Surfactant composition for flexible polyurethane foam

Abstract

The invention relates to a silicone surfactant composition for the use in polyurethane foam, comprising A) one or more silicone surfactant compounds; B) one or more surfactant potency-enhancing agents, in particular one or more organic acids; and C) optionally one or more diluents. The invention further relates to a process for the production of a polyurethane foam comprising the silicone surfactant composition, a polyurethane foam-forming composition comprising the silicone surfactant composition, and a polyurethane foam formed from polyurethane foam-forming compositions comprising the silicone surfactant composition.

Description

[0001] SURFACTANT COMPOSITION FOR FLEXIBLE POLYURETHANE FOAM

[0002] The present invention relates to a high potency silicone surfactant composition containing a surfactant potency-enhancing agent, in particular an organic acid, for flexible polyurethane foam, a method for preparing a high potency silicone surfactant composition containing a surfactant potency-enhancing agent, in particular an organic acid, the use of a high potency silicone surfactant composition containing a surfactant potency-enhancing agent, in particular an organic acid, in the production of flexible polyurethane foam, a process for the production of flexible polyurethane foam relying on a high potency silicone surfactant composition containing a surfactant potency-enhancing agent, in particular an organic acid, and polyurethane foam prepared with a silicone surfactant composition containing a surfactant potency-enhancing agent, in particular an organic acid.

[0003] In polyurethane foam processing technology, the main effect of silicone surfactants is to stabilize the foam cell structure. The stabilization-capability (potency) of silicone surfactants is dependent on the silicone surfactant’s molecular structure, typically including a silicone backbone and polyether chain structures bonded to the silicone backbone of the silicone surfactant.

[0004] Critical polyurethane systems, such as low-density foam or filled foam, are easy to split and collapse, so, high potency silicone surfactants are required to stabilize the foam until the product-forming chemical reaction completes sufficiently, and the foam is self-supporting. Accordingly, there is a demand for silicone surfactants with a high stabilization capability in the stabilization of the urethane foam cell structure.

[0005] The present inventory provides a new approach: the combination of a surfactant potencyenhancing agent, in particular an organic acid, and one or more silicone surfactant compounds in a silicone surfactant composition, which increases the silicone surfactant stabilization capability further.

[0006] This new approach for the provision of a high potency silicone surfactant composition comprising a surfactant potency-enhancing agent, in particular an organic acid, silicone surfactant compounds, and optionally one or more diluents brings surprisingly high potency for urethane foam processing at low weight percentage of the surfactant potency-enhancing agent, in particular an organic acid.

[0007] Background art

[0008] In US 9334382 B2, a process for producing flexible polyurethane foam is disclosed, wherein the composition disclosed in said document comprises a cell opener, a cell opener aid, a tertiary amine catalyst and optionally an acid. Examples of suitable acids comprise any organic carboxylic acids containing any saturated or unsaturated and substituted or unsubstituted aliphatic or aromatic group with single or multiple acid groups with or without isocyanate reactive groups. The acid therein is added to block the amine catalyst used in the foaming process. The composition as claimed in US9334382 B2 requires the presence of at least one silicone surfactant, wherein the type and the amount of the silicone surfactant and the amount of the optional acid constituent of the composition are not specified.

[0009] US5489617A is directed at high viscosity nonhydrolyzable silicone surfactants for the manufacture of polyurethane foams, wherein they give a high height of rise and little top collapse.

[0010] In US8044109 B2, a process for preparing low density polyurethane foams is disclosed, wherein a high potency silicone copolymer surfactant is applied to address the problem of coarse cell structure and low surfactant potency in cell stabilization.

[0011] In W02008 / 019928 A1 , silicone surfactant compositions comprising a polyethersiloxane, water, dipropylene glycol and the sodium salts of linear alkylbenzenesulfonate are disclosed. Further, a surfactant composition comprising a polyethersiloxane, water and a surfactant, which may be PEG 20 sorbitanmonolaurate, and ester, or cocoamphoacetate, a carboxylic acid salt, is disclosed, however, the document does not disclose any surfactant composition comprising a carboxylic acid.

[0012] In WO 2024 / 020776 A1 , a surfactant composition comprising a silicone surfactant with pendant alkyl chains, water and acetic acid, which is then introduced into a Pll foam-forming composition to make a Pll foam is disclosed.

[0013] In WO 2017 / 180741 A1 , a composition consisting of a silicone surfactant and rapeseed methyl ester, which is used for making polyurethane foam from a foam-forming composition is disclosed.

[0014] The present invention is intended to provide a simple method for the production of silicone surfactant compositions containing a surfactant potency-enhancing agent, in particular an organic acid, that have a high potency in urethane foam stabilization, to provide the silicone surfactant compositions containing a surfactant potency-enhancing agent, in particular an organic acid, that have a strong stabilizing effect in the processing of polyurethane foam with or without a filler, and to provide a process for the production of polyurethane foams in which the silicone surfactant composition containing a surfactant potency-enhancing agent, in particular an organic acid, is applied in order to benefit from the superior stabilizing properties of the surfactant.

[0015] The invention as disclosed herein provides a new approach to design silicone surfactant compositions displaying a high potency in foam stabilization at a lower silicone copolymer concentration. The silicone surfactant compositions according to this invention are less viscous and easy to charge during the foaming process. The silicone surfactant compositions according to the invention provide foam blocks displaying an improved, i.e. higher, stabilization, offer a broad processing latitude for both pure and high filled foam formulations with less metal gelling catalyst, for example stannous octoate, in the formulations. The foams formed with this type of silicone surfactant composition have better firmness and tensile strength in the flexible polyurethane foam. The foam performance of a flexible polyurethane foam is optimized when the airflow is reduced. A lowered airflow of the polyurethane foam is beneficial because the airflow has a direct correlation to hardness in polyurethane foam. In general, lower airflow leads to higher hardness as the Pll foam struts and cell walls can get thicker. When using the silicone surfactant composition according to the invention in the preparation of polyurethane foams, a lower airflow is achieved while not impacting significantly other properties, and hardness improvement is achieved.

[0016] Thus, the present invention aims also at silicone surfactant compositions providing polyurethane foams with lower airflow while maintaining or even improving firmness and tensile strength of the flexible polyurethane foams. Likewise, the improved properties of the flexible polyurethane foams regarding uniformity of the polyurethane foam obtained when using the silicone surfactant compositions described herein are indicated by the lowered difference of top and bottom core density values of the polyurethane foams, and the lowered difference of top and bottom compression force deflection (CFD) at 40% values obtained when using the surfactant compositions according to the invention.

[0017] SUMMARY OF THE INVENTION

[0018] Addressing the need for surfactant compositions displaying an improved performance in stabilizing PU foams, the present invention relates to a silicone surfactant composition containing a surfactant potency-enhancing agent, in particular an organic acid, which is a silicone surfactant composition for the use in polyurethane foam, comprising

[0019] A) one or more silicone surfactant compounds

[0020] B) one or more surfactant potency-enhancing agents

[0021] C) optionally one or more diluents.

[0022] The invention further relates to a method for preparing a silicone surfactant composition containing a surfactant potency-enhancing agent, in particular an organic acid, the use of a silicone surfactant composition containing a surfactant potency-enhancing agent, in particular an organic acid, in the production of flexible polyurethane foam, a process for the production of flexible polyurethane foam relying on a silicone surfactant containing a surfactant potencyenhancing agent, in particular an organic acid, and polyurethane foam prepared with a silicone surfactant composition containing a surfactant potency-enhancing agent, in particular an organic acid.

[0023] DETAILED DESCRIPTION OF THE INVENTION

[0024] In the following, the invention is described in detail.

[0025] All features and specific selections of features and ranges described in the following as being according to the invention may be combined without any restrictions or limitations unless a combination is not possible due to the mere requirements of logic. In the same manner, different embodiments according to the invention described below may be combined, and single features or selections of features and ranges of embodiments of the invention may be combined with other embodiments of the invention.

[0026] As stated above, the invention relates to a silicone surfactant composition for the use in polyurethane foam, comprising

[0027] A) one or more silicone surfactant compounds

[0028] B) one or more surfactant potency-enhancing agents

[0029] C) optionally one or more diluents.

[0030] In this description of the invention, the terms “silicone surfactant composition” and “surfactant composition” may be used interchangeably. In an embodiment, one or more of the silicone surfactant compounds A) is a silicone surfactant compound comprising a silicone backbone and one or more polyether substituents R*, which may be the same or different, attached to one or more Si atoms of the silicone backbone.

[0031] According to the invention, it is preferred that the component B) of the silicone surfactant composition is a carboxylic acid with 4 or more carbon atoms, wherein one or more of the silicone surfactant compounds A) is a silicone surfactant comprising a silicone backbone and one or more polyether substituents R*, which may be the same or different, attached to one or more Si atoms of the silicone backbone, and wherein the amount of component A) in the silicone surfactant composition is 15.0 weight-% or more based on the overall weight of the surfactant composition. Preferably, the carboxylic acid is a monocarboxylic acid, and also preferably it is a carboxylic acid with 6 or more carbon atoms, even more preferably a monocarboxylic acid with 6 or more carbon atoms.

[0032] Silicone surfactant compounds A)

[0033] According to the invention, a silicone surfactant compound is a class of surfactants with a polydimethylsiloxane backbone and one or more groups R attached to the internal or terminal Si atoms of the siloxane backbone, wherein the groups R are hydrophilic polar organyl groups and the polydimethylsiloxane backbone is hydrophobic.

[0034] According to the invention, any structure comprising 5 or more, preferably 10 or more, more preferably 15 or more, and still more preferably 20 or more siloxy units selected from

[0035] M* representing (CH3)3SiOi / 2 or (CH3)2RSiOi / 2;

[0036] D representing (CH3)2SiO2 / 2;

[0037] D” representing (CH3)RSiO2 / 2;

[0038] T representing (CH3)SiO3 / 2 or RSiC>3 / 2; and Q-units SiC>2 directly bonded to each other forms a silicone backbone, specifically a polydimethylsiloxane backbone. The silicone backbone may be linear, branched, cyclic, or linear comprising a cyclic structure. The silicone backbone formed by the above-cited units bears at least one hydrophilic polar organyl group R, which is preferably a polyether group R*. The silicone surfactant compounds A) as defined above are preferably prepared by hydrosilylation reactions of polysiloxane hydride compounds containing corresponding to the structure of the polysiloxane backbone defined above, which thus comprise 5 or more, preferably 10 or more, more preferably 15 or more, and still more preferably 20 or more siloxy units selected from

[0039] MF* representing (CH3)3SiOi / 2 or (CH3)2HSiOi / 2;

[0040] DF representing (CH3)2SiO2 / 2;

[0041] DF” representing (CH3)HSiO2 / 2;

[0042] TFrepresenting (CH3)SiO3 / 2 or HSiO3 / 2; and Q-units SiC>2 directly bonded to each other, and comprise one or more terminal, internal, or both terminal and internal Si-H moieties, with precursor compounds of the hydrophilic polar organyl groups R, in particular with polyether compounds containing at least one unsaturated C-C bond, in particular a terminal C- C double bond, which are the precursors of the polyether groups R*.

[0043] Preferably, the polysiloxane hydrides providing the backbone structure of the silicone surfactant compounds have the formula

[0044] MF* (DF)x(DF”)y MF*, with

[0045] MF*, DF and DF” as defined above, x is 0-200; y is 2 or more; x+y is 10 to 250; the ratio of x to y is 2 to 50, resulting in the formation of a silicone surfactant compound of the general formula M*DxD”yM* (I), wherein

[0046] M* represents (CH3)3SiOi / 2 or (CH3)2RSiOi / 2;

[0047] D represents (CH3)2SiO2 / 2;

[0048] D” represents (CH3)RSiO2 / 2; with x, y, x+y and the ratio of x to y being as defined above, and R is a hydrophilic group as described before, preferably R represents a polyether substituent R*.

[0049] More preferably, in the formula

[0050] MF* (DF)x(DF”)yMF*,

[0051] MF* represents (CH3)3SiOi / 2 exclusively, while DF and DF”, X, y, x+y and the ratio of x to y are as defined above, resulting in silicone surfactant compounds bearing no terminal hydrophobic groups.

[0052] Hydride-containing silicone compounds as described above are commercially available and procedures for their synthesis are known to those skilled in the art. For example, the synthesis of hydride containing silicone compounds often referred to as silicone fluids is described in US 5489617 A.

[0053] While various silicone compounds with polyether substituents are commercially available, e.g. under the trademark NIAX® of Momentive Performance Materials such as NIAX® L-895, L- 865 or L-580, the hydrosilylation reactions and the methods for the provision of the starting materials required therefore are known to those skilled in the art and are disclosed, for example, in W02023 / 009390 A1 , US 5489617 A and US 2009 / 0253817 A1 , which are hereby incorporated by reference.

[0054] The hydrosilylation reaction is preferably a transition metal-catalyzed hydrosilylation reaction, typically a hydrosilylation reaction catalyzed by platinum compounds, e.g. H2PtCle or Karstedt’s catalyst, and may be performed in the presence or absence of a solvent. The hydrosilylation reaction usually proceeds in a quantitative manner.

[0055] Silicone surfactants can be divided into nonionic, anionic, cationic and zwitterionic silicone surfactants according to the chemical properties of the hydrophilic group R in their chemical structure. According to the invention, nonionic silicone surfactants are preferred.

[0056] Cationic silicone surfactants contain cationic structural groups in the groups R, such as alkyl quaternary ammonium compounds, amido quaternary ammonium compounds and imidazoline derived quaternary ammonium compounds, anionic silicone surfactants contain anionic structural units in the group R, such as phosphate ester salt, sulfate salt, carboxylate salt, sulfonate salt and sulfosuccinamide ester, and amphoteric or zwitterionic silicone surfactants contain a structure having both anionic and cationic properties in the group R, such as phosphate betaine or betaine groups.

[0057] In nonionic silicone surfactants, the groups R do not contain any anionic or cationic groups. The groups R contain units such as polyether, alkanolamide, ester, and glycoside, wherein according to the invention groups R containing polyether units, in the following also referred to as polyether substituents R*, are preferred. Such silicone surfactants are generally referred to as polyether functional silicone surfactants, polyether silicone surfactants, silicone polyether surfactants, or siloxane-oxyalkylene copolymer surfactants. Herein, these terms and similar terms may be used interchangeably. By definition, any organyl group R containing two or more ether moieties -O-, i.e. oxygen atoms substituted with two organyl residues, is considered a polyether substituent R*.

[0058] More specifically, a group of polyether substituents R* is generally characterized by containing one or more polyalkylene oxide units, preferably polyalkylene oxide units selected from ethylene oxide (EO), propylene oxide (PO) and butylene oxide (BO) units, wherein the polyether substituents may contain one, two or three types of the aforementioned EO, PO and BO units without a general limitation of the ratio of the units.

[0059] The precursor compounds of the polyether substituents R* attached to the silicone backbone of the silicone surfactant compounds, in particular alkenyl-terminated polyesters, are commercially available or may be prepared by combining an alcohol comprising a C-C double bond, specifically an allyl alcohol, with one or more alkylene oxides, in particular with one, two or three of ethylene oxide, propylene oxide and butylene oxide, in the presence of a Lewis acid or a base, to yield the desired polyether with a terminal hydroxy group. The epoxides may be block-fed or randomly distributed along the ether chain. The resulting polyether is then typically capped by further reaction with an alkylating or acylating agent such as a methyl halide or acetic anhydride. Such procedures are common in the art and known to the person skilled in the art, and are disclosed, for example, in US 4814409, which is hereby incorporated by reference.

[0060] In an embodiment of the invention, the silicone surfactant compound A) comprises two or more different types of polyether substituents R*, preferably the silicone surfactant compound A) contains two different types of polyether substituents R*

[0061] The types of R* may differ, e.g., by their molecular weight, the number of ether groups, the number of alkyleneoxide repeating units, and / or the type of termination of the substituents, for example by alkoxy groups or by alkanoyl groups.

[0062] In many cases, the number of repeating units and the molecular weight of polyethers available is not entirely uniform, and in such cases the molecular weight of the such precursors and the resulting groups R* is indicated by the number average molecular weight. The number average molecular weight of the polyether compounds which are the precursors of R* groups is evaluated by gel permeation chromatography (GPC) standard methods, wherein it is determined by GPC after appropriate calibration, in particular with a polystyrene standard.

[0063] In a preferred embodiment according to the invention, the polyether substituents R* of the silicone surfactant compound A) are the same or different and have the formula -CnH2nO(C2H4O)a(C3H6O)bR1(II) wherein n is 2-10, a is a number such that the ethylene oxide residues constitute from about 30% to about 100% by weight of the alkylene oxide residues of the polyether substituent R*; b is a number such that the propylene oxide residues constitute from about 0% to about 70% by weight of the alkylene oxide residues of the polyether substituent R*;

[0064] R1is a C1-C10 alkyl group or a C2-C11 alkanoyl group, preferably a methyl group or an acetyl group; and the substituents R* have a number average molecular weight of from about 200 Dalton to about 6000 Dalton.

[0065] The number average molecular weight refers to the number average of the mass of the groups R* present in the silicone surfactant. Accordingly, in case there is only one type of groups R* in a silicone surfactant, the number average molecular weight of the substituents R* is equal to the mass of such substituent R*.

[0066] As the residues R* are linked to the surfactant backbone by a hydrosilylation reaction, it is clear to one skilled in the art that the mass of a residue R*, mR«, in Dalton is equal to the molecular mass of the corresponding unsaturated polyether compound, m unsaturated poiyether, plus 1 , as in the hydrosilylation reaction a hydrogen and the Si atom of the silicone backbone are added to the site of unsaturation, mostly a C-C double bond.

[0067] This is displayed by the following formula: mR* [Dalton] = mUnsaturate poiyether [Dalton] + 1 Dalton

[0068] Further preferred, in formula (II), n, b and R1are as defined above, and

[0069] “a” in the poiyether substituents R* is such that the ethylene oxide residues constitute from about 35% to about 100% by weight of the alkylene oxide residues of the poiyether substituent R, preferably 40% to 100% by weight, more preferably 70% to 100% by weight, and even more preferably 80% to 100% by weight of the alkylene oxide residues of the poiyether substituent R*.

[0070] In another preferred embodiment according to the invention, the poiyether substituents R* of the silicone surfactant compound A) are poiyether substituents having a number average molecular weight of from 400 Dalton to 4000 Dalton, preferably of from 500 Dalton to 3000 Dalton, even more preferably of from 700 Dalton to 2000 Dalton.

[0071] In a preferred embodiment according to the invention, the silicone surfactant compound A) comprises one or more poiyether substituents R* selected from the group (i) of poiyether substituents having a structure of the formula (II’)

[0072] (i) -Cn’H2n’O(C2H4O)a’(C3H6O)b’R2(II’) , wherein n’ is 2-10; a’ is a number such that ethylene oxide residues constitute 30% to 60% by weight of the alkylene oxide residues of the poiyether substituent; b’ is a number such that propylene oxide residues constitute 40% to 70% by weight of the alkylene oxide residues of the poiyether;

[0073] R2represents a C1-C10 alkyl group or a C2-C11 alkanoyl group, preferably a methyl group or an acetyl group; and one or more poiyether substituents R* selected from the group (ii) having a structure of the formula (II’)

[0074] (ii) -CnH2n”O(C2H4O)a(C3H6O)b”R3(II”)

[0075] , wherein n” is 2-10; a” is a number such that ethylene oxide residues constitute 30% to 100% by weight of the alkylene oxide residues of the poiyether substituent; b” is 0 to a number such that propylene oxide residues constitute less than or equal 70% by weight of the alkylene oxide residues of the polyether;

[0076] R3represents a C1-C10 alkyl group or a C2-C11 alkanoyl group, preferably a methyl group or an acetyl group.

[0077] Further preferably, the silicone surfactant compound A) comprises one or more polyether substituents R* selected from the group (i) of polyether substituents having a structure of the formula (II’)

[0078] (i) -CnH2n’O(C2H4O)a’(C3H6O)b’R2(II’) having a mass in the range of from 2000 Dalton to 6000 Dalton, and wherein at least one polyether substituent R* of type (i) has a mass above 3000 Dalton; n’ is 2-10; a’ is a number such that ethylene oxide residues constitute 30% to 60% by weight of the alkylene oxide residues of the polyether substituent; b’ is a number such that propylene oxide residues constitute 40% to 70% by weight of the alkylene oxide residues of the polyether;

[0079] R2represents a C1-C10 alkyl group or a C2-C11 alkanoyl group, preferably a methyl group or an acetyl group; and one or more polyether substituents R* selected from the group (ii) having a structure of the formula (II’)

[0080] (ii) -CnH2n”O(C2H4O)a’(C3H6O)b”R3(II”) having a mass in the range of from 350

[0081] Dalton to 1800 Dalton, and wherein n” is 2-10; a” is a number such that ethylene oxide residues constitute 30% to 100% by weight of the alkylene oxide residues of the polyether substituent; b” is 0 to a number such that propylene oxide residues constitute less than or equal 70% by weight of the alkylene oxide residues of the polyether;

[0082] R3represents a C1-C10 alkyl group or a C2-C11 alkanoyl group, preferably a methyl group or an acetyl group.

[0083] Therein, it is preferred that all polyether substituents R* present in the silicone surfactant compound A) are selected from polyether substituents of the types (i) and (ii).

[0084] The connection between the groups R in general (and also of R* specifically) and the siloxane backbone has two ways, namely Si-O-C type and Si-C type. The former is unstable under aqueous conditions and belongs to the hydrolysis type; the latter is stable to water and is called the non-hydrolysis type. According to the invention, the non-hydrolysis type is preferred.

[0085] According to the invention, the siloxane backbone is preferably represented by the general formula M*DxD”yM* (I), wherein

[0086] M* represents (CH3)3SiOi / 2 or (CH3)2RSiOi / 2;

[0087] D represents (CH3)2SiO2 / 2;

[0088] D” represents (CH3)RSiO2 / 2; x is 0-200; y is 2 or more; x+y is 10 to 250; the ratio of x to y is 2 to 50; and R is a hydrophilic group as described before, preferably R represents a polyether substituent R*.

[0089] In a preferred embodiment of the invention, one or more of the silicone surfactant compounds A) has the formula

[0090] M*DxD”yM* (I), wherein

[0091] M* represents (CH3)3SiOi / 2 or (CH3)2R*SiOi / 2;

[0092] D represents (CH3)2SiO2 / 2;

[0093] D” represents (CH3)R*SiC>2 / 2; x is 0-200; y is 2 or more; x+y is 10 to 250; the ratio of x to y is 2 to 50; and R* is a polyether substituent independently selected from the same or different -CnH2nO- group-started polyether substituents, wherein n is 2-10.

[0094] The term “-CnH2nO-group-started polyether substituent” means that the polyether group R* is linked to the silicone backbone by the terminal C-atom of an alkylene group of n carbon atoms constituting the non-terminal part of the polyether substituent R*.

[0095] In a further preferred embodiment of the invention, one or more of the silicone surfactant compounds A) has the formula M*DxD”yM* (I), wherein

[0096] M* represents (CH3)3SiOi / 2 or (CH3)2R*SiOi / 2;

[0097] D represents (CH3)2SiO2 / 2;

[0098] D” represents (CH3)R*SiC>2 / 2; x is 0-200; y is 2 or more; x+y is 10 to 250; the ratio of x to y is 2 to 50; and R* is a polyether substituent independently selected from the same or different -CnH2nO- group-started polyether substituents, wherein n is 2-10 and the substituents R* have a number average molecular weight of from 200 Dalton to 6000 Dalton.

[0099] The -CnH2nO-group-started polyether substituent means that the polyether group R* is linked to the silicone backbone by the terminal C-atom of an alkylene group of n carbon atoms constituting the non-terminal part of the polyether substituent R*.

[0100] Therein, it is further preferred that y is 3 to 20, more preferably 4 to 10, while M*, D, and D”, x, x+y, the ratio of x to y and R* are as defined above.

[0101] In a further preferred embodiment according to the invention, one or more of the polyether substituents R* of the silicone surfactant compound A) are independently terminated by an alkoxy group or an acyl group, preferably by a methoxy group or an acetoxy group.

[0102] Further preferred, the silicone surfactants according to the invention, in particular silicone surfactant compounds represented by the formula (I), comprise one or more polyether substituents R* of the general structure of the formula (II)

[0103] -CnH2nO(C2H4O)a(C3H6O)bR1(II) wherein n is 2-10, a is a number such that the ethylene oxide residues constitute from about 30% to about 100% by weight of the alkylene oxide residues of the polyether substituent R*; b is a number such that the propylene oxide residues constitute from about 0% to about 70% by weight of the alkylene oxide residues of the polyether substituent R*;

[0104] R1is a C1-C10 alkyl group or a C2-C11 alkanoyl group, preferably a methyl group or an acetyl group. Still further preferred, therein the substituents R* have a number average molecular weight of from about 200 Dalton to about 6000 Dalton.

[0105] In a further preferred embodiment according to the invention, the silicone surfactant compound A) has the formula

[0106] M*DxD”yM* (I), wherein

[0107] M*, D, and D” are as defined above, x is 45 to 90, preferably 55 to 80; y is 2 to 10, preferably 3 to 9; x+y is 50 to 90, preferably 55 to 85; the ratio of x to y is 5 to 20, preferably 7 to 15; and the silicone surfactant compound A) comprises one or more polyether substituents R* selected from the group (iii) having a structure of the formula (II’”)

[0108] (iii) ”Cn”H2n ’O(C2H4O)a ’(C3H6O)b ”b ”R4(II’”), wherein n’” is 2 to 4, preferably 3; a’” is a number such that ethylene oxide residues constitute 30% to 60% by weight of the alkylene oxide residues of the polyether substituent R*; b’” is a number such that propylene oxide residues constitute 40% to 70% by weight of the alkylene oxide residues of the polyether substituent R*;

[0109] R4represents a methyl group or an acetyl group; and one or more polyether substituents R* selected from the group (iv) having a structure of the formula (II””)

[0110] (iv) -Cn' ”H2n ’ ”O(C2H4O)a ’ "(CsHeOJb ” ”R5, wherein n”” is 2 to 4, preferably 3; a”” is a number such that ethylene oxide residues constitute 30% to 100% by weight of the alkylene oxide residues of the polyether substituent R*; b”” is 0 to a number such that propylene oxide residues constitute less than or equal 70% by weight of the alkylene oxide residues of the polyether R*;

[0111] R5represents a methyl group or an acetyl group.

[0112] According to this embodiment, it is preferred that the one or more polyether substituents R* selected from the group (iii) having a structure of the formula (II’”) have a mass in the range of 3500 to 6000 Dalton, and the one or more polyether substituents R* selected from the group (iv) having a structure of the formula (II””) have a mass in the range of from 350 to1800 Dalton.

[0113] It is further preferred that all polyether substituents R* present in the silicone surfactant compound A) are selected from polyether substituents from the groups (iii) and (iv).

[0114] According to the invention, it is preferred that one or more, more preferable all of the polyether substituents R*, in particular polyether substituents having the formula (II), are bonded directly to one or more internal or terminal Si atoms of the siloxane backbone, i.e. in a non-hydrolyzable manner. For silicone surfactant compounds represented by the formula (I), this is implicitly clear regarding the polyether substituents R* of the general formula (II).

[0115] In an embodiment of the invention, the amount of component A) in the silicone surfactant composition is 15.0 weight-% or more based on the overall weight of the surfactant composition, preferably 20.0 weight-% or more, more preferably 30.0 weight-% or more, further preferably 40.0 weight-% or more, still more preferably 50 weight-% or more based on the overall weight of the surfactant composition.

[0116] In particular in the absence of a diluent C), the silicone surfactant A) is typically the main component of the silicone surfactant compositions according to the invention. Surfactant potency-enhancing agents B)

[0117] According to the invention, a surfactant potency-enhancing agent is any compound capable of enhancing the performance of a silicone surfactant in the Pll foam forming process. This means that addition of the surfactant potency-enhancing agent to the silicone surfactant used in Pll foam formation provides foam blocks displaying an improved, higher stabilization, and a broader processing latitude for both pure and high filled foam formulations with less metal gelling catalyst, for example stannous octoate, in the formulations, and provides foams which have better firmness and tensile strength in the flexible polyurethane foam. This also implies that by the addition of the surfactant-potency-enhancing agent, the amount of silicone surfactant reguired to achieve a specific level of a parameter, for example of stabilization of polyurethane foams or firmness or tensile strength of flexible polyurethane foam, is reduced.

[0118] According to the invention, the surfactant potency-enhancing agents are preferably organic acids or organic acid-based compounds. Therein, according to the invention “organic acidbased compounds” are compounds formed from organic acids by salt formation, i.e. organic acid salts, or by esterification, i.e. organic acid esters. Therein, the cationic counter-ion of the anions formed from the organic acids as defined herein is not limited in a particular manner. Preferred cations of the organic acid salts of the invention are the alkali metal ions Li+, Na+, K+, Rb+, Cs, in particular Na+and K+, the earth alkaline metal ions, in particular Mg2+, Ca2+, and further metal ions such as Al3+, Sn4+, or Fe2+or Fe3+, as well as the ammonium cation NF and organosubstituted ammonium cations, in particular guarternary ammonium cations bearing four organyl groups, preferably hydrocarbyl groups, such as N(Me)4+, N(Et)4+, N(Bu)4+, dimethyldialkylammonium cations, diester guats, the phosphonium cation PH4+and organosubstituted phosphonium cations, in particular guarternary phosphonium cations bearing four organyl groups.

[0119] In an embodiment according to the invention, one or more of the component B) is an organic acid.

[0120] According to the invention, the organic acids are selected from the group consisting of organic acids having at least one acidic functional group A* that are preferably selected from the group consisting of:

[0121] -C(=O)(-OH);

[0122] -C(=S)(-OH);

[0123] -S(=O)2(-OH);

[0124] -O-S(=O)2(-OH);

[0125] -S(=O)(-OH);

[0126] -O-S(=O)(-OH);

[0127] (-O)2P(=O)(-OH);

[0128] -O-P(=O)(-OH); -O-P(=O)2(-OH); and

[0129] -O-N(=O)(-OH), and preferably the at least one acidic functional group is a carboxylic acid group (-C(=O)(-OH)) or a sulfonic acid group

[0130] (-S(=O)2(-OH)), most preferably a carboxylic acid group (-C(=O)(-OH)).

[0131] Such organic acids may be of the general formula (V):

[0132] R**-(A*)0(V), wherein R** is an organic group such as an optionally substituted aromatic or aliphatic group which may have up to 30, preferably up to 20, more preferably up to 12 carbon atoms, and which may optionally comprise additional heteroatoms apart from those provided by the acidic functional groups A*, such as halogen (F, Cl, Br, I) O, N, S, P, Si, B, etc., and wherein the optional substituent groups are preferably selected from halogen (F, Cl, Br, I ), hydroxy, alkoxy, acyl, cyano, nitro, etc., and wherein the acidic functional groups A* are as defined previously and wherein o is an integer of 1 to 4, preferably, 1 to 3, and more preferably 1 to 2.

[0133] As defined before, the organic acid-based compounds corresponding to the organic acids are obtained therefrom by salt formation, wherein the groups A* form anions by abstraction of a proton, or by esterification, wherein the (-OH) groups of the functional groups A* are formally replaced by organyloxy groups, preferably alkoxy groups, (-OR***), wherein R*** is an organyl group, preferably a C1-C24 alkyl group.

[0134] The organic acids can be selected from the group consisting of organic acids having four or more carbon atoms selected from carboxylic, sulfonic, sulfinic, phosphonic, phosphinic and phosphoric acids connected to organic groups, such as alkyl, haloalkyl, perfluoroalkyl, cycloalkyl, alkenyl, aryl, aralkyl or substituted alkyl, cycloalkyl, alkenyl, aryl, aralkyl, optionally containing halides such as F, Cl, Br, I, nitro groups, cyano groups, thiocyano groups, hydroxy groups, sulfhydryl groups, alkoxy groups, alkylthio or arylthiol groups, acyl groups, carboxylic ester or acid groups, sulfonate ester or acid groups, and phosphate ester or acid groups as substituents. Preferably, the organic acids are selected from carboxylic, sulfonic, sulfinic, phosphonic, phosphinic and phosphoric acids connected to organic groups as defined above wherein the organic groups have four or more consecutive carbon atoms, more preferably the organic groups are alkyl groups having four or more carbon atoms, most preferably the organic groups are unsubstituted alkyl groups having four or more carbon atoms. Therein, carboxylic acids are most preferred.

[0135] In an embodiment of the invention, the component B) is an organic acid, an organic acid salt, or an organic acid ester containing 4 or more carbon atoms, preferably 6 or more carbon atoms, more preferably 8 or more carbon atoms, even more preferably 10 or more carbon atoms. Therein, the number of carbon atoms refers to the entirety of the carbon atoms present in the specific structure of the compounds, i.e. in case of the organic acid salts, the number of carbon atoms in the anions and, if present, in the cations is combined.

[0136] The acids can be organic sulfonic or organic sulfinic acids, such as benzenesulfinic acid, 4- dodecylbenzenesulfonic acid, p-toluenesulfonic acid, halogenated such as fluorinated or chlorinated carboxylic acids, such as perfluorobutanoic acid, 2-bromobenzoic acid, phosphorus-based organic acids, such as octylphosphonic acid, 12- mercaptododecylphosphonic acid, carboxylic acids such as oxalic acid, pyruvic acid, 3- oxobutanoic acid, maleic or fumaric acid, cis or trans- 1 ,2-cyclopropanedicarboxylic acid and terephthalic acid, etc. and combinations thereof. Further examples include: salicylic acid, malic acid, 1-naphthalene sulfonic acid, 4-hydroxybenzene sulfonic acid, 1 ,5- naphthalenedisulfonic acid, 10-camphor sulfonic acid, 1 -hexane sulfonic acid, aminoethanesulfonic acid, diphenyl phosphate, phenylphosphonic acid, p-nitrobenzene sulfonic acid, and combinations thereof. The organic acid-based compounds according to this aspect are selected from the corresponding salts or esters formed from the aforementioned organic acids.

[0137] According to the invention, it is preferred that the organic acids or organic acid-based compounds are selected from carboxylic acids, carboxylic acid salts, carboxylic acid esters, organosulfuric acids, organosulfate salts, organosulfate esters, organosulfonic acids, organosulfonic acid salts, organosulfonic acid esters, organophosphoric acids, organophosphoric acid salts, organophosphoric acid esters, organophoshonic acids, organophosphonic acid salts, organophosphonic acid salts.

[0138] Therein, the group of carboxylic acids, carboxylic esters and carboxylic acid salts, i.e. of organic acids containing a carboxylic group -C(O)O-, is further preferred as surfactant potencyenhancing agent. The most preferred type of surfactant-enhancing agents are carboxylic acids.

[0139] In a preferred embodiment according to the invention, the component B) is an organic acid with 4 or more carbon atoms, preferably 6 or more carbon atoms, more preferably a carboxylic acid with 6 or more carbon atoms, even more preferably a monocarboxylic acid with 6 or more carbon atoms, or the component B) is an organic acid salt with 4 or more carbon atoms in the anionic part, preferably 6 or more carbon atoms in the anionic part, more preferably a carboxylic acid salt with 6 or more carbon atoms in the anionic part, even more preferably a monocarboxylic acid salt with 6 or more carbon atoms in the anionic part, or the component B) is an organic acid ester with 4 or more carbon atoms in the structure corresponding to the organic acid, preferably 6 or more carbon atoms in the structure corresponding to the organic acid, more preferably a carboxylic acid ester with 6 or more carbon atoms in the structure corresponding to the organic acid, even more preferably a monocarboxylic acid ester or dicarboxylic acid ester with 6 or more carbon atoms in the structure corresponding to the organic acid.

[0140] Herein, for the organic salts only the number of carbon atoms present in the anion of the salt constituting the component B), which results from the corresponding organic acid by deprotonation, is considered, i.e. the carbon atoms of an organosulfonate or a carboxylate anion. Regarding the organic acid esters, the number of carbon atoms in the structure corresponding to the organic acid is taken into account, which means that the carbon atoms comprised by the organyloxy groups, in particular alkoxy groups, which formally replace the -OH-groups of the underlying organic acids when forming the organic acid esters are not taken into account. For example, methyl oleate has a total of 19 carbon atoms, whereas the number of carbon atoms in the structure corresponding to the organic acid, in this case oleic acid, is 18.

[0141] In a preferred embodiment of the invention, one or more of the component B) is a carboxylic acid, preferably a monocarboxylic acid, or a carboxylic acid salt, preferably a monocarboxylic salt, or carboxylic acid ester, preferably a monocarboxylic acid ester or a dicarboxylic acid ester.

[0142] Carboxylic acid

[0143] As defined above, any organic compound comprising at least one -C(O)OH group, i.e at least one carboxylic group, is considered a carboxylic acid.

[0144] In an embodiment of the invention, the component B) is an aliphatic carboxylic acid or aromatic carboxylic acid, preferably an aliphatic carboxylic acid, more preferably an alkanoic acid.

[0145] In a preferred embodiment of the invention, the component B) is an alkanoic acid or alkenoic acid with 4 to 30 carbon atoms, preferably with 6 to 24 carbon atoms, more preferably with 9 to 20 carbon atoms. Therein, it is preferred that the carboxylic acid is selected from saturated, mono-and di-unsaturated fatty acids, in particular caproic acid, caprylic acid, capric acid, myristic acid, palmitic acid, stearic acid, arachidic acid, behenic acid, lignoceric acid, cerotic acid, myristoleic acid, palmitoleic acid, sapienic acid, oleic acid, linoleic acid, a-linoleic acid, arachidonic acid, eicosapentaenoic acid, erucic acid, and ricinoleic acid.

[0146] According to the invention, preferred monocarboxylic acids are selected from C4 to C24 carboxylic acids, in particular from butyric acid, valeric acid, caproic acid, enanthic acid, caprylic acid, pelargonic acid, capric acid, undecanoic acid, lauric acid, tridecanoic acid, myristic acid, pentadecanoic acid, palmitic acid, margaric acid, stearic acid, linoleic acid, a- linolenic acid, y-linolenic acid, nonadecylic acid, arachidic acid, mead’s acid, arachidonic acid, heneicosanoic acid, docosanoic acid, tricosylic acid and lignoceric acid, benzoic acid and 4- methoxy benzoic acid. The carboxylic acids may also be selected from dicarboxylic acids, preferably dicarboxylic acids having 9 or more carbon atoms, in particular from the dicarboxylic acids sebacic acid, dimer acids, amino-functional dicarboxylic acids, and tricarboxylic acids, preferably tricarboxylic acids having 13 or more carbon atoms, and tetracarboxylic acids, preferably tetracarboxylic acids having 16 or more carbon atoms. Examples of preferred dicarboxylic acids are succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, undecanedioic acid, dodecanedioic acid, tridecanedioic acid, hexadecanedioic acid, maleic acid, fumaric acid, glutaconic acid, muconic acid, citraconic acid, mesaconic acid and itaconic acid.

[0147] As described above, in an aspect of the invention, the carboxylic acids are preferably selected from fatty acids.

[0148] The term “fatty acid” herein refers to carboxylic acids with chain-shaped organyl groups, which typically have terminal carboxylic groups, in particular unbranched aliphatic monocarboxylic acids with terminal carboxylic acid groups. Fatty acids differ from each other by their number of carbon atoms (chain length) and, when referring to unsaturated fatty acids, the number and position of double bonds. Fatty acids may be classified as short chain fatty acids with up to 7 carbons atoms, middle chain fatty acids with 8 to 12 carbon atoms, long chain fatty acids with 13 to 21 carbon atoms, and very long chain fatty acids with more than 22 carbon atoms. C7- C25 fatty acid having a terminal carboxylic group and bearing no further substituents are preferred.

[0149] In a further preferred embodiment of the invention, the component B) is a branched or cyclic alkanoic acid, preferably a branched alkanoic acid, more preferably a branched alkanoic acid with 5 to 24 carbon atoms.

[0150] In a preferred embodiment according to the invention, the component B) is a carboxylic acid containing one or more quaternary carbon atoms, preferably an aliphatic carboxylic acid containing one or more quaternary carbon atoms, more preferably an acyclic alkanoic acid containing one or more quaternary carbon atoms.

[0151] Carboxylic acids containing a quaternary C-atom, which is a C-atom linked to four other carbon atoms via single bonds, have been found to be a particularly preferred group of carboxylic acids, in particular of alkanoic acids.

[0152] Therein, it is further preferred that the component B) is a branched alkyl monocarboxylic acid with 5 to 20 carbon atoms containing one or more quaternary carbon atoms, preferably containing a quaternary carbon atom in a-position to the carboxylic acid group. Even further preferred, the component B) is selected from the group consisting of C8-neoalkanoic acids, C9-neo-alkanoic acids, C10-neoalkanoic acids, C11-neoalkanoic acids, C12-neoalkanoic acids, C13-neoalkanoic acids, C-14-neoalkanoic acids, wherein neononanoic acid, neodecanoic acid and neoundecanoic acid are preferred.

[0153] Carboxylic acid salt

[0154] As defined above, any organic compound comprising at least one carboxylate anion, i.e at least one deprotonated carboxylic group (-C(O)O' group), is considered a carboxylic acid salt. According to the invention, all salts of the carboxylic acids mentioned in a generic or specific form above may also be applied according to the invention, and salts of carboxylic acids preferred according to the invention are likewise preferred.

[0155] Therein, there is no restriction to the cations used as counter-ions to the anions formed from the carboxylic acids. The same cations as described above as being preferred in the organic acid salts are preferred regarding the carboxylic acid salts.

[0156] Accordingly, in an embodiment of the invention, the component B) is an aliphatic carboxylic acid salt or aromatic carboxylic acid salt, preferably an aliphatic carboxylic acid salt, more preferably an alkanoic acid salt. Also preferably, the component B) is an alkanoic acid salt or alkenoic acid salt with 4 to 30 carbon atoms in the anionic part, preferably with 6 to 24 carbon atoms in the anionic part, more preferably with 9 to 20 carbon atoms in the anionic part.

[0157] In a preferred embodiment according to the invention, the component B) is a branched or cyclic alkanoic acid salt, preferably a branched alkanoic acid salt, more preferably a branched alkanoic acid salt with 5 to 24 carbon atoms in the anionic part.

[0158] In a further preferred embodiment of the invention, it is preferred that component B) is a carboxylic acid salt containing one or more quaternary carbon atoms, preferably an aliphatic carboxylic acid containing one or more quaternary carbon atoms, more preferably an acyclic alkanoic acid containing one or more quaternary carbon atoms.

[0159] Carboxylic acid ester

[0160] As defined above, any organic compound comprising at least one ester -C(O)OR*** group, i.e at least one group formally derived from a carboxylic group by esterification with an alcohol R***-OH, is considered a carboxylic acid ester.

[0161] According to the invention, all esters of the carboxylic acids mentioned in a generic or specific form above may also be applied according to the invention, and esters of carboxylic acids preferred according to the invention are likewise preferred. The ester groups are not restricted in a particular manner regarding the structure of the organyloxy groups R***, but preferably R*** is a C1 to C24 alkyl group, which may be linear branched or cyclic. Preferred groups R*** are methyl, ethyl, n-propyl, i-propyl, n-butyl, i-butyl, s-butyl, t-butyl, pentyl, hexyl, cyclopentyl, cyclohexyl, heptyl, octyl, nonyl, decyl, undecyl and dodecyl groups, wherein methyl, ethyl and propyl groups are particularly preferred. Thus, in an embodiment of the invention, the component B) is an aliphatic carboxylic acid ester or aromatic carboxylic acid ester, preferably an aliphatic carboxylic acid ester, more preferably an alkanoic acid ester.

[0162] In a preferred embodiment of the invention, the component B) is an alkanoic acid ester or alkenoic acid ester with 4 to 30 carbon atoms in the structure corresponding to the organic acid, preferably with 6 to 24 carbon atoms in the structure corresponding to the organic acid, more preferably with 9 to 20 carbon atoms in the structure corresponding to the organic acid. In a further preferred embodiment of the invention, the component B) is a linear or branched alkanoic acid ester, preferably a linear alkanoic acid ester, more preferably a linear alkanoic acid ester with 5 to 24 carbon atoms in the structure corresponding to the organic acid, even more preferably a linear mono- or dialkanoic acid ester with 5 to 24 carbon atoms in the structure corresponding to the organic acid.

[0163] In an embodiment of the invention, the component B) is contained in the composition in an amount of 0.01 to 70 weight-% on the basis of the total weight of the surfactant composition, preferably in an amount of 0.2 to 20 weight-% on the basis of the total weight of the surfactant composition. According to this embodiment, it is preferred when further the ratio of the components A) to B) (w / w) is in the range of 100 : 1 to 2 : 1 , preferably 50 : 1 to 3 : 1 , more preferably 20 : 1 to 4 : 1 , even more preferably 15 : 1 to 5 : 1.

[0164] In another embodiment of the invention, the amount of component B) in the silicone surfactant composition is 0.02 to 50 weight-%, preferably 0.5 to 25 weight-%, more preferably 1.0 to 10 weight-%, even more preferably 1.5 to 8 weight-%, and still more preferred 2.5 to 7 weight-% on the basis of the overall weight of the components A), B) and C) of the silicone surfactant composition.

[0165] Diluent C)

[0166] Further, according to the invention a diluent is any liquid compound or liquid mixture of compounds other than components A) and B). Preferably, the diluent is fully miscible with both A), B), and A) and B) combined, more preferably in any ratio.

[0167] Examples of types of diluents C) according to the invention are water, alcohols, in particular alkanols, di- and polyols, in particular di- and polyhydroxylated alkanes, mono-, di- and polyethers, in particular alkyl and alkylene di-and polyethers, aliphatic and aromatic hydrocarbons, in particular alkanes and alkylated phenyl compounds, halogenated hydrocarbons, in particular partially or perhalogenated alkanes and partially or perhalogenated alkylated phenyl compounds, ketones, organic amides, organic nitriles, organic sulfoxides, and organocarbonates. Thus, in an embodiment of the invention, the diluent C) is selected from water, a monoalcohol, a di- or polyol, a mono-, di- or polyethers, aliphatic and aromatic hydrocarbons, and halogenated hydrocarbons, in particular partially or perhalogenated alkanes and partially or perhalogenated alkylated phenyl compounds, ketones, amides, nitriles, sulfoxides, ororganocarbonates, or a combination of two or more thereof.

[0168] In a preferred embodiment of the invention, the diluent C) is fully miscible with A) and B), preferably therein the diluent C) is a monoether or a polyether having up to 40 ether groups, more preferably a mono- or polyether having up to 8 ether groups.

[0169] With regard to the requirement of full miscibility, it is noted that full miscibility first refers to cases in which the surfactant compound A) and the compound B) are liquid compounds at room temperature (20 °C), and which can be diluted to achieve a homogeneous mixture by the diluent C) in any mixing ratio. In case the compound A) and / or in particular the compound B) is a solid at room temperature (20 °C), for example when component B) is a solid organic acid salt, it is considered that full miscibility is given when at least 100 g of component A) and / or B) can be fully dissolved in 1 L of the diluent at room temperature (20 °C), preferably more than 200 g per L, more preferably more than 300 g per L, still more preferably more than 500 g per L, even more preferably more than 750 g per L, even further preferably more than 1000 g per L, and most preferably more than 1500 g per L. Preferred diluents are polyalkylene oxides, polyols, glycols, in particular glycols selected from the group of hexylene glycol, dipropylene glycol, diethylene glycol, monopropylene glycol, monoethylene glycol, methylpentanediol, methylpropanediol.

[0170] In a preferred embodiment according to the invention, the diluent C) comprises a mono- or polyether alcohol, preferably a glycol ether, further preferably the diluent C) is a mono- or polyether alcohol, specifically a glycol ether. Specifically, it is preferred that the diluent C) comprises an ethylene glycol ether or a propylene glycol ether, preferably dipropylene glycol, further preferably the diluent C) is an ethylene glycol ether or a propylene glycol ether, specifically dipropylene glycol.

[0171] In an embodiment of the invention, the composition comprises one or more diluents C), wherein preferably the amount of the diluent is 20 weight-% or more, more preferably 35 weight-% or more, even more preferably 50 weight-% or more, still more preferably 65 weight- % or more, further more preferably 75 weight-% or more, and most preferably 85 weight-% or more on the basis of the overall weight of the surfactant composition

[0172] Surfactant Composition

[0173] For the application of the silicone surfactant composition in Pll foam-forming compositions, highly viscous silicone surfactant compositions are not suitable in view of processability. In an embodiment of the invention, the viscosity of the surfactant composition is below 5000 cSt at 25 °C, preferably below 4000 cSt at 25 °C, more preferably below 3000 cSt at 25 °C, even more preferably below 2500 cSt at 25 °C, and most preferably below 2000 cSt at 25 °C as determined by capillary viscosimetry.

[0174] According to the invention, the surfactant composition can be prepared by mixing the components A), B) and, if present, C), and optional additives, wherein there is no limitation regarding the order of addition, or the device used for mixing. In general, all types of commercial and industrial mixers can be used, for example drum mixers, ribbon blenders, planetary mixers, paddle mixers, or any vessel or tank equipped with an agitator.

[0175] The mixture can also be prepared by mixing the components in a vessel, closing the vessel and shaking it manually or in a shaker.

[0176] In an embodiment of the invention, the components A) and B) add up to 20 weight-% or more of the total weight of the composition, preferably to more than 25 weight-% or more of the total weight of the composition, more preferably 30 weight- % or more of the total weight of the composition, even more preferably to 35 weight-% or more of the total weight of the components A), B) and C) of the silicone surfactant composition.

[0177] In a preferred embodiment of the invention, the components A) and B) add up to 100 weight- % of the total weight of the composition.

[0178] In a further embodiment of the invention, the components A), B) and C) add up to 70 weight- % or more of the total weight of the composition, preferably to more than 80 weight-% or more of the total weight of the composition, more preferably 85 weight- % or more of the total weight of the composition, even more preferably to 90 weight-% or more of the total weight of the composition, and most preferably to 95 weight-% or more of the total weight of the silicone surfactant composition. Preferably, the components A), B) and C) add up to 100 weight-% of the total weight of the surfactant composition.

[0179] In a preferred embodiment of the invention, in the silicone surfactant composition, the silicone surfactant compound A) has the formula (I)

[0180] M*DxD”yM* (I), wherein

[0181] M*, D, and D” are as defined above, x is 45 to 90, preferably 55 to 80; y is 2 to 10, preferably 3 to 9; x+y is 50 to 90, preferably 55 to 85; the ratio of x to y is 5 to 20, preferably 7 to 15; and the silicone surfactant compound A) comprises one or more polyether substituents R* selected from the group (i) of polyether substituents having a structure of the formula (II’) (i) -CnH2n’O(C2H4O)a’(C3H6O)b’R2(II’) having a mass in the range of from

[0182] 2000 Dalton to 6000 Dalton, and wherein at least one polyether substituent R* of type (i) has a molecular weight above 3000; n’ is 2-10; a’ is a number such that ethylene oxide residues constitute 30% to 60% by weight of the alkylene oxide residues of the polyether substituent; b’ is a number such that propylene oxide residues constitute 40% to 70% by weight of the alkylene oxide residues of the polyether;

[0183] R2represents a C1-C10 alkyl group or a C2-C11 alkanoyl group, preferably a methyl group or an acetyl group; and / or and one or more polyether substituents R* selected from the group (ii) having a structure of the formula (II’)

[0184] (ii) -CnH2n”O(C2H4O)a’(C3H6O)b”R3(II”) having a mass in the range of from

[0185] 350 Dalton to 1800 Dalton, and wherein n” is 2-10; a” is a number such that ethylene oxide residues constitute 30% to 100% by weight of the alkylene oxide residues of the polyether substituent; b” is 0 to a number such that propylene oxide residues constitute less than or equal 70% by weight of the alkylene oxide residues of the polyether;

[0186] R3represents a C1-C10 alkyl group or a C2-C11 alkanoyl group, preferably a methyl group or an acetyl group, the component B) is a carboxylic acid, a carboxylic acid salt or carboxylic acid ester, preferably a carboxylic acid, and the composition optionally comprises a diluent C), which is preferably a glycol ether, most preferably dipropylene glycol.

[0187] In another preferred embodiment of the invention, the silicone surfactant compound A) has the formula (I)

[0188] M*DxD”yM* (I), wherein

[0189] M*, D, and D” are as defined above, x is 45 to 90, preferably 55 to 80; y is 2 to 10, preferably 3 to 9; x+y is 50 to 90, preferably 55 to 85; the ratio of x to y is 5 to 20, preferably 7 to 15; and the silicone surfactant compound A) comprises one or more polyether substituents R* selected from the group (iii) having a structure of the formula (II’”)

[0190] (iii) -Cn”H2n ’O(C2H4O)a ’(C3H6O)b ”R4, wherein n’ is 2 to 4, preferably 3; a’” is a number such that ethylene oxide residues constitute 30% to 60% by weight of the alkylene oxide residues of the polyether substituent; b’” is a number such that propylene oxide residues constitute 40% to 70% by weight of the alkylene oxide residues of the polyether;

[0191] R4represents a methoxy group, an acetoxy group, or a butoxyl group; and one or more polyether substituents R* selected from the group (iv) having a structure of the formula (II””)

[0192] (iv) -Cn' ”H2n ” ”O(C2H4O)a ” ”(C3H6O)b ” ”R5, wherein n”” is 2 to 4, preferably 3; a”” is a number such that ethylene oxide residues constitute 30% to 100% by weight of the alkylene oxide residues of the polyether substituent; b”” is 0 to a number such that propylene oxide residues constitute less than or equal 70% by weight of the alkylene oxide residues of the polyether;

[0193] R5represents a methoxy group, an acetoxy group, or a butoxyl group, the component B) is an organic acid, wherein the organic acid B) is an alkyl carboxylic acid with 5 to 24 carbon atoms, preferably a branched alkyl carboxylic acid with 5 to 24 carbon atoms, more preferably selected from the group consisting of C8-neoalkanoic acids, C9-neo- alkanoic acids, C10-neoalkanoic acids, C11-neoalkanoic acids, C12-neoalkanoic acids, C13- neoalkanoic acids, C-14-neoalkanoic acids, most preferably neodecanoic acid, and wherein the composition optionally comprises a diluent C), which is preferably a glycol ether, most preferably dipropylene glycol.

[0194] More preferably according to this embodiment, therein the silicone surfactant compound A) comprises one or more polyether substituents R* selected from the group (iii) having a structure of the formula (II’”)

[0195] (iii) -Cn” H2n” O(C2H4O)a "(CsHeOJb ” R4having a mass in the range of from 3500 to 6000 Dalton, n’ is 2 to 4, preferably 3; a’” is a number such that ethylene oxide residues constitute 30% to 60% by weight of the alkylene oxide residues of the polyether substituent; b’” is a number such that propylene oxide residues constitute 40% to 70% by weight of the alkylene oxide residues of the polyether;

[0196] R4represents a methoxy group, an acetoxy group, or a butoxyl group; and one or more polyether substituents R* selected from the group (iv) having a structure of the formula (II””)

[0197] (iv) -Cn' ” H2n” ”O(C2H4O)a ” "(CsHeOJb ’ ”R5having a mass in the range of from 350 to 1800 Dalton; n”” is 2 to 4, preferably 3; a”” is a number such that ethylene oxide residues constitute 30% to 100% by weight of the alkylene oxide residues of the polyether substituent; b”” is 0 to a number such that propylene oxide residues constitute less than or equal 70% by weight of the alkylene oxide residues of the polyether;

[0198] R5represents a methoxy group, an acetoxy group, or a butoxyl group.

[0199] According to the embodiment, further preferably all polyether substituents R* present in the silicone surfactant compound A) are selected from polyether substituents from the groups (iii) and (iv).

[0200] In an embodiment of the invention, the silicone surfactant composition comprises

[0201] 20 -80 weight-% of the silicone surfactant compound A),

[0202] 1-8 weight-% of the component B), and

[0203] 12-79 weight-% of the diluent C), each on the basis of the total weight of the surfactant composition, and the components A), B) and C) add up to 95 weight-% or more, preferably to 100 weight- % of the surfactant composition.

[0204] Therein, preferably the component B) is an organic acid B), more preferably a carboxylic acid as described above.

[0205] In a further preferred embodiment of the invention, the ratio of the components A) to B) (w / w) is in the range of 100 : 1 to 2 : 1 , preferably 50 : 1 to 3 : 1 , more preferably 20 : 1 to 4 : 1 , even more preferably 15 : 1 to 5 : 1.

[0206] An aspect of the invention refers to a method for the preparation of the surfactant composition according to the description above, comprising a step of mixing the components A), B), and optionally C). As noted before, in general, all types of commercial and industrial mixers known to the skilled person can be used, for example drum mixers, ribbon blenders, planetary mixers, paddle mixers, or any vessel or tank equipped with an agitator. The mixture can also be prepared by mixing the components in a vessel, closing the vessel and shaking it manually or in a shaker. Preferably, the mixing process results in a homogeneous surfactant composition devoid of solids or phase separation.

[0207] An aspect of the invention is directed at the use of the surfactant composition according to the invention as described before in the production of polyurethane foam, in particular of flexible polyurethane foam. Therein, preferably the surfactant composition is used as a component of a polyurethane foam-forming composition, from which the polyurethane foam is formed. According to the invention, it is preferred that the surfactant composition as described herein is added as a formulation when combining the components of a Pll foam-forming composition. Alternatively, the components of the silicone surfactant composition can be combined when forming the Pll foam-forming composition by adding the components separately.

[0208] According to the invention, in a process for the production of a polyurethane foam, the surfactant compositions as described above are combined with at least one polyol and at least one isocyanate compound. Thus, in an embodiment of the invention, the process for the production of a polyurethane foam comprises a step of combining the surfactant composition as described above with at least one isocyanate and at least one polyol. As noted above, the components A), B) and C) may be added separately.

[0209] While there is no particular limitation to the order of combining the surfactant composition, the polyol, the isocyanate and further optional components and additives for forming a polyurethane foam, such as catalysts, solvents, fillers and further process aids, it is preferred that the surfactant composition and the polyol are combined before a catalyst and the isocyanate are added. It is more preferred that the surfactant composition, the polyol, optionally a filler and / or a solvent, and further additives are combined and mixed before the catalyst is added, followed by the addition of the isocyanate. By such process, a polyurethane foam comprising the silicone surfactant composition as described above is obtained.

[0210] By combining the surfactant composition of the invention, a polyol, an isocyanate and preferably a catalyst and further additives, a polyurethane foam is formed.

[0211] In an aspect according to the invention, a polyurethane foam-forming composition comprises

[0212] (a) one or more polyols;

[0213] (b) one or more polyisocyanates;

[0214] (c) one or more catalysts;

[0215] (d) water

[0216] (e) a silicone surfactant composition of the invention as described herein,

[0217] (f) and optionally further additives and auxiliary compounds.

[0218] In such polyurethane foam-forming composition, the foaming processing is more stable than those without surfactant potency-enhancing agents applied according to the invention, as indicated by less settling values, and no split issues.

[0219] Also, the physical performances of the polyurethane foam formed from above compositions according to the invention are better than those without surfactant potency-enhancing agents, as indicated by relatively low density, high hardness (CFD), and uniform foam as shown by relatively low density difference and low CFD difference. Further, in the polyurethane foams formed from the above-described foam-forming compositions according to the invention, a higher hardness of the polyurethane foam is indicated by lowered airflow values. The lower airflow leads to higher hardness as the polyurethane foam struts and cell walls can get thicker. The lower airflow is observed while other properties of the foam are not impacted significantly, and hardness improvement is achieved.

[0220] In a preferred embodiment of the invention, in the above-cited polyurethane foam-forming composition, the silicone surfactant composition of the invention is present in an amount of from about 0.1 to 7.0 parts by weight based on the total weight of the polyol component.

[0221] In a further preferred embodiment of the invention, the amount of the silicone surfactant composition is such that the amount of organic acid B) contained in the polyurethane foamforming composition is of from about 0.01 to 1.0 parts by weight based on the total weight of the polyol component, and the amount of the silicone surfactant compound A) contained in the silicone surfactant composition is of from about 0.099 to 6.99 parts by weight based on the total weight of the polyol component.

[0222] In another preferred embodiment of the invention, the CFD top-bottom difference of a Pll foam sample obtained when foaming the polyurethane foam-forming composition is 15% or less.

[0223] The “CFD difference”, also referred to as “CFD top-bottom difference”, refers to the difference of the numerical values obtained in the measurement of the CFD value at 40 % according to ISO3386 / 1 of a top foam sample and a bottom foam sample taken from a polyurethane block each having a 10 cm x 10 cm base and a height of 5 cm in percent, calculated by the expression [(higher CFD value - lower CFD value) / average value] x 100. The term “average value” is the average value of the “higher CFD value” and the “lower CFD value” (sum of both divided by 2). Therein, the foam sample considered the “top” foam sample refers to a sample taken from a position at about 3 cm below the top surface of a foam block and 5 cm downwards from there, and the foam sample considered the “bottom” foam sample refers to a sample taken from the position at about 3 cm above the bottom of the polyurethane block and 5 cm upwards from there. The foam block from which the samples are taken is obtained by mixing the components of a Pll foam-forming composition and pouring the liquid foam into a 20x20x20 cm paper box, followed by curing the foams upon completion of rising in a forced air oven for 15 minutes and cooling for 24 hours before collecting the foam samples.

[0224] From the polyurethane foam-forming compositions described above, polyurethane foams according to the invention are obtained. As described before, these foams preferably display a CFD top-bottom difference which is 15% or less.

[0225] The components of the polyurethane foam-forming composition according to this aspect of the invention are further described in the following: Polyols (a)

[0226] The polyols (a) include single polyols and mixtures thereof used in the manufacture of polyurethanes, and polyurethane foams, in particular (see e.g. Polyurethanes Science, Technology, Markets, and Trends, Mark F. Sonnenschein, Ph.D, Wiley 2015). The polyols (a) are used in commercial purity grades of at least 95 wt-%.

[0227] The kinematic viscosity of component (a) is preferably in the range of about 200 to 6500 cSt (25°C), preferably about 300 to about 1000 cSt (25°C).

[0228] As the polyols (a), e.g. polyether polyols, polyester polyols, copolymer polyols also known as graft polyols can be used. Typically, the polyol (a) is a polyol having a hydroxyl number from about 10 to about 700 [see e.g. Chemistry and Technology of Polyols for Polyurethanes, by Mihail lonescu, Rapra Technology LTD. (2005)]. Polyols which are useful in the composition of the invention and for making polyurethanes, particularly via the one-shot foaming procedure, are any of the types presently employed in the art for the preparation of flexible slabstock foams, flexible molded foams, semi-flexible foams, and rigid foams. Such polyols are typically liquids at ambient temperatures and pressures and include polyether polyols and polyester polyols having hydroxyl numbers in the range of from about 15 to about 700. The hydroxyl numbers are preferably between about 20 to about 60 for flexible foams, between about 100 to about 300 for semi-flexible foams and between about 250 to about 700 for rigid foams. For flexible foams the preferred functionality, i.e. the average number of hydroxyl groups per molecule of polyol, of the polyols is about 2 to about 4 and most preferably about 2.3 to about 3.5. For rigid foams, the preferred functionality is about 2 to about 8 and most preferably about 3 to about 5. The compositions of the invention include as polyol (a) for example any of the following non-limiting classes of polyols:

[0229] (1) polyether polyols derived from the reaction of polyhydroxyalkanes with one or more alkylene oxides, e.g. ethylene oxide, propylene oxide, etc.;

[0230] (2) polyether polyols derived from the reaction of high-functionality alcohols, sugar alcohols, saccharides and / or high functionality amines, if desired in admixture with low-functionality alcohols and / or amines with alkylene oxides, e.g. ethylene oxide, propylene oxide, etc.;

[0231] (3) polyether polyols derived from the reaction of phosphorus and polyphosporus acids with alkylene oxides, e.g. ethylene oxide, propylene oxide, etc.,

[0232] (4) polyether polyols derived from the reaction of polyaromatic alcohols with alkylene oxides, e.g. ethylene oxide, propylene oxide, etc.;

[0233] (5) polyether polyols derived from the reaction of ring-opening polymerization of tetrahydrofurane;

[0234] (6) polyether polyols derived from the reaction of ammonia and / or an amine with alkylene oxides, e.g. ethylene oxide, propylene oxide, etc.; (7) polyester polyols derived from the reaction of a polyfunctional initiator, e.g. a diol, with a hydroxycarboxylic acid or lactone thereof, e.g. hydroxylcaproic acid or s-caprolactone;

[0235] (8) polyoxamate polyols derived from the reaction of an oxalate ester and a diamine, e.g. hydrazine, ethylenediamine, etc. directly in a polyether polyol;

[0236] (9) polyurea polyols derived from the reaction of a diisocyanate and a diamine, e.g. hydrazine, ethylenediamine, etc. directly in a polyether polyol.

[0237] For flexible foams, preferred types of alkylene oxide adducts of polyhydroxyalkanes are the ethylene oxide and propylene oxide adducts of aliphatic triols such as glycerol, trimethylol propane, etc. For rigid foams, the preferred class of alkylene oxide adducts are the ethylene oxide and propylene oxide adducts of ammonia, toluene diamine, sucrose, and phenol- formaldehyde-amine resins (Mannich bases). Grafted or polymer polyols are used extensively in the production of flexible foams and are, along with standard polyols, one of the preferred class of polyols useful in this invention. Polymer polyols are polyols that contain a stable dispersion of a polymer, for example in the polyols 1) to 5) above and more preferably the polyols of type 1). Other polymer polyols useful in this invention are polyurea polyols and polyoxamate polyols. Preference is given to using polyesterols and / or polyetherols as polyols (a). The average hydroxy-functionality of the polyetherols and / or polyesterols is generally from 1.9 to 8, preferably from 2.4 to 6, particularly preferably from 2.6 to 4. In the case of polyetherols, the hydroxy-functionality of the starter molecules is assumed to calculate the average functionality. The polyols (a) suitably have a hydroxyl number of generally greater than 20 mg KOH / g, preferably greater than 30 mg KOH / g, particularly preferably greater than 40 mg KOH / g. 700 mg KOH / g, preferably 600 mg KOH / g, particularly 500 mg KOH / g, very particularly 400 mg KOH / g, has generally been found to be an appropriate upper limit to the hydroxyl number. The OH numbers indicated above relate to the totality of the polyols (a), which does not preclude individual constituents of the mixture from having higher or lower values. The number-average molecular weight of the polyols (a) is preferably greater than 400 g / mol. Component (a) preferably comprises polyether polyols which are produced by known methods, for example from one or more alkylene oxides having from 2 to 4 carbon atoms in the alkylene radical by anionic polymerization using alkali metal hydroxides such as sodium or potassium hydroxide or alkali alkoxides such as sodium methoxide, sodium or potassium ethoxide or potassium isopropoxide as catalysts and with addition of at least one starter molecule comprising from 2 to 8, preferably from 3 to 8, reactive hydrogen atoms in bound form or by cationic polymerization using Lewis acids such as antimony pentachloride, boron fluoride etherate, etc., or bleaching earth as catalysts. Suitable alkylene oxides are, for example, tetrahydrofuran, 1 ,3-propylene oxide, 1 ,2- or 2,3-butylene oxide, styrene oxide and preferably ethylene oxide and 1 ,2-propylene oxide. The alkylene oxides may be used individually, alternately in succession or as mixtures. Possible starter molecules are alcohols such as glycerol, trimethylolpropane (TMP), pentaerythritol, sugar compounds such as sucrose, sorbitol and also amines such as methylamine, ethylamine, isopropylamine, butylamine, benzylamine, aniline, toluidine, toluenediamine (TDA), naphthylamine, ethylenediamine (EDA), diethylenetriamine, 4,4'-methylenedianiline, 1 ,3-propanediamine, 1 ,6- hexanediamine, ethanolamine, diethanolamine, triethanolamine and the like. Furthermore, condensation products of formaldehyde, phenol and diethanolamine or ethanolamine, formaldehyde, alkylphenols and diethanolamine or ethanolamine, formaldehyde, bisphenol A and diethanolamine or ethanolamine, formaldehyde, aniline and diethanolamine or ethanolamine, formaldehyde, cresol and diethanolamine or ethanolamine, formaldehyde, toluidine and diethanolamine or ethanolamine and formaldehyde, toluenediamine (TDA) and diethanolamine or ethanolamine and the like can be used as starter molecules. Preference is given to using glycerol, sucrose, sorbitol and TDA as starter molecule. Such polyols are commercially available for example under the trademark Voranol® from Dow Corning such a VORANOL™ 3322 Polyol (nominal 3400 molecular weight, heteropolymer triol), and others, such as RENUVA™ FF 60, VORANOL™ 3010, VORANOL™ 3010A, VORANOL™ 3011 , VORANOL™ 3022J, VORANOL™ 3322, VORANOL™ 3535, VORANOL™ 4730-N, VORANOL™ 8010, VORANOL™ 8010A, VORANOL™ 8010G, VORANOL™ 8022, VORANOL™ 8136, VORANOL™ 8322, VORANOL™ 8595, VORANOL™ WK 3138, VORANOL™ WL 4010, VORANOL™ 3136, DWJ 4001.01 DEV, VORALUX™ HF 505, VORALUX™ HN 395, VORANOL™ 4150, VORANOL™ 6150, SPECFLEX™ 334-028, VORALUX™ HK 643, VORALUX™ HT 760, VORALUX™ HT 762, VORALUX™ HT 767, VORALUX™ HT 1080, VORANOL™ 8150, VORANOL™ WK 3140, VORANOL™ WK 8140, VORANOL ™ WL 4099.

[0238] Polyisocanates (b)

[0239] The polyisocyanates (b) that are useful in the polyurethane foam formation process of this invention are organic compounds that contain at least two isocyanate groups and generally will be any of the known aromatic or aliphatic polyisocyanates. Suitable organic polyisocyanates (b) include, for example, the hydrocarbon diisocyanates, (e.g. the alkylenediisocyanates and the arylene diisocyanates), such as methylene diphenyl diisocyanate (MDI) and 2,4- and 2,6-toluene diisocyanate (TDI), as well as known triisocyanates and polymethylene poly(phenylene isocyanates) also known as polymeric or crude MDI. For flexible and semi-flexible foams, the preferred isocyanates generally are, e.g., mixtures of 2,4-tolulene diisocyanate and 2,6-tolulene diisocyanate (TDI) in proportions by weight of about 80% and about 20% respectively and also about 65% and about 35% respectively based on the total weight of the composition of TDI; mixtures of TDI and polymeric MDI, preferably in the proportion by weight of about 80% TDI and about 20% of crude polymeric M DI to about 50% TDI and about 50% crude polymeric MDI based on the total weight of the composition; and all polyisocyanates of the MDI type. For rigid foams, the preferred isocyanates are, e.g., polyisocyanates of the MDI type and preferably crude polymeric MDI. The amount of polyisocyanate included in the foam formulations used relative to the amount of other materials in the formulations is described in terms of “Isocyanate Index”. “Isocyanate Index” means the actual amount of polyisocyanate used divided by the theoretically required stoichiometric amount of polyisocyanate required to react with all the active hydrogen in the reaction mixture multiplied by one hundred (100) [see e.g. Oertel, Polyurethane Handbook, ibid.]. The Isocyanate Indices in the reaction mixtures used in the process of this invention generally are between 60 and 140. More usually, the Isocyanate Index is: for flexible TDI foams, typically between 80 and 130; for molded TDI foams, normally between 90 and 105; for molded MDI foams, most often between 70 and 90; and for rigid MDI foams, generally between 90 and 130. Some examples of polyisocyanurate rigid foams are produced at indices as high as 250-400.

[0240] Catalysts (c)

[0241] As polyurethane foaming additives, the polyurethane foam-forming compositions of the invention comprise one or more catalysts. The catalyst may include any suitable catalysts or mixtures of catalysts known in the art as catalysts in polyurethane formation. Examples of suitable catalysts include, but are not limited to, gelation amine catalysts, such as triethylenediamine ; amine blowing catalysts, such as bis(dimethylaminoethyl)ether; and metal catalysts, such as stannous octoate, or bismuth octoate, etc. as described in more detail below.

[0242] Amine catalysts

[0243] Particularly preferred additives include amine catalysts for the formation of polyisocyanate polyaddition products, such as amines different from the isocyanate-reactive compounds used for the polyurethane formation. For example such catalysts include alkyl amines such as bis(2- dimethylaminoethyl)ether, N,N-dimethylcyclohexylamine, N,N,N’,N’,N”- pentamethyldiethylenetriamine, N,N,N’,N’,N”-pentamethyldipropylenetriamine triethylenediamine, ethanol amines, such as 2-aminoethanol, diethanolamine, triethanolamine, N-methyldiethanolamine, N,N-dimethylethanolamine, N,N-diethylethanolamine, N- methylethanolamine, N-ethylethanolamine, diisopropylamine, bis(2-hydroxypropyl)amine, 2- [2-(dimethylamino)ethoxy]ethanol, 1-[bis[3-(dimethylamino)propyl]amino]-2-propanol, 3- dimethylamino-N,N-dimethylpropionamide, N,N’-dimorpholinodiethyl ether, N,N’- dimethylpiperazine, N-methylmorpholine, N-ethylmorpholine, 2-{[2- (dimethylamino)ethyl]methylamino}ethanol, 3,3'-iminobis(N,N-dimethylpropylamine), 3- (dimethylamino)-l-propylamine, 3-(diethylamino)-1-propanol, 1-(3-hydroxypropyl)pyrrolidine, 1-(2-hydroxypropyl)pyrrolidine, 1-(2-hydroxyethyl)pyrrolidine, 1-(2-hydroxyethyl)piperidine, 1- (3-hydroxypropyl)piperidine, 1-(2-hydroxypropyl)piperidine, 1-(3-aminopropyl)pyrrolidine, 1-(2- aminoethyl)pyrrolidine, 1-(3-aminopropyl)piperidine, 1-(2-aminoethyl)piperidine, 1-(1- pyrolidineyl)-2-propanamine, 1-(piperidin-1-yl)propan 2-amine, N-methoxyethylmorpholine, N- methylimidazole, 1-(3-aminopropyl) imidazole, 2-[2-[2-(dimethylamino)ethoxy]ethyl- methylamino]ethanol, N-methyl dicyclohexylamine, 3-{[3-

[0244] (dimethylamino)propyl]methylamino}propanol, tris (dimethyl aminopropyl)amine, 2-{[3- (dimethylamino)propyl]methylamino}ethanol, N,N,N’,N’-tetramethyl-hexamethylene diamine, N,N,N’,N’-tetramethylethylenediamine, 2,4,6-tris(dimethylaminomethyl)phenol, 1 ,3,5- tris(dimethylaminopropyl)- hexahydrotriazine, N,N-dimethylbenzylamine, 1 ,8 diaza bicyclo 5,4,0 undecene 7, N-methyl-N’-(2-dimethylamino) ethyl-piperazine, N,N'-bis[3- (dimethylamino)propyl]urea, N-[3-(dimethylamino)propyl]urea. N,N,N',N'-tetrakis(2- hydroxypropyl)ethylenediamine, and N,N,N',N'-tetrakis(2-hydroxyethyl)ethylenediamine. Preferred amines include alkyl amines, such as bis(2-dimethylaminoethyl)ether, N,N- dimethylaminopropylamine, N,N-dimethylcyclohexylamine, N,N,N’,N’,N”- pentamethyldiethylenetriamine, triethylenediamine, ethanol amines, such as diethanolamine, 2(2-dimethylaminoethoxy)ethanol, N-[2-(dimethylamino)ethyl]-N-methylethanolamine, dimethylethanolamine, or other amines such as 3-dimethylamino-N,N-dimethylpropionamide and N-ethylmorpholine, triethanolamine, 2-dimethylaminoethanol, N,N- dimethylaminopropylamine, diethanolamine, trimethylamine, triethylenediamine, bis(2- dimethylaminoethyl)ether._Such amine catalysts are commercially available, e.g. as shown in the following: 2, 4, 6-Tris(Dimethylaminomethyl)phenol (DABCO TMR-30; JEFFCAT TR30; RC Catalyst 6330), N,N,N’,N’-Tetramethyl-1 ,3-butanediamine (TMBDA), N,N- Dimethylcyclohexylamine (POLYCAT 8; JEFFCAT DMCHA), N,N-Diethylethanolamine (DEEA), N-Ethylmorpholine (JEFFCAT NEM; TOYOCAT NEM; RC Catalyst 6072), 1- azabicyclo[2.2.2]octane (QUINICLIDINE), Triethanolamine (TEA), N,N,4-Trimethyl-1- piperazineethanamine (TOYOCAT -NP), N,N’-Dimethylpiperazine (JEFFCAT DMP; RC Catalyst 6117), Dimethylethanolamine (DABCO DMEA; JEFFCAT DMEA), N- Methylmorpholine (JEFFCAT NNM; RC Catalyst 101), N,N-Dimethylaminopropylamine (DMAPA; TOYOCAT RH2), N,N,N’,N’-Tetramethylethylenediamine (TMEDA; TOYOCAT-TE; JEFFCAT TMEDA), 1 ,3-bis(dimethylamino)propane, N,N,N’,N’-

[0245] Tetramethylhexamethylenediamine (TMHDA; TOYOCAT-MR), Diethanolamine DABCO DEOA-LF; DEOA LFG; DEA), Dimethyldodecylamine (DM-12D, N,N-dimethylhexadecylamine (DM-16D; DABCO B-16), Triethylamine (ACCLIRE C (Allied), N,N-Diisopropylethanolamine (DIEA), Ethanolamine (Monoethanolamine) EA (MEA), Triethylenediamine (TEDA; NIAX A- 100, DABCO Crystal; RC Catalyst 105; JEFFCAT TD-100; TOYOCAT TEDA; RC Catalyst 104), 4-butyl-morpholine (NBM), 2(2-Dimethylaminoethoxy)ethanol (PAK-LOC V; JEFFCAT ZR-70), 1 ,2-Dimethylimidazole (DIME 12), N-[2-(dimethylamino)ethyl]-N-methylethanolamine (DABCO T; TOYOCAT RX55), N,N,N’,N’,N”-Pentamethyldiethylenetriamine (POLYCAT 5; TOYOCAT DT; JEFFCAT PMDETA), bis(2-Dimethylaminoethyl)ether (NIAX A-99; DABCO BL-19; TOYOCAT ETS; JEFFCAT ZF-20;RC Catalyst 6433), N,N’-bis(1 ,4-dimethylpentyl)-1 ,4- benzenediamine (TENAMENE 4), N-[3-(dimethylamino)propyl]-N,N’,N’-trimethyl-1 ,3- propanediamine (POLYCAT 77; JEFFCAT ZR40), 4-[2-(dimethylamino)ethyl]-morpholine (DABCO XDM), N-cyclohexyldiethanolamine (DECA), N-Hydroxyethyl-N’-methylpiperazine (TOYOCAT-HP), N-(3-Dimethylaminopropyl)formamide, 1 ,3-bis(dimethylamino)-2-propanol (UC-2 (Sipene)), 2,2’-dimorpholinodiethylether (JEFFCAT DMDEE), 1 ,8- diazabicyclo[5.4.0]undec-7-ene (POLYCAT DBU; RC Catalyst 6180), Tetramethylimino- bis(propylamine) (POLYCAT 15; JEFFCAT ZR-50B), N-Methyldicyclohexylamine (POLYCAT 12), 4-(2-methoxyethyl)-morpholine (JEFFCAT MM), N,N,N'-tris(2- hydroxypropyl)ethylenediamine (EFFCAT DPA), 1 ,3,5-tris[3-

[0246] (dimethylamino)propyl]hexahydro-s-triazine (POLYCAT 41 ; JEFFCAT TR41 ; TOYOCAT TRC; RC Catalyst 6099), 3-Dimethylamino-N,N-Dimethylpropionamide (DDPA; NIAX A4; NIAX C- 191), N,N-dimethyl-(4-methyl-1-piperazinyl)-ethanamine (JEFFCAT TAP; RC Catalyst 6076), Tris(3-Dimethylamino)propylamine (POLYCAT 9; JEFFCAT Z80), ethanamine, 2,2’- [methylene bis(oxy)]bis[N,N-dimethyl- (CI-710), 4-(2-aminopropyl)morpholine (MAEM), 1- [bis(3-dimethylaminopropyl)amino]-2-propanol (JEFFCAT ZR-50), N,N,N’,N’-2-pentamethyl- 1 ,2-propanediamine (PMT), N-Cocomorpholine (DABCO NCM; JEFFCAT NCM), N-Methyl,N- (N’,N’-2-Dimethylaminopropyl)ethanolamine (POLYCAT 17), 2-(2-(2-dimethylamino ethoxy)- ethylmethylamino)-amino (JEFFCAT ZF-10).

[0247] Further mention can be made of the amine catalysts disclosed in WO 2021 / 177946, the catalyst compositions disclosed in WO 2021 / 177944, the entire content of which is included herewith by reference to such documents.

[0248] Particularly amine catalysts are selected from: i. tertiary amino compounds having at least one further amino group, selected from primary, secondary and tertiary amino groups, ii. tertiary amino compounds having at least one active hydrogen or hydroxyl group, such as -OH, -NH, NH2, and -SH groups, iii. tertiary amino compounds having at least one ether group, wherein the number of carbon atoms connecting the nitrogen atom of the tertiary amino group, iv. aliphatic saturated tertiary amino compounds, v. tertiary amino compounds selected from the group of dimethylaminopropyl urea N,N'-bis[3-(dimethylamino)propyl]urea triethylamine

[0249] 1 ,2-dimethylimidazole

[0250] N-(3-aminopropyl)imidazole

[0251] N-(hydroxypropyl)imidazole

[0252] N-(2-hydroxyethyl)imidazole tris(dimethylaminopropyl)hexahydro-1 ,3,5-triazine

[0253] 1 , 1 ,3,3-tetramethylguanidine,

[0254] 1 ,5,7-triaza-bicyclo[4.4.0]dec-5-ene,

[0255] 2,2,4-trimethyl-1-oxa-4-aza-2-silacyclohexane, N,N,N',N'-tetramethyl-2,2'-oxybis(ethylamine), 4-ethyl-2,2-dimethyl-1-oxa-4-aza-2-silacyclohexane, N,N,N',N'-tetramethyl-2,2'-oxybis(ethylamine) (bis(2-dimethylaminoethyl)ether), and triethylenediamine (1,4-diazabicyclo[2.2.2]octane); vi. any of the above amine catalysts blocked with an organic acid, and vii. mixtures of the above amine catalysts.

[0256] Particular preferred amine catalysts are bis(dimethylaminoethyl)ether ((BDMAEE) BDMAEE: Niax catalyst A-99), triethylenediamine (TEDA: Niax catalyst A-100) and N,N’-Bis[3- (dimethylamino)propyl]urea (Niax Catalyst EF-700).

[0257] Metal catalysts

[0258] Apart from amine catalysts suitable catalysts include metal catalysts such as: strong metal bases compounds such as alkali and alkaline earth metal hydroxides, alkoxides, phenoxides, and the like, acidic metal salts of strong acids such as ferric chloride, stannous chloride, antimony trichloride, bismuth nitrate and chloride, and the like; chelates of various metals such as those which can be obtained from acetylacetone, benzoylacetone, trifluoroacetylacetone, ethyl acetoacetate, salicylaldehyde, cyclopentanone-2-carboxylate, acetylacetoneimine, bis-acetylacetone alkylenediimines, salicylaldehydeimine, and the like, with various metals such as Be, Mg, Zn, Cd, Pb, Ti, Zr, Sn, As, Bi, Cr, Mo, Mn, Fe, Co, Ni, or metal ion compounds such as MOC>2++, UC>2++, and the like; alcoholates and phenolates of various metals such as Ti(OR)4, Sn(OR)4, Sn(OR)2, AI(OR)3, and the like, wherein R is an organic group such as alkyl or aryl of from 1 to about 12 carbon atoms, and reaction products of alcoholates with carboxylic acids, beta-diketones, and 2-(N,N-dialkylamino) alkanols, such as well-known chelates of titanium obtained by this or equivalent procedures; salts of organic acids with a variety of metals such as alkali metals, alkaline earth metals, Al, Sn, Pb, Mn, Co, Bi, and Cu, including, for example, sodium acetate, potassium laurate, calcium hexanoate, stannous acetate, stannous octoate, stannous oleate, lead octoate, metallic driers such as manganese and cobalt naphthenate, and the like; organometallic derivatives of tetravalent tin, tri valent and pentavalent As, Sb, and Bi, and metal carbonyls of iron and cobalt; and combinations of two or more thereof.

[0259] In one embodiment, the catalyst additive is an organotin compound that is a dialkyltin salt of a carboxylic acid, including the non-limiting examples of dibutyltin diacetate, dibutyltin dilaureate, dibutyltin maleate, dilauryltin diacetate, dioctyltin diacetate, dibutyltin-bis(4-methylarnino benzoate), dibutyltindilauryl mercaptide, dibutyl tin-bis(6-methylaminocaproate), and the like, and combinations of two or more thereof.

[0260] Similarly, in another embodiment there may be used trialkyltin hydroxide, dialkyltin oxide, dialkyltin dialkoxide, or dialkyltin dichloride, and combinations of two or more thereof can be employed. Non-limiting examples of these compounds include trimethyltin hydroxide, tributyltin hydroxide, trioctyltin hydroxide, dibutyltin oxide, dioctyltin oxide, dilauryltin oxide, dibutyltin- bis(isopropoxide) dibutyltin-bis(2-dimethylaminopentylate), dibutyltin dichloride, dioctyltin dichloride, and the like, and combinations of two or more thereof.

[0261] In one embodiment, the catalyst can be an organotin catalyst such as stannous octoate, dibutyltin dilaurate, dibutyltin diacetate, stannous oleate, or combinations of two or more thereof.

[0262] Water (d)

[0263] Water is used as a reactive / chemical blowing agent in both flexible and rigid polyurethane foams. In the production of flexible slabstock foams, water generally can be used in concentrations of, e.g., between 0.5 to 6.5 parts per hundred parts (pphp) of polyol blend, and more often between 1 to 4.5 pphp of polyol blend. Water levels for TDI molded foams normally range, e.g., from 2 to 3.5 pphp of polyol blend. For MDI molded foam, the water level, for example, is more normally between 2.5 and 5 pphp. Rigid foam water levels, for example, range from 0.5 to 5 pphp, and more often from 0.5 to 2 pphp of polyol blend. Physical blowing agents such as blowing agents based on volatile hydrocarbons or halogenated hydrocarbons and other non-reacting gases can also be used in the production of polyurethane foams in accordance with the present invention. Typical physical blowing agents include, but are not limited to methylene chloride, acetone, hydrochlorofluorocarbons, hydrocarbons pentane, cyclopentane, and liquid carbon dioxide. In the production of flexible slabstock foams, water is the main blowing agent; however, other blowing agents can be used as auxiliary blowing agents.

[0264] Silicone surfactant composition (e)

[0265] The polyurethane foam-forming composition includes a silicone surfactant composition according to the present invention as described above in general and as further defined by the embodiments disclosed above. The silicone surfactant compositions are thus based on polyether functional silicone compounds A). The surfactant compositions typically support homogenization of a blowing agent and the polyol component and regulate the cell structure of the polyurethane foam article by modification of the foam stability during the foaming process. The surfactant composition according to the invention may include any suitable surfactant compound A) or mixtures of surfactant compounds A) known in the art as falling within the definition of the surfactant compounds described herein. Suitable silicone surfactant compounds are for example described in US 5,489,617, US 8,044,109, US 5,145,879, EP3307801A1 / W02016201073A1) WO16164552 A1 ,_W016201073 A1 , EP1753799B1, US9587068B2, W02023 / 009390 and Dipak D. Pukale et al.: “Review on Silicone Surfactants: Silicone-based Gemini Surfactants, Physicochemical Properties and Applications”, Tenside Surf. Det. 56 (2019) 4 all incorporated by reference here. They are commercially available for example under the trademark NIAX® of Momentive Performance Materials such as NIAX® L- 895 or L-865.

[0266] A particular preferred silicone surfactant compound is a polyether-functional silicone surfactant compound, preferably comprising two different polyether substituents (as described in W02016201073A1), having preferably an average molecular weight of about 500 to 10000 such as 1500 or 4000, wherein the polyether moiety comprises ethylene oxide units (EO), preferably at least 20 % EO, more preferably at least 40 % EO).

[0267] Further preferred silicone surfactants are the polyether functional silicone compounds described in W02023 / 009390, which is also incorporated herein by reference.

[0268] Further additives and auxiliary compounds (f)

[0269] The polyurethane foam-forming composition according to the invention may further comprise additives and auxiliary compounds, which help in particular polyurethane foam processing at low dosage levels, typically only several weight part per hundred polyol. These may be flame or fire retardants such as chlorinated phosphate esters, chlorinated paraffins, and melamine powders; chain extenders, chain-terminators, cross-linking agents, adhesion promoters, antistatic additives, hydrolysis stabilizers, light stabilizers, such as Ultraviolet Light Absorbers (UVAs), Hindered Amine Light Stabilizers (HALS); lubricants, anti-microbial agents, processing aid additives, anti-oxidants, such hindered phenols and hindered amine stabilizers, phosphites, hydroxylamines, lactone based stabilizers; defoamers, anti-foaming agents, emission control agents (such as disclosed in WO23034354A1 included herein by reference to such document) water scavengers, molecular sieves, fumed silicas, fillers such as calcium carbonate, microcellulose, thixotropic agents, silicones, colorants or pigments such as titanium dioxide (white), iron (III) oxide (red), chromium (III) oxides (green), carbon (black), color pastes, inert diluents, and combinations thereof (see e.g. The polyurethanes book, Editors David Randall and Steve Lee, John Willey & Sons, LTD, 2002; Szycher's Handbook of Polyurethanes, 2nd edition, 2013, chapter 18 in particular, each included herein by reference to such documents). Preferred additives are flame lamination additives, antioxidants and processing aid additives. Flame lamination additives are for example described in WO16164552 A1 and include, in particular, compounds for improving the bond strength in flame lamination. Examples of suitable flame lamination additives include, but are not limited to, phosphorus-containing flame retardants and polyols having aromatic structural units. Particularly suitable flame lamination additives include, but are not limited to, high molecular weight flame retardants such as Fyrol PNX from AKZO and Exolit OP 560 from Clariant, bisphenol A alkoxylates and commercially available_flame lamination additives such as Niax Flame Lamination Additive FLE-200LF, Niax Flame Lamination Additive FLE-500LF etc..

[0270] The flame lamination additive may be used in the polyurethane foam-forming compositions at a concentration of from about 1 to about 10 pphp, more particularly in an amount of from about 1 to about 8 pphp and even more particularly in an amount of from about 1 to about 6 pphp, were pphp means parts per hundred parts of the total polyol used.

[0271] Antioxidants retard the thermal oxidation of polyurethanes by stopping the chain-breaking reactions initiated by oxygen and / or oxygen free radicals. Antioxidants in synergistic mixtures with phosphites or phosphines are particularly effective. A comprehensive list of possible antioxidants to be used in polyurethane foams is disclosed for example in WO2019 / 110726 (see in particular the “Background of the invention”) the disclosure of which is incorporated herein by reference to such document. Further suitable antioxidants are described in Szycher's Handbook of Polyurethanes, 2nd edition, 2013, see chapter 18 in particular).

[0272] Processing aids additives include for example products stabilizing foaming process, preventing foam splitting, and unifying foaming performance along foaming rising direction, such as Geocell GM-280, GM-225, Niax GM-206, and GM-210, and other products improving foaming processing capability, such as lubricants, including (C14-C18) fatty alcohols, dicarboxylic acid esters, fatty acid esters, fatty acids, fatty acid soaps, and fatty acid amines, high-polymeric processing aids, and mold-release agents.

[0273] Methods for producing polyurethane foam from the polyurethane foam-forming composition of the present invention comprising the silicone surfactant composition as described herein are not particularly limited. Various methods commonly used in the art may be employed. For example, various methods described in “Polyurethane Resin Handbook,” by Keiji Iwata, Nikkan Kogyo Shinbun, Ltd., 1987 may be used. For example, the composition of the present invention can be prepared by combining the polyols, catalyst, surfactants, blowing agent, polyether functional siloxane, and additional compounds including optional ingredients into a premix.

[0274] The viscosity of the surfactant compounds and the surfactant compositions can be determined using an Ubbelohde glass capillary viscometer according to ISO 3105.

[0275] The viscosities referred to in this application are determined according to the above-cited standard.

[0276] Preferred embodiments according to the invention

[0277] In the following, the preferred embodiments according to the invention are summarized:

[0278] 1. A surfactant composition for the use in polyurethane foam, comprising

[0279] A) one or more silicone surfactant compounds

[0280] B) one or more surfactant potency-enhancing agents

[0281] C) optionally one or more diluents.

[0282] 2. The surfactant composition according to the previous embodiment 1 , wherein one or more of the silicone surfactant compounds A) is a silicone surfactant comprising a silicone backbone and one or more polyether substituents R*, which may be the same or different, attached to one or more Si atoms of the silicone backbone.

[0283] 3. The surfactant composition according to embodiment 1 or 2, wherein one or more of the component B) is an organic acid or an organic acid-based compound, preferably an organic acid.

[0284] 4. The surfactant composition according to any of the embodiments 1 to 3, wherein one or more of the component B) is an organic acid, an organic acid salt, or an organic acid ester.

[0285] 5. The surfactant composition according to any of the embodiments 1 to 4, wherein one or more of the component B) is an organic acid.

[0286] 6. The surfactant composition according to any of the embodiments 1 to 4, wherein one or more of the component B) is a carboxylic acid, a carboxylic acid salt or carboxylic acid ester, preferably a carboxylic acid.

[0287] 7. The surfactant composition according to any of the previous embodiments 1 to 6, wherein one or more of the component B) is a carboxylic acid, preferably a monocarboxylic acid.

[0288] 8. The surfactant composition according to any of the previous embodiments 1 to 4 and 6, wherein one or more of the component B) is a carboxylic acid salt, preferably a monocarboxylic acid salt. 9. The surfactant composition according to any of the previous embodiments 1 to 4 and 6, wherein one or more of the component B) is a carboxylic acid ester, preferably a monocarboxylic acid ester or a dicarboxylic acid ester.

[0289] 10. The surfactant composition according to any of the previous embodiments 1 to 4 and 6, wherein the component B) is an organic acid, an organic acid salt, or an organic acid ester containing 4 or more carbon atoms, preferably 6 or more carbon atoms, more preferably 8 or more carbon atoms, even more preferably 10 or more carbon atoms.

[0290] 11. The surfactant composition according to any of the previous embodiments 1 to 7 and

[0291] 10, wherein the component B) is an organic acid with 4 or more carbon atoms, preferably 6 or more carbon atoms, more preferably a carboxylic acid with 6 or more carbon atoms, even more preferably a monocarboxylic acid with 6 or more carbon atoms.

[0292] 12. The surfactant composition according to any of the previous embodiments 1 to 7, 10 or

[0293] 11 , wherein the component B) is a carboxylic acid, preferably a monocarboxylic acid, with 4 or more carbon atoms, more preferably with 6 or more carbon atoms, even more preferably a monocarboxylic acid with 6 or more carbon atoms, and wherein one or more of the silicone surfactant compounds A) is a silicone surfactant comprising a silicone backbone and one or more polyether substituents R*, which may be the same or different, attached to one or more Si atoms of the silicone backbone, and wherein the amount of component A) in the silicone surfactant composition is 15.0 weight-% or more based on the overall weight of the surfactant composition.

[0294] 13. The surfactant composition according to any of the previous embodiments 1 to 4, 6, 8, and 10 wherein the component B) is an organic acid salt with 4 or more carbon atoms in the anionic part, preferably 6 or more carbon atoms in the anionic part, more preferably a carboxylic acid salt with 6 or more carbon atoms in the anionic part, even more preferably a monocarboxylic acid salt with 6 or more carbon atoms in the anionic part.

[0295] 14. The surfactant composition according to any of the previous embodiments 1 to 4, 6, 9 and 10, wherein the component B) is an organic acid ester with 4 or more carbon atoms in the structure corresponding to the organic acid, preferably 6 or more carbon atoms in the structure corresponding to the organic acid, more preferably a carboxylic acid ester with 6 or more carbon atoms in the structure corresponding to the organic acid, even more preferably a monocarboxylic acid ester or dicarboxylic acid ester with 6 or more carbon atoms in the structure corresponding to the organic acid.

[0296] 15. The surfactant composition according to any of the previous embodiments 1 to 14, wherein the component B) is contained in the composition in an amount of 0.01 to 70 weight- % on the basis of the total weight of the surfactant composition, preferably in an amount of 0.2 to 20 weight-% on the basis of the total weight of the surfactant composition, wherein optionally the ratio of the components A) to B) (w / w) is in the range of 100 : 1 to 2 : 1 , preferably 50 : 1 to 3 : 1 , more preferably 20 : 1 to 4 : 1 , even more preferably 15 : 1 to 5 : 1.

[0297] 16. The surfactant composition according to any of the previous embodiments 1 to 15, wherein the siloxane backbone of one or more of the silicone compounds A) is represented by the general formula

[0298] M*DxD”yM* (I), wherein

[0299] M* represents (CH3)3SiOi / 2 or (CH3)2RSiOi / 2;

[0300] D represents (CH3)2SiO2 / 2;

[0301] D” represents (CH3)RSiO2 / 2; x is 0-200; y is 2 or more; x+y is 10 to 250; the ratio of x to y is 2 to 50; and R is a polyether substituent R*.

[0302] 17. The surfactant composition according to any of the previous embodiments 1 to 16, wherein one or more of the silicone surfactant compounds A) has the formula M*DxD”yM* (I), wherein

[0303] M* represents (CH3)3SiOi / 2 or (CH3)2R*SiOi / 2;

[0304] D represents (CH3)2SiO2 / 2;

[0305] D” represents (CH3)R*SiC>2 / 2; x is 0-200; y is 2 or more; x+y is 10 to 250; the ratio of x to y is 2 to 50; and R* is a polyether substituent independently selected from the same or different -CnH2nO- group-started polyether substituents, wherein n is 2-10.

[0306] 18. The surfactant composition according to any of the previous embodiments 1 to 17, wherein one or more of the silicone surfactant compounds A) has the formula

[0307] M*DxD”yM* (I), wherein

[0308] M* represents (CH3)3SiOi / 2 or (CH3)2R*SiOi / 2;

[0309] D represents (CH3)2SiO2 / 2;

[0310] D” represents (CH3)R*SiC>2 / 2; x is 0-200; y is 2 or more; x+y is 10 to 250; the ratio of x to y is 2 to 50; and R* is a polyether substituent independently selected from the same or different -CnH2nO- group-started polyether substituents, wherein n is 2-10 and the substituents R* have a number average molecular weight of from 200 Dalton to 6000 Dalton.

[0311] 19. The surfactant composition according to any of the previous embodiments 2 to 18, wherein one or more of the polyether substituents R* of the silicone surfactant compound A) are independently terminated by an alkoxy group or an acyl group, preferably by a methoxy group or an acetoxy group.

[0312] 20. The surfactant composition according to any of the previous embodiments 2 to 19, wherein the polyether substituents R* of the silicone surfactant compound A) are the same or different and have the formula

[0313] -CnH2nO(C2H4O)a(C3H6O)bR1(II) wherein n is 2-10, a is a number such that the ethylene oxide residues constitute from about 30% to about 100% by weight of the alkylene oxide residues of the polyether substituent R*; b is a number such that the propylene oxide residues constitute from about 0% to about 70% by weight of the alkylene oxide residues of the polyether substituent R*;

[0314] R1is a C1-C10 alkyl group or a C2-C11 alkanoyl group, preferably a methyl group or an acetyl group.

[0315] 21. The surfactant composition according to any of the previous embodiments 2 to 20, wherein the polyether substituents R* of the silicone surfactant compound A) are the same or different and have the formula

[0316] -CnH2nO(C2H4O)a(C3H6O)bR1(II) wherein n is 2-10, a is a number such that the ethylene oxide residues constitute from about 30% to about 100% by weight of the alkylene oxide residues of the polyether substituent R*; b is a number such that the propylene oxide residues constitute from about 0% to about 70% by weight of the alkylene oxide residues of the polyether substituent R*;

[0317] R1is a C1-C10 alkyl group or a C2-C11 alkanoyl group, preferably a methyl group or an acetyl group; and the substituents R* have a number average molecular weight of from about 200 Dalton to about 6000 Dalton.

[0318] 22. The surfactant composition according to the previous embodiments 20 and 21 , wherein in formula (II), n, b and R1as defined in the previous embodiment, and

[0319] “a” in the polyether substituents R* is such that the ethylene oxide residues constitute from about 35% to about 100% by weight of the alkylene oxide residues of the polyether substituent R, preferably 40% to 100% by weight, more preferably 70% to 100% by weight, and even more preferably 80% to 100% by weight of the alkylene oxide residues of the polyether substituent R*.

[0320] 23. The surfactant composition according to any of the previous embodiments 2 to 22, wherein the polyether substituents R* of the silicone surfactant compound A) are polyether substituents having a number average molecular weight of from 400 Dalton to 4000 Dalton, preferably of from 500 Dalton to 3000 Dalton, even more preferably of from 700 Dalton to 2000 Dalton.

[0321] 24. The surfactant composition according to any of the previous embodiments 16 to 23, wherein in the silicone surfactant compound A) of the formula (I) M*, D, and D”, x, x+y, the ratio of x to y and R* are as defined above, and y is 3 to 20, more preferably 4 to 10.

[0322] 25. The surfactant composition according to any of the previous embodiments 2 to 24, wherein the silicone surfactant compound A) comprises two or more different types of polyether substituents R*, preferably the silicone surfactant compound A) contains two different types of polyether substituents R*.

[0323] 26. The surfactant composition according to any of the previous embodiments 2 to 25, wherein the silicone surfactant compound A) comprises one or more polyether substituents R* selected from the group (i) of polyether substituents having a structure of the formula (II’)

[0324] (i) -Cn’H2n’O(C2H4O)a’(C3H6O)b’R2(II’), wherein n’ is 2-10; a’ is a number such that ethylene oxide residues constitute 30% to 60% by weight of the alkylene oxide residues of the polyether substituent; b’ is a number such that propylene oxide residues constitute 40% to 70% by weight of the alkylene oxide residues of the polyether;

[0325] R2represents a C1-C10 alkyl group or a C2-C11 alkanoyl group, preferably a methyl group or an acetyl group; and one or more polyether substituents R* selected from the group (ii) having a structure of the formula (II’)

[0326] (ii) -CnH2n ’O(C2H4O)a(C3H6O)b ”R3(II”), wherein n” is 2-10; a” is a number such that ethylene oxide residues constitute 30% to 100% by weight of the alkylene oxide residues of the polyether substituent; b” is 0 to a number such that propylene oxide residues constitute less than or equal 70% by weight of the alkylene oxide residues of the polyether;

[0327] R3represents a C1-C10 alkyl group or a C2-C11 alkanoyl group, preferably a methyl group or an acetyl group. l. The surfactant composition according to any of the previous embodiments 2 to 26, wherein the silicone surfactant compound A) comprises one or more polyether substituents R* selected from the group (i) of polyether substituents having a structure of the formula (II’)

[0328] (i) -CnH2n’O(C2H4O)a’(C3H6O)b’R2(II’) having a mass in the range of from

[0329] 2000 Dalton to 6000 Dalton, and wherein at least one polyether substituent R* of type (i) has a mass above 3000 Dalton; n’ is 2-10; a’ is a number such that ethylene oxide residues constitute 30% to 60% by weight of the alkylene oxide residues of the polyether substituent; b’ is a number such that propylene oxide residues constitute 40% to 70% by weight of the alkylene oxide residues of the polyether;

[0330] R2represents a C1-C10 alkyl group or a C2-C11 alkanoyl group, preferably a methyl group or an acetyl group; and one or more polyether substituents R* selected from the group (ii) having a structure of the formula (II’)

[0331] (ii) -CnH2n”O(C2H4O)a’(C3H6O)b”R3(II”) having a mass in the range of from 350

[0332] Dalton to 1800 Dalton, and wherein n” is 2-10; a” is a number such that ethylene oxide residues constitute 30% to 100% by weight of the alkylene oxide residues of the polyether substituent; b” is 0 to a number such that propylene oxide residues constitute less than or equal 70% by weight of the alkylene oxide residues of the polyether;

[0333] R3represents a C1-C10 alkyl group or a C2-C11 alkanoyl group, preferably a methyl group or an acetyl group.

[0334] 28. The surfactant composition according to the previous embodiments 26 and 27, wherein all polyether substituents R* present in the silicone surfactant compound A) are selected from polyether substituents of the types (i) and (ii), and wherein the silicone surfactant compound A) contains at least one type of polyether substituent of the group (i) and at least one type of polyether substituent of the group (ii).

[0335] 29. The surfactant composition according to any of the previous embodiments 16 to 28, wherein the silicone surfactant compound A) has the formula

[0336] M*DxD”yM* (I), wherein

[0337] M*, D, and D” are as defined above, x is 45 to 90, preferably 55 to 80; y is 2 to 10, preferably 3 to 9; x+y is 50 to 90, preferably 55 to 85; the ratio of x to y is 5 to 20, preferably 7 to 15; and the silicone surfactant compound A) comprises one or more polyether substituents R* selected from the group (iii) having a structure of the formula (II’”)

[0338] (iii) -Cn” H2n ’O(C2H4O)a’(C3H6O)b”b ” R4(II’”), wherein n’” is 2 to 4, preferably 3; a’” is a number such that ethylene oxide residues constitute 30% to 60% by weight of the alkylene oxide residues of the polyether substituent; b’” is a number such that propylene oxide residues constitute 40% to 70% by weight of the alkylene oxide residues of the polyether;

[0339] R4represents a methyl group or an acetyl group; and one or more polyether substituents R* selected from the group (iv) having a structure of the formula (II””)

[0340] (iv) n'”’H2n””O(C2H4O)a” (C3H6O)b””R5, wherein n”” is 2 to 4, preferably 3; a”” is a number such that ethylene oxide residues constitute 30% to 100% by weight of the alkylene oxide residues of the polyether substituent; b”” is 0 to a number such that propylene oxide residues constitute less than or equal 70% by weight of the alkylene oxide residues of the polyether;

[0341] R5represents a methyl group or an acetyl group.

[0342] 30. The surfactant composition according to any of the previous embodiments 16 to 29, wherein the silicone surfactant compound A) has the formula

[0343] M*DxD”yM* (I), wherein

[0344] M*, D, and D” are as defined above, x is 45 to 90, preferably 55 to 80; y is 2 to 10, preferably 3 to 9; x+y is 50 to 90, preferably 55 to 85; the ratio of x to y is 5 to 20, preferably 7 to 15; and the silicone surfactant compound A) comprises one or more polyether substituents R* selected from the group (iii) having a structure of the formula (II’”)

[0345] (iii) -Cn’”H2n”O(C2H4O)a”(C3H6O)b”b” R4(II’”), wherein n’” is 2 to 4, preferably 3; a’” is a number such that ethylene oxide residues constitute 30% to 60% by weight of the alkylene oxide residues of the polyether substituent; b’” is a number such that propylene oxide residues constitute 40% to 70% by weight of the alkylene oxide residues of the polyether;

[0346] R4represents a methyl group or an acetyl group; and one or more polyether substituents R* selected from the group (iv) having a structure of the formula (II””) (iv) -Cn' ” H2n ” O(C2H4O)a” ’(CsHeOJb ” ”R5, the moieties having a mass in the range of from 350 to1800 Dalton; n”” is 2 to 4, preferably 3; a”” is a number such that ethylene oxide residues constitute 30% to 100% by weight of the alkylene oxide residues of the polyether substituent; b”” is 0 to a number such that propylene oxide residues constitute less than or equal 70% by weight of the alkylene oxide residues of the polyether;

[0347] R5represents a methyl group or an acetyl group.

[0348] 31. The surfactant composition according to the previous embodiments 29 and 30, wherein all polyether substituents R* present in the silicone surfactant compound A) are selected from polyether substituents from the groups (iii) and (iv), and wherein the silicone surfactant compound A) contains at least one type of polyether substituent R of the group (iii) and at least one type of polyether substituent R of the group (iv).

[0349] 32. The surfactant composition according to any of the previous embodiments 1 to 7,10, 11 and 15 to 31 , wherein the component B) is an aliphatic carboxylic acid or aromatic carboxylic acid, preferably an aliphatic carboxylic acid, more preferably an alkanoic acid.

[0350] 33. The surfactant composition according to any of the previous embodiments 1 to 7, 10, 11 and 15 to 32, wherein the component B) is an alkanoic acid or alkenoic acid with 4 to 30 carbon atoms, preferably with 6 to 24 carbon atoms, more preferably with 9 to 20 carbon atoms.

[0351] 34. The surfactant composition according to any of the previous embodiments, 1 to 7, 10, 11 and 15 to 33, wherein the component B) is a branched or cyclic alkanoic acid, preferably a branched alkanoic acid, more preferably a branched alkanoic acid with 5 to 24 carbon atoms.

[0352] 35. The surfactant composition according to any of the previous embodiments 1 to 7, 10, 11 and 15 to 34, wherein the component B) is a carboxylic acid containing one or more quaternary carbon atoms, preferably an aliphatic carboxylic acid containing one or more quaternary carbon atoms, more preferably an acyclic alkanoic acid containing one or more quaternary carbon atoms.

[0353] 36. The surfactant composition according to any of the previous embodiments 1 to 7, 10, 11 and 15 to 35, wherein the component B) is an organic acid which is a branched alkyl monocarboxylic acid with 5 to 20 carbon atoms containing one or more quaternary carbon atoms, preferably containing a quaternary carbon atom in a-position to the carboxylic acid group.

[0354] 37. The surfactant composition according to any of the previous embodiments 1 to 7, 10, 11 and 15 to 36, wherein the component B) is an organic acid selected from the group consisting of C8-neoalkanoic acids, C9-neo-alkanoic acids, C10-neoalkanoic acids, C11- neoalkanoic acids, C12-neoalkanoic acids, C13-neoalkanoic acids, C-14-neoalkanoic acids, wherein neononanoic acid, neodecanoic acid and neoundecanoic acid are preferred.

[0355] 38. The surfactant composition according to any of the previous embodiments 1 to 4, 6, 8, 10, 13 and 15 to 31 , wherein the component B) is an aliphatic carboxylic acid salt or aromatic carboxylic acid salt, preferably an aliphatic carboxylic acid salt, more preferably an alkanoic acid salt.

[0356] 39. The surfactant composition according to any of the previous embodiments 1 to 4, 6, 8, 10, 13 and 15 to 31 , and 38, wherein the component B) is an alkanoic acid salt or alkenoic acid salt with 4 to 30 carbon atoms in the anionic part, preferably with 6 to 24 carbon atoms in the anionic part, more preferably with 9 to 20 carbon atoms in the anionic part.

[0357] 40. The surfactant composition according to any of the previous embodiments 1 to 4, 6, 8, 10, 13, 15 to 31 , 38 and 39, wherein the component B) is a branched or cyclic alkanoic acid salt, preferably a branched alkanoic acid salt, more preferably a branched alkanoic acid salt with 5 to 24 carbon atoms in the anionic part.

[0358] 41. The surfactant composition according to any of the previous embodiments 1 to 4, 6, 8, 10, 13, 15 to 31 , and 38 to 40, wherein the component B) is a carboxylic acid salt containing one or more quaternary carbon atoms, preferably an aliphatic carboxylic acid containing one or more quaternary carbon atoms, more preferably an acyclic alkanoic acid containing one or more quaternary carbon atoms.

[0359] 42. The surfactant composition according to any of the previous embodiments 1 to 4, 6, 9, 10, and 14 to 31 , wherein the component B) is an aliphatic carboxylic acid ester or aromatic carboxylic acid ester, preferably an aliphatic carboxylic acid ester, more preferably an alkanoic acid ester.

[0360] 43. The surfactant composition according to any of the previous embodiments 1 to 4, 6, 9, 10, 14 to 31 and 42, wherein the component B) is an alkanoic acid ester or alkenoic acid ester with 4 to 30 carbon atoms in the structure corresponding to the organic acid, preferably with 6 to 24 carbon atoms in the structure corresponding to the organic acid, more preferably with 9 to 20 carbon atoms in the structure corresponding to the organic acid.

[0361] 44. The surfactant composition according to any of the previous embodiments 1 to 4, 6, 9, 10, 14 to 31 , 42 and 43, wherein the component B) is a linear or branched alkanoic acid ester, preferably a linear alkanoic acid ester, more preferably a linear alkanoic acid ester with 5 to 24 carbon atoms in the structure corresponding to the organic acid, even more preferably a linear mono- or dialkanoic acid ester with 5 to 24 carbon atoms in the structure corresponding to the organic acid.

[0362] 45. The surfactant composition according to any of the previous embodiments 1 to 44, wherein the amount of component A) in the silicone surfactant composition is 15.0 weight-% or more based on the overall weight of the surfactant composition, preferably 20.0 weight-% or more, more preferably 30.0 weight-% or more, further preferably 40.0 weight-% or more, still more preferably 50 weight-% or more based on the overall weight of the surfactant composition.

[0363] 46. The surfactant composition according to any of the previous embodiments 1 to 45, wherein the amount of component B) in the silicone surfactant composition is 0.02 to 50 weight- %, preferably 0.5 to 25 weight-%, more preferably 1.0 to 10 weight-%, even more preferably 1.5 to 8 weight-%, and still more preferred 2.5 to 7 weight-% on the basis of the overall weight of the components A), B) and C) of the silicone surfactant composition.

[0364] 47. The surfactant composition according to any of the previous embodiments 1 to 46, wherein the components A) and B) add up to 20 weight-% or more of the total weight of the composition, preferably to more than 25 weight-% or more of the total weight of the composition, more preferably 30 weight- % or more of the total weight of the composition, even more preferably to 35 weight-% or more of the total weight of the components A), B) and C) of the silicone surfactant composition

[0365] 48. The surfactant composition according to the previous embodiments 1 to 47, wherein the components A), B) and C) add up to 70 weight-% or more of the total weight of the composition, preferably to more than 80 weight-% or more of the total weight of the composition, more preferably 85 weight- % or more of the total weight of the composition, even more preferably to 90 weight-% or more of the total weight of the composition, and most preferably to 95 weight-% or more of the total weight of the silicone surfactant composition.

[0366] 49. The surfactant composition according to any of the previous embodiments 1 to 48, wherein the composition comprises one or more diluents C), wherein preferably the amount of the diluent is 20 weight-% or more, more preferably 35 weight-% or more, even more preferably 50 weight-% or more, still more preferably 65 weight-% or more, further more preferably 75 weight-% or more, and most preferably 85 weight-% or more on the basis of the overall weight of the surfactant composition.

[0367] 50. The surfactant composition according to any of the previous embodiments 1 to 49, wherein diluent C) is selected from water, a monoalcohol, a di- or polyol, a mono-, di- or polyethers, aliphatic and aromatic hydrocarbons, and halogenated hydrocarbons, in particular partially or perhalogenated alkanes and partially or perhalogenated alkylated phenyl compounds, ketones, amides, nitriles, sulfoxides, ororganocarbonates, or a combination of two or more thereof.

[0368] 51. The surfactant composition according to any of the previous embodiments 1 to 50, wherein the diluent C) is fully miscible with A) and B), preferably therein the diluent C) is a monoether or a polyether having up to 40 ether groups, more preferably a mono- or polyether having up to 8 ether groups. 52. The surfactant composition according to any of the previous embodiments 1 to 51 , wherein the diluent C) comprises a mono- or polyether alcohol, preferably a glycol ether, further preferably the diluent C) is a mono- or polyether alcohol, specifically a glycol ether.

[0369] 53. The surfactant composition according to any of the previous embodiments 1 to 52, wherein the diluent C) comprises an ethylene glycol ether or a propylene glycol ether, preferably dipropylene glycol, further preferably the diluent C) is an ethylene glycol ether or a propylene glycol ether, specifically dipropylene glycol.

[0370] 54. The surfactant composition according to any of the previous embodiments 1 to 53, wherein the viscosity of the surfactant composition is below 5000 cSt at 25 °C, preferably below 4000 cSt at 25 °C, more preferably below 3000 cSt at 25 °C, even more preferably below 2500 cSt at 25 °C, and most preferably below 2000 cSt at 25 °C as determined by capillary viscosimetry.

[0371] 55. The surfactant composition according to any of the previous claims 1 to 29 and 32 to 54, wherein the silicone surfactant compound A) has the formula (I)

[0372] M*DxD”yM* (I), wherein

[0373] M*, D, and D” are as defined above, x is 45 to 90, preferably 55 to 80; y is 2 to 10, preferably 3 to 9; x+y is 50 to 90, preferably 55 to 85; the ratio of x to y is 5 to 20, preferably 7 to 15; and the silicone surfactant compound A) comprises one or more polyether substituents R* selected from the group (i) of polyether substituents having a structure of the formula (II’)

[0374] (i) -CnH2n’O(C2H4O)a’(C3H6O)b’R2(II’) having a mass in the range of from

[0375] 2000 Dalton to 6000 Dalton, and wherein at least one polyether substituent R* of type (i) has a molecular weight above 3000; n’ is 2-10; a’ is a number such that ethylene oxide residues constitute 30% to 60% by weight of the alkylene oxide residues of the polyether substituent; b’ is a number such that propylene oxide residues constitute 40% to 70% by weight of the alkylene oxide residues of the polyether;

[0376] R2represents a C1-C10 alkyl group or a C2-C11 alkanoyl group, preferably a methyl group or an acetyl group; and / or and one or more polyether substituents R* selected from the group (ii) having a structure of the formula (II’)

[0377] (ii) -CnH2n”O(C2H4O)a’(C3H6O)b”R3(II”) having a mass in the range of from

[0378] 350 Dalton to 1800 Dalton, and wherein n” is 2-10; a” is a number such that ethylene oxide residues constitute 30% to 100% by weight of the alkylene oxide residues of the polyether substituent; b” is 0 to a number such that propylene oxide residues constitute less than or equal 70% by weight of the alkylene oxide residues of the polyether;

[0379] R3represents a C1-C10 alkyl group or a C2-C11 alkanoyl group, preferably a methyl group or an acetyl group, the component B) is a carboxylic acid, a carboxylic acid salt or carboxylic acid ester, preferably a carboxylic acid, and wherein the composition optionally comprises a diluent C), which is preferably a glycol ether, most preferably dipropylene glycol.

[0380] 56. The surfactant composition according to any of the previous embodiments 1 to 55, wherein the silicone surfactant compound A) has the formula (I)

[0381] M*DxD”yM* (I), wherein

[0382] M*, D, and D” are as defined above, x is 45 to 90, preferably 55 to 80; y is 2 to 10, preferably 3 to 9; x+y is 50 to 90, preferably 55 to 85; the ratio of x to y is 5 to 20, preferably 7 to 15; and the silicone surfactant compound A) comprises one or more polyether substituents R* selected from the group (iii) having a structure of the formula (II’”)

[0383] (iii) -Cn”H2n ’O(C2H4O)a ’(C3H6O)b ”R4wherein n’ is 2 to 4, preferably 3; a’” is a number such that ethylene oxide residues constitute 30% to 60% by weight of the alkylene oxide residues of the polyether substituent; b’” is a number such that propylene oxide residues constitute 40% to 70% by weight of the alkylene oxide residues of the polyether;

[0384] R4represents a methoxy group, an acetoxy group, or a butoxyl group; and one or more polyether substituents R* selected from the group (iv) having a structure of the formula (II””)

[0385] (iv) -Cn"”H2n””O(C2H4O)a””(C3H6O)b””R5; wherein n”” is 2 to 4, preferably 3; a”” is a number such that ethylene oxide residues constitute 30% to 100% by weight of the alkylene oxide residues of the polyether substituent; b”” is 0 to a number such that propylene oxide residues constitute less than or equal 70% by weight of the alkylene oxide residues of the polyether; R5represents a methoxy group, an acetoxy group, or a butoxyl group, the component B) is an organic acid, wherein the organic acid B) is an alkyl carboxylic acid with 5 to 24 carbon atoms, preferably a branched alkyl carboxylic acid with 5 to 24 carbon atoms, more preferably selected from the group consisting of C8-neoalkanoic acids, C9-neo- alkanoic acids, C10-neoalkanoic acids, C11-neoalkanoic acids, C12-neoalkanoic acids, C13- neoalkanoic acids, C-14-neoalkanoic acids, most preferably neodecanoic acid, and wherein the composition optionally comprises a diluent C), which is preferably a glycol ether, most preferably dipropylene glycol.

[0386] 57. The surfactant composition according to any of the previous embodiments 1-7, 10, 11 , 15-37, and 45 to 56, wherein the silicone surfactant compound A) has the formula (I) M*DxD”yM* (I), wherein

[0387] M*, D, and D” are as defined above, x is 45 to 90, preferably 55 to 80; y is 2 to 10, preferably 3 to 9; x+y is 50 to 90, preferably 55 to 85; the ratio of x to y is 5 to 20, preferably 7 to 15; and the silicone surfactant compound A) comprises one or more polyether substituents R* selected from the group (iii) having a structure of the formula (II’”)

[0388] (iii) -Cn” H2n ” O(C2H4O)a’ (CsHeOJb ” R4having a mass in the range of from 3500 to 6000 Dalton, n’ is 2 to 4, preferably 3; a’” is a number such that ethylene oxide residues constitute 30% to 60% by weight of the alkylene oxide residues of the polyether substituent; b’” is a number such that propylene oxide residues constitute 40% to 70% by weight of the alkylene oxide residues of the polyether;

[0389] R4represents a methoxy group, an acetoxy group, or a butoxyl group; and one or more polyether substituents R* selected from the group (iv) having a structure of the formula (II””)

[0390] (iv) -Cn' ” H2n ” ”O(C2H4O)a ” "(CsHeOJb ” ”R5having a mass in the range of from 350 to 1800 Dalton; n”” is 2 to 4, preferably 3; a”” is a number such that ethylene oxide residues constitute 30% to 100% by weight of the alkylene oxide residues of the polyether substituent; b”” is 0 to a number such that propylene oxide residues constitute less than or equal 70% by weight of the alkylene oxide residues of the polyether;

[0391] R5represents a methoxy group, an acetoxy group, or a butoxyl group, the component B) is an organic acid, wherein the organic acid B) is an alkyl carboxylic acid with 5 to 24 carbon atoms, preferably a branched alkyl carboxylic acid with 5 to 24 carbon atoms, more preferably selected from the group consisting of C8-neoalkanoic acids, C9-neo- alkanoic acids, C10-neoalkanoic acids, C11-neoalkanoic acids, C12-neoalkanoic acids, C13- neoalkanoic acids, C-14-neoalkanoic acids, most preferably neodecanoic acid, and wherein the composition optionally comprises a diluent C), which is preferably a glycol ether, most preferably dipropylene glycol.

[0392] 58. The surfactant composition according to any of the previous embodiments 55 to 57, wherein the organic acid B) is a branched alkanoic carboxylic acid with 5 to 24 carbon atoms, more preferably selected from the group consisting of C8-neoalkanoic acids, C9-neo-alkanoic acids, C10-neoalkanoic acids, C11-neoalkanoic acids, C12-neoalkanoic acids, C13- neoalkanoic acids, C-14-neoalkanoic acids, most preferably neodecanoic acid, and wherein the composition comprises as a diluent C) a glycol ether, preferably dipropylene glycol.

[0393] 59. The surfactant composition according to the previous embodiments 56 to 58, wherein all polyether substituents R* present in the silicone surfactant compound A) are selected from polyether substituents from the groups (iii) and (iv), and wherein the silicone surfactant compound A) contains at least one type of polyether substituent R of the group (iii) and at least one type of polyether substituent R of the group (iv).

[0394] 60. The surfactant composition according to any of the previous embodiments 1 to 59, wherein the composition comprises

[0395] 20 -80 weight-% of the silicone surfactant compound A),

[0396] 1-8 weight-% of the component B), and

[0397] 12-79 weight-% of the diluent C), each on the basis of the total weight of the surfactant composition, and wherein the components A), B) and C) add up to 95 weight-% or more, preferably to 100 weight-% of the surfactant composition.

[0398] 61. The surfactant composition according to any of the previous embodiments 1-7, 10, 11 , 15-37, and 45 to 60, wherein the composition comprises

[0399] 20 -80 weight-% of the silicone surfactant compound A),

[0400] 1-8 weight-% of the organic acid B), and

[0401] 12-79 weight-% of the diluent C), each on the basis of the total weight of the surfactant composition, and wherein the components A), B) and C) add up to 95 weight-% or more, preferably to 100 weight-% of the surfactant composition.

[0402] 62. The surfactant composition according to any of the previous embodiments 1 to 61 , wherein the ratio of the components A) to B) (w / w) is in the range of 100 : 1 to 2 : 1 , preferably 50 : 1 to 3 : 1 , more preferably 20 : 1 to 4 : 1 , even more preferably 15 : 1 to 5 : 1.

[0403] 63. The surfactant composition according to any of the previous embodiments 1 to 62, wherein the components A), B) and C) add up to 100 weight-% of the total weight of the surfactant composition.

[0404] 64. The surfactant composition according to any of the previous embodiments 1 to 63, wherein the components A) and B) add up to 100 weight-% of the total weight of the composition.

[0405] 65. A method for the preparation of the surfactant composition according to any of the previous embodiments 1 to 64, comprising a step of mixing the components A), B), and optionally C).

[0406] 66. A process for the production of a polyurethane foam, comprising a step of combining the surfactant composition according to any of the previous embodiments 1 to 63 with a at least one isocyanate and at least one polyol.

[0407] 67. A polyurethane foam obtained by the process according to the previous embodiment 66.

[0408] 68. A polyurethane foam-forming composition comprising:

[0409] (a) one or more polyols;

[0410] (b) one or more polyisocyanates;

[0411] (c) one or more catalysts;

[0412] (d) water;

[0413] (e) a silicone surfactant composition of the invention according to any of the previous embodiments 1 to 63,

[0414] (f) and optionally further additives and auxiliary compounds.

[0415] 69. The polyurethane foam-forming composition according to the previous embodiment 68, wherein the silicone surfactant composition is present in an amount of from about 0.1 to 7.0 parts by weight based on the total weight of the polyol component.

[0416] 70. The polyurethane foam-forming composition according to the previous embodiments 68 and 69, wherein the amount of the silicone surfactant composition is such that the amount of organic acid B) contained in the polyurethane foam-forming composition is of from about 0.01 to 1.0 parts by weight based on the total weight of the polyol component, and the amount of the silicone surfactant compound A) contained in the silicone surfactant composition is of from about 0.099 to 6.99 parts by weight based on the total weight of the polyol component.

[0417] 71. The polyurethane foam-forming composition according to the previous embodiments 68 to 70, wherein the CFD top-bottom difference of the foam formed from the composition is 15% or less. 72. A polyurethane foam formed from the compositions of any of the previous embodiments 68 to 71.

[0418] 73. The polyurethane foam of the previous embodiment 72, wherein the CFD top-bottom difference is 15% or less.

[0419] 74. Use of the surfactant composition according to any of the previous embodiments 1 to 64 in the production of polyurethane foam, in particular of flexible polyurethane foam.

[0420] EXAMPLES

[0421] The materials used and foams obtained according to the invention and the process to obtain the foam as displayed in the examples are characterized by the following parameters:

[0422] Blow off time: The blow off time is the time during which blow off (cell-opening and gas release) is observed during foaming rising procedure from starting to mix isocyanate.

[0423] Settling: Settling is the percentage of height loss at 5 minutes during the foaming procedure to compare with the highest value.

[0424] Core density: Core density was measured on 10 x 10 x 5 cm3foam samples according to ASTM D3576.

[0425] Compression force deflection (CFD) at 40% and Comfort Factor (SAG) are measured according to ISO3386 / 1 on 10 x 10 x 5 cm3foam samples.

[0426] The “CFD difference”, also referred to as “CFD top-bottom difference”, refers to the difference of the numerical values obtained in the measurement of the CFD value at 40 % according to ISO3386 / 1 on two foam samples taken from a polyurethane block, a top foam sample and a bottom foam sample each having a 10 cm x 10 cm base and a height of 5 cm in percent, calculated by the expression [(higher CFD value - lower CFD value) / average value] x 100. Therein, the foam sample considered the “top” foam sample refers to a sample taken from a position at about 3 cm below the top surface of a foam block and 5 cm downwards from there, and the foam sample considered the “bottom” foam sample refers to a sample taken from the position at about 3 cm above the bottom of the polyurethane block and 5 cm upwards from there. The foam block from which the samples are taken is obtained by mixing the components of a PU foam-forming composition and pouring the liquid foam into a 20x20x20 cm paper box, followed by curing the foams upon completion of rising in a forced air oven for 15 minutes and cooling for 24 hours before collecting the foam samples.

[0427] CFD at 40% indicates compression stress at 40% compression. Comfort Factor (SAG) is the ratio between the compression stress at 65% compression and the compression stress at 25% compression. Airflow or foam porosity was measured on 5 x 5 x 2.5 cm3foam samples, according to the A STM D3574 test method.

[0428] The cell structure is characterized by visual observation. The relative cell structure scale spans from “very coarse”, which is less than 7 cells / cm on average to “very fine”, which represents more than about 16-18 cells / cm on average. The other designations fall between these two extremes, wherein a cell structure is considered to be “fine” when it is in the range of from 13 to 15 cells / cm on average.

[0429] Viscosity measurements of the surfactant compounds and the surfactant compositions are performed using capillary viscosimetry using a Schott Instruments AVS 470 capillary viscosimeter. The measurement is performed at a temperature of 25 °C.

[0430] Materials

[0431] DPG: industrial grade dipropylene glycol (99 % m / m, mixture of isomers; Sigma-Aldrich) Monol Polyol with Mw 1500, EO 60%: n-butanol-initiated ethyleneoxide-based solvent VA10: Versatic acid 10 (neodecanoic acid) (min. 90 % m / m; Hexion)

[0432] Polyol Voranol 3322 is flexible urethane foam polyols with hydroxyl number of 48 from Dow Chemical (glycerine-initiated polyoxypropylene polyoxyethylene triol, with a molecular weight of 3500 g / mol).

[0433] TDI 80 / 20 is a mixture of 80 weight percent 2,4 toluene diisocyanate and 20 weight percent 2,6 toluene diisocyanate from Covestro (brand name Desmodur T80).

[0434] Niax™ catalyst B-18 is a balance amine catalyst from Momentive Performance Materials Corporation.

[0435] Niax™ catalyst EF-133 is a low emission blowing amine catalyst from Momentive Performance Materials Corporation.

[0436] Niax™ catalyst A-33 is a gelling amine catalyst from Momentive Performance Materials Corporation.

[0437] Niax™ catalyst Stannous Octoate is a metal gelling catalyst from Momentive Performance Materials Corporation.

[0438] The silicone surfactant compounds used in the examples and referred to in the following as “Copolymer C1 ”, “Copolymer C2” and “Copolymer C3” are as follows:

[0439] The copolymers C1 , C2 and C3 are each silicone surfactant compounds obtained from silicone fluids having the general formula MDxD’yM, wherein

[0440] M is (CH3)3SiOi / 2, D is (CH3)2SiO2 / 2, D’ is (H)(CH3)2SiO2 / 2, by a quantitative Pt-catalyzed hydrosilylation reaction with a blend of allyl-terminated polyethers. Accordingly, the copolymers are characterized by the specific silicone fluid applied providing the silicone backbone, and the specific allyl-terminated polyethers forming the sidechains of the copolymer, and the ratio of the polyether chains bonded to the silicone backbone.

[0441] The allyl-terminated polyethers forming the blend of allyl-terminated polyethers are characterized in the following by an initial number followed by H indicating the nominal % of ethylene oxide residues in a polyether based on ethylene oxide and propylene oxide; the letter A indicates that the polyether is allyl-started; the numbers following thereto indicate the nominal molecular weight of the allyl polyether; the letters “Me” and “Ac” indicate whether the polyether is methoxy-capped (Me) or acetoxy-capped (OAc). An exception from this nomenclature is the polyether “APEG800-Ac”, wherein A indicates that the ether is allyl- started, the letters “PEG” stand for polyethylene glycol (no propylene-oxide-based units included), the number 800 indicates the nominal molecular weight, and the letters “Ac” indicate that the polyether is acetoxy-terminated.

[0442] Copolymer C1 :

[0443] In copolymer C1 , in the underlying silicone fluid of the formula MDxD’yM x is = 78 and y is = 7, and the copolymer is formed by the hydrosilylation of the silicone fluid with a blend of the polyethers “50HA1000-Me” and “50HA4800-Me”, wherein the blend average molecular weight of the blend (the number average molecular weight of the combined polyethers of the mixture) of said polyethers is 2500 g / mol.

[0444] Copolymer C2:

[0445] In copolymer C2, in the underlying silicone fluid of the formula MDxD’yM x is = 78 and y is = 7, and the copolymer is formed by the hydrosilylation of the silicone fluid with a blend of the polyethers “50HA1000-Ac” and “50HA4800-Ac”, wherein the blend average molecular weight of the blend (the number average molecular weight of the combined polyethers of the mixture) of said polyethers is 2000 g / mol.

[0446] Copolymer C3:

[0447] In copolymer C3, in the underlying silicone fluid of the formula MDxD’yM x is = 56 and y is = 5, and the copolymer is formed by the hydrosilylation of the silicone fluid with a blend of the polyethers “50HA4800-Ac” and “APEG800-Ac”, wherein the balance molecular weight of the blend (the number average molecular weight of the combined polyethers of the mixture) of said polyethers is 1600 g / mol.

[0448] In each case, the blend average molecular weight is determined based on the nominal molecular weights of the specific polyethers used and their ratio in the respective blends. A detailed procedure for the synthesis of MDxD’yM fluids serving as starting materials for CI- 03 and for the preparation of the corresponding MDxD’yM surfactant compounds is provided in US 5,489,617.

[0449] Preparation of silicone surfactant compositions

[0450] For the preparation of the silicone surfactant compositions, a silicone surfactant compound A), a surfactant potency-enhancing agent B) being an organic acid or organic acid derivative and a diluent C) were blended according to the weight percentages, as specified in the following.

[0451] Example 1 - Surfactant composition 1 (IN 1)

[0452] A first base solution 1 (BS 1) was prepared by mixing 40.2 of copolymer C2 and 59.8g DPG. The surfactant composition 1 (IN 1) was prepared by completing 5 g of VA-10 to a total weight of 100 g with the above-described BS1 solution, leading to a solution of 5 weight-% VA-10, 38.2 weight-% of 02 and 56.8 weight-% DPG.

[0453] Example 2 - Surfactant composition 2 (IN 2)

[0454] A second base solution 2 (BS 2) was prepared by mixing 40.0g of copolymer C3 and 60.0g of DPG. The surfactant composition 2 (IN 2) was prepared by completing 5 g of VA-10 to a total weight of 100 g with the above-described BS2 solution, leading to a solution of 5 weight-% VA 10, 38 weight-% of C3 and 57 weight-% of DPG.

[0455] Example 3 - Surfactant composition 3 (IN 3)

[0456] As a third base solution 3 (BS3), 100 g of a mixture comprising 57 weight-% of copolymer C1 and 43 weight-% of DPG were taken. The surfactant composition 3 (IN 3) was prepared by mixing 5 g of VA10 and 53g of the above-described preformed mixture comprising copolymer C1 BS3, and completing the mixture with DPG to a total weight of 100 g, leading to a solution of 5 weight-% VA 10, 30.2 weight-% of copolymer C1 and 64.8 weight-% of DPG.

[0457] Example 4 - Surfactant compositions 4a (IN 4a) and 4b (IN 4b)

[0458] As a further base solution 4 (BS4), 100 g of a mixture comprising 50 weight-% of copolymer C3 and 50 weight-% of DPG were taken.

[0459] The surfactant composition 4a (IN 4a) was prepared by mixing 3 g of VA10 and 76 g the abovedescribed mixture comprising copolymer C3, and completing the mixture with DPG to a total weight of 100 g, leading to a solution of 3 weight-% VA 10, 38 weight-% of C3, and 59 weight- % of DPG. The surfactant composition 4b (IN 4b) was prepared by mixing 3 g of VA10 and 70 g of the above-described preformed mixture comprising copolymer C3, and completing the mixture with DPG to a total weight of 100 g, leading to a solution of 3 weight-% VA 10, 35 weight-% of 03, and 62 weight-% of DPG.

[0460] Example 5 - Surfactant compositions 5a (IN 5a), 5b (IN 5b), 5c (IN 5c), 5d (IN 5d), 5e (IN 5e) and 5f (IN 5f)

[0461] As a fifth base solution 5 (BS5), 100 g of a mixture comprising 70 weight-% of copolymer 03 and 30 weight-% of Monol Polyol were taken.

[0462] The surfactant composition 5a (IN 5a) was prepared by mixing 1.51 g of potassium isobutyrate and 80 g of BS5, and completing the mixture with DPG to a total weight of 100 g, leading to a solution of 1.51 weight-% potassium isobutyrate, 56 weight-% of copolymer C3, 24 weight-% Monol polyol, and 18.49 weight-% of DPG.

[0463] The surfactant composition 5b (IN 5b) was prepared by mixing 2.82 g of potassium ethylhexanoate and 80 g of BS5, and completing the mixture with DPG to a total weight of 100 g, leading to a solution of 2.82 weight-% potassium ethylhexanoate, 56 weight-% of copolymer C3, 24 weight-% Monol polyol, and 17.18 weight-% of DPG.

[0464] The surfactant composition 5c (IN 5c) was prepared by mixing 4 g of oleic acid and 80 g of BS5, and completing the mixture with DPG to a total weight of 100 g, leading to a solution of 4 weight-% oleic acid, 56 weight-% of copolymer C3, 24 weight-% Monol polyol, and 16 weight-% of DPG.

[0465] The surfactant composition 5d (IN 5d) was prepared by mixing 4 g of oleic acid and 96 g of BS5, leading to a solution of 4 weight-% oleic acid, 68.6 weight-% of copolymer C3, and 27.4 weight-% Monol polyol.

[0466] The surfactant composition 5e (IN 5e) was prepared by mixing 4 g of methyloleate and 80 g of BS5, and completing the mixture with DPG to a total weight of 100 g, leading to a solution of 4 weight-% methyloleate, 56 weight-% of copolymer C3, 24 weight-% Monol polyol, and 16 weight-% of DPG.

[0467] The surfactant composition 5f (IN 5f) was prepared by mixing 4 g of bis(2-ethylhexyl) adipate and 80 g of BS5, and completing the mixture with DPG to a total weight of 100 g, leading to a solution of 4 weight-% bis(2-ethylhexyl) adipate, 56 weight-% of copolymer C3, 24 weight-% Monol polyol, and 16 weight-% of DPG.

[0468] Preparation of flexible slabstock polyurethane foam formulations

[0469] Three formulations (I) to (III) with or without a filler have been prepared for testing the surfactant compositions IN 1 , IN 2, IN 3, IN 4a, IN 4b, IN 5a, IN 5b, IN 5c, IN 5d, IN 5e and IN 5f as described above.

[0470] For preparing the polyether foams in the laboratory, the components as displayed in the Tables 1 to 3 were blended according to the following procedure in the relative amounts as indicated in the tables (“phpp” refers to the ratios by weight): polyols, amine catalysts, water, silicones and other additives (such as solvent / filler, if present) were mixed for 60 seconds. Stannous octoate was added and mixing continued for 10 seconds. After that, TDI (TDI 80 / 20) was added and the mixing continued for 5 seconds. Once the mixing process was finished, the liquid foam was poured into a 20x20x20 cm paper box. The foam rise profile was recorded, and the foams were cured in a forced air oven for 15 minutes at 100 °C and then cooled for 24 hours. The amount of components was chosen such to ensure that the volume of the polyurethane material filled out the 20 x 20 x 20 cm paper box. Table 1. Formulation (I) having a density of 20kg / m3(with filler)

[0471] Table 2. Formulation (II) having a density of 32 kg / m3(without filler)

[0472] Table 3. Formulation (III) having a density of density 16 kg / m3(without filler) Examples 6, 7 and Comparative Examples 6a and 7a

[0473] The formation of Pll foam using the Pll formulation (I) displayed in Table 1 has been tested using the base solutions BS1 and BS2 (no acid contained), and using the surfactant compositions IN 1 and IN 2 (containing 5 weight- % of VA10 each).

[0474] In the Pll formulation (I) 1.2 phpp of surfactant corresponds to 1.2 phpp of either BS 1 or IN 1 or BS 2 or IN 2. The results displayed in Table 4 have been obtained:

[0475] Table 4. Foaming and Physical Performance of Formulation (I)

[0476] The foam appearance is displayed graphically (photo) in Fig.1.

[0477] Table 4 shows the results of the foaming process and the foam physical performance of the Formulation (I) using BS1 , IN2, BS2 and IN2 as surfactant additives. Comparative examples 6a (with BS1) and 7a (with BS2) are comparative experiments with the silicone surfactant mixture comprising 60 weight-% of copolymer C2 and 40 weight-% of DPG, and the mixture comprising 50 weight-% of copolymer C3 and 50 weight-% of DPG, respectively. Example 6 (with IN 1) and Example 7 (with IN 2) are experiments according to the present invention, wherein the silicone surfactant composition contains 5 weight-% of the organic acid VA10 (neodecanoic acid) with 95 weight-% of the silicone surfactant mixture comprising 60 weight- % of copolymer C2 and 40 weight-% of DPG, or with 95 weight-%of the the mixture comprising 50 weight-% of copolymer C3 and 50 weight-% of DPG, respectively. While the surfactants BS 1 and BS 2 could not lead to the formation of stable foams and both foams formed are split inside, IN1 and IN 2 led to good quality foams.

[0478] Examples 8, 9, 10 and Comparative Examples 8a, 9a and 10a

[0479] The formation of Pll foam using the Pll formulation (II) displayed in Table 2 has been tested using the base solutions BS1 and BS2 (no acid contained), and using the surfactant compositions IN1 and IN 2 (containing 5 weight-% of VA10 each). In the Pll formulation (II) 0.8 phpp of surfactant corresponds to 0.8 phpp of either BS 1 or IN 1 , BS 2 or IN 2, or BS3 or IN 3.

[0480] The results displayed in Table 5 have been obtained:

[0481] Table 5. Foaming and Physical Performance of Formulation (II)

[0482] Table 5 shows the results of the foaming process and the foam physical performance of the Formulation (II) using BS1 , IN2, BS2, IN2, BS3 and IN3 as surfactant composition additives. Comparative Example 8a (with BS1) and comparative Example 9a (with BS2) are comparative experiments with the silicone surfactant mixture comprising 60 weight-% of copolymer C2 and 40 weight-% of DPG, and the mixture comprising 50 weight-% of copolymer C3 and 50 weight- % of DPG, respectively. Example 8 (with IN1) and Example 9 (with IN3) are experiments related to the present invention, wherein the silicone surfactant composition contains 5 weight- % organic acid (VA10) with 95 weight-% of the silicone surfactant mixture comprising 60 weight-% of copolymer C2 and 40 weight-% of DPG, or with the mixture comprising 50 weight- % of copolymer C3 and 50 weight-% of DPG, respectively. Example 8 and Example 9 show less settling, tighter airflow, and lower density than comparative example 8a and comparative example 9a. Therefore, the blends containing a small amount of organic acid improve stability over the silicone surfactant not containing the organic acid additive significantly.

[0483] Furthermore, comparative example 10a uses a mixture comprising 57 weight-% of copolymer C1 and 43 weight-% of DPG only. The formulation of example 10 leads to the formation of stable Pll foam with about half the amount of the mixture comprising 57 weight-% of copolymer C1 and 43 weight-% of DPG due to the addition of 5 weight-% VA10, i.e. neodecanoic acid, in comparison to comparative example 10a. The foam obtained in example 10 surprisingly shows higher potency than the foam obtained in comparative example 10a with lower airflow and lower density.

[0484] Examples 11, 12 and Comparative Example 11a

[0485] The formation of Pll foam using the Pll formulation (III) displayed in Table 3 has been tested using the base solution BS4 (no acid contained), and using the surfactant compositions IN 4a and IN 4b (containing 3 weight-% of VA10 each).

[0486] In the Pll formulation (III) 1.1 phpp of surfactant corresponds to 1.1 phpp of either BS 4, or of IN 4a or IN 4b.

[0487] The results displayed in Table 6 have been obtained:

[0488] Table 6. Foaming and Physical Performance of Formulation (III)

[0489] Table 6 shows the results of the foaming process and the foam physical performance of the Pll Formulation (III). By optimizing the contents of organic acid and silicone surfactant, it is possible to reach the similar performance as pure silicone surfactant alone (BS 4). Table 6 displays the results of the Examples 11 and 12, in which foams are formed with the silicone surfactant compositions according to the invention, and of comparative example 11a, in which a comparative foam is formed. Comparative example 11a is the control experiment with the silicone surfactant in BS4. IN 4a and IN 4b applied in examples 11 and 12 are silicone surfactant compositions including 3 weight-% neodecanoic acid (VA10), and 76 weight-% or 70 weight-% of BS4, respectively. In the low-density foam of Pll formulation III, it is expected less difference of physical performance along the foam rising direction. The neodecanoic acid (VA 10)-containing surfactant compositions IN 4a and 4b lead to similar foaming performance in Pll formulation III as the surfactant BS4, and also more uniform hardness distribution shown by a lower CFD difference than in comparative example 10a. In addition, the Pll foams of the examples 10 and 11 based on formulation III and containing the surfactant compositions IN 4a or 4b have slightly more hardness than the Pll foam of example 10a obtained with the surfactant composition BS4.

[0490] Examples 13, 14, 15, 16, 17, 18 and Comparative Example 13 a

[0491] Further, the formation of Pll foam using the Pll formulation (III) displayed in Table 3 has been tested using the base solution BS5 (no organic acid, salt or ester contained), and using the surfactant compositions IN 5a, IN 5b, IN 5c, IN 5d, IN 5e or IN 5f (containing an amount of 1.51 weight-% to 4.00 weight-% of an acid, salt or ester each).

[0492] The base solution BS5 and the surfactant compositions IN 5a, IN 5b, IN 5c, IN 5d, IN 5e and IN 5f are displayed in Table 7 below.

[0493] Table 7. Components of base solution BS5 and the surfactant compositions IN 5a- 5f

[0494] In the Pll formulation (III), therein 1.1 phpp of surfactant thus corresponds to 1.1 phpp of either BS 5, or of IN 5a or IN 5b, IN 5c, IN 5d, IN 5e or IN 5f.

[0495] Table 8 below shows the results of the foaming process and the foam physical performance of the Pll Formulation (III). Table 8. Foaming and Physical Performance of Formulation (III)

[0496] By optimizing the contents of organic acid salts (IN 5a and IN 5b), organic acid (IN 5c and IN 5d), or organic acid ester (IN 5e and IN 5f) and silicone surfactant, it is possible to reach the higher potency performance for the surfactant compositions than with pure silicone surfactant alone (BS 5). Table 8 displays the results of the Examples 13 to 18, in which foams are formed with the silicone surfactant compositions according to the invention, and of comparative example 13a, in which a comparative foam is formed. Comparative example 13a is the control experiment with the silicone surfactant of BS5. IN 5a, 5b, 5c, 5d, 5e, and 5f according to the invention are applied in examples Ex.13, Ex.14, Ex.15, EX.16, Ex.17, and Ex.18, respectively. The potassium isobutyrate, potassium ethylhexanoate, oleic acid, methyloleate, or bis(2- ethylhexyl) adipate-containing surfactant compositions IN 5a, 5b, 5c ,5d, 5e, or 5f, respectively, lead to higher potency foaming performance in Pll formulation III than the surfactant BS5 with lower airflow and lower density. Ex. 13 to 18 also bring more uniform hardness (CFD 40%) distributions and more uniform density distributions shown by lower CFD differences and lower core density differences than in comparative example 13a.

[0497] Examples 19, 20, 21, 22 and comparative examples 19a, 19b and 19c

[0498] The formation of Pll foam using the Pll formulation (III) displayed in Table 3 has also been tested using the base solution BS4 (no organic acid, salt or ester contained), and using the surfactant compositions IN 6a, IN 6b, IN 6c, IN 6d, IN 6e or IN 6f (containing an amount of 3.0 weight-% of an carboxylic acid each)

[0499] The base solution BS4 and the surfactant compositions IN 6a, IN 6b, IN 6c, IN 6d, IN 6e and IN 6f are displayed in Table 9 below. Table 9. Components of base solution BS4 and the surfactant compositions IN 6a-6f

[0500] In the Pll formulation (III) of these examples, the1.1 phpp of surfactant thus corresponds to 1.1 phpp of either BS 4, or of IN 6a or IN 6b, IN 6c, IN 6d, IN 6e or IN 6f. Table 10 below shows the results of the foaming process and the foam physical performance of the Pll Formulation (III) using said surfactant compositions.

[0501] Table 10. Foaming and Physical Performance of Formulation (III) Comparing the results of BS4 (Comparative Example 19a) to IN 6a and 6b (Comparative Examples 19b and 19c), the surfactants with acetic acid and propionic acid provide even relative higher airflow than the control (BS4). That indicates that such organic acids have no potency-enhancing effect for surfactant composition.

[0502] Comparing the results of BS4 (Comparative Example 19a) to IN 6c to 6f (Examples 19 to 22), the surfactants with butyric acid, hexanoic acid, versatic acid and oleic acid provide relatively lower airflow than the control (BS4). That indicates that organic acids with such structures provide potency-enhancing effects for silicone surfactant composition. Example 23 and Comparative Example 23a

[0503] The formation of Pll foam using the representative Pll formulation (III) displayed in Table 3 has further been compared when using the base solution BS4 (no organic acid, salt or ester contained), and using the surfactant compositions IN 7a and IN 7b. The results are displayed in Table 11 below.

[0504] Table 11 : Components of surfactant compositions IN 7a and IN 7b and their performance in Formulation (III) The surfactant composition with only 10 wt-% silicone surfactant compound (IN 7a) does not provide enough potency to stabilize the foam, and the foam is collapsed. The surfactant composition with 20 wt-% silicone surfactant compound (IN 7b) provides enough potency to stabilize the foam during the foaming process, and the cell structure obtained is fine.

Claims

CLAIMS1. A surfactant composition for the use in polyurethane foam, comprisingA) one or more silicone surfactant compounds;B) one or more surfactant potency-enhancing agents selected from an organic acid, an organic acid salt, or an organic acid ester;C) optionally one or more diluents, wherein one or more of the silicone surfactant compounds A) is a silicone surfactant comprising a silicone backbone and one or more polyether substituents R*, which may be the same or different, attached to one or more Si atoms of the silicone backbone, wherein one or more of the component B) is a carboxylic acid with 4 or more carbon atoms, and wherein the amount of component A) in the silicone surfactant composition is 15.0 weight-% or more based on the overall weight of the surfactant composition.

2. The surfactant composition according to the previous claim 1 , wherein the component B) is contained in the composition in an amount of 0.01 to 70 weight- % on the basis of the total weight of the surfactant composition, and wherein the ratio of the components A) to B) (w / w) is in the range of 100 : 1 to 2 : 1 , preferably 50 : 1 to 3 : 1 , more preferably 20 : 1 to 4 : 1 , even more preferably 15 : 1 to 5 : 1.

3. The surfactant composition according to any of the previous claims 1 or 2, wherein one or more of the silicone surfactant compounds A) has the formulaM*DxD”yM* (I), whereinM* represents (CH3)3SiOi / 2 or (CH3)2 *SiOi / 2;D represents (CH3)2SiO2 / 2;D” represents (CH3) *SiC>2 / 2; x is 0-200; y is 2 or more; x+y is 10 to 250; the ratio of x to y is 2 to 50; and R* is a polyether substituent independently selected from the same or different -CnH2nO- group-started polyether substituents, wherein n is 2-10.

4. The surfactant composition according to any of the previous claims 1 to 3, wherein the polyether substituents R* of the silicone surfactant compound A) are the same or different and have the formula-CnH2nO(C2H4O)a(C3H6O)bR1(II) whereinn is 2-10, a is a number such that the ethylene oxide residues constitute from about 30% to about 100% by weight of the alkylene oxide residues of the polyether substituent R*; b is a number such that the propylene oxide residues constitute from about 0% to about 70% by weight of the alkylene oxide residues of the polyether substituent R*;R1is a C1-C10 alkyl group or a C2-C11 alkanoyl group, preferably a methyl group or an acetyl group.

5. The surfactant composition according to any of the previous claims 1 to 4, wherein one or more of the silicone surfactant compounds A) has the formulaM*DxD”yM* (I), whereinM* represents (CH3)3SiOi / 2 or (CH3)2R*SiOi / 2;D represents (CH3)2SiO2 / 2; D” represents (CH3)R*SiC>2 / 2; x is 0-200; y is 2 or more; x+y is 10 to 250; the ratio of x to y is 2 to 50; and R* is a polyether substituent independently selected from the same or different -CnH2nO- group-started polyether substituents, wherein n is 2-10, and the substituents R* have a number average molecular weight of from 200 Dalton to 6000 Dalton, and are independently terminated by an alkoxy group or an acryl group, preferably by a methoxy group or an acetoxy group.

6. The surfactant composition according to any of the previous claims 1 to 5, wherein the component B) is an alkanoic acid or alkenoic acid with 4 to 30 carbon atoms, preferably with 6 to 24 carbon atoms, more preferably with 9 to 20 carbon atoms.

7. The surfactant composition according to any of the previous 1 to 6, wherein the component B) is a branched alkanoic acid, more preferably a branched alkanoic acid with 5 to 24 carbon atoms.

8. The surfactant composition according to any of the previous 1 to 7, wherein the component B) is a branched alkyl monocarboxylic acid with 5 to 20 carbon atoms containing one or more quaternary carbon atoms, preferably containing a quaternary carbon atom in a- position to the carboxylic acid group 9. The surfactant composition according to any of the previous claims 1 to 8, wherein the amount of component B) in the silicone surfactant composition is 1.0 to 10 weight-%, preferablyI .5 to 8 weight-%, and more preferred 2.5 to 7 weight-% on the basis of the overall weight of the components A), B) and C) of the silicone surfactant composition.

10. The surfactant composition according to any of the previous claims 1 to 9, wherein the components A) and B) add up to 20 weight-% or more of the total weight of the composition, preferably to more than 25 weight-% or more of the total weight of the composition, more preferably 30 weight- % or more of the total weight of the composition, even more preferably to 35 weight-% or more of the total weight of the componentsA), B) and C) of the silicone surfactant compositionI I . The surfactant composition according to any of the previous claims 1 to 10, wherein diluent C) is fully miscible with A) and B), wherein C) is water, a monoalcohol, a di- or polyol, a mono-, di- or polyethers, aliphatic and aromatic hydrocarbons, and halogenated hydrocarbons, in particular partially or perhalogenated alkanes and partially or perhalogenated alkylated phenyl compounds, ketones, amides, nitriles, sulfoxides, or organocarbonates, or a combination of two or more thereof, preferably ethylene glycol ether or a propylene glycol ether, specifically dipropylene glycol.

12. The surfactant composition according to any of the previous claims 1 to 11 , wherein the diluent C) is an ethylene glycol ether or a propylene glycol ether, specifically dipropylene glycol.

13. The surfactant composition according to any of the previous claims 1 to 12, wherein the composition comprises one or more diluents C), wherein the amount of the diluent is 20 weight-% or more, more preferably 35 weight-% or more, even more preferably 50 weight-% or more, still more preferably 65 weight-% or more, further more preferably 75 weight-% or more, and most preferably 85 weight-% or more on the basis of the overall weight of the surfactant composition.

14. The surfactant composition according to any of the previous claims 1 to 13, wherein the silicone surfactant compound A) has the formula (I)M*DxD”yM* (I), whereinM*, D, and D” are as defined above, x is 45 to 90, preferably 55 to 80; y is 2 to 10, preferably 3 to 9; x+y is 50 to 90, preferably 55 to 85; the ratio of x to y is 5 to 20, preferably 7 to 15;and the silicone surfactant compound A) comprises one or more polyether substituents R* selected from the group (iii) having a structure of the formula (II’”)(iii) -Cn”H2n ’O(C2H4O)a ’(C3H6O)b ”R4, wherein n’ is 2 to 4, preferably 3; a’” is a number such that ethylene oxide residues constitute 30% to 60% by weight of the alkylene oxide residues of the polyether substituent; b’” is a number such that propylene oxide residues constitute 40% to 70% by weight of the alkylene oxide residues of the polyether;R4represents a methoxy group, an acetoxy group, or a butoxyl group; and one or more polyether substituents R* selected from the group (iv) having a structure of the formula (II””)(iv) n'”’H2n””O(C2H4O)a” (C3H6O)b””R5; wherein n”” is 2 to 4, preferably 3; a”” is a number such that ethylene oxide residues constitute 30% to 100% by weight of the alkylene oxide residues of the polyether substituent; b”” is 0 to a number such that propylene oxide residues constitute less than or equal 70% by weight of the alkylene oxide residues of the polyether;R5represents a methoxy group, an acetoxy group, or a butoxyl group, the organic acid B) is an alkyl carboxylic acid with 5 to 24 carbon atoms, preferably a branched alkyl carboxylic acid with 5 to 24 carbon atoms, more preferably selected from the group consisting of C8-neoalkanoic acids, C9-neo-alkanoic acids, C10-neoalkanoic acids, C11- neoalkanoic acids, C12-neoalkanoic acids, C13-neoalkanoic acids, C-14-neoalkanoic acids, most preferably neodecanoic acid, and wherein the composition optionally comprises a diluent C), which is preferably a glycol ether, most preferably dipropylene glycol.

15. The surfactant composition according to any of the previous claims 1 to 12 and 14, wherein the composition comprises20 -80 weight-% of the silicone surfactant compound A),1-8 weight-% of the carboxylic acid B, and12-79 weight-% of the diluent C), each on the basis of the total weight of the surfactant composition, and wherein the components A), B) and C) add up to 95 weight-% or more, preferably to 100 weight-% of the surfactant composition.

16. The surfactant composition according to any of the previous claims 1 to 10 or 14, wherein the components A) and B) add up to 100 weight-% of the total weight of the composition.

17. Use of the surfactant composition according to any of the previous claims 1 to 16 in the production of polyurethane foam, in particular of flexible polyurethane foam.

18. A process for the production of a polyurethane foam, comprising a step of combining the surfactant composition according to any of the previous claims 1 to 16 with a at least one isocyanate and at least one polyol.

19. A polyurethane foam-forming composition comprising:(a) one or more polyols;(b) one or more polyisocyanates;(c) one or more catalysts;(d) water;(e) a silicone surfactant composition of the invention according to any of the previous claims 1 to 16,(f) and optionally further additives and auxiliary compounds.

20. A polyurethane foam formed from the composition of the previous claim 19.

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