A process for making a molded flexible foam. The processes includes: (a) depositing a foam-forming reaction mixture onto a surface of a mold cavity, and (b) allowing the foam-forming reaction mixture to react in the mold cavity. The foam-forming reaction mixture includes: (1) a polyisocyanate present in an amount of less than 45% by weight, based on the total weight of the reaction mixture; (2) an isocyanate-reactive composition; (3) a blowing agent; and (4) a catalyst. The isocyanate-reactive composition includes: (i) at least 50% by weight, based on the total weight of polyol in the isocyanate-reactive composition, of a polyether polyol having a functionality of greater than 2, an oxyethylene content of 0 to 50% by weight, based on the total weight of the polyether polyol, more than 50 mol % of primary OH groups and an OH number of 8 to 112 mg KOH/g; and (ii) a component comprising: (A) an amine-initiated polyether polyol (II), wherein amine-initiated polyether polyol (II) has an OH number of at least 500 mg KOH/g and a functionality of 2.5 to 4, and wherein amine-initiated polyether polyol (II) is present in an amount of greater than 0 and no more than 10% by weight, based on the total weight of polyol in the isocyanate-reactive composition; (B) a CO.sub.2-producing carbamic acid which is present in an amount of greater than 0 and no more than 10% by weight, based on the total weight of polyol in the isocyanate-reactive composition; or (C) both (A) and (B).

Processes for making a molded flexible foam. The processes include: (a) depositing a foam-forming reaction mixture onto a surface of a mold cavity, and (b) allowing the foam-forming reaction mixture to react in the mold cavity. The foam-forming reaction mixture comprises: (1) a polyisocyanate present in an amount of less than 45% by weight, based on the total weight of the foam-forming reaction mixture; (2) an isocyanate-reactive composition comprising at least 50% by weight, based on the total weight of polyol in the isocyanate-reactive composition, of a polyether polyol having a functionality of greater than 2, an oxyethylene content of 0 to 50% by weight, based on the total weight of the polyether polyol, more than 50 mol % of primary OH groups, and an OH number of 8 to 112 mg KOH/g; (3) a blowing agent comprising water present in an amount of at least 0.5% by weight, based on the total weight of the foam-forming reaction mixture; and (4) a tin-free metallic catalyst composition comprising a bismuth-based catalyst and a zinc-based catalyst.

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.

Tertiary amine catalysts having isocyanate reactive groups that are capable of forming thermally stable covalent bonds able to withstand temperatures up to 120° C. are disclosed. These catalyst can be used to produce polyurethane foam having the following desirable characteristics: a) very low chemical emissions over a wide range of environmental conditions and isocyanate indexes (e.g., indexes as low as 65 but higher than 60) while meeting all physical property requirements; b) sufficient hydrolytic stability to maintain the catalyst covalently bound to foam without leaching of tertiary amine catalyst when foam is exposed to water or aqueous solutions even at temperatures higher than ambient (temperature range 25° C. to 90° C.); and c) stable contact interface between the polyurethane polymer and other polymers (for example polycarbonate) with minimal migration of tertiary amine catalyst from polyurethane polymer to other polymers yielding no noticeable polymer deterioration at the point of contact even under conditions of heat and humidity.

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.

Disclosed are keratin fibre cellular components, specifically keratin fibre cuticle and cortical cells, and their use as absorption and filtration media, and in thermal insulation materials. The keratin fibre cellular components may be oxidised. The keratin fibre cellular components have improved absorbency and filtration capacity compared to the source keratin fibres. The keratin fibre cellular components may be used in, for example, various products for passive absorption and active filtration of gas or liquid media.

Provided is a tire that prevents a polyurethane foam layer from discoloring to brown. A tire comprises: a polyurethane foam layer laminated on an outer layer of the tire with a barrier layer therebetween, wherein the polyurethane foam layer contains a polyurethane foam, and the barrier layer is formed from a rubber composition containing butyl rubber as a rubber component.

The disclosure includes brominated alkenyl alcohols, their use as a flame retardant in polyurethane and polyurethane foams, and polyurethanes containing the brominated alkenyl alcohols. Compositions, methods, and processes are disclosed. The brominated alkenyl alcohols used as flame retardants in polyurethanes can be generally described by Formula (I), the scope of which is disclosed herein.

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The present invention relates to phosphoric ester preparations with reduced hygroscopicity, to use of these as flame retardants and hydraulic fluids, and to polyurethanes which comprise the phosphoric ester preparations of the invention.

The present invention relates to a process for producing flame-retarded polyurethane foams, in particular flexible polyurethane foams, using halogen-free flame retardants, wherein the resulting flame-retarded polyurethane foams exhibit low emission values coupled with good mechanical properties. The present invention further relates to halogen-free flame retardants.