SHAPED FLEXIBLE PU FOAM ARTICLES

Abstract

Shaped flexible PU foam articles, preferably mattresses and/or cushions, may use a flexible polyurethane foam obtained by reaction of at least one polyol component and at least one isocyanate component in the presence of at least one blowing agent and one or more catalysts that catalyze the isocyanate-polyol and/or isocyanate-water reactions and/or isocyanate trimerization and further additives, wherein the additives include one or more organic esters.

Claims

1. A shaped flexible PU foam article, comprising: a flexible PU foam obtained by reaction of at least one polyol component and at least one isocyanate component in the presence of agents comprising a blowing agent, a catalyst suitable to catalyze isocyanate-polyol and/or isocyanate-water reactions and/or isocyanate trimerization, and a further additive, wherein the further additive comprises a first organic ester.

2. The article of claim 1, wherein the flexible PU foam is a standard flexible PU foam, a viscoelastic PU foam, an HR PU foam, or a hypersoft PU foam.

3. The article of claim 1, having a height in a range of from 1 to 50 cm and a width in a range of from 20 to 300 cm.

4. The article of claim 1, which based on its starting volume, is compressed by at least 20%, and kept in compressed form by an auxiliary material, which is optionally packaging, for at least 20 hours.

5. The article of claim 1, which is in a compressed and optionally a vacuum-packed state.

6. The article of claim 1, wherein the organic ester is of formula (I): ##STR00005## wherein R.sup.1 is an optionally substituted hydrocarbon radical, and R.sup.2 is an optionally substituted hydrocarbon radical.

7. The article of claim 1, wherein the organic ester is selected from the group consisting of octanoyl/decanoyl triglyceride, octanoyl triglyceride, ethylhexyl triglyceride, decanoyl triglyceride, glyceryl oleates, glyceryl isostearates, ethylhexyl stearate, ethylhexyl palmitate, ethylhexyl hydroxystearate, isostearyl isostearate, isostearyl palmitate, isostearyl neopentanoate, tridecyl stearate, cetearyl octanoate, coco-caprylate, coco-laprylate/caprate, C.sub.2-C.sub.15-alkyl benzoate, C.sub.2-C.sub.15-alkyl ethylhexanoate, propylene glycol dioleate, propylene glycol dicaprylate, propylene glycol dicaprylate/dicaprate, propylene glycol distearate, propylene glycol dipalmitate, propylene glycol dimyristate, propylene glycol dilaurate, propylene glycol dicocoate, propylene glycol diisostearate, pentaerythrityl tetraoctanoate, pentaerythrityl tetraethylhexanoate, pentaerythrityl tetrastearate, pentaerythrityl tetraisostearate, isopropyl myristate, isopropyl isostearate, isocetyl stearate, isopropyl palmitate, decyl cocoate, ethylhexyl cocoate, decyl oleate, cetyl octanoate, diisopentyl terephthalate, isononyl nonanoate, myristyl myristate, cetyl ricinoleate, cetearyl isononanoate, cetearyl ethylhexanoate, cetyl ethylhexanoate, cetyl palmitate, oleyl erucate, stearyl heptanoate, isocetyl palmitate, diisostearyl malate, hexyl laurate, octyldodecyl myristate, isotridecyl isononanoate, isodecyl neopentanoate, myristyl lactate, cetyl lactate, dridecyl trimellitate, octyldodecyl neopentanoate, ethylhexyl salicylate, trimethylolpropane triisostearate, trimethylolpropane tricaprylate/tricaprate, diisopropyl dimer dilinoleate, benzyl salicylate, benzyl benzoate, trioctyldodecyl citrate, triisostearyl citrate, and mixtures thereof, preferably selected from the group consisting of octanoyl/decanoyl triglyceride, octanoyl triglyceride, ethylhexyl triglyceride, decanoyl triglyceride, glyceryl oleates, glyceryl isostearates, ethylhexyl stearate, ethylhexyl palmitate, isostearyl isostearate, isostearyl palmitate, isostearyl neopentanoate, tridecyl stearate, cetearyl octanoate, coco-caprylate, coco-laprylate/caprate, C.sub.12-C.sub.15-alkyl benzoate, C.sub.12-C.sub.15-alkyl ethylhexanoate, propylene glycol dioleate, propylene glycol dicaprylate, propylene glycol dicaprylate/dicaprate, propylene glycol distearate, propylene glycol dipalmitate, propylene glycol dimyristate, propylene glycol dilaurate, propylene glycol dicocoate, propylene glycol diisostearate, pentaerythrityl tetraoctanoate, pentaerythrityl tetraethylhexanoate, pentaerythrityl tetrastearate, pentaerythrityl tetraisostearate, isopropyl myristate, isopropyl isostearate, isocetyl stearate, isopropyl palmitate, decyl cocoate, ethylhexyl cocoate, decyl oleate, cetyl octanoate, diisopentyl terephthalate, isononyl nonanoate, myristyl myristate, cetearyl isononanoate, cetearyl ethylhexanoate, cetyl ethylhexanoate, cetyl palmitate, oleyl erucate, stearyl heptanoate, isocetyl palmitate, diisostearyl malate, hexyl laurate, octyldodecyl myristate, isotridecyl isononanoate, isodecyl neopentanoate, dridecyl trimellitate, octyldodecyl neopentanoate, trimethylolpropane triisostearate, trimethylolpropane tricaprylate/tricaprate, diisopropyl dimer dilinoleate, benzyl benzoate, trioctyldodecyl citrate, triisostearyl citrate, and a mixture thereof.

8. The article of claim 1, comprising the organic ester(s) in a total range of from 0.05 to 7 wt. %, based on the entire flexible PU foam.

9. The article of claim 1, which is obtained using one or more recycled polyols, which are polymerized into the PU foam.

10. A process for improving dimensional recovery of the shaped flexible PU foam article of claim 1 after compression thereof over a period of at least 20 hours, the process comprising: reacting at least one polyol component and at least one isocyanate component in the presence of at least one blowing agent, at least one catalyst, and at least one further additive, the further additive(s) comprising an organic ester.

11. A process for storing and/or for transporting a shaped flexible PU foam article, the process comprising: (a) reacting at least one polyol component and at least one isocyanate component in the presence of at least one blowing agent, at least one catalyst, and at least one further additive comprising an organic ester, to provide a shaped flexible PU foam article; (b) optionally, subjecting the shaped flexible PU foam article to processing to prepare it for an application; (c) finally, compressing the shaped flexible PU foam article by at least 20%, based on its starting volume, and optionally vacuum-packing and keeping in compressed form by an auxiliary, optionally packaging, and sending for storage and/or transport.

12. The process of claim 11, wherein a sufficient amount of organic esters is added in the reacting (a) so that a proportion by mass thereof in a finished polyurethane foam is in a range of from 0.05 to 7 wt. %.

13. A process for producing flexible polyurethane foam, the process comprising: reacting at least one polyol component and at least one isocyanate component in the presence of at least one blowing agent, at least one catalyst, and at least one further additive, wherein the further additive(s) comprise organic esters.

14. A mattress and/or cushion, comprising the flexible PU foam obtained by the process of claim 13, wherein the at least catalyst is suitable to catalyze a isocyanate-polyol and/or isocyanate-water reaction and/or isocyanate trimerization.

15. The article of claim 1, which is a mattress.

16. The article of claim 1, which is a cushion.

17. The article of claim 1, wherein the further additive further comprises a second organic ester.

18. The article of claim 1, wherein the flexible PU foam is a standard flexible PU foam or a hypersoft PU foam.

19. The article of claim 1, wherein the flexible PU foam is a hot-cure flexible PU foam.

Description

EXAMPLES

[0165] Physical properties of the flexible PU foams:

[0166] The flexible PU foams produced were assessed according to the following physical properties a) to g): [0167] a) Rise time: The period of time between the end of mixing of the reaction components and the blow-off of the polyurethane foam. [0168] b) Rise height or foam height: the height of the free-risen foam formed after 3 minutes. Foam height is reported in centimetres (cm). [0169] c) Settling of the foam at the end of the rise phase (=fallback): The settling is found from the difference of the foam height after direct blow-off and 3 minutes after foam blow-off. The foam height is measured at the maximum in the middle of the foam crest by means of a needle secured to a centimetre scale. A negative value here describes settling of the foam after blow-off; a positive value correspondingly describes further rise of the foam. [0170] d) Number of cells per cm (cell count): This is determined visually on a cut surface (measured to DIN EN 15702). [0171] e) Foam density (FD): Determined as described in ASTM D 3574-11 under Test A by measuring the core density. Foam density is reported in kg/m.sup.3. [0172] f) Porosity determined by the flow method: In the airflow method in accordance with ASTM D 3574 (2011-00), the volume of air that flows through a defined foam specimen in a particular period of time on application of a pressure differential is determined. For this purpose, 12 test specimens having dimensions of 5 cm×5 cm×2.5 cm were cut out of each of the finished foams transverse to the direction of rise of the foam, and successively inserted into an analytical instrument constructed for this method. The construction of this instrument is described in ASTM D 3574 (2011-00). The analytical instrument generates an air pressure differential of 125 Pa between the inside of the instrument and the surrounding atmosphere by sucking just enough air in through the test specimen for the differential to be kept constant. The air flow through the test specimen is thus a measure of the porosity of the foam. Values in the range from 0-6.5 scfm (standard cubic feet per min) were measured, with lower values within the interval characterizing a more closed foam and higher values a more open foam. [0173] g) Result of the rolling test: This specific test is described in detail further down.

[0174] For the sake of completeness, the measurement principle of DIN EN ISO 16000-9:2008-04 is also elucidated hereinafter.

[0175] The materials are characterized here with regard to the type and the amount of the organic substances outgassable therefrom. The analysis method serves to ascertain emissions from materials that are used in furniture and mattresses. This is done by using test chambers to measure the emissions.

[0176] Analysis:

[0177] Test specimen: sample preparation, sampling and specimen dimensions:

[0178] The reaction mixture is introduced into a PE plastic bag which is open at the top. After the foam has risen and blown off, the PE bag is closed 3 min after the blow-off. The foam is stored in this way at room temperature for 12 hours in order to enable complete reaction, but simultaneously in order to prevent premature escape of VOCs. Subsequently, the PE bag is opened and a 7 cm×7 cm×7 cm cube is taken from the centre of the foam block and immediately wrapped in aluminium foil and sealed airtight in a PE bag. It was then transported to the analytical laboratory, and the foam cube was introduced into a cleaned 30 l glass test chamber. The conditions in the test chamber were controlled climatic conditions (temperature 21° C., air humidity 50%). Half the volume of the test chamber is exchanged per hour. After 24 hours, samples are taken from the test chamber air. Tenax adsorption tubes serve to absorb the VOCs. The Tenax tube is then heated, and the volatile substances released are cryofocused in a cold trap of a temperature-programmable evaporator with the aid of an inert gas stream. After the heating phase has ended, the cold trap is rapidly heated to 280° C. The focused substances vaporize in the process. They are subsequently separated in the gas chromatography separation column and detected by mass spectrometry. Calibration with reference substances permits a semi-quantitative estimate of the emission, expressed in “μg/m.sup.3”. The quantitative reference substance used for the VOC analysis (VOC value) is toluene. Signal peaks can be assigned to substances using their mass spectra and retention indices. The following equipment is used for the analysis: Gerstel, D-45473 Muhlheim an der Ruhr, Eberhard-Gerstel-Platz 1, Germany, TDS-3/KAS-4, Tenax® desorption tubes, Agilent Technologies 7890A (GC)/5975C (MS), column: HP Ultra2 (50 m, 0.32 mm, 0.52 μm), carrier gas: helium. More specific procedural instructions can be taken from DIN EN ISO 16000-9:2008-04.

[0179] The analytical principles of VDA 278 are also described hereinbelow for the sake of completeness.

[0180] VDA 278 analytical principles:

[0181] The materials are characterized with regard to the type and the amount of the organic substances outgassable therefrom. To this end, two semi-quantitative empirical values are determined to estimate the emission of volatile organic compounds (VOC value) and also the proportion of condensable substances (fogging value). Individual substances of the emission are also determined. In the analysis, the samples are thermally extracted and the emissions are separated by gas chromatography and detected by mass spectrometry. The overall concentrations thus obtained for the VOC fraction are arithmetically converted into toluene equivalents and provide the VOC value as a result; the FOG fraction is represented in hexadecane equivalents and provides the FOG value. The analytical method serves to determine emissions from non-metallic materials used for moulded parts in motor vehicles; they also include foams.

[0182] In thermal desorption analysis (TDS), small amounts of material are heated up in a desorption tube in a defined manner and the volatile substances which are emitted in the course of heating are cryofocused by means of an inert gas stream in a cold trap of a temperature-programmable vaporizer. After the heating phase has ended, the cold trap is rapidly heated to 280° C. The focused substances vaporize in the process. They are subsequently separated in the gas-chromatographic separation column and detected by mass spectrometry. Calibration with reference substances permits a semi-quantitative estimate of the emission, expressed in “μg/g”. The quantitative reference substances used are toluene for the VOC analysis (VOC value) and n-hexadecane for the fogging value. Signal peaks can be assigned to substances using their mass spectra and retention indices. Source: VDA 278/10.2011, www.vda.de

[0183] Analysis:

[0184] Test specimen: sample preparation, sampling and sample dimensions:

[0185] After the foams have been demoulded, they are stored at 21° C. and about 50% relative humidity for 24 hours. Samples of the moulding are then taken at suitable and representative sites distributed uniformly across the width of the (cooled) moulding. The foams are then wrapped in aluminium foil and sealed in a polyethylene bag.

[0186] The amount of the foam samples introduced into the desorption tubes is 10-15 mg in each case.

[0187] Test procedure: VOC/FOG thermal desorption:

[0188] The sealed samples are sent for direct determination immediately after receipt. The samples are weighed out on an analytical balance to an accuracy of 0.1 mg before starting the analysis and the corresponding amount of foam placed centrally in the desorption tube. A helium stream is passed over the sample and the latter heated to 90° C. for 30 minutes. All volatile substances are collected in a cold trap cooled with liquid nitrogen. After 30 minutes the cold trap is heated to 280° C. The vaporizing substances are separated from one another using the described gas chromatography column and then analysed by mass spectroscopy.

[0189] GC-MS instrument parameters.

[0190] The following instrument was used for the analysis:

[0191] from Gerstel

[0192] D 45473 Muhlheim an der Ruhr,

[0193] Eberhard-Gerstel-Platz 1 TDS-3/KAS-4

[0194] Tenax® desorption tube

[0195] Agilent Technologies 7890A (GC)/5975C (MS)

[0196] Column: HP Ultra2 (50 m, 0.32 mm, 0.52 μm)

[0197] Carrier gas: Helium

[0198] Described below is the rolling deformation test which makes it possible to test dimensional recovery after compression in the context of the present invention.

[0199] Rolling Deformation Test (“Rolling Test” for Short)

[0200] Objective:

[0201] The test has for its object to simulate the conditions of rolled mattresses in the laboratory. Since there is no meaningful industry standard for this a novel test was developed which simulates the rolling-up of mattress foams on a small scale.

[0202] Sample Preparation:

[0203] Test specimens having dimensions of 12 cm (width), 16 cm (length) and 2.5 cm (thickness) are cut out of the flexible PU foam blocks as obtained from manual foaming for example, using a band saw. A central position in the foam blocks from manual foaming is selected. The test specimen is cut out such that the rise direction of the foam during production is at right angles to the length and width of the test specimen. Test specimens are marked with a felt pen.

[0204] Test Procedure:

[0205] The test specimen is compressed with a thin metal rod of diameter 5-8 mm (e.g. metal ballpoint pen) at a 12 cm edge. The foam test specimen is then rolled up around this metal rod by hand. This significantly compresses the foam, forming a roll having a diameter of about 3-4 cm. This roll is held manually in this compressed state and pushed completely into a cardboard tube. The cardboard tube has an internal diameter of 4 cm and a length of at least 13 cm. As soon as the rolled-up foam is fully inserted in the tube the metal rod is removed. To minimize friction during removal the metal rod may be lightly greased before the rolling of the foam. The foam then fills the volume of the tube. The compression of the foam in the centre is much more severe than at the edge of the tube. The roll is then stored under controlled, constant conditions (temperature: 21° C., atmospheric humidity: 60%) for 7 days. After 168 hours the foam is manually removed from the tube and placed on an even surface, and the unrolling of the foam is observed. The expansion of the foam must not be disturbed or influenced.

[0206] Evaluation:

[0207] The shaped flexible PU foam article is left to expand for 10 minutes. The test specimens are then evaluated. The most important criterion is whether the foam has completely recovered its original thickness or—especially at the more severely compressed edge—still has compression zones. In some cases a groove from the compression is still also apparent on the surface of the test specimen. Very poor test specimens remain rolled up at one end. A slight bend in the test specimen after expansion is normal and is not considered in the assessment. The following grades were used for the evaluation:

[0208] ++++: Test specimen has fully unrolled, no compression lines or compressions apparent whatsoever, expansion occurs rapidly and completely after removal from the tube.

[0209] +++: Test specimen has fully unrolled, no compression lines or compressions apparent whatsoever, expansion occurs rapidly and is already complete after 5 min.

[0210] ++: The test specimen has regained a thickness of 2.5 cm at all sites. No indentations and grooves remain visible at the surface after 10 minutes (particularly at the more severely compressed end).

[0211] +: The test specimen has regained a thickness of 2.5 cm at all sites. However, slight indentations and grooves remain visible at the surface (particularly at the more severely compressed end).

[0212] 0: The test specimen exhibits a slight compression at the more severely compressed end. The thickness there is more than 2.0 cm but less than 2.5 cm. An indentation is clearly visible at this end.

[0213] −: Test specimen exhibits a slight compression at the more severely compressed end. The thickness of the sample there is more than 1 cm but still markedly less than 2.0 cm.

[0214] −−: Test specimen exhibits a severe compression at the more severely compressed end. The thickness of the sample there is less than 1 cm. The sample is still partly rolled up at this end.

[0215] −−−: Test specimen remains rolled up and compressed at the more severely compressed end.

[0216] −−−−: Test specimen remains rolled up and compressed almost completely.

[0217] The evaluation is preferably undertaken by at least two people. The results are documented. In the context of the present invention the evaluation was undertaken by four people who arrived at consistent results.

[0218] Deficiencies and constraints of the test: Correct dimensions of the test specimen and uniform rolling must be ensured in the test. The foam test specimen must have constant cell structure parameters, i.e. in particular a constant cell size and a constant air permeability. The metal rod must not be excessively greased so that no grease penetrates into the sample. Constant storage conditions must be maintained. Test specimens given the various evaluation grades must be kept available for comparison.

[0219] Precision of the Test:

[0220] Performance of the test with two or more people for evaluation regularly results in consistent assessments. In duplicate measurements too the same result was regularly confirmed. The test has thus proven reliable.

[0221] Hot-Cure Flexible PU Foam—Foaming Examples

Example 1: Production of Hot-Cure Flexible PU Foams (Flexible Slabstock Foam)

[0222] For the performance testing the hot-cure flexible PU foam formulation specified in Table 1 was used.

TABLE-US-00002 TABLE 1 Formulation 1 for hot-cure flexible PU foam production. Formulation 1 Parts by mass (pphp) Polyol 1.sup.1) 100 parts water 4.00 parts Tin catalyst.sup.2) 0.20-0.28 part TEGOAMIN ® DMEA.sup.3) 0.15 part TEGOSTAB ® B 8228.sup.4) 0.9 part Optionally organic ester additives.sup.6) 1.5 part Desmodur ® T 80.sup.6) 50.0 part .sup.1)Polyol 1: Voranol ® CP 3322 available from Dow Chemical, this is a glycerol-based polyether polyol having an OH number of 48 mg KOH/g and predominantly secondary OH groups, average molar mass = 3500 g/mol. .sup.2)KOSMOS ® 29, available from Evonik Industries: tin(II) salt of 2-ethylhexanoic acid. .sup.3)TEGOAMIN ® DMEA: dimethylethanolamine, available from Evonik Industries. Amine catalyst for production of polyurethane foams. .sup.4)TEGOSTAB ® B 8228, available from Evonik Industries. Foam stabilizer for the production of polyurethane foams. In the inventive experiments, organic esters were added to a hot-cure flexible PU foam formulation. The selected organic ester additives are characterized as follows: .sup.5)Organic ester 1 Ethylhexyl stearate Organic ester 2 C12-C15 alkyl benzoate Organic ester 3 octanoyl/decanoyl triglyceride .sup.6)tolyene diisocyanate T 80 (80% 2,4 isomer, 20% 2,6 isomer) from Covestro, 3 mPa .Math. s, 48% NCO, functionality 2. 400 g of polyol was used in each foaming operation; the other formulation constituents were recalculated accordingly. 1.00 part of a component denoted 1.00 g of this substance per 100 g of polyol for example.

[0223] The foaming was carried out by what is called manual mixing. Formulation 1 as specified in table 2 was used. To this end, a paper cup was charged with polyol, the respective amine catalyst mixture, the tin catalyst tin(II) 2-ethylhexanoate, water, foam stabilizer and the contents were mixed at 1000 rpm for 60 seconds with a disc stirrer. After the first stirring the isocyanate (TDI) was added to the reaction mixture and stirred at 2500 rpm for 7 s and then immediately transferred into a paper-lined box (30 cm×30 cm base area and 30 cm height). After being poured in, the foam rose up in the foaming box. In the ideal case, the foam blew off on attainment of the maximum rise height and then fell back slightly. This opened the cell membranes of the foam bubbles and an open-pore cell structure of the foam was obtained. To assess the properties, the following characteristic parameters were determined: rise time, rise height and fallback of the foam after the end of the rise phase (=settling).

[0224] Defined foam bodies were cut out of the resulting hot-cure flexible PU foam blocks and were analysed further. The following physical properties were determined on the test specimens: cell count, porosity by the flow method, foam density (FD) and rolling deformation at room temperature.

[0225] The results of the influence of the organic esters according to the invention with regard to foaming and the physical properties of the resulting hot-cure flexible PU foams are compiled in the tables that follow.

TABLE-US-00003 TABLE 2 Reference Reference Reference Organic Organic Organic (non- (non- (non- ester 1 ester 1 ester 1 inventive) inventive) inventive) (inventive) (inventive) (inventive) Amount of 0.20 0.24 0.28 0.20 0.24 0.28 Sn catalyst Additive — — — 1.5 1.5 1.5 a) Rise time (s) 103 94 89 107 97 89 b) Rise height 30.2 31.2 32.8 30.8 31.3 31.7 (cm) c) Settling (cm) −0.1 0.0 0.0 −0.2 −0.3 −0.3 d) Cell count 13 13 13 13 13 13 (per cm) e) Density 24.7 24.4 24.1 24.5 24.8 24.9 (kg/m.sup.3) f) Porosity 3.52 1.62 0.73 5.16 2.63 1.59 (SCFM) g) Rolling + − − − − − − − + + + + + − − deformation (7 d, 21° C.)

TABLE-US-00004 TABLE 3 Organic Organic Organic Organic Organic Organic ester 2 ester 2 ester 2 ester 3 ester 3 ester 3 (inventive) (inventive) (inventive) (inventive) (inventive) (inventive) Amount of 0.20 0.24 0.28 0.20 0.24 0.28 Sn catalyst Additive 1.5 1.5 1.5 1.5 1.5 1.5 a) Rise time (s) 108 98 90 107 95 92 b) Rise height 30.6 31.2 31.8 32.5 33.1 33.4 (cm) c) Settling (cm) −0.3 −0.3 −0.3 −0.2 −0.3 0.0 d) Cell count 13 13 13 13 13 13 (per cm) e) Density 25.2 25.1 24.7 25.1 24.4 24.2 (kg/m.sup.3) f) Porosity 5.29 3.01 1.00 5.18 3.07 0.38 (SCFM) g) Rolling + + + + + − − + + + + + − − − deformation (7 d, 21° C.)

[0226] The organic ester additives were investigated in comparison to reference foams without additives. This investigation was carried out under variation of the KOSMOS® T9 use level to be able to determine the effect of the inventive additives on foams of different porosity (scfm). The rolling deformation as determined by the roll test is significantly improved for the inventive foams using the organic esters as additives. The roll test result is improved by at least one and up to five categories in the rating between −−−− and ++++. The recovery of the original shape of the test specimens after rolling deformation therefor was improved to a quite crucial degree.

[0227] The flexible PU foams according to the invention are also found to have low emissions if emissions-optimized additives are used. This can be seen in the VOC tests according to DIN EN ISO 16000-9:2008-04. It is found here, in a low-emissions formulation, that total emissions not increased when organic ester 1 is added (20 μg/m.sup.3, cf. Table 4 vs. 21 μg/m.sup.3, cf. Table 5), and generally the emissions are well below the typical limits for TVOC of 500 μg/m.sup.3. The organic ester additive 1 is thus also highly suitable for use in low-emissions formulations.

TABLE-US-00005 TABLE 4 VOC test according to DIN EN ISO 16000-9:2008-04: reference hot-cure PU flexible foam Sample name: Reference Instrument: 7890/5975C Sample volume: 2.000 I   Mass of standard: 0.396 μg Area of standard: 129693683 Retention Concentration time equivalent [min] Area to toluene  4.1  665070  1 μg/m.sup.3  4.2 2919571  4 μg/m.sup.3  6.2  675481  1 μg/m.sup.3  9.5  797724  1 μg/m.sup.3 21.7 3941979  6 μg/m.sup.3 Ethylhexanoicacid 28.6 2447621  4 μg/m.sup.3 29.0 1232087  2 μg/m.sup.3 29.2  844226  1 μg/m.sup.3 Total (TVOC) 20 μg/m.sup.3

TABLE-US-00006 TABLE 5 VOC test according to DIN EN ISO 16000-9:2008-04: reference hot-cure PU flexible foam + 1.5 pphp organic ester 1 (Ethylhexyl stearate) Sample name: Reference + 1.5 pphp organic ester 1 Instrument: 7890/5975C Sample volume: 2.000 I   Mass of standard: 0.396 μg Area of standard: 129693683 Retention Concentration time equivalent [min] Area to toluene  4.0  563179 <1 μg/m.sup.3   4.2 2339607 4 μg/m.sup.3  6.2  594658 <1 μg/m.sup.3   9.5  832531 1 μg/m.sup.3 21.7 4066921 6 μg/m.sup.3 Ethylhexanoicacid 29.0 1523691 2 μg/m.sup.3 29.2 1181819 2 μg/m.sup.3 29.3  868711 1 μg/m.sup.3 30.2 1694284 3 μg/m.sup.3 30.7 1444495 2 μg/m.sup.3 42.0  369347 <1 μg/m.sup.3  Total (TVOC) 21 μg/m.sup.3 

[0228] The flexible PU foams according to the invention are also found to have low emissions if emissions-optimized additives are used. This can be seen in the VOC and FOG tests according to VDA 278. It is found here, in a low-emissions formulation, that total emissions found in the FOG value are slightly increased when organic ester additive 3 is added (from <10 μg/g, cf. Table 6, to 48 μg/g, cf. Table 7), but are nevertheless still well below the typical limits for the VOC (100 μg/g) and FOG (250 μg/g) values. The organic ester additive 3 is thus also highly suitable for use in low-emissions formulations.

TABLE-US-00007 TABLE 6 VOC test according to VDA 278: reference hot-cure PU flexible foam Sample name: Reference Instrument: 7890/5975C Amount:   6.7 mg Mass Standard: 0.492 μg  Area Standard: 114243323 Retention Concentration time equivalent [min] Area to toluene 21.6 4047508 <1 μg/g 23.2 2746716 <1 μg/g 24.5 2545816 <1 μg/g 25.5 2423983 <1 μg/g 26.3 2525536 <1 μg/g 28.7 2552234 <1 μg/g 30.5 4376449 <1 μg/g 34.4 3035015 <1 μg/g Total (TVOC) <10 μg/m.sup.3

TABLE-US-00008 TABLE 7 FOG test according to VDA 278: reference hot-cure PU flexible foam + 1.5 pphp organic ester 3 (octanoyl/decanoyl triglyceride) Sample name: Reference Instrument: 7890/5975C Amount:   6.7 mg Mass of standard: 0.429 μg  Area of standard: 132580100 Retention Concentration time equivalent [min] Area to hexadecane 10.8 128816292  4 μg/g 10.9  19814395  3 μg/g 17.4  3860142 <1 μg/g 29.7  60770214 29 μg/g Glyceroltricaprylate 36.4  24793049 12 μg/g Total (TVOC) .sup.  48 μg/m.sup.3

[0229] The overall advantageousness of the invention has also been confirmed in the case of HR and viscoelastic flexible foams.