adipates made with two or more aliphatic diols. These are used to make solid and microcellular elastomers, flexible coatings, and adhesives. Relatively low-cost polyester polyols based on recovered materials from recycling 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 more resistant to oils, greases, solvents, and oxidation. They have better properties related to tensile and tear strength, flex fatigue, abrasion, adhesion, and dimensional stability. On the other hand, PU-based esters are more susceptible to hydrolysis and microbiological attack. The manufacturing process for flexible polyurethane foams based on polyester polyols follows the same principles as for polyurethane flexible foams based on polyether polyols. Thus, the machinery is comparable.According to an embodiment of the present invention, a simulation of the manufacturing process can be derived from the 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 called "polyester foams". It is also possible to combine polyether and polyester polyols in flexible PU foam formulations. Such foams are often called "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.

[0084] In a further preferred embodiment of the present invention, recycled polyols are used. The recycled polyols are polyols obtained from PU foam waste. This can be manufacturing waste from thermosetting flexible PU foam production or from thermosetting flexible PU foam waste after consumer use (e.g. old mattresses). In both cases, the PU foam is liquefied by chemical processes. Various processes are useful here, for example glycolysis, hydrolysis, or acidolysis. The resulting liquid recycled polyol can then be reused in the production of thermosetting flexible PU foam. However, such thermosetting flexible PU foams are often characterized by apparently detrimental mechanical properties, such as resistance to roll compression. One source of further information on the use of recycled polyols in thermosetting flexible PU foams is the following BMBF research report: https: / / www.cleaner-production.de / fileadmin / assets / bilder / BMBF-Projekte / 01RI05070-075_-_Abschlussbericht.pdf.

[0085] The further use of recycled polyol in the context of the present invention corresponds to a preferred embodiment of the present invention for each item of the claimed subject matter.

[0086] 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.

[0087] 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.

[0088] Suitable catalysts are known and are in particular substances which catalyse the gel reaction (isocyanate-polyol), the blow 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.

[0089] 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-methylpropanol Pan-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-tert-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.

[0090] Catalysts and / or mixtures of this kind are, for example, Jeffcat® ZF-10, Lupragen® DMEA, Lupragen® API, Toyocat® RX 20 and Toyocat® RX 21, DABCO® RP 202, DABCO® RP 204, DABCO® NE 300, DABCO® NE 310, DABCO® NE 400, DABCO® NE 500, DABCO® NE 600, DABCO® NE 650, DABCO® NE 660, DABCO® NE 740, DABCO® NE 750, DABCO® NE 1060, DABCO® NE 1080, DABCO® NE 1082 and DABCO® NE 2039, Niax® EF 860, Niax® EF 890, Niax® EF 700, Niax® EF 705, Niax® EF 708, Niax® EF 600, Niax® EF 602, Kosmos® 54, Kosmos® EF, as well as Tegoamin® ZE 1.

[0091] Metal compounds suitable as catalysts can 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 salts" in the context of the present invention particularly includes the use of metal compounds that do not have direct carbon-metal bonds and are at the same time metal salts, in which either the anion or the cation is an organic compound (e.g. tin(II) carboxylate). The expression "inorganic metal salts" in the context of embodiments of the present invention particularly includes the use of metal compounds or metal salts in which neither the anion nor the cation is 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. metal compounds or metal salts containing 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 complexes" in the context of embodiments of the present invention particularly includes the use of metal coordination compounds with ligands having 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.

[0092] 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 salts 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 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 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 preferably selected such that they do not have any inherent unpleasant odor, are substantially toxicologically benign, and impart the lowest possible levels of catalyst-induced emissions to the resulting polyurethane system, particularly polyurethane foam.

[0093] In addition to amines and metal compounds, it is also possible to use ammonium salts as catalysts. Suitable examples are ammonium formate and / or ammonium acetate.

[0094] Suitable catalysts are mentioned, for example, in DE 102007046860, EP 1985642, EP 1985644, EP 1977825, US 2008 / 0234402, EP 0656382 and US 2007 / 0282026 and the patent documents cited therein.

[0095] The appropriate 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 based on 100 parts by weight of polyol).

[0096] The optional additives used may be all substances which are known from the prior art and are used in 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 as defined above.

[0097] Water is commonly used as a blowing agent in the production of flexible PU foams. It is preferred to use an amount of water such that the water concentration is 0.10-10.0 pphp (pphp=parts by weight based on 100 parts by weight of polyol).

[0098] 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.

[0099] Apart from water and physical blowing agents, it is also possible to use other chemical blowing agents, such as formic acid, which react with isocyanates to generate gas.

[0100] The optional crosslinker and optional chain extender are low molecular weight polyfunctional compounds that are reactive towards isocyanates. Suitable compounds are, for example, 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 based on 100 parts polyol, but may deviate from this depending on the formulation.

[0101] 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: 2-(2'-hydroxyphenyl)benzotriazoles, 2-hydroxybenzophenones, benzoic acid and benzoates, phenols, especially phenols with tert-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.

[0102] 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 organophosphorus compounds, such as halogen-free organophosphates, 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.

[0103] Due to their influence on the stabilization of rising foam mixtures and foam properties of polyurethane foams, organomodified siloxanes are commonly used in the production of thermoset flexible PU foams. Suitable (organically modified) siloxanes for this purpose are described, for example, in 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 can 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 thermoset 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 preferably such that, for example, long-chain copolymers of ethylene oxide and propylene oxide are bonded to polydimethylsiloxane radicals. The link between the polydialkylsiloxane and the polyether moiety may be via a Si-C linkage 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 radicals of the siloxane may be aliphatic, cycloaliphatic, or aromatic. Methyl groups are very particularly advantageous. The organomodified polydialkylsiloxanes may be linear or contain branches. Suitable stabilizers, especially foam stabilizers, are described, inter alia, in US Pat. No. 2,834,748, US Pat. No. 2,917,480 and US Pat. No. 3,629,308.The function of the foam stabilizer is to ensure the stability of the foaming reaction mixture. The contribution to foam stabilization here correlates with the siloxane chain length. Without the foam stabilizer, collapse is observed and no homogeneous foam is obtained. For some flexible PU foam types, which have a higher stability and therefore a lower 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-cured flexible PU foams or flexible foams based on polyester polyols, unmodified or modified short-chain siloxanes are used. In contrast, if long-chain and therefore more powerful siloxane stabilizers are used, then overstabilization and therefore shrinkage after foam production is observed for such foam types. The foam stabilizer can in principle be selected as desired in the context of the embodiments of the present invention.

[0104] The above compounds can be used, for example, together with suitable solvents and / or further additives. As optional solvents, it is possible to use 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), as well as 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 can be easily employed in the foaming operation and that do not adversely affect the foam properties are particularly preferred. For example, isocyanate-reactive compounds are suitable as 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 glycol (PEG) with an average molecular mass between 200 g / mol and 3000 g / mol.Particularly preferred OH-functional compounds further include polyethers having an average molecular mass of 200 g / mol to 4500 g / mol, in particular 400 g / mol to 2000 g / mol, among which preferably water-, allyl-, butyl- or nonyl-initiated polyethers, in particular those based on propylene oxide (PO) and / or ethylene oxide (EO) blocks.

[0105] 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.

[0106] 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 raw materials distributed to the mixhead. Pressures of >40 bar are used in high pressure machines and pressures of <30 bar are used in low pressure machines. To achieve these pressure ranges, different pumps and injection devices to the mixhead are utilized. Generally, the various liquid raw material streams are pumped to the mixhead. In the mixhead, an agitator homogenizes the various raw materials and initiates the reaction. Also, gas can be added to the mixhead, for example to assist in nucleation. The reaction mixture then exits the mixhead and is either distributed directly onto a moving process liner (called liquid laydown technology) or is 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 either at the top or bottom, or in both directions simultaneously. For foam expansion to the top, a flat horizontal conveyor is used. For foam expansion to the bottom, a drop plate system is used. The position of the drop plate resembles the foam rise profile and needs to be precisely adjusted to avoid foam defects. This is the main task to be solved by this invention. When the foam reaches full rise, a blow-off is usually observed, and the foam changes from a closed-cell to an open-cell material. This is also the moment when the foam reaches full rise. The cell opening is driven by the destabilization and rupture of membranes within the polyhedral structure. The cell opening is driven by phase separation processes in the material. The foam block settles a little (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 saws cut the continuously produced flexible foam into blocks. The length of these foam blocks is typically 2 to 80 meters.The blocks are then transferred to a storage rack where the hot foam blocks are cooled and undergo the final hardening reaction. This takes 1-2 days, as temperatures are typically as high as 140°C and the material has good insulating properties. The foam blocks are then either transferred to a storage area or used directly in further manufacturing steps.

[0107] For the production of flexible PU foams it is possible to use any method known to those skilled in the art, for example the foaming operation can be carried out either horizontally or vertically.

[0108] The compositions used according to the embodiments of the present invention can be used for liquid CO2 technology as well. 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.

[0109] Exemplary formulations for the production of thermoset flexible PU foam (flexible slabstock foam) and a comparison of 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.

[0110] 1 illustrates a foam manufacturing machine 100 according to one embodiment of the present disclosure. The machine 100 includes a mix head 102 configured to produce foam 137, a plurality of inclined drop plates 104a, 104b, 104c, 104d, 104e, and a conveyor 106. The mix head 102 is configured to mix raw materials (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 shaped foam block.

[0111] In one embodiment, the precursor reagents are received by the mix head 102 via one or more transport 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.

[0112] 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 substantially 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 substantially uniform height on pour plate 110.

[0113] In one embodiment, the transport medium 114 positioned 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 covers other known media (e.g., impregnated paper, plastic, foil) that can be formed as a thin layer or sheet used to receive the mixed reagent. The transport medium 114 is pulled across the pour plate 110, the inclined drop 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 drop plate 104 and attaching it 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 friction or mechanically (e.g., via surface protrusions (not shown) of the conveyor belt, such as hooks). The conveyor belt 106 can have an adjustable speed for pulling the transport medium 114 and the reactive mixture positioned on top of the transport medium 114 at an adjustable speed. In one embodiment, the conveyor belt 106 is positioned substantially horizontally as shown. As shown, the transport medium 114 is positioned between the bottom surface 135 of the reactive mixture 136, the inclined drop plate 104, and the conveyor 106.

[0114] In one embodiment, a first inclined drop plate 104a is configured to receive the reactive mixture from the pour plate 104 as the transport medium 114 holding the reactive mixture is pulled across the drop plate 110 by the action (i.e., movement) of the conveyor 106. Although five inclined drop plates 104 are shown for ease of illustration, the scope of the present disclosure covers any number of inclined drop plates.

[0115] In one embodiment, each inclined drop plate 104 has two ends (i.e., a proximal end 118 and a distal end 120). Both ends of the inclined drop plate 104 are vertically adjustable. In one embodiment, each end of each inclined drop plate 104 is configured to be removably attached to an inclined drop plate framework (not shown) to secure each end in a respective vertical position.

[0116] 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. Once the vertical positions of the two adjacent pivots 122 are selected, the vertical positions of the two ends 118, 120 of the inclined drop plate 104 that connect to the two adjacent pivots 122 are also determined, and thus the inclination of the inclined drop 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 drop plate connected to the first pivot 122a, 104a is at the same height as the pour plate 110 (i.e., at the same vertical height of the pour plate 110). Then, the vertical position of the second pivot 122b may be set to determine the inclination of the first inclined drop plate 104a, taking into account the length of the first inclined drop plate 104a. The slope of the first drop plate is the rise / run, 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 between the vertical positions of the first and second pivot axes.

[0117] 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 drop plate 104a and pour plate 110.

[0118] In one embodiment, the machine 100 with n inclined drop plates has n pivots, with n=5 as shown. The scope of the present disclosure covers any number n of inclined drop plates 104 and pivots 122. In the illustrated embodiment, the ends of adjacent inclined drop plates share a pivot (i.e., are connected to the same pivot). For example, the distal end 122a of the first inclined drop plate 104a and the proximal end 118b of the second inclined drop 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 drop plate 104a and the proximal end 118b of the second inclined drop plate.

[0119] However, the scope of the present disclosure covers an embodiment having n inclined drop plates and 2(n-1)+1 pivot axes, in which the distal and proximal ends of each inclined drop 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 drop plates can be formed by adjusting the respective pivot axes connected to the distal and proximal ends of the two adjacent inclined drop plates to have different vertical positions.

[0120] As shown, in one embodiment, the conveyor 106 is configured to receive the reactive mixture from the last inclined drop plate 104e as the transport medium 114 holding the reactive mixture is pulled across the last inclined drop plate 104e and onto the conveyor 106 by the action (i.e., movement) of the conveyor 106.

[0121] 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.

[0122] In step 202, two or more precursor reagents are mixed together to form a reactive mixture (also referred to as a laboratory-based reactive mixture). In one embodiment, two or more precursor reagents are mixed together in a receptacle (FIG. 5) to form a reactive mixture. The receptacle is external to and not a component of the foam-making machine 100. In another embodiment, two or more precursor reagents are mixed together in a separate receptacle, such as a paper cup or beaker, and then the mixed reagents are poured into the receptacle (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 combinations of reagents described above in connection with flexible PU foam.

[0123] In step 204, the height of the top surface of the laboratory-based reactive mixture in the receptacle is measured over time, and the top surface height as a function of time is defined as a rise profile. The rise profile can 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. In another embodiment, the time is measured relative to when full rise is reached and bubble opening occurs.

[0124] In one embodiment, the rise profile is the height of the mixture measured in the laboratory as the precursor reagents react to form a foam. The height of the mixture is measured in the 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 full rise / blow-off point. Creaming time is the time it takes from the initial stage of mixing of the raw materials until the volume expansion of the reactive mixture begins due to the formation of gas that converts the liquid reaction mixture into foam. In other words, creaming time is the length of time to start the volume expansion, measured from the initial mixing of the precursor reagents. The blow-off point is reached when the closed-cell polyhedral structure changes to an open-cell structure and the foam settles a little. The expansion of the foam stops suddenly at the blow-off point. So, at the moment of blow-off, full rise is reached, which is also called the full rise point. The full rise point is often visible by the bursting of larger bubbles at the top surface of the foam.

[0125] The creaming point, creaming time, and blow-off point (=full rise point), blow-off time (=full rise time) are well known to those skilled in the art and will not be explained in further detail.

[0126] In one embodiment, the receptacle is stationary, i.e., in contrast to processing the reactive mixture through a foam-making machine in which the reactive mixture is transported through the machine via the action of a conveyor or other transport means, the reactive mixture is provided to a stationary receptacle that is not a component of the foam-making machine, and the reactive mixture reacts to produce foam in the stationary receptacle. In another embodiment, movement of the reactive mixture relative to the receptacle includes only movement of a top surface of the mixture as the height of the top surface increases or expands upwardly as the mixture is converted into foam.

[0127] In one embodiment, a laser beam is used to measure the height of the top surface of a laboratory-based reactive mixture in a receptacle at different times, however, the scope of this disclosure includes other conventionally known methods of measuring the surface of the liquid and / or foam mixture in a receptacle as the top surface height increases.

[0128] In one embodiment, steps 202 and 204 include a discontinuous box foaming procedure (also called discontinuous receptacle foaming procedure, e.g., performed in a receptacle (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 for various raw materials in the actual slabstock foam production, in the laboratory, the average temperature was used for preconditioning of the raw materials. The raw materials were then weighed into paper cups. Only TDI (i.e., tolylene diisocyanate) was left and later added 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 receptacle to the temperature of the same precursor reagents in the foam making machine and / or matching the ambient temperature of the receptacle to the ambient temperature of the foam making machine, other environmental conditions in the laboratory, represented by environmental parameters such as ambient pressure and ambient humidity, can also be adjusted or selected to match the corresponding environmental conditions of 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, ambient temperature, ambient pressure, and / or ambient humidity of the precursor reagents (i.e., raw materials).

[0129] Mixing was done in a paper cup filled with the raw materials (TDI was added last while the stirrer was 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.

[0130] Inside the box, a process liner (Figure 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 drop plate, and can extend over the side walls of the drop 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 side walls of the drop plate. The process liner can be, for example, paper, impregnated paper, PE-coated paper, etc. Impregnated paper is a sheet that has liquid-retaining properties and is well known in the industry. It is typically 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.

[0131] According to an embodiment, the process liner of the box (i.e., receptacle) is the same as the process liner of the foam manufacturing machine (referred to as transport medium 114) of method 200 in order to obtain high accuracy between the rise profile measured from the discontinuous foam process in the laboratory receptacle and the true rise profile of the continuous foam process in the foam manufacturing machine. Conventional laboratory boxes used to measure the properties of 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 transport medium 114 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, the surface being the surface in contact with 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 receptacle, as well as the side and / or bottom panels being 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 retention properties and is well known in the industry. It is typically 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.

[0132] The process liner was folded and secured into the box by staples. The process liner consists of a layer of robust, tear-resistant brown paper covered by 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 transport of the reaction mixture and the formed foam block. The process liner can be used in commercial flexible foam slabstock production.

[0133] 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, the height recording begins as the mixed raw materials are poured into the box. The rise curve can be recorded and displayed.

[0134] 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.

[0135] In step 208, one or more rise profiles are stored in a database.

[0136] In step 210, the database is accessed by a computer system 600 (FIG. 6) to read (also referred to as import) a rise 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 rise profile. According to one embodiment, a user of the computer system can define the components and / or component ratios 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) from the database a profile corresponding to the parameters defined by the user. In one embodiment, the processor, upon executing the software, queries the user for input parameters. In one embodiment, the rise profile data includes values ​​for creaming time and full rise time, which the software imports along with other rise profile data. In another embodiment, the software requests the user to provide the creaming time and full rise time for the corresponding rise profile. In another embodiment, the software determines the creaming time as well as the full rise time by automatically analyzing the shape of the rise profile, which can be done when the slope of the rise profile changes at both positions. At the creaming point, the differential quotient changes from 0 to a positive value. At the full rise point, the differential quotient changes from a positive value to 0 or even to a negative value.

[0137] Alternatively, when the software is first run, the computer system can authenticate the user, and upon authentication, the processor reads (or imports) the Rise 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 Rise Profile is to be imported from the Rise Profiles associated with the user and stored in the database.

[0138] In step 212, the vertical position (e.g., vertical position with respect to the pivot axis) and conveyor speed (e.g., conveyor belt speed) of the end of each inclined drop plate are calculated by software executed by the computer system based on the imported rise profile, resulting in a predefined predicted profile of the reactive mixture on the multiple inclined drop plates as the reactive mixture is transported along the multiple inclined drop plates. As described above in connection with FIG. 1, the reactive mixture may be transported along the multiple inclined drop plates as the transport medium on which the reactive mixture is positioned is transported along the multiple inclined drop plates via the action of a conveyor that pulls the transport medium across the pour plate and the inclined drop plates.

[0139] In one embodiment, the software includes an algorithm that selects a conveyor speed within the range of conventional conveyor belt speeds for a 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 drop plate) and determines the vertical position of the end of each inclined drop plate (e.g., the vertical position of the pivot axis corresponding to the vertical position of the end of each drop plate) such that the creaming line and the full rise line are at predefined positions, such that the change in height of the reactive mixture on any particular inclined drop plate over the time interval that the reactive mixture is on the particular inclined drop plate is at least partially offset by the drop in vertical height due to the tilt of the particular inclined drop plate.

[0140] As an example, if the conveyor belt speed is Vx, where x is the horizontal direction, the velocity of the mixture in the y direction on the inclined drop plate is the slope of the inclined drop plate multiplied by Vx. In one embodiment, the algorithm selects the vertical positions of the ends of the inclined drop plate (i.e., selects the slope of the inclined drop plate) such that the time interval the mixture is on the inclined drop plate times the velocity of the mixture on the inclined drop 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 drop plate is the length of the drop plate divided by the velocity of the mixture on the drop 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 drop plates to the change in vertical height between the end points of each of the respective inclined drop plates, a predefined predicted profile for the reactive mixture across all of the inclined drop plates can be obtained. In the particular embodiment described above, the predefined predicted profile has a substantially flat horizontal profile (i.e., a substantially flat horizontal top surface).

[0141] However, in a preferred embodiment, the vertical position of the end of each inclined drop plate (e.g., vertical position relative to 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 predefined predicted profile of the reactive mixture on multiple inclined drop plates having substantially flat inclined upper surfaces.

[0142] 3 illustrates a predefined predicted profile 302 of the reactive mixture on a plurality of inclined drop 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 drop plates 104 is approximately arctan[(height of the foam 137 above the conveyor h f x) / (horizontal length of multiple inclined drop plates d)]=arctan[(x h fIn 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 position of the vertical position of the end of the inclined drop plate and the conveyor speed results in a predicted rise profile having a positive slope angle (i.e., not zero), and more specifically, a positive slope angle on the reactive mixture 136 rising about 30% while being transported across the multiple inclined drop plates, resulting in a foam 137 on the conveyor having a substantially flat (i.e., not domed) top surface 306. 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 drop plate 104e.

[0143] In one embodiment, the user selects the conveyor speed and / or the number of inclined drop plates 104 and / or the length of the inclined drop plates 104 and / or the positioning 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), as described in connection with FIG. 3 below, and / or the position of the trough's side trough flip 130 relative to the trough's bottom surface 126) so that the reactive mixture rises approximately 30% while being transported across the multiple inclined drop plates. The vertical position (e.g., vertical position with respect to the pivot axis) of the end of each inclined drop plate given the conveyor speed selected as described above is calculated by software executed by the computer system based on the imported rise profile, resulting in a predefined predicted profile of the reactive mixture on the multiple inclined drop plates having a substantially flat upper surface with an inclination angle α.

[0144] 4 illustrates a foam-making machine 400 according to another embodiment of the present disclosure. Reference numbers of the foam-making machine 400 having the same reference numbers 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 including 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 drop plate 104a. That is, the first inclined drop plate is configured to receive the reactive mixture from the trough.

[0145] 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 referred to as the mixhead / trough parameters), the creaming line 132 will be positioned 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 and the number of inclined drop plates and / or the length of each inclined drop plate are selected, and in some embodiments, the mixhead / trough parameters are selected to provide a blow line (location of the full rise line) 134 located somewhere above the conveyor, as shown. Trials have proven that best results are obtained when the blow line (full rise line location) 134 is 0.2-1.2 m after passing the last drop plate. This is the preferred location for the blow line (full rise line location) 134. Depending on the variations in conveyor speed, trough size, and raw material output, the creaming line location and full rise line location are set to coincide with predefined positions. Thereafter, in order to obtain a foam 137 positioned 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 select the vertical position of each end of the inclined drop plates (or in some embodiments the vertical position of the pivot axis) and the conveyor speed based on the imported rise profile, as well as to select one or more of the parameters of the number of inclined drop plates and / or the length of each drop plate, the conveyor speed and / or the mixing head / trough to give a blow line 134 located 0.2m to 1.2m horizontally after the last drop plate on the conveyor 106, as well as a creaming line 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).

[0146] Referring back to FIG. 2 , step 212 may further include calculating, by the software executed by the computer system, a vertical position of the end of each inclined drop 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 drop 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, resulting in a substantially horizontal or inclined predicted profile of the reactive mixture on the multiple inclined drop plates 104 as the reactive mixture is transported along the multiple inclined drop plates 104.

[0147] 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 drop 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 drop 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 drop plate 104 and / or the conveyor 106. For example, if the machine settings initially determined by the software do not cause the machine 100, 400 to produce a foam 137 having a substantially flat top surface on 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 on the inclined drop plate in order to achieve a substantially flat top surface of the foam 137 on the conveyor 106, the user can input or modify one or more of the vertical positions of the end portions 118, 120 of the inclined drop 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 drop plate 104) and / or the conveyor speed initially selected / determined by the software. Upon receiving the user input, the software calculates a new predicted profile of the reactive mixture on the inclined drop plate 104 based on the imported rise profile and the user input.

[0148] 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.

[0149] 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.

[0150] In optional step 218, the processor of the cloud server automatically reads (or imports) from the cloud database a rise profile for the reactive mixture of precursor reagents based on, for example, a user profile stored in the cloud database. In one embodiment, the user profile includes purchase information for at least one of the precursor reagents of the reactive mixture.

[0151] In optional step 220, user purchase information for one or more precursor reagents is obtained by scanning a machine readable code associated with at least one precursor reagent 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) a rise profile for the reactive mixture of precursor reagents from the cloud database based on the machine readable code scanned in optional step 220.

[0152] 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 ) that 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 that includes 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 initially set) one or more of the vertical position of each end of the inclined drop plate, the rate of flow of the mixture from the mix head 102 to the pour plate 110 or trough 123, the speed of the conveyor 106, the longitudinal (i.e., in a direction parallel to the movement of the conveyor 106 and the form 137) positioning of the nozzle 103 of the mix head 102, or in other words, the longitudinal positioning of the laydown position 139 (FIG. 1) and / or the vertical positioning 141 of the nozzle 103 (FIG. 1), the vertical position 155 of the pour plate relative to the position of the conveyor, the volume of the trough 123 (FIG. 4) via adjusting and / or setting one or more of the width 147, length 149, and height 145 of the trough, and the vertical position 153 of the trough 123 relative to the position of the conveyor 106, e.g., the vertical position of the lip of the trough. Actuators are commonly known and can include pneumatic or electrical control elements that adjust the position and velocity of components of the manufacturing machine 100,400.

[0153] 2, the method 200 may optionally include step 222. In optional step 222, the processor outputs the calculated vertical positions and conveyor belt speeds for the ends of each inclined drop plate, the at least one machine processor 140 executes the controller software 142, the at least one machine processor 140 receives the output calculated vertical positions and conveyor belt speeds for the ends of each inclined drop plate, 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.

[0154] FIG. 5 shows a receptacle 500 according to one embodiment of the present disclosure. The receptacle 500 has four side walls 502 and a bottom surface 504. The side walls 502 and bottom surface 504 are covered by a process liner 506, as described above. Although the illustrated receptacle is shaped as a box, the scope of the present invention includes any polygonal shaped container, preferably without a top or lid. The characteristics of the receptacle 500 are described above. For example, the receptacle 500 may be an insulated box or other polygonal shaped container. In one embodiment, the side walls 502 and / or bottom surface 504 are made from a rigid foam insulation board 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 surface 504.

[0155] 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 and a cloud server 608. The cloud server 608 may also include a cloud database 610. In one embodiment, the cloud server may optionally include at least one processor 602.

[0156] 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.

[0157] For purposes of the description of the embodiments of the present disclosure, the reactive mixture 136 (FIGS. 1, 3, and 4) is continuously transformed from a more liquid state to a more solid state via chemical reactions as it is transported along the drop 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.

[0158] 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 Operations: 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 T80 (80% 2,4 isomer, 20% 2,6 isomer), from Covestro, 3 mPa·s, 48% NCO, functionality 2.

[0159] Methods for characterization of PU foam samples: The produced flexible PU foams can be evaluated according to the following physical properties a) to g): a) Full Rise Time: The period between the end of mixing of the reactive components and the blow-off of the polyurethane foam. Full rise time can also be measured from the first moment of volume expansion (end of creaming time). The scope of the embodiments herein covers full rise times measured from the initial mixing of the reactive components and full rise times measured from the creaming time. b) Maximum Rise Height: The maximum height of the free rise foam. Foam height is reported in centimeters (cm). c) Settlement of the foam at the end of the rise phase (=fallback): Settlement is determined from the difference in foam height directly after blow-off and 3 min 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 the settling of the foam after blow-off and positive values ​​represent correspondingly further rise of the foam. d) Number of bubbles per cm (bubble count): This is determined visually on a cut surface (measured in accordance with DIN EN 15702). e) Foam Density (FD): Determined by measuring the core density as described in ASTM D 3574-11 under test A. Foam density is expressed in kg / m 3The foam density is reported in mm. For full-scale industrial blocks, it is common to measure foam density in three locations (top-middle-bottom) since density usually exhibits a gradient within the foam block. Therefore, the density spread across the block is an important quality criterion. For laboratory box foaming, the exact center of the test block is used to measure foam density. 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, 12 specimens with dimensions of 5 cm x 5 cm x 2.5 cm were cut transversely from each of the finished foams to the foam rise direction and inserted consecutively 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 an air 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 more closed foams and higher values ​​characterizing more open foams. 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 spread of hardness across the 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. h) Creaming time: The period between the end of mixing of the reactants and the beginning of the volume expansion of the reaction mixture.

[0160] For completeness, the measurement principle of DIN EN ISO 16000-9:2008-04 is also elucidated below.

[0161] 400 g of polyol was used in each box foam run and other formulation components were recalculated accordingly, e.g., 1.00 part of the ingredient shown for 1.00 g of this material per 100 g of polyol.

[0162] 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 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 of rigid foam insulation boards 1 cm thick. The process liner was the same as that used in the subsequent industrial trials (Olmo paper by Mondi).

[0163] After pouring, the foam was allowed to rise in a 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 following characteristic parameters were determined: creaming time, complete rise time, rise height and foam fallback (=settling) after the end of the rise phase.

[0164] Results of discontinuous foaming Full rise time including creaming time: 100 seconds Creaming time: 14 seconds Full 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 Breathability: 3.1scfm Hardness, CLD40: 4.1kPa

[0165] The recorded full 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 height was then recalculated to a relative height by dividing by the maximum height. The rise profile with relative height was exported to the simulation software. The measured full rise time as well as the creaming time were included as separate data in the exported file.

[0166] Data processing and development of optimized machine settings Then, industrial trials were planned on an FB-20 5-section drop plate foaming machine manufactured by LaaderBerg Aps, Langrabben 14, 6013, Ålesund, Norway. The machine was used without a flat top processing unit. The machine uses a trough and five drop plates. In these trials, 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.

[0167] The machine has the following overall dimensions and certain settings: Trough volume: 80 L (for all trials) Trough height: 30cm Height of trough above conveyor: 66 cm (2 / 3 of block height for all trials) Falling board 1 length: 175cm Drop plate 2 length: 60cm Falling board 3 length: 120cm Falling board 4 length: 120cm Falling board 5 length: 85cm

[0168] In total, the length of the entire drop 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 trial. 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.

[0169] In total, the length of the entire drop 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 trial. 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.

[0170] For the trials, machine parameters were determined (i.e., optimized) based on a) calculated rise profiles, b) experimental rise profiles generated in discontinuous box foaming 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.

[0171] For the simulation of the correct machine parameters, the rise profile was loaded into the software, which converted the time-resolved expansion curve of the rise profile into a distance-resolved expansion curve of the top of the drop plate system and the subsequent conveyor system. An expansion of 2 / 3 at the bottom and 1 / 3 at the top was considered ideal. Furthermore, the position of the full rise line was placed about 0.5 m after the end of the last drop plate by selecting different conveyor speeds. The position of the creaming line was within the trough as required. With a trough volume of 80 L, the creaming line was about 2 / 3 of the trough height, which was considered optimal. The power factor was selected to result in a foam height of about 1.00 m after expansion. After the adjustment of the power factor, the position of the creaming line and the blow-off / full rise line were checked again. Again the conveyor speed had to be readjusted a little. Then the power had to be adjusted again, followed by checking the position of the creaming line and the position of the blow-off / full rise line. Two iterative cycles were necessary to minimize deviations from predefined values ​​so that they were considered acceptable (+ / - 5 cm for the position of the full rise line, + / - 2 cm for the creaming line, + / - 0.5 cm for the block height). The calculation of the rise profile for scenario a) was performed by assuming that the foam expansion always follows an S-curve: slow start when the reaction mixture is cold - fast expansion when the reaction mixture warms up - final slowdown when a particular raw material becomes less concentrated and the increase in viscosity reduces its reactivity. The S-curve was symmetrical with a slope turning point placed exactly in the middle. To determine the rise time, a set of parameters was developed that shows the influence of the various individual raw materials on the rise time. These parameters were determined by plotting the rise time in a double logarithmic diagram against the variation of the focus and concentration of the raw materials in foaming trials. The slope defines the parameter and is used in an exponential function to calculate the contribution of the raw materials to the rise time. By summing up the influence of the various raw materials, the rise time could be calculated. The following times were calculated: Full rise time including creaming time: 110 seconds Creaming time: 11 seconds Full rise time without creaming: 99 seconds

[0172] The full rise time including the creaming time was used as the full rise time. A symmetrical S-curve appeared between the start of foam expansion (after the creaming time) and the full 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 conventionally known. However, differences between such calculated rise profiles and the actually measured rise profiles can be observed.

[0173] 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 was shortened, which means that the expansion of the reaction mixture starts from zero. However, note that the creaming times are also slightly different.

[0174] While both curves appear similar, the time to full rise differs by more than 10 seconds, and the heights at various times vary to such an extent that different settings of the drop plate height are required (i.e., at various times, the drop plate height set according to the measured rise profile deviates significantly from the drop 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 creaming line within the trough (2 / 3 of the trough height), place the full rise / blow off line position 0.5 m after the end of the drop 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 foam manufacturers to produce foam according to Formulation 1.

[0175] a) Machine parameters for the calculated rise 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 drop plate 1: 37 cm above the conveyor baseline Height end of drop plate 2: 27 cm above the conveyor baseline Height end of drop plate 3: 8 cm above the conveyor baseline Height end of drop plate 4: 2 cm above the conveyor baseline Height of fall plate 5 end: conveyor height

[0176] b) Machine parameters for the measured rise 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 drop plate 1: 49 cm above the conveyor baseline Height end of drop plate 2: 40 cm above the conveyor baseline Height end of drop plate 3: 21 cm above the conveyor baseline Height end of drop plate 4: 7 cm above the conveyor baseline Height of fall plate 5 end: conveyor height

[0177] c) Empirical machine parameters used by foam manufacturers to produce foams 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 drop plate 1: 46 cm above the conveyor baseline Height end of drop plate 2: 39 cm above the conveyor baseline Height end of drop plate 3: 24 cm above the conveyor baseline Height end of drop plate 4: 7 cm above the conveyor baseline Height of fall plate 5 end: conveyor height

[0178] Industrial trial results Industrial trials were performed by using an FB 20 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 for the machine.

[0179] During the run the following observations were made: [Table 2]

[0180] 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]

[0181] 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), it was 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 higher in the center (1 cm higher). Naturally, the ideal blocks are rectangular with the same height at the center and on the sides to minimize scrap formation during cutting of the foam blocks into mattresses and other consumer goods.

[0182] Moreover, by using the machine parameters generated on the basis of the measured rise profile, a significantly more homogeneous density distribution could be obtained over the block cross section. The density deviation is even slightly better than the values ​​obtained by using the foam manufacturer's empirical parameters. The spread of low densities within 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 more smoothly, resulting in a more homogeneous density distribution. The calculated rise results in the highest density spread.

[0183] A similar trend can be observed for hardness, but the difference is smaller. The bubble count is comparable.

[0184] Overall, the results of the industrial trial using the exemplary reactive mixture (i.e., Formulation 1) demonstrate the advantageous use of rise profile data obtained from discontinuous box foam trials by the simulation software for predicting continuous flexible foam machine parameters and settings in optimizing the manufacturing process. By importing the measured rise profile data from the tailored box foaming experiments, more constant and consistent foam quality is obtained in continuous flexible foam production.

[0185] FIG. 8 illustrates a method 800 for setting machine parameters of a foam making machine according to one embodiment of the disclosure. The method covers setting machine parameters of foam making machine 100 (FIG. 1) and foam making machine 400 (FIG. 4). Foam making machine 100, 400 includes a mix head 102 configured to mix precursor reagents for forming reactive mixture 136, an intermediate transport unit 110, 123 configured to receive the reactive mixture from the mix head, a plurality of drop plates 104, and a conveyor 106 configured to receive the reactive mixture from the last drop plate 104e. The scope of this embodiment covers the intermediate transport unit being a pour plate 110 (FIG. 1) or a trough 123 (FIG. 4). Each drop plate has a vertically adjustable end 118, 120. A proximal end 118a of the first drop plate 104a is configured to receive the reactive mixture from the intermediate transport unit. The reactive mixture forms foam on the conveyor. In one embodiment, the method includes optional steps 802-808 that are identical to steps 202-208 described above in relation to Figure 2. Optional steps 802-808 will not be described in further detail here.

[0186] In step 810, the database is accessed by computer system 600 (FIG. 6) to read (also referred to as import) the characteristics of the foam making machine. In one embodiment, the computer system is a conventional computer system including at least one processor 602 configured to execute software for setting machine parameters of the foam making machine. According to one embodiment, a user of the computer system inputs, during execution or initialization of the software, identification information of the foam making machine utilized by the user, such as machine name, model number, name of the machine manufacturer, and / or other information identifying the foam making machine. In response, the processor reads (or imports) the characteristics of the respective machine based on the identification information from database 604 or by accessing an internet website containing information of the respective machine via network 606. In another embodiment, the processor queries the user for the identification information of the foam making machine during execution of the software, and then imports the machine characteristics based on the identification information from database 604 or by accessing an appropriate internet website via network 606.

[0187] Alternatively, upon initial execution of the software, the computer system may authenticate the user, and upon authentication, the processor reads (i.e., imports) the characteristics of the foam making machines from the database based on a user profile stored in the database. The user profile may include one or more foam making machines and one or more characteristics corresponding to each foam making machine. For example, the foam making machines corresponding to the user's profile (i.e., stored in association with the user's profile) may include machines whose machine settings were previously determined by the user or whose respective characteristics were previously imported. In one embodiment, the user indicates from which of two or more foam making machines corresponding to the user's profile and stored in the database to import characteristics.

[0188] In one embodiment, the characteristics include at least one dimension of the intermediate transport unit, a range of conveyor speeds, a number of drop plates, and / or a range of vertical positions for the vertically adjustable ends of the drop plates. As described in further detail below, the executed software is configured to determine the vertical position of the adjustable ends of the drop plates based on an iterative process of adjusting one or more of the flow rate (output) of the reactive mixture for the first drop plate given at least one dimension of the intermediate transport unit, the conveyor speed, and a predefined target height of the foam on the conveyor, the imported rise profile, the position of the creaming line of the reactive mixture before the proximal end of the first drop plate, and the position of the blow-off / full rise line of the reactive mixture about 0.5 m after the distal end of the last drop plate.

[0189] In step 812, the database is accessed by the computer system 600 (FIG. 6) to read (also referred to as import) a rise profile for the reactive mixture of precursor reagents. The rise profile includes the height of the mixture as a function of time as the precursor reagents react. According to one embodiment, a user of the computer system can define the components and / or component ratios 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) from the database a profile that corresponds to the parameters defined by the user. In one embodiment, the processor, upon executing the software, queries the user for input parameters. In another embodiment, the software directly imports the creaming time and complete rise time from a rise profile file. In another embodiment, the software requests the user to input the measured creaming time and complete rise time. In another embodiment, the software analyzes the rise profile curve and determines the creaming time and complete rise time by itself.

[0190] In one embodiment, the rise profile imported from the database is a laboratory rise profile, as described above in connection with steps 202-208 of FIG.

[0191] Alternatively, when the software is first run, the computer system can authenticate the user, and upon authentication, the processor reads (or imports) the Rise 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 Rise Profile is to be imported from the Rise Profiles associated with the user profile and stored in the database.

[0192] In step 814, a conveyor speed is selected from a range of conveyor speeds by the software executed by the computer system. In one embodiment, a conveyor speed approximately in the middle of the range of conveyor speeds of the identified foam making machine is selected. By selecting a conveyor speed that is approximately the average of the maximum and minimum conveyor speeds, the determination of the machine parameters, including determining the vertical position of the end of the drop plate, may advantageously require fewer iterations of the iterative process. In another embodiment, a maximum conveyor speed is selected from a range of conveyor speeds. By selecting a maximum conveyor speed from a range of conveyor speeds, the foam making machine advantageously allows for the foam block to be produced at a maximum production rate. In yet another embodiment, the software determines the conveyor speed and positions the full rise line 134 at a predefined location. The full rise line is also referred to as the blow off line 134. For example, the software calculates the conveyor speed as the length of the blow off position divided by the full rise time obtained from the imported rise profile. In one embodiment, the full rise time as well as the creaming time are used from the measurement data (i.e. also referred to as full rise time without creaming time). In one embodiment, the length of the full rise / blow off position is defined as the distance 151 after the distal end 120e of the last fall plate 104e (in some embodiments, a predefined distance of 0.5m) plus the total length of the fall plates (equal to the length of each fall plate times the number of fall plates).

[0193] In step 816, the software executed by the computer system determines the creaming line 132 based on the calculated conveyor speed using the creaming time obtained from the imported rise profile.

[0194] In step 818, the software executed by the computer system determines a value for at least one dimension of the intermediate transport units 110, 123 based at least on the determined conveyor speed, the determined position of the full rise line, and / or the determined position of the creaming line 132 of the reactive mixture, as determined in steps 816 and 814.

[0195] Referring to the pour plate embodiment (FIG. 1), the pour plate 110 is configured to receive the reactive mixture from the mix head 102. The position of the mix head 102 is adjustable in a longitudinal direction 143 to deposit the reactive mixture at a laydown location 139 on the pour plate. In one embodiment, the laydown location is measured (i.e., defined) relative to the proximal end 118a of the first drop plate 104a. A dimension of the pour plate 110 includes the laydown location 139. Another dimension of the pour plate is the vertical height 141 of the nozzle 103 of the mix head 102 as measured from the pour plate 110.

[0196] In one embodiment, the position of the creaming line 132 (FIG. 1) is measured relative to the proximal end 118a of the first fall plate 104a (see, e.g., measurement 133). Thus, as an illustrative example, given a fixed flow rate and a fixed laydown position, as the conveyor speed increases, the creaming line position value decreases (i.e., moves away from the laydown position toward or past the proximal end of the first fall plate) and the block height h decreases. In contrast, given a fixed flow rate and a fixed laydown position, as the conveyor speed decreases, the creaming line position value increases (i.e., moves away from the proximal end of the first fall plate toward the laydown position) and the block height h increases.

[0197] Thus, in one embodiment of step 818, the software is configured to receive as input the determined conveyor speed of the reactive mixture in front of the proximal end 118a of the first drop plate and the determined creaming line 132 as determined in step 816, and determine a laydown location where the creaming line is approximately equal to the creaming line determined in step 816. In one embodiment, the creaming line is located approximately 15 cm in front of the proximal end 118a of the first drop plate 104a.

[0198] Referring to the trough embodiment (FIG. 4), the trough 123 includes a lip 130 and a volume for holding the reactive mixture. In one embodiment, the reactive mixture is received from the mixhead 102 via the MTT 124 and the input port 127. The proximal end 118a of the first drop plate 104a is configured to receive the reactive mixture from the lip 130 of the trough 123. The dimensions of the trough include a trough height 145, a trough width 147, and a trough length 149. If the trough does not have a constant width or length, average values ​​can be used to define the width and length. According to one embodiment, the trough height is the distance between the bottom 126 of the trough 123 and the lip 130 of the trough 123. The trough volume is defined as the trough width x trough height x trough length.

[0199] In one embodiment, the position of the creaming line 132 (FIG. 4) is measured relative to the bottom 126 of the trough 123. Thus, as an illustrative example, the flow rate, trough volume, and possibly conveyor speed determine the position of the creaming line. In a first example, as shown by FIG. 4, if the creaming line 132 is positioned inside the trough, the flow rate and trough volume determine the position of the creaming line within the trough as measured from the bottom 126 of the trough 123. However, the flow rate, trough volume, and conveyor speed determine the position of the creaming line. In a preferred embodiment, the creaming line is a position within the trough 123, and therefore the position of the creaming line as measured from the bottom of the trough depends only on the volume of the trough and the flow rate of the reactive mixture from the mixhead to the trough.

[0200] Considering that the creaming line is positioned in the trough, for a given selected conveyor speed, as the flow rate increases, the height h of the block of foam on the conveyor 106 increases and the creaming line value 132 (measured from the bottom of the trough) increases. On the other hand, as the flow rate decreases, the height h of the block of foam on the conveyor 106 decreases and the creaming line value 132 (measured from the bottom of the trough) decreases.

[0201] Thus, in another embodiment of step 818, the software is configured to receive as input the determined conveyor speed of the reactive mixture in the trough and the creaming line 132 (i.e., the creaming line position value 132 measured relative to the bottom of the trough) as determined in step 816, and determine a trough volume at which the position of the creaming line is approximately equal to the position of the creaming line determined in step 816.

[0202] In one embodiment, the software is configured to determine the trough volume by adjusting at least one of the height, width, and length of the trough such that the creaming line of the reactive mixture is equal to the creaming line location determined in step 816, which in one embodiment is located inside the trough. In another embodiment, the creaming line of the reactive mixture is located at a distance of about 1 / 3 of the height of the trough below the lip, and the height of the trough is defined as the distance from the lip of the trough to the bottom of the trough.

[0203] The flow rate (output) of the reactive mixture is directly proportional to the flow rate of the precursor reagent through one or more transport conduits 108. The conduits 108 may be connected to one or more storage containers (not shown) that store the reagent under predetermined conditions. The flow rate of the precursor reagent through the transport conduits, and thus the flow rate of the reactive reagent through the nozzle 103 of the mix head 102 in the embodiment of the pour plate 110 of the intermediate transport unit, and through the MTT 124 in the embodiment of the trough of the intermediate transport unit, can be controlled by a pump or pump system (not shown).

[0204] In step 820, the software is configured to determine a flow rate (output) based on the determined conveyor speed such that a foam block having a height of approximately the predetermined height hf with a (predetermined) density is produced. For example, increasing the flow rate increases the block height given the determined conveyor speed and a given block width, and decreasing the flow rate decreases the block height given the determined conveyor speed and a given block width. Thus, in one embodiment, the software is configured to receive the predefined block width, predefined block height hf, predefined block density, and conveyor speed as determined in step 814, and determine a flow rate that will result in a block having these characteristics.

[0205] Thus, in step 822, the software executed by the computer system iteratively repeats steps 814-820, thereby adjusting (i.e., fine-tuning) the parameters of the conveyor speed, the creaming line (i.e., the position of the creaming line), the position of the full rise line, at least one dimension of the intermediate transport unit (e.g., the size of the trough of the pour plate or the laydown position), and the flow rate to provide a final flow rate, final values ​​for at least one dimension of the intermediate transport unit, the final creaming line position, the final position of the full rise line, and the final conveyor speed, so that the blocks have a predefined block height and density, and the creaming line and blow off line are equal to or approximately equal to their predefined (also called preselected) values ​​set by a user or defined in a data input file to the software.

[0206] For example, in a first iteration of steps 814-820, in connection with an embodiment of the pour plate of the intermediate transport unit (FIG. 1), the software initially determines a new flow rate of the reactive mixture onto the first drop plate 104a, a new position of the creaming line, and new values ​​for at least one dimension of the pour plate 110 (e.g., laydown position and / or vertical nozzle height) based at least on a new conveyor speed (i.e., the new conveyor speed adjusted in step 814) and a predetermined target height hf and density of the foam 137 on the conveyor 106, all of which are defined and / or selected by the user.

[0207] For example, in a first iteration of steps 814-820, in connection with an embodiment of the trough of the intermediate transport unit (FIG. 4), the software initially determines a new flow rate of the reactive mixture to the first drop plate 104a, a new position of the creaming line, and a new value for at least one dimension of the trough 123 (e.g., a new value for the trough volume based on adjusting at least one of the three trough dimensions as described above) based at least on a new conveyor speed (i.e., the new conveyor speed adjusted in step 814) and a predefined target height hf and density of the foam 137 on the conveyor 106, all of which are defined and / or selected by the user.

[0208] In one embodiment, according to step 822, the software determines the degree of convergence of one or more of the parameters determined in steps 814-820. If the software determines acceptable convergence of one or more of the determined parameters, the method continues to step 826. In one embodiment, the software receives as input, at start-up or initialization, one or more predefined convergence percentages. An exemplary embodiment of the predefined convergence percentage values ​​is 0.2%-0.02%. In one embodiment, the predefined convergence percentage is 0.1%. For example, if there is less than 0.1% change between successive values ​​of any particular parameter, or in one embodiment, between each of the determined parameters, the solution has converged and the method continues to step 826. In another embodiment, the software is configured to repeat steps 814-820 a predefined number of times, for example, 1-3 times. In one embodiment, the software repeats steps 814-820 two times.

[0209] In step 822, if at some point in the iteration the software is unable to repeat steps 814-820, for example because the intermediate transport unit does not have parameters to which further adjustments can be made, or in other words because adjustments to any of the characteristics of the foam-making machine's components are limited, the method continues to step 824. In step 824, in one embodiment, the method informs the user that additional user-initiated steps will be performed. Additional user steps may include replacing the intermediate transport unit 110, 123 with a different transport unit having, for example, a different range of adjustable trough or pour plate dimensions and / or a different range of movement of the mix head 102, or importing a different rise profile or forming a different reactive mixture from a different mixture of reagents not currently stored as a rise profile in the database. Thus, depending on the decision made by the user in step 824, which may be received as an input to the software being executed, the method continues to either step 802 if the user decides to mix different reagents to create a rise profile not currently stored in the database, step 810 if the user decides to replace one or more components of the foam manufacturing machine (e.g., replacing the intermediate transport unit with a different transport unit having, for example, a different range of trough sizes or a different range of laydown positions, or replacing the conveyor with a different conveyor having a different range of conveyor speeds), or step 812 if the user decides to import a different rise profile.

[0210] In step 826, the software executed by the computer system determines a vertical position for the end of each drop plate based on the rise profile and the final conveyor speed that results in a predefined predicted profile of the reactive mixture on the multiple drop plates as the reactive mixture is transported along the multiple drop plates by the conveyor moving at the final conveyor speed. Step 212 (FIG. 2) discloses in more detail the determination of a vertical position for the end of each drop plate that results in a predefined predicted profile of the reactive mixture on the multiple drop plates based on the rise profile and the final conveyor speed. Step 212 is incorporated into the FIG. 8 embodiment of the present disclosure.

[0211] In one embodiment, the predefined predicted profile has a substantially flat top surface 304 (FIG. 3). The substantially flat top surface has a slope angle of approximately arctan [(predefined percentage of foam height above conveyor) / (horizontal length of the plurality of inclined drop plates)]. As shown by FIG. 3, the predefined percentage of foam height above conveyor is defined as xhf and the horizontal length of the plurality of inclined drop plates is defined by reference numeral 308. In one embodiment, the predefined percentage of foam height above conveyor xhf is approximately 1 / 3 of the foam height hf above conveyor 106.

[0212] In step 828, a formula using data on the exothermic energy of the various reactions, the heat capacity of the raw materials used, the heat of vaporization of the physical blowing agent, as well as the starting temperatures of the raw materials is used to calculate the maximum temperature of the foam during production by chemical reaction. The temperature obtained represents the maximum temperature if all raw materials react completely in one step at a time. The value for this maximum temperature is compared with a value for a maximum foam temperature that is considered safe in foam production. If the value is exceeded, a warning is issued. Potentially, printouts, export from the simulation software, or further processing are also automatically blocked. Thus, the software is configured to compare the calculated maximum temperature with a predefined maximum foam temperature, and if the calculated temperature is less than or equal to the predefined maximum temperature, the method continues with step 830. If the calculated temperature is higher than the predefined maximum temperature, the method continues with step 802.

[0213] In step 830, the software executed by the computer system stores at least one of the final flow rate, the final value for at least one dimension of the intermediate transport unit, the final conveyor speed, and the vertical position for the end of each drop plate in database 604 and / or 610 (FIG. 6).

[0214] According to another embodiment in which the intermediate transport unit comprises a trough 123 (FIG. 4), the software executed by the computer system is configured to adjust the position of the trough 123 such that the vertical distance 153 between the lip 130 of the trough 123 and the conveyor 106 is approximately 2 / 3 of the predefined target height hf of the form. In one embodiment, the software adjusts the position of the trough between steps 824 and 826 (FIG. 8). However, the scope of this disclosure includes software adjusting the position of the trough at or before step 812 (FIG. 8). In yet another embodiment in which the intermediate transport unit comprises a pouring plate 110 (FIG. 1), the software executed by the computer system is configured to adjust the vertical position of the pouring plate such that the vertical distance 155 between the pouring plate and the conveyor is approximately 2 / 3 of the predefined target height hf of the form. In one embodiment, the software adjusts the position of the pouring plate between steps 824 and 826 (FIG. 8). However, the scope of this disclosure includes software adjusting the position of the pouring plate at or before step 812 (FIG. 8).

[0215] According to a further embodiment, the software executed by the computer system is configured to iteratively, i.e., repeat once or twice, the determination and adjustment (i.e., steps 814-820) to provide a final flow rate, a final value for at least one dimension of the intermediate conveying unit, and a final conveyor speed.

[0216] In another embodiment, the software executed by the computer program is configured to prompt the user to adjust one or more of the determined vertical positions of the ends of each inclined drop plate and / or the conveyor speed to adjust the predicted profile of the reactive mixture on the conveyor. For example, in one embodiment, the predicted profile calculated by the software based on using the final values ​​for the flow rate, at least one dimension of the intermediate transport unit, and the conveyor speed, and further based on using the determined vertical positions of the ends of the drop plates and the imported rise profile to generate a foam of predefined height hf, is displayed to the user of the software via a display or monitor (not shown) communicatively coupled to the computer system 600 (FIG. 6). The user may wish to adjust the predicted profile, such as adjusting the shape of the top surface 304 (FIG. 3) of the profile, or adjusting the inclination angle of the top surface, or possibly adjusting the top surface to have different portions with different inclination angles. If the user wishes to adjust the predicted profile, the user, in response to a prompt, inputs one or more vertical positions of the end of each inclined drop plate (e.g., knowing the determined final vertical positions, the user can make adjustments to one or more of the determined final vertical positions and input the adjustments as new vertical positions) and / or inputs a new conveyor speed (e.g., knowing the determined final conveyor speed, the user can make adjustments to the final conveyor speed and input the adjustments as new conveyor speeds). In response to the user inputting new values ​​for one or more machine parameters, the software executed by the computer processor is configured to replace any previously determined final values ​​with the new values ​​and then calculate a new predicted profile based on the rise profile and the previously determined or newly replaced machine parameters. The software can then display the new predicted profile of the reactive mixture on the conveyor to the user via a display or monitor.

[0217] In another embodiment, the foam making machine 100, 400 further includes a machine control unit 138 (FIGS. 1 and 4). The machine control unit includes at least one machine processor 140, controller software 142 executable by the processor, and an actuator unit 146 including one or more actuators for controlling settings of the foam making machine. In one embodiment, the machine control unit includes a memory 144 configured to store the controller software 142. The method further includes executing the controller software by the at least one machine processor, where executing the controller software includes (1) receiving data including at least one of a final value for at least one dimension of the intermediate transport unit, a final conveyor speed, a final flow rate, and a determined vertical position for an end of each drop plate, (2) generating control signals based on the received data, and (3) sending control signals to the actuator unit to automatically control settings of the foam making machine (e.g., automatically adjusting or setting machine parameters to the final values ​​in the received data, including setting or adjusting the vertical positions for the ends of each drop plate to the determined vertical positions in the received data).

[0218] 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.

[0219] 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.

[0220] 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 of the above. A non-exhaustive list of more 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 on them, and any suitable combination 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.

[0221] Although the present description and examples describe a method, software, and / or machine having an inclined drop 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 drop plate having vertically increasing foam formation, whereby the embodiments, details, examples, and any aspects described herein shall apply accordingly insofar as practicable. As an example of a similar method, the following shall apply:

[0222] 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, the conveyor having an adjustable conveyor speed, the method including executing software by a computer system, the computer system including at least one processor, the executing the software including accessing a database to read a rise profile for the reactive mixture of precursor reagents, the rise profile including a height of the mixture as a function of time as the precursor reagents react to form foam, and calculating, based on the rise profile, a conveyor speed that results in a predefined predicted profile of the reactive mixture on the conveyor as the reactive mixture is transported along it.

[0223] In one preferred embodiment, based on the rise profile, machine parameters are further calculated that result in a predefined predicted profile of the reactive mixture on the conveyor as the reactive mixture is transported along it.

Claims

1. A method for automatically setting the machine parameters of a foam making machine (100, 400), the foam making machine comprising: a mixing head (102) configured to mix a precursor reagent for forming a reactive mixture (136); intermediate transport units (110, 123) configured to receive the reactive mixture from the mixing head; a plurality of drop plates (104), the proximal end (118a) of a first drop plate (104a) configured to receive the reactive mixture from the intermediate transport units, each drop plate comprising a plurality of drop plates having vertically adjustable ends (118, 120); and a conveyor (106) configured to receive the reactive mixture from the last drop plate (104e), the reactive mixture forming a foam (137) on the conveyor, the method comprising: The process includes executing software by a computer system (600), wherein the computer system includes at least one processor (602), and the execution of the software is performed by: Importing the characteristics of the foam manufacturing machine from a database (604, 610), wherein the characteristics include one or more of the dimensions of at least one intermediate transport unit, the range of conveyor speeds, the number of drop plates, and the range of vertical positions of the vertically adjustable ends of the drop plates. Importing the rise profile of the reactive mixture of the precursor reagent from the database, wherein the rise profile includes the height of the mixture as a function of time when the precursor reagent reacts, The conveyor speed is determined from the range of conveyor speeds based on the rise profile, The position of the creaming line (132) and / or the full rise line (134) is determined based on the rise profile and the determined conveyor speed, The determined conveyor speed, the determined position of the creaming line, the determined position of the full rise line, and / or the predefined target height h of the form ｆ Based on at least one of the following, the values ​​for the at least one dimension of the intermediate transport unit and the flow rate of the reactive mixture to the first drop plate are determined, The determination to provide the final flow rate, the final value for at least one dimension of the intermediate conveying unit, the final conveyor speed, the final position of the creaming line, and / or the final position of the full rise line is repeated iteratively, Based on the rise profile and the final conveyor speed, the vertical position of each end of the drop plate is determined to result in a predefined predicted profile of the reactive mixture on the drop plates when the reactive mixture is transported along the drop plates by the conveyor moving at the final conveyor speed. including, method.

2. The determined conveyor speed, the determined position of the creaming line and / or the determined position of the full rise line, and the predefined target height h of the form. ｆ and, based at least on a predetermined density of the foam on the conveyor, determine values ​​for at least one dimension of the intermediate transport unit and the flow rate of the reactive mixture to the first drop plate. The method according to claim 1, further comprising:

3. The method according to claim 1, further comprising storing in the database the final flow rate, the final value for at least one dimension of the intermediate conveying unit, the final conveyor speed, and at least one of the vertical position for the end of each drop plate.

4. The intermediate transport unit comprises a trough (123) having a lip (130) and volume and configured to receive the reactive mixture from the mixing head, or a pouring plate (110) configured to receive the reactive mixture from the mixing head, wherein the position of the mixing head is adjustable to deposit the reactive mixture at a laydown position (139) on the pouring plate, the proximal end of the first drop plate is configured to receive the reactive mixture from the lip of the trough or from the end of the pouring plate distal to the laydown position, the at least one dimension of the trough includes at least one of the height (145), width (147), and length (149) of the trough, the height of the trough is the distance between the bottom (126) of the trough and the lip, and the at least one dimension of the pouring plate includes the distance between the laydown position on the pouring plate and the proximal end of the first drop plate.

5. Between the repeated process and determining the vertical position of the end of each drop plate, the vertical distance (153) between the lip of the trough and the conveyor is such that the form reaches the predefined target height h ｆ Adjust the position of the trough so that it is approximately 2 / 3 of the form, or the vertical distance (155) between the pouring plate and the conveyor is the predefined target height h of the form. ｆ The method according to claim 1, further comprising adjusting the position of the pouring plate so that it is approximately two-thirds of the total.

6. The method according to claim 1, wherein determining a value for the at least one dimension of the trough involves adjusting the volume of the trough by adjusting the height, width, and length such that the determined position of the creaming line of the reactive mixture is located inside the trough.

7. The method according to claim 1, wherein the determined position of the creaming line is located at a distance of about one-third of the height of the trough below the lip.

8. The method according to claim 1, wherein determining a value for the at least one dimension of the pouring plate includes selecting the distance between the laydown position on the pouring plate and the proximal end of the first drop plate such that the determined position of the creaming line is located about 15 cm in front of the proximal end of the first drop plate.

9. Determining the flow rate of the reactive mixture to the first drop plate is done by taking into account the predetermined density, such that the height of the form on the conveyor is the predetermined target height h of the form. ｆ The method according to claim 1, comprising determining the flow rate to match the following.

10. The method according to claim 1, wherein determining the value of the at least one dimension of the intermediate transport unit is based on positioning the determined position of the creaming line of the reactive mixture in front of the proximal end of the first drop plate.

11. The method according to claim 1, wherein the predetermined distance from the distal end of the last drop plate to the determined position of the complete rise line is in the range of 0.2 m to 1.2 m.

12. The method according to claim 1, wherein the iterative repetition of the determination to provide the final flow rate, the final value for at least one dimension of the intermediate conveying unit, the final conveyor speed, the final position of the creaming line, and / or the final position of the full rise line is repeated once, twice, or several times until the values ​​converge to a constant value.

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

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

15. The software, executed by a computer program, prompts the user to adjust one or more of the conveyor speeds to adjust the determined vertical position of the end of each inclined drop plate and / or the predicted profile of the reactive mixture on the conveyor. The method according to claim 1, further comprising:

16. The manufacturing machine further includes a machine control unit (138), the machine control unit includes at least one machine processor (140), controller software (142) executable by the processor, and an actuator unit (146) including one or more actuators for controlling the settings of the foam manufacturing machine, and the method is The process further includes executing the controller software by at least one machine processor, and executing the controller software means Receiving data including the final value for at least one dimension of the intermediate transport unit, the final conveyor speed, the final flow rate, and at least one of the determined vertical positions for the ends of each drop plate, To generate a control signal based on the received data, To automatically control the settings of the foam manufacturing machine, the control signal is transmitted to the actuator unit. including, The method according to claim 1.

17. The method according to claim 1, wherein the rise profile is a laboratory rise profile.

18. The method according to claim 1, wherein the sensor for determining the rise profile is an ultrasonic measuring sensor and / or a 3D laser scanner.

19. A computer-readable medium that, when executed by a processor or computer, stores instructions causing the processor or computer to perform the method according to any one of claims 1 to 18.

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