A process of making a polyurethane or polyisocyanurate foam comprises the step of mixing under low pressure: (A) An isocyanate; (B) A compound reactive with the isocyanate, e.g., a polyol; (C) A liquid blowing agent; and (D) Carbon dioxide.

An organophosphorus compound useful in a phosphorus containing flame retardant and a flame retardant polyurethane foam, where the organophosphorus compound is shown in Formula (I) where Y is selected from the group consisting of an —OH group, an —NH.sub.2 group, an —NHR.sup.3 group, and an —SH group, where R.sup.3 is a monovalent hydrocarbyl group having 1 to 10 carbon atoms; R is a divalent hydrocarbyl group; X is a heteroatom group; and R.sup.1 and R.sup.2 are each independently a substituted or unsubstituted hydrocarbyl group, wherein R.sup.1 and R.sup.2 can be optionally joined to form a ring. ##STR00001##

The present invention relates to an insulation body based a hard, fine-cell and open-cell polyurethane/polyisocyanurate foam with a barrier film, and a method for producing same.

An impact protection foam includes the reaction product of an isocyanate component and an isocyanate-reactive component. The isocyanate component includes at least one isocyanate. The isocyanate-reactive component includes from 20 wt % to 80 wt % of a hydrophobic polyol component and from 20 wt % to 80 wt % of a hydrophilic polyol component, based on the total weight of the isocyanate reactive component. The hydrophobic polyol component includes at least one natural oil hydrophobic polyol, and the hydrophilic polyol component includes at least a polyether polyol having a number average molecular weight from 3,000 g/mol to 10,000 g/mol and a primary hydroxyl content of at least 50 wt %. The isocyanate index is from 50-120. The foam article has a rate of energy dissipation less than 35 KN over the temperature range from 10 C to 40 C and a Shore A hardness of less than 55 at both 23° C. and −10° C.

A reaction system for forming a polyurethane foam includes an isocyanate component that has at least one isocyanate and an isocyanate-reactive component that is a mixture formed by adding at least a polyol component, an additive component, and a preformed aqueous polymer dispersion. The mixture includes, based on the total weight of the mixture, from 50.0 wt % to 99.8 wt % of a polyol component including at least one polyether polyol, from 0.1 wt % to 50.0 wt % of an additive component including at least one catalyst, and from 0.1 wt % to 6.0 wt % of a preformed aqueous polymer dispersion. The preformed aqueous polymer dispersion has a solids content from 10 wt % to 80 wt %, based on the total weight of the preformed aqueous polymer dispersion, and is one of an aqueous acid polymer dispersion or an aqueous acid modified polyolefin polymer dispersion in which the polyolefin is derived from at least one C.sub.2 to C.sub.20 alpha-olefin.

A surfactant and a method of forming the surfactant having the formula (I) where a is an integer from 1 to 10, b is an integer from 0 to 10, R.sub.1 is —CH.sub.3 or —H, n is an integer from 0 to 20, and R.sub.2 is a moiety selected from the group consisting of (II), (III), (IV), (V), (VI), (VII) or (VIII) where m is an integer from 0 to 4. The surfactant can be used in a method for preparing a rigid polyurethane foam.

##STR00001##

Polyurethane composites and methods of preparing polyurethane composites are described herein. The polyurethane composite can comprise (a) a polyurethane formed by the reaction of (i) one or more isocyanates selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof, and (ii) one or more polyols; (b) fly ash comprising 50% or greater by weight, fly ash particles having a particle size of from 0.2 micron to 100 microns; and (c) a coarse filler material comprising 80% or greater by weight, filler particles having a particle size of from greater than 250 microns to 10 mm. The coarse filler material can be present in the composite in an amount of from 1% to 40% by weight, based on the total weight of the composite. The weight ratio of the fly ash to the coarse filler material can be from 9:1 to 200:1.

A molded flexible polyurethane foam having a hardness gradient going from soft to hard from the top to the bottom of the foam. The hardness gradient in the foam is a result of a foam elasticity gradient which arises from a polymer elasticity gradient and/or density gradient. A method for producing a flexible foam having a hardness gradient and a reactive mixture suitable for making said flexible foam is disclosed. Furthermore, the use of the flexible foams having a hardness gradient in matrasses, cushions for seating (more in particular for use in automotive seating), furniture, automotive under-carpets and dash insulators is disclosed.

Described herein is a process for producing polyurethane foams having a density of 30 g/dm.sup.3 to 70 g/dm.sup.3, in which (a) aromatic polyisocyanate is mixed with (b) polymeric compounds having isocyanate-reactive groups, (c) optionally chain extender and/or crosslinking agent, (d) catalyst, (e) blowing agent including water, (f) 0.1% to 5% by weight of lactam, and (g) optionally additives, at an isocyanate index of 50 to 95 to form a reaction mixture, and the reaction mixture is converted to the polyurethane foam, wherein the catalyst includes metal catalyst and amine catalyst, and the amine catalyst has tertiary nitrogen atoms and the content of tertiary nitrogen atoms in the amine catalyst is from 0.0001 to 0.003 mol/100 g of foam. Also described herein is a polyurethane foam and a method of using such a flexible polyurethane foam for the production of cushions, seat cushions, or mattresses.

Embodiments of the present disclosure are directed towards formulated polyol compositions that include a sucrose propoxylated polyol, a polyether triol, and a propoxylated homopolymer triol.