A flexible discontinuous process produces a series of at least two articles containing thermally insulating polyurethane foam from at least three streams (A), (B) and (C). The process involves mixing the at least three streams with different mixing ratios and injecting the mixture into cavities of the articles. A production unit can be used for performing this process.

The subject application relates to polyurethane foam and methods of forming the same. A polyurethane foam may include a polyurethane foam may include a first polyol component, a second polyol component, and a third polyol component. The first polyol component may include at least one component selected from the group of a polyether polyol and a polyester polyol. The second polyol component may include a polyether polyol. The third polyol component may include a grafted polyether polyol. The polyurethane foam may have a density of at least about 100 kg/m.sup.3 and not greater than about 800 kg/m.sup.3. The polyurethane foam may have an adjusted compression force deflection to density ratio of at least about 0.3.

To provide a polyether polyol having a high degree of freedom in the design of a polyurethane foam, and capable of providing a polyol system solution excellent in storage stability. A polyether polyol having a polyoxyalkylene chain consisting of oxyalkylene units, and having a degree of unsaturation of at most 0.020 meq/g, a hydroxy value of from 1 to 80 mgKOH/g, a content of oxyethylene units of from 0 to 50 mass %, and a content of ultra-high molecular weight components which have molecular weights of from 12 to 46 times the number average molecular weight of at most 1,000 mass ppm. The number average molecular weight is a molecular weight as calculated as polystyrene measured by gel permeation chromatography (GPC) method, and the content of ultra-high molecular weight components is a value measured by high performance liquid chromatography (HPLC) method using a charged aerosol detector (CAD).

Polyurethane foams that are hydrophilic but nonetheless have low compression sets are made from a combination of MDI and TDI prepolymers, water, and a polymer polyol. The foams optionally are made incorporating a phase change material in the foam formulation. The phase change material does not require encapsulation.

Polyurethane foams that are hydrophilic but nonetheless have low compression sets are made from a combination of MDI and TDI prepolymers, water, and a polymer polyol. The foams optionally are made incorporating a phase change material in the foam formulation. The phase change material does not require encapsulation.

Polyether polyols are prepared by polymerizing unsaturated monomers in a continuous phase of a base polyol. A macromer or polymerization produce of such a macromer is present during the polymerization to stabilize the polymer particles as they form. The macromer is a polyether capped with certain unsaturated epoxide compounds.

The present disclosure relates to spray polyether and polyester polyurethane elastomeric articles and associated methods of producing such elastomer articles. More specifically, the invention provides spray polyester polyurethane elastomer articles that exhibit excellent tensile and tear strength, superior elongation performance and improved abrasion resistance performance with tunable tensile modulus.

The present disclosure relates to spray polyether and polyester polyurethane elastomeric articles and associated methods of producing such elastomer articles. More specifically, the invention provides spray polyester polyurethane elastomer articles that exhibit excellent tensile and tear strength, superior elongation performance and improved abrasion resistance performance with tunable tensile modulus.

Polyurethane foams are made by curing a reaction mixture that contains an aromatic polyisocyanate, at least one isocyanate-reactive material having an average functionality of at least 2 and an equivalent weight of at least 200 per isocyanate-reactive group, at least one blowing agent, at least one surfactant and at least one catalyst, at least one cyclic 1,3-diketone compound, at least one aminoalcohol or alkylhydroxylamine and an alkali metal, phosphonium or ammonium sulfite. Foams so produced emit low levels of formaldehyde, acetaldehyde, acrolein and propionaldehyde.

A method for producing a polyurethane polymer comprises the steps of: (a) providing a polyol; (b) providing an additive composition comprising a polyethylenimine compound and a sulfite compound; (c) combining the polyol and the additive composition to produce a polyol composition; (d) providing an isocyanate compound; and (e) combining and reacting the polyol composition and the isocyanate composition to produce a polyurethane polymer.