Flexible foams

Abstract

The present invention relates to a composition for preparing flexible foams and the application thereof. The composition comprises the following components: a. an isocyanate mixture comprising: a1) an aliphatic and/or alicyclic isocyanate monomer, and a2) an aliphatic and/or alicyclic; isocyanate trimer, wherein the mass ratio of said monomer to said trimer is in a range of 3:1-200:1; b. a polymer polyol mixture comprising: b1) a first polyether polyol having a number average molecular weight of not less than 3000 g/mol with an ethylene oxide content of 5-20 wt. %, b2) a second polyether polyol having a number average molecular weight of not less than 3000 g/mol with an ethylene oxide content of more than 60 wt. %, wherein the mass ratio of said first polyether polyol to said second polyether polyol is in a range of 4:1-100:1; c. an isocyanate-reactive group comprising compound having a number average molecular weight of 32-400 g/mol; d. a catalyst; e. a foaming agent; and f. optionally, an additive; wherein said composition has an isocyanate index of 70-120.

Claims

1. A composition comprising the following components: a) an isocyanate mixture, comprising: a1) an aliphatic and/or alicyclic isocyanate monomer, and a2) an aliphatic and/or alicyclic isocyanate trimer, wherein the mass ratio of said monomer to said trimer is in a range of 3:1-200:1; b) a polymer polyol mixture, comprising: b1) a first polyether polyol having a number average molecular weight of not less than 3000 g/mol, wherein said first polyether polyol is obtained by the polymerization of a component comprising ethylene oxide, and said first polyether polyol has an ethylene oxide content of 5-20 wt. %, based on the amount of the component for preparing said first polyether polyol as 100 wt. %, b2) a second polyether polyol having a number average molecular weight of not less than 3000 g/mol, wherein said second polyether polyol is obtained by the polymerization of a component comprising ethylene oxide, and said second polyether polyol has an ethylene oxide content of more than 60 wt. %, based on the amount of the component for preparing said second polyether polyol as 100 wt. %, and b3) optionally, a third polyether polyol having a number average molecular weight of not less than 500 g/mol, wherein the mass ratio of said first polyether polyol to said second polyether polyol is in a range of 4:1-100:1, and the amount of said third polyether polyol is not more than 20 wt. %, based on the amount of said polymer polyol mixture as 100 wt. %; c) an isocyanate-reactive group comprising compound having a number average molecular weight of 32-400 g/mol; d) a catalyst; e) a foaming agent; and f) optionally, an additive; wherein the isocyanate index of said composition is in a range of 70-120.

2. The composition according to claim 1, wherein the mass ratio of said monomer to said trimer is in a range of 3:1-120:1.

3. The composition according to claim 1, wherein the alicyclic monomer is isophorone diisocyanate and/or dicyclohexylmethane diisocyanate.

4. The composition according to claim 1, wherein alicyclic isocyanate trimer is one or more selected from the group consisting of isophorone diisocyanate trimer, and 1,5-cyclopentane diisocyanate trimer, or wherein the aliphatic isocyanate trimer is hexamethylene diisocyanate trimer.

5. The composition according to claim 1, wherein the mass ratio of said first polyether polyol to said second polyether polyol is in a range of 4:1-30:1.

6. The composition according to claim 1, wherein the ethylene oxide content in said first polyether polyol is in a range of 10-20 wt. %, based on the amount of the component for preparing said first polyether polyol as 100 wt. %.

7. The composition according to claim 1, wherein the ethylene oxide content in said second polyether polyol is more than 65 wt. %, based on the amount of the component for preparing said second polyether polyol as 100 wt. %.

8. A method for preparing a flexible foam, comprising the following steps: i. mixing each of the components of the composition according to claim 1; and ii. obtaining said flexible foam by means of foaming.

Description

DETAILED DESCRIPTION

(1) The present invention provides a composition comprising the following components:

(2) a. an isocyanate mixture, comprising:

(3) a1) an aliphatic and/or alicyclic isocyanate monomer, and

(4) a2) an aliphatic and/or alicyclic isocyanate trimer,

(5) wherein the mass ratio of said monomer to said trimer is in a range of 3:1-200:1;

(6) b. a polymer polyol mixture, comprising:

(7) b1) a first polyether polyol having a number average molecular weight of not less than 3000 g/mol, wherein said first polyether polyol is obtained by the polymerization of a component comprising ethylene oxide, and said first polyether polyol has an ethylene oxide content of 5-20 wt. %, based on the amount of the component for preparing said first polyether polyol as 100 wt. %,

(8) b2) a second polyether polyol having a number average molecular weight of not less than 3000 g/mol, wherein said second polyether polyol is obtained by the polymerization of a component comprising ethylene oxide, and said second polyether polyol has an ethylene oxide content of more than 60 wt. %, based on the amount of the component for preparing said second polyether polyol as 100 wt. %, and

(9) b3) optionally, a third polyether polyol having a number average molecular weight of not less than 500 g/mol,

(10) wherein the mass ratio of said first polyether polyol to said second polyether polyol is in a range of 4:1-100:1, and the amount of said third polyether polyol is not more than 20 wt. %, based on the amount of said polymer polyol mixture as 100 wt. %;

(11) c. an isocyanate-reactive group comprising compound having a number average molecular weight of 32-400 g/mol;

(12) d. a catalyst;

(13) e. a foaming agent; and

(14) f. optionally, an additive;

(15) wherein the isocyanate index of said composition is in a range of 70-120. The present invention further provides a method for preparing a flexible foam using the composition, the prepared flexible foam and the application thereof, and a fabrics comprising the flexible foam.

(16) Isocyanate Mixture

(17) The isocyanate group content in said isocyanate mixture may be in a range of 20-54 wt. %, based on the amount of said isocyanate mixture as 100 wt. %.

(18) The isocyanate group content in said isocyanate mixture is preferably in a range of 20-37.5 wt. %, based on the amount of said isocyanate mixture as 100 wt. %.

(19) The mass ratio of said isocyanate monomer to the trimer is preferably in a range of 3:1-120:1, and most preferably in a range of 3:1-20:1.

(20) Isocyanate Monomer

(21) The isocyanate functionality of said isocyanate monomer is preferably 2.

(22) The isocyanate group content in said isocyanate monomer may be in a range of 20-40 wt. %, based on the amount of said isocyanate monomer as 100 wt. %.

(23) Said aliphatic isocyanate monomer is preferably one or more selected from the group consisting of: hexamethylene diisocyanate (HDI), 2,2-dimethyl pentamethylene diisocyanate, 2,2,4-trimethylhexamethylene diisocyanate, butylene diisocyanate, 1,3-butadiene-1,4-di isocyanate, 2,4,4-trimethyl-1,6-hexamethylene diisocyanate and lysine methyl ester diisocyanate.

(24) Said alicyclic isocyanate monomer is preferably one or more selected from the group consisting of: isophorone diisocyanate (IPDI), isomeric bis(4,4′-isocyanatocyclohexyl)methane or their mixtures with any isomer content, 1,4-cyclohexylidene diisocyanate, 1,3-bis(isocyanatomethyl)benzene (XDI), 1,3- and/or 1,4-bis(2-isocyanatoprop-2-yl)-benzene (TMXDI), norbornane diisocyanate (NBDI), hydrogenated xylylene diisocyanate (H.sub.6XDI), 1,4-cyclohexylene diisocyanate (H.sub.6PPDI), 1,5-pentamethylene diisocyanate (PDI) and dicyclohexylmethane diisocyanate (H.sub.12MDI).

(25) Said isocyanate monomer is preferably an alicyclic isocyanate, further preferably isophorone diisocyanate and/or dicyclohexylmethane diisocyanate, and most preferably isophorone diisocyanate.

(26) Isocyanate Trimer

(27) The viscosity of said isocyanate trimer is preferably in a range of 1000-10000 mPa.Math.s, as measured at 23° C. It is preferred to use a DV-II+Pro. rotational viscometer available from Brookfield Company and to perform the measurement according to DIN 53019.

(28) The isocyanate group content in said isocyanate trimer is preferably in a range of 20-25 wt. %, based on the amount of said trimer as 100 wt. %.

(29) Said aliphatic and/or alicyclic isocyanate trimer is preferably one or more selected from the group consisting of: isophorone diisocyanate trimer, 1,5-cyclopentane diisocyanate trimer and hexamethylene diisocyanate trimer.

(30) The amount of said isocyanate mixture and said polymer polyol mixture may be more than 50 wt. %, and most preferably more than 85 wt. %, based on the amount of said composition as 100 wt. %.

(31) Polymer Polyol Mixture

(32) The hydroxyl group functionality of said polymer polyol mixture may be in a range of 2-4, and preferably in a range of 3-4.

(33) The mass ratio of said first polyether polyol to said second polyether polyol is preferably in a range of 4:11-30:1.

(34) First Polyether Polyol

(35) The number average molecular weight of said first polyether polyol may be in a range of 4000-6000 g/mol.

(36) The hydroxyl value of said first polyether polyol may be in a range of 20-80 mg KOH/g, and preferably in a range of 25-40 mg KOH/g.

(37) The ethylene oxide content in said first polyether polyol is preferably in a range of 10-20 wt. %, based on the amount of the component for preparing said first polyether polyol as 100 wt. %.

(38) The viscosity of said first polyether polyol is preferably in a range of 750-1500 mPa.Math.s.

(39) The hydroxyl group functionality of said first polyether polyol is preferably in a range of 2-4.

(40) Said first polyether polyol is preferably one or more selected from the group consisting of: Arcol Polyol 3553, Acrol Polyol 1362 and Acrol polyol 1026.

(41) Second Polyether Polyol

(42) The number average molecular weight of said second polyether polyol may be in a range of 3000-6000 g/mol, and preferably in a range of 4000-5000 g/mol.

(43) The hydroxyl value of said second polyether polyol may be in a range of 20-80 mg KOH/g, and preferably in a range of 25-40 mg KOH/g.

(44) The ethylene oxide content in said second polyether polyol may be more than 65 wt. %, and most preferably more than 65 wt. % and less than 80 wt. %, based on the amount of the component for preparing said second polyether polyol as 100 wt. %.

(45) The viscosity of said second polyether polyol is preferably in a range of 1000-1500 mPa.Math.s.

(46) The hydroxyl group functionality of said second polyether polyol may be in a range of 2-4, and preferably 3.

(47) Said second polyether polyol is preferably Bayflex VP PU 191F03.

(48) Optional Third Polyether Polyol

(49) Said third polyether polyol is different from said first polyether polyol and said second polyether polyol.

(50) The number average molecular weight of said third polyether polyol may be in a range of 500-1000 g/mol.

(51) The hydroxyl value of said third polyether polyol may be more than 200 mg KOH/g, and preferably in a range of 200-250 mg KOH/g.

(52) The viscosity of said third polyether polyol is preferably in a range of 200-500 mPa.Math.s.

(53) The hydroxyl group functionality of said third polyether polyol may be in a range of 2-4, and preferably 3.

(54) The amount of said third polyether polyol is preferably not more than 10 wt. %, based on the amount of said polymer polyol mixture as 100 wt. %.

(55) Said third polyether polyol is preferably obtained by the polymerization of a component that comprises no ethylene oxide.

(56) Said third polyether polyol is preferably Arcol Polyol 1071.

(57) Isocyanate Reactive Group Comprising Compound Having a Number Average Molecular Weight of 32-400 g/mol

(58) The isocyanate-reactive group as used herein refers to a group capable of reacting with an isocyanate group.

(59) Said isocyanate-reactive group comprising compound having a number average molecular weight of 32-400 g/mol is preferably an aliphatic and/or alicyclic compound.

(60) Said isocyanate-reactive group is preferably one or more selected from the group consisting of: hydroxyl, primary amino and secondary amino.

(61) Said isocyanate-reactive group comprising compound having a number average molecular weight of 32-400 g/mol further preferably comprises at least two isocyanate-reactive groups.

(62) Said isocyanate-reactive group comprising compound having a number average molecular weight of 32-400 g/mol is most preferably one or more selected from the group consisting of glycerol, 1,1,1-trimethylolethane, 1,1,1-trimethylolpropane, 1,2,3-trimethylolhexane, poly(propylene oxide-ethylene oxide), polypropylene oxide), poly(ethylene oxide), monoethanolamine, diethanolamine, triethanolamine, 2-amino-2-methyl-1-propanol and hydrazine.

(63) The amount of said isocyanate-reactive group comprising compound having a number average molecular weight of 32-400 g/mol may be in a range of 0.5-5.0 wt. %, and preferably in a range of 2-3 wt. %, based on the amount of said composition as 100 wt. %.

(64) Catalyst

(65) The amount of said catalyst may be in a range of 0.5-3.0 wt. %, and preferably in a range of 0.5-1.5 wt. %, based on the amount of said composition as 100 wt. %.

(66) Said catalyst may be those commonly used in the industry, for example: (1) tertiary amines such as bis(2,2′-dimethylamino)ethyl ether, bis(dimethylaminoethyl)ether, N-methylmorpholine, N-ethylmorpholine, N,N-dimethylbenzylamine, N,N-dimethylethanolamine, N,N,N′,N′-tetramethyl-1,3-butanediamine, pentamethyl dipropylenetriamine, trimethylamine, triethylamine, triethanolamine, triethylenediamine, and pyridine oxide; (2) compounds containing >N—C═N— structure such as diazabicycloalkenes or guanidine-based compounds; available compounds including 1,5-diazabicyclo-(4,3,0)-5-nonene, 1,8-diazabicyclo-(5,4,0)-7-undecene, 1,8-diazabicyclo-(5,3,0)-7-decene, 1,5-diazabicyclo-(5,4,0)-5-undecene, 1,4-diazabicyclo-(3,3,0)-4-octene, guanidine, 1,3-diphenylguanidine, 1,1,3,3-tetramethylguanidine, cyclohexyltetramethylguanidine, N-dodecyltetramethylguanidine, guanidinium thiocyanate, 1,3-di(tert-butyloxycarbonyl)guanidine, 1,3-di-tert-butyloxycarbonyl-2-(2-hydroxyethyl)guanidine, 1,3-di-tert-butyloxycarbonyl-2-(carbonylmethyl)guanidine, 1,8-di(tetramethylguanidino)naphthalene, 1-(2,2-diethoxyethyl)guanidine, 1-(4-methoxyphenyl)guanidine and organic salts of diazabicycloalkenes or guanidine-based compounds such as phenates, formates, acetates and carbonates; (3) strong bases such as alkali metal salts, alkaline earth metal alkoxides, hydroxides or phenates; (4) acidic metal salts of strong acids such as stannous chloride, ferric chloride, antimony trichloride, bismuth chloride and nitrates; (5) chelates of various metals, for example, those obtained from acetylacetone, benzoylacetone, trifluoroacetylacetone, ethyl acetoacetate, salicylaldehyde, cyclopentanone-2-carboxylate, acetylacetone-imine, diacetylacetone-alkylene diimine, and salicylaldehyde imine and various metals such as Be, Mg, Zn, Pb, Ti, Zr, Sn, Bi, Mo, Mn, Fe, C, and Ni; (6) alkoxides and phenates of various metals, such as Ti(OR).sub.4 and Al(OR).sub.3, wherein R is an alkyl or aryl group, and the reaction products of an alkoxide with a carboxylic acid, a β-diketone and a 2-(N,N-dialkylamino)alkanol, for example titanium chelates obtained via such or similar steps; (7) salts of organic acids with various metals such as alkali metals and alkaline earth metals, such as calcium hexanoate; (8) organometallic derivatives of trivalent and pentavalent As, Sb and Bi, and metal carbonyl compounds of iron and cobalt.

(67) Said catalyst is preferably tin-based catalysts and/or base catalysts.

(68) Said tin-based catalysts are preferably organotin catalysts and/or organic stannous catalysts.

(69) Said organotin catalysts may be one or more selected from the group consisting of: dialkyltin salts of carboxylic acids, trialkyltin hydroxides, dialkyltin oxides, dialkoxydialkyltins, dialkyltin dichlorides and dithiol dialkyltins.

(70) Said organic stannous catalysts may be stannous salts of carboxylic acids, such as stannous acetate, stannous octoate, and stannous oleate.

(71) Said tin-based catalysts are most preferably stannous isooctoate.

(72) Said base catalysts may be salts of Brønsted acids and various alkali metals; and preferably sodium bicarbonate or sodium carbonate.

(73) When said catalyst is a combination of tin-based catalysts and base catalysts, the amount of said tin-based catalysts is preferably in a range of 0.5-1.5 wt. % and the amount of said base catalysts is preferably in a range of 0.1-1.0 wt. %, based on the amount of said composition as 100 wt. %.

(74) Foaming Agent

(75) Said foaming agent may be water and/or other known foaming agents.

(76) Said water reacts with said isocyanate mixture to produce carbon dioxide, resulting in flexible polyurethane foams having varying density ranges. When the water content in the composition is relatively high, more carbon dioxide can be produced and flexible polyurethane foams having a relatively low density can be obtained.

(77) Said other known foaming agents may be hydrochloroflurocarbons and/or carbon dioxide, preferably carbon dioxide (gas or liquid).

(78) The amount of said foaming agent may be in a range of 0.3-5.0 wt. %, and preferably in a range of 0.5-2.5 wt. %, based on the amount of said composition as 100 wt. %.

(79) Additive

(80) The amount of said additive is preferably in a range of 0.5-15 wt. %, based on the amount of said composition as 100 wt. %.

(81) Said additive may be one or more selected from the group consisting of: surfactants, pigments, antioxidants, UV light absorbers, UV light stabilizers, flame retardants, fillers, recycled foam powders, antimicrobial compounds and antistatic agents.

(82) Said surfactant may be one or more selected from the group consisting of: polysiloxane-polyalkylene oxide copolymers, silicon-free nonionic surfactants, cationic surfactants, anionic surfactants, and polymeric surfactants with a relative molecular weight of higher than 1,000 g/mol.

(83) Said polysiloxane-polyalkylene oxide copolymer is preferably a polysiloxane-polyalkylene oxide copolymer having a hydrophilic-lipophilic balance (HLB) between 3-33, and most preferably a polysiloxane-polyalkylene oxide copolymer having an HLB between 6-20.

(84) Said silicon-free nonionic surfactant is preferably a silicon-free non-ionic surfactant having an HLB between 1-20, and most preferably a silicon-free non-ionic surfactant having an HLB between 6-20.

(85) Said surfactant is most preferably Niax silicone Y-10366.

(86) The amount of said surfactant is preferably in a range of 1-2 wt. %, based on the amount of said composition as 100 wt. %.

(87) Although the flexible polyurethane foam of the present invention does not tend to discolor under the exposure of ultraviolet (UV) radiation, UV light stabilizers, UV light absorbers, or antioxidants may be added into said composition in order to improve the light stability of the foam.

(88) Said UV light stabilizer is preferably a hindered amine UV light stabilizer.

(89) Said hindered amine UV light stabilizer is preferably one or more selected from the group consisting of: di(2,2,6,6-tetramethylpiperidinyl)sebacate, poly[[6-[(1,1,3,3-tetramethylbutyl)amino]-s-triazine-2,4-diyl]-[(2,2,6,6-tetramethyl-4-piperidinyl)imino]-hexamethylene-[(2,2,6,6-tetramethyl-4-piperidinyl)imino]] (CAS No, 71878-19-8), di(1,2,2,6,6-pentamethyl-4-piperidinyl)-[[3,5-di(1,1-dimethylethyl)-4-hydroxyphenyl]methyl]butylmalonate and 4-benzoyloxy-2,2,6,6-tetramethylpiperidine.

(90) Said UV light absorbers may be salicylates, benzotriazoles and benzophenones.

(91) Said salicylates are preferably phenyl salicylate and/or tert-butylphenyl salicylate.

(92) Said benzotriazoles are preferably one or more selected from the group consisting of: 2-(2′-hydroxy-3′,5′-diisopentylphenyl)benzotriazole, 2-(2′-hydroxy-3′-tert-butyl-5′-methylphenyl)-5-chlorobenzotriazole, 2-(2′-hydroxy-3′,5′-di-tert-butylphenyl)-5-chlorobenzotriazole and 2-(2′-hydroxy-3′,5′-di-tert-butylphenyl) benzotriazole.

(93) Said benzophenones are preferably one or more selected from the group consisting of: 2,2′-dihydroxy-4,4′-dimethoxybenzophenone, 2-hydroxy-4-n-octyloxybenzophenone, 2,2′-dihydroxy-4-methoxybenzophenone and 2-hydroxy-4-methoxybenzophenone.

(94) Said antioxidant can be a free-radical chain blocking agent and/or peroxide decomposer.

(95) Said peroxide decomposer is preferably thioesters and/or phosphites.

(96) The amount of said antioxidant or UV absorber is preferably in a range of 0.5-5 wt. %, based on the amount of said composition as 100 wt. %.

(97) The isocyanate index of said composition is preferably in a range of 100-120.

(98) A Method for Preparing a Flexible Foam

(99) The mixing of each of the components of said step i can be carried out at the same time.

(100) The mixing of each of the components of said step i can also be carried out step by step. For example, the components except for component a and component d of said composition are mixed previously, followed by adding said component d and finally adding component a.

(101) The cream time of said method is preferably not more than 35 seconds, and the rise time is preferably not more than 300 seconds.

(102) The cream time refers to the period required for starting from the mixing of the isocyanate mixture and other components in the composition till the obtained mixture turns into a whitish cream.

(103) The rise time refers to the period required for starting from the mixing of the isocyanate mixture and other components in the composition till the completion of the foaming.

(104) The component b can be premixed or each of the polyether polyols can also be added one by one. Preference is given to the former.

(105) The component a can be premixed or each of the isocyanates can also be added one by one. Preference is given to the former.

(106) Flexible Foam

(107) The density of said flexible foam can be in a range of 20-120 kg/m.sup.3, and preferably in a range of 20-80 kg/m.sup.3.

(108) The air flow rate of said flexible foam is preferably not less than 30 L/min; the drop-ball rebound rate is preferably not less than 35%; the UV stability is preferably not less than 4; and the washing deformation rate is preferably zero.

(109) Use for Manufacturing a Fabric

(110) Said fabric can be a pillow, a back cushion, a garment pad, or a vamp.

EXAMPLES

(111) All technical and scientific terms used herein share the same meaning as generally understood by a person skilled in the art, unless otherwise defined. In case of conflict between the definitions of terms in this specification and the meanings generally understood by a person skilled in the art, the definitions set forth herein shall control.

(112) All values for expressing the amounts of ingredients and reaction conditions, etc. used in the specification and claims are to be understood as being modified by the term “about”, unless otherwise specified. Therefore, the numerical parameters set forth herein are approximations that can vary depending upon the desired properties required to be Obtained, unless indicated to the contrary.

(113) As used herein, “and/or” refers to one or all of the elements mentioned.

(114) As used herein, “including” and “comprising” covers the situation of only the recited elements existing and the situation of other elements not mentioned existing besides the recited elements.

(115) All percentages in the present invention are percentages by weight, unless otherwise specified.

(116) The analytical measurements of the present invention were performed at 23° C., unless otherwise specified.

(117) The number average molecular weight was determined at 23° C. by gel permeation chromatography using tetrahydrofuran as the mobile phase with reference to polystyrene standard.

(118) The hydroxy/value was determined according to ASTM D4274.

(119) The isocyanate group (NCO) content was determined by volume according to DIN-EN ISO 11909 and the data obtained includes the free and potentially free NCO content.

(120) The viscosity was measured using a DV-II+Pro, rotational viscometer available from Brookfield Company according to DIN 53019 at 23° C.

(121) Isocyanate index=(total mole number of NCO of the composition/total mole number of NCO reactive components of the composition)*100.

(122) The ethylene oxide content in the polyether polyol refers to the percentage by weight of the ethylene oxide component based on all components for preparing the polyether polyol during the preparation of the polyether polyol.

(123) Calculation method of the isocyanate group content in the isocyanate mixture: Σ(weight of each of the isocyanate components×corresponding isocyanate group content (NCO %))/sum of the weight of each of the isocyanate components. The isocyanate group content in the isocyanate mixture can also be determined by volume according to DIN-EN ISO 11909, and the data obtained includes the free and potentially free NCO content.

(124) Raw Materials and Reagents

(125) Desmodur® I: isophorone diisocyanate (IPDI), having an isocyanate group (NCO) content of 37.5±0.5%, a viscosity of 10 mPa.Math.s and a NCO functionality of 2, purchased from Covestro Polymers (China) Co., Ltd.

(126) Desmodur® W: dicyclohexylmethane diisocyanate (H.sub.12MDI), having a NCO group content of 31.8%+0.5%, a viscosity of 30 mPa.Math.s and a NCO functionality of 2, purchased from Covestro Polymers (China) Co., Ltd.

(127) Desmodur XP2838: isophorone diisocyanate trimer, having a NCO content of 21±0.5%, a HDI monomer content of <0.2%, a IPDI monomer content of <0.15% and a viscosity (23° C.) of 2700 mPa.Math.s, purchased from Covestro Polymers (China) Co., Ltd.

(128) Desomodur N7300: 1,5-pentamethylene diisocyanate trimer (hereinafter abbreviated as PDI trimer), having a NCO content of 21.5% and a viscosity of 9500 mPa.Math.s, purchased from Covestro Polymers (China) Co., Ltd.

(129) Desomodur N3600: hexamethylene diisocyanate trimer, having a NCO content of 23±0.5%, a HDI monomer content of <0.25% and a viscosity of 1100 mPa.Math.s, purchased from Covestro Polymers (China) Co., Ltd.

(130) Desomodur N3300: hexamethylene diisocyanate trimer, having a NCO content of 21.8±10.3%, a HDI monomer content of <0.15% and a viscosity of 2500 mPa.Math.s, purchased from Covestro Polymers (China) Co., Ltd.

(131) Arcol Polyol 3553: a polyether triol having a hydroxyl value of approximately 35 mg KOH/g, a number average molecular weight of 4800 g/mol, a viscosity of 1000 mPa.Math.s, a hydroxyl functionality of 3 and a EO content of 14 wt. %, purchased from Covestro Polymers (China) Co., Ltd.

(132) Arcol Polyol 1362: a polyether triol having a hydroxyl value of approximately 28 mg KOH/g, a number average molecular weight of 6000 g/mol, a viscosity of 1200±200 mPa.Math.s, a hydroxyl functionality of 3 and a EO content of 15 wt. %, purchased from Covestro Polymers (China) Co., Ltd.

(133) Arcol Polyol 1026: a polyether diol having a hydroxyl value of approximately 28 mg KOH/g, a number average molecular weight of 4000 g/mol, a viscosity of 880±100 mPa.Math.s, a hydroxyl functionality of 2 and a EU content of 20 wt. %, purchased from Covestro Polymers (China) Co., Ltd.

(134) Bayflex VP PU 191F03: a high active polyether polyol having a hydroxyl value of approximately 37 mg KOH/g, a number average molecular weight of 4550 g/mol, a viscosity of approximately 1070 mPa.Math.s, a hydroxyl functionality of 3 and a EO content of 71 wt. %, purchased from Covestro Polymers (China) Co., Ltd.

(135) Arcol Polyol 1071: a polyether triol having a hydroxyl value of approximately 235 mg KOH/g, a number average molecular weight of 700 g/mol, a viscosity of approximately 250 mPa.Math.s and a hydroxyl functionality of 3, purchased from Covestro Polymers (China) Co., Ltd.

(136) Arcol Polyol 5603: a polyether triol having a hydroxyl value of approximately 56 mg KOH/g, number average molecular weight of 3000 g/mol, a viscosity of 530 mPa.Math.s and a hydroxyl functionality of 3, purchased from Covestro Polymers (China) Co., Ltd.

(137) GLY: glycerin, with a purity of ≥99%, purchased from Sinopharm Chemical Reagents Co., Ltd., used as an isocyanate-reactive group comprising compound having a number average molecular weight of 32-400 g/mol.

(138) TEOA: triethanolamine, with a purity of ≥99.0%, purchased from Sinopharm Chemical Reagents Co., Ltd., used as an isocyanate-reactive group comprising compound having a number average molecular weight of 32-400 g/mol.

(139) DEOA: diethanolamine, with a purity of ≥99.0%, purchased from Sinopharm Chemical Reagents Co., Ltd., used as an isocyanate-reactive group comprising compound having a number average molecular weight of 32-400 g/mol.

(140) Sodium carbonate aqueous solution: sodium carbonate was weighed and dissolved in water to obtain an aqueous solution with a mass fraction (sodium carbonate) of 10%. The sodium carbonate solid has a purity of ≥99.0%, and is purchased from Sinopharm Chemical Reagents Co. LTD; and the water is produced using the Ming-Che-D24UV Water Purification Unit available from Millipore Co., Ltd.

(141) Niax silicone Y-10366: a surfactant, purchased from Momentive Performance Materials Inc., used as an additive.

(142) Niax CS_22LF: a surfactant, having a hydroxyl value of approximately 350 mg KOH/g and a viscosity (23° C.) of 650 mPa.Math.s, purchased from Momentive Performance Materials Inc., used as an additive.

(143) Dabco T-9: stannous octoate, a catalyst, purchased from American Air Products & Chemicals Inc., Ltd, used as a catalyst.

(144) Test Method

(145) Foam density: measured according to the standard ASTM D3574.

(146) Drop-ball rebound rate: measured according to the standard ASTM D3574.

(147) Compression force deflection at 40%: CFD (Compression Force Deflection) 40%, measured according to the standard ASTM D3574.

(148) Tensile strength: Measured according to the standard ASTM D3574.

(149) Elongation: measured according to the standard ASTM D3574.

(150) Air flow rate: measured with IDM's F0023 digital foam porosity tester according to the standard ASTM D3574 under the test conditions of 23° C., at 1 atm. When the foam with a dimension (length×width×height) of 50 mm×50 mm×25 mm is kept under a pressure difference of 125 Pa, the volume of air passing through the foam per unit time is measured to obtain an air flow rate in a unit of L/min.

(151) UV stability: measured with Q-Lab's QUV/se UV accelerated weathering tester according to the standard GB/T 23983-2009. The test is carried out using an UVA-340 UV lamp with an irradiance of 0.68 W/m.sup.2 and a black panel temperature of (60±3)° C. in exposure to light for continuous 24 hours. The result is expressed in a scale of 1-5 compared with a standard grayscale card.

(152) Washing deformation rate: measured with a Whirlpool's 3LWTW4840YW washing machine and a 3LWED4900YW clothes dryer according to the standard AATCC 135-2012. The test is carried out using AATCC 1993 standard laundry powder, AATCC standard test fabrics TYPE 1 under ordinary water flow setting with the water temperature of 60±3° C., drum-type ordinary drying with the drying temperature of 66±5° C. and the cooling time of 10 min, and washing for once and drying for once. The foam sample has a dimension of 5 cm×5 cm×5 cm and the mark distance is 3.5 cm. The result is shown in volume change rate.

(153) Foam Test References

(154) Table 1 is the foam performance test indices and the references thereof.

(155) TABLE-US-00001 TABLE 1 Foam Performance Test Indices and References thereof. Foam performance test index References Cream time <35 s, the shorter the time, the higher the reaction efficiency of the composition. Rise time <300 s, the shorter the time, the higher the reaction efficiency of the composition. Drop-ball >50%, the greater the percentage value, rebound rate the higher the rebound resilience of the foam. Air flow rate ≥30 L/min. the greater the air flow rate, the better the breathability of the foam. Washing 0 indicates that the foam has a good deformation rate washing resistance and is not easily deformable; negative values indicate foam is susceptible to deformation. UV stability 1.fwdarw.5, scales 4 and 5 represents that there is no color change visible to the naked eye, indicating that the foam is not susceptible to yellowing. Scale 1 refers to that the foam becomes dark and is susceptible to yellowing.

(156) The tensile strength and elongation indices of the foam indicate its tensile and ductibility; and CFD 40% of the foam indicates its tunability in hardness and hand feel.

(157) Preparation of Flexible Foam Campus

(158) According to the components shown in Table 2 and Table 3, each of the components was stored in a room at 23° C. for at least 24 hours. In a 1.5-liter stainless steel cup or plastic beaker, the components except for the isocyanates and the catalyst were premixed within 40 seconds using a Pendraulic mixer at a rotation speed of 1500 rpm. The catalyst was then added into the cup and stirred continuously for additional 20 seconds using the Pendraulic mixer at a rotation speed of 1500 rpm. Each of the isocyanate components were then added into the cup and stirred for 7 seconds using the Pendraulic mixer at a rotation speed of 3000 rpm to obtain a mixture. The mixture was poured into a paper-lined wooden box of 45 cm (length)×45 cm (width)×45 cm (height) opened at the top to foaming. When the foam height no longer changed, the form was removed from the wooden box after standing for 10 minutes and then stored in a ventilated room at 23° C. for at least 72 hours.

(159) Foam samples of various dimensions which met the test requirements were cut out from the foam using an electric saw machine. The foam samples were placed hermetically in a room with a humidity of 50% at 23° C. for at least 24 hours before each of the properties of the foam samples was tested.

(160) TABLE-US-00002 TABLE 2 Components of the Compositions of Examples 1-12 and Properties of Flexible Foams Exam- Exam- Exam- Exam- Exam- Exam- Exam- ple 1 ple 2 ple 3 ple 4 Example 5 Example 6 Example 7 Example 8 Example 9 ple 10 ple 11 ple 12 Components, unit: g Arcol Polyol 3553 200 Arcol Polyol 1362 200 200 200 200 200 200 200 200 200 200 Arcol Polyol 1026 200 Bayflex VP PU 24 8 12 12 12 20 10 12 12 15 48 2 19IF03 Arcol Polyol 1071 20 10 Desmodur I 116 102 109 108 118 105 107 108 108 54 103 104 Desmodur W 54 Desmodur XP2838 1 Desomodur N7300 26 Desomodur N3600 12 13 12 19 12 12 26 Desomodur N3300 12 27 18 GLY 3.5 3.5 TEOA 5.74 5.74 5.74 5.74 5.74 5.74 5.74 5.74 5.74 5.74 DEOA 4 4 4 4 4 4 4 4 4 4 4 4 Sodium carbonate 6.1 6.1 6.1 6.1 6.1 6.1 6.1 6.1 6.1 6.1 6.1 6.1 aqueous solution Niax silicone Y- 6 6 6 12 6 6 6 6 6 6 6 6 10366 Niax CS_22LF 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 Dabco T-9 4 4 4 4 4 4 4 4 4 4 4 4 Isocyanate index 108 108 108 108 108 108 108 108 108 108 108 108 Properties of Flexible Foams Visual appearance ok ok ok ok ok ok ok ok ok ok ok ok Cream time (s) 23 21 30 22 25 25 23 30 19 28 27 17 Rise time (s) 197 145 163 151 168 170 145 111 121 191 225 114 Foam density 47.2 45.7 37.7 45.8 47.7 49.6 46.3 48.1 41.7 58.2 61.0 47.6 (kg/m.sup.3) Drop-ball rebound 64 64 52 59 50 55 58 58 54 69 63 64 rate (%) CFD 40% (kPa) 2.6 2.5 2.9 2.6 3.7 2.2 3.6 2.4 1.8 3.1 2.2 3.0 Tensile strength 121.5 116.6 135.8 121.8 127.0 82.0 140.8 128.2 127.2 73.7 37.8 144 (kPa) Elongation (%) 147 140 147 151 148 124 137 170 220 94 74.9 153.7 Air flow rate 71 69 43 59 67 57 30 45 51 61 55 68 (L/min) UV stability 5 5 5 5 5 5 5 5 5 5 5 5 Washing deformation 0 0 0 0 0 0 0 0 0 0 0 0 rate (%)

(161) It can be seen from Table 2 that the cream time and rise time of the composition of the examples according to the present invention are short and the reaction efficiency is high. The flexible polyurethane foams prepared from the composition of the examples according to the present invention not only have good tensile strength, ductility, hardness and hand feel tunability, but also have good non-yellowing property, rebound resilience, breathability, and washing resistance. Thus said foams can meet the requirements for flexible polyurethane foams in the textile industry.

(162) TABLE-US-00003 TABLE 3 Components of the Compositions of Comparative Examples 1-6 and Properties of Flexible Foams Comparative Comparative Comparative Comparative Comparative Comparative Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Components of the Comparative Examples Arcol Polyol 3553 Arcol Polyol 1362 200 200 200 200 Arcol Polyol 5603 200 200 Bayflex VP PU 19IF03 12 65 10 12 Desmodur I 116 112 106 115 1.9 Desmodur W 150 Desomodur N3600 14 20 186 Desomodur N3300 15 GLY 3.5 3.5 3.5 TEOA 5.74 5.74 5.74 DEOA 4 4 4 4 4 4 Sodium carbonate aqueous 6.1 6.1 6.1 6.1 6.1 6.1 solution Niax silicone Y-10366 6 6 6 12 6 6 Niax CS_22LF 1.5 1.5 1.5 1.5 1.5 1.5 Debco T-9 4 4 4 4 4 4 Isocynate index 108 108 108 108 108 108 Properties of Flexible Foams of the Comparative Examples Visual appearance Ok Severe cell collapse Ok Severe Foam breaking shrinkage shrinkage and powdering Cream time (s) 28 90 40 38 28 84 Rise time (s) 114 >480 191 120 180 >300 Foam density (kg/m.sup.3) 43.7 / / 53.1 / / Drop-ball rebound rate 56 / / 69 / / (%) CFD 40% (kPa) 2.6 / / 3.9 / / Tensile strength (kPa) 151.4 / / 173 / / Elongation (%) 184 / / 113.6 / / Air flow rate (L/min) 24 / / 36 / / UV stability 5 / / 5 / / Washing deformation −25.2 / / −18.0 / / rate (%)

(163) By comparing the foam properties of Example 8 and Comparative Example 1, the composition of Comparative Example 1 does not comprise an isocyanate trimer. The foam prepared has poor breathability and poor washing resistance.

(164) By comparing Example 3 and Comparative Example 4, the composition of Comparative Example 4 which does not comprise the second polyether polyol has a long cream time and a low reaction efficiency. The foam prepared has poor washing resistance.

(165) By comparing Example 7 and Comparative Example 5, the composition of Comparative Example 5 does not comprise the first polyether polyol. The foam prepared therefrom severely shrinks which leads to a failure in the performance testing.

(166) It can be seen from Comparative Example 2 that when the composition does not comprise the second polyether polyol and the isocyanate trimer, the composition has a long cream time, a long rise time and a low reaction efficiency. And the foam prepared severely shrinks which leads to a failure in the performance testing.

(167) It can be seen from Comparative Example 3 that when the mass ratio of the first polyether polyol to the second polyether polyol of the composition is less than 4:1, the cream time is long and the reaction efficiency is low. The foam prepared collapses which leads to a failure in the performance testing.

(168) It can be seen from Comparative Example 6 that when the mass ratio of the isocyanate monomer to the trimer of the composition is less than 3:1, the cream time is long, the rise time is long and the reaction efficiency is low. The foam prepared breaks and shatters into powder which leads to a failure in the performance testing.

(169) It is easily known for a person skilled in the art that the present invention is not limited to the specific details as described above. The present invention may be embodied in other specific forms without departing from the spirit or main characteristics of the present invention. The embodiments as described are therefore to be considered in all respects as illustrative instead of restrictive, so that the scope of the invention is indicated by the claims rather than the foregoing description; and thus any changes should be regarded as belonging to the present invention as long as the changes are within the meaning and scope of the equivalents of the claims.