COMPRESSION SET

Abstract

What are described are shaped hot-cure flexible PU foam articles, preferably mattresses and/or cushions, wherein the hot-cure flexible polyurethane foam has been obtained by reaction of at least one polyol component and at least one isocyanate component in the presence of at least one compound of formula (1a) and at least one compound of formula (1b) and at least one blowing agent and at least one catalyst.

Claims

1. A shaped hot-cure flexible polyurethane foam article, mattress and/or cushion, wherein the hot-cure flexible PU foam was obtained by reaction of at least one polyol component and at least one isocyanate component in the presence of at least one compound of formula (Ta) and at least one compound of formula (b) and at least one blowing agent and at least one catalyst, where
[R.sup.1Me.sub.2SiO.sub.1/2].sub.a[Me.sub.2SiO.sub.2/2].sub.b[R.sup.2MeSiO.sub.2/2].sub.c[MeSiO.sub.3/2].sub.d[SiO.sub.4/2].sub.e  Formula (1a) with a=2 to 10, b=25 to 200, c=2 to 40, d=0 to 10, e=0 to 5, where: a+b+c+d+e>48 R.sup.1=Me or R.sup.2 R.sup.2=identical or different polyethers obtainable from the polymerization of ethylene oxide, propylene oxide and/or other alkylene oxides such as butylene oxide or styrene oxide, ##STR00005## and where
[R.sup.4Me.sub.2SiO.sub.1/2].sub.i[Me.sub.2SiO.sub.2/2].sub.j[R.sup.5MeSiO.sub.2/2].sub.k[MeSiO.sub.3/2].sub.l[SiO.sub.4/2].sub.m  Formula (1b) with i=2 to 10, j=0 to 20, k=0 to 20, l=0 to 10, m=0 to 5, where: i+j+k+l+m<20 R.sup.4=Me or R.sup.5 R.sup.5=identical or different polyethers obtained from the polymerization of ethylene oxide, propylene oxide and/or other alkylene oxides such as butylene oxide or styrene oxide, ##STR00006## R.sup.6=OH, alkyl or acetyl.

2. The shaped hot-cure flexible polyurethane foam article according to claim 1, wherein the hot-cure flexible polyurethane foam has a porosity of 1 to 6 scfm.

3. The shaped hot-cure flexible polyurethane foam article according to claim 1, wherein the hot-cure flexible polyurethane foam has a rebound resilience of 1% to 50%, measured in accordance with DIN EN ISO 8307:2008-03, and/or a foam density of 5 to 150 kg/m.sup.3 and/or a porosity of 1 to 6 scfm.

4. The shaped hot-cure flexible polyurethane foam article according to claim 1, wherein the hot-cure flexible polyurethane foam has a compressive strength CLD, 40% in accordance with DIN EN ISO 3386-1:2015-10, of 0.1 to 8.0 kPa.

5. The shaped hot-cure flexible polyurethane foam article according to claim 1, wherein the hot-cure flexible polyurethane foam has a compressive strength CLD, 40% in accordance with DIN EN ISO 3386-1:2015-10, of 2.0-8.0 kPa and/or a rebound resilience of 15-50%, measured in accordance with DIN EN ISO 8307:2008-03, and/or a foam density of 8 to 80 kg/m.sup.3 and/or a porosity of 1 to 6 scfm.

6. The shaped hot-cure flexible polyurethane foam article according to claim 1, wherein the hot-cure flexible polyurethane foam is a viscoelastic flexible polyurethane foam and preferably has a glass transition temperature between −20° C. and +15° C. and/or a compressive strength CLD, 40% in accordance with DIN EN ISO 3386-1:2015-10, of 0.1-5.0 kPa, in particular 0.5-2.5 kPa, and/or a rebound resilience of <10%, measured in accordance with DIN EN ISO 8307:2008-03, and/or a foam density of 30 to 130 kg/m.sup.3 and/or a porosity of 1 to 6 scfm.

7. The shaped hot-cure flexible polyurethane foam article according to claim 1, wherein the shaped article has a height of from at least 1 cm to not more than 50 cm and a width of from at least 20 cm to not more than 300 cm, and a length of from at least 20 cm to not more than 300 cm.

8. The shaped hot-cure flexible polyurethane foam article according to claim 1, wherein based on its starting volume the shaped PU foam article is compressed by at least 20%, preferably 30%, and kept in compressed form by an auxiliary means, especially packaging means, for at least 20 hours.

9. The shaped hot-cure flexible polyurethane foam article according to claim 8, wherein the shaped hot-cure flexible polyurethane foam article is in a compressed and vacuum-packed state, and is a roll-up mattress.

10. The shaped hot-cure flexible polyurethane foam article according to claim 1, wherein shaped hot-cure flexible polyurethane was obtained with additional use of recycled polyols.

11. The shaped hot-cure flexible polyurethane foam article comprising a combination of at least one compound of formula (1a) and at least one compound of formula (1b), with (1a) and (1b) each as defined in claim 1, for improving the dimensional recovery of the shaped hot-cure flexible polyurethane foam articles after compression thereof over a period of at least 20 hours, wherein the shaped hot-cure flexible polyurethane foam article is 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 of at least one catalyst in the presence of at least one compound of formula (1a) and at least one compound of formula (1b), wherein the hot-cure flexible polyurethane foam has a porosity of 1.75 to 4.25 scfm.

12. A process for storing and/or for transporting shaped hot-cure flexible polyurethane foam articles, where (a) in a first step a shaped hot-cure flexible polyurethane foam article is provided by reaction of at least one polyol component and at least one isocyanate component in the presence of at least one compound of formula (1a) and at least one compound of formula (1b), with (1a) and (1b) each as defined in claim 1, and of at least one blowing agent and at least one catalyst, (b) in optional subsequent steps the shaped hot-cure flexible polyurethane foam article obtained may optionally be subjected to further processing to prepare it for the application, (c) and wherein in a final step the shaped hot-cure flexible polyurethane foam article (optionally prepared for the application) is compressed by at least 20%, based on its starting volume, and optionally vacuum-packed and kept in compressed form by auxiliary means, in particular packaging means, and sent for storage and/or transport, wherein the hot-cure flexible polyurethane foam advantageously has a porosity of 1 to 6 scfm.

13. The process according to claim 12, wherein a sufficient amount of compounds having the formula (1a) is added in step (a) that the proportion by mass thereof in the finished polyurethane foam is from 0.1% to 5% by weight, and a sufficient amount of compounds of formula (1b) is added in step (a) that the proportion by mass thereof in the finished polyurethane foam is from 0.1% to 5% by weight.

14. A process for producing hot-cure flexible polyurethane foam having a porosity of 1 to 6 scfm, by reaction of at least one polyol component and at least one isocyanate component in the presence of at least one compound of formula (1a) and at least one compound of formula (1b) and at least one blowing agent and at least one catalyst, where formulae (1a) and (1b) are defined below:
[R.sup.1Me.sub.2SiO.sub.1/2].sub.a[Me.sub.2SiO.sub.2/2].sub.b[R.sup.2MeSiO.sub.2/2].sub.c[MeSiO.sub.3/2].sub.d[SiO.sub.4/2].sub.e  Formula (1a) with a=2 to 10, b=25 to 200, c=2 to 40, d=0 to 10, e=0 to 5, where: a+b+c+d+e>48 R.sup.1=Me or R.sup.2 R.sup.2=polyethers of the general formula (c), ##STR00007## where f=0-6, g=0 to 150, h=0 to 150, preferably 0 to 100, more preferably 0 to 80 where g+h>0 R.sup.3=OH, alkyl or acetyl, and where
[R.sup.4Me.sub.2SiO.sub.1/2].sub.i[Me.sub.2SiO.sub.2/2].sub.j[R.sup.5MeSiO.sub.2/2].sub.k[MeSiO.sub.3/2].sub.l[SiO.sub.4/2].sub.m  Formula (1b) with i=2 to 10, j=0 to 20, k=0 to 20, l=0 to 10, m=0 to 5, where: i+j+k+l+m<20 R.sup.4=Me or R.sup.5 R.sup.5=polyethers of the general formula (d), or alkyl C.sub.3 to C.sub.15, ##STR00008## where n=0-6, o=0 to 100, p=0 to 100, where o+p>0 R.sup.6=OH, alkyl or acetyl, especially with additional use of recycled polyols.

15. A mattress comprising a hot-cure flexible polyurethane foam, wherein the hot-cure flexible polyurethane foam has been obtained by reaction of at least one polyol component and at least one isocyanate component in the presence of at least one compound of formula (Ta) and at least one compound of formula (Tb), with (Ta) and (Tb) each as defined in claim 1, and of at least one blowing agent and at least one catalyst, for provision of compressed mattresses having improved dimensional recovery after compression over a period of at least 20 hours, having improved emissions characteristics, wherein the hot-cure flexible polyurethane foam has a porosity of 1 to 6 scfm.

16. The mixture comprising at least one compound of the formula (1b) and at least one compound of the formula (1a), with (1a) and (1b) each as defined in claim 1, and/or glycols, polyethers, organic esters and/or other solvents suitable for the purposes of flexible polyurethane foam production.

17. The shaped hot-cure flexible polyurethane foam article according to claim 1, wherein the hot-cure flexible polyurethane foam has a porosity of 1.5 to 4.5 scfm, wherein
[R.sup.1Me.sub.2SiO.sub.1/2].sub.a[Me.sub.2SiO.sub.2/2].sub.b[R.sup.2MeSiO.sub.2/2].sub.c[MeSiO.sub.3/2].sub.d[SiO.sub.4/2].sub.e  Formula (1a) with a=2 to 8, b=40 to 150, c=2 to 30, d=0 to 8, e=0 to 3, where: a+b+c+d+e>48 R.sup.1=Me or R.sup.2 R.sup.2=polyethers of the general formula (c), ##STR00009## where f=0-4, g=3 to 100, h=0 to 100, where g+h>0 R.sup.3=OH, methyl, acetyl or butyl, and where
[R.sup.4Me.sub.2SiO.sub.1/2].sub.i[Me.sub.2SiO.sub.2/2].sub.j[R.sup.5MeSiO.sub.2/2].sub.k[MeSiO.sub.3/2].sub.l[SiO.sub.4/2].sub.m  Formula (1b) with i=2 to 8, j=0 to 18, k=0 to 15, l=0 to 8, m=0 to 3, where: i+j+k+l+m<20 R.sup.4=Me or R.sup.5 R.sup.5=polyethers of the general formula (d), or alkyl C.sub.3 to C.sub.15, ##STR00010## where n=0-6, o=0 to 50, p=0 to 100, where o+p>0 R.sup.6=OH, methyl, acetyl or butyl.

18. The shaped hot-cure flexible polyurethane foam article according to claim 1, wherein the hot-cure flexible polyurethane foam has a porosity of 1.75 to 4.25-scfm, wherein
[R.sup.1Me.sub.2SiO.sub.1/2].sub.a[Me.sub.2SiO.sub.2/2].sub.b[R.sup.2MeSiO.sub.2/2].sub.c[MeSiO.sub.3/2].sub.d[SiO.sub.4/2].sub.e  Formula (1a) with a=2 to 5, b=40 to 150, c=2 to 40, d=0 to 10, e=0 to 5, where: a+b+c+d+e>48 R.sup.1=Me or R.sup.2 R.sup.2=polyethers of the general formula (c), ##STR00011## where f=0-6, g=0 to 150, h=0 to 150, where g+h>0 R.sup.3=OH, alkyl or acetyl, and where
[R.sup.4Me.sub.2SiO.sub.1/2].sub.i[Me.sub.2SiO.sub.2/2].sub.j[R.sup.5MeSiO.sub.2/2].sub.k[MeSiO.sub.3/2].sub.l[SiO.sub.4/2].sub.m  Formula (1b) with i=2 to 10, j=0 to 20, k=0 to 20, l=0 to 10, m=0 to 5, where: i+j+k+l+m<20 R.sup.4=Me or R.sup.5 R.sup.5=polyethers of the general formula (d), or alkyl C.sub.3 to C.sub.15, ##STR00012## where n=0-6, o=0 to 100, p=0 to 100, where o+p>0 R.sup.6=OH, alkyl or acetyl.

19. The shaped hot-cure flexible polyurethane foam article according to claim 1, wherein the hot-cure flexible polyurethane foam has a porosity of 1.5 to 4.5 scfm, wherein
[R.sup.1Me.sub.2SiO.sub.1/2].sub.a[Me.sub.2SiO.sub.2/2].sub.b[R.sup.2MeSiO.sub.2/2].sub.c[MeSiO.sub.3/2].sub.d[SiO.sub.4/2].sub.e  Formula (1a) with a=2 to 8, b=40 to 150, c=2 to 30, d=0 to 8, e=0 to 3, where: a+b+c+d+e>48 R.sup.1=Me or R.sup.2 R.sup.2=polyethers of the general formula (c), ##STR00013## where f=0-4, g=3 to 100, h=0 to 100, where g+h>0 R.sup.3=OH, methyl, acetyl or butyl and where
[R.sup.4Me.sub.2SiO.sub.1/2].sub.i[Me.sub.2SiO.sub.2/2].sub.j[R.sup.5MeSiO.sub.2/2].sub.k[MeSiO.sub.3/2].sub.l[SiO.sub.4/2].sub.m  Formula (1b) with i=2 to 8, j=0 to 18, k=0 to 15, =0 to 8, m=0 to 3, where: i+j+k+l+m<20 R.sup.4=Me or R.sup.5 R.sup.5=polyethers of the general formula (d), or alkyl C.sub.3 to C.sub.15, ##STR00014## where n=0-4, o=0 to 50, p=0 to 50, where o+p>0 R.sup.6=OH, methyl, acetyl or butyl.

20. The shaped hot-cure flexible polyurethane foam article according to claim 1, wherein the hot-cure flexible polyurethane foam has a porosity of 1.5 to 4.5 scfm, wherein
[R.sup.1Me.sub.2SiO.sub.1/2].sub.a[Me.sub.2SiO.sub.2/2].sub.b[R.sup.2MeSiO.sub.2/2].sub.c[MeSiO.sub.3/2].sub.d[SiO.sub.4/2].sub.e  Formula (1a) with a=2 to 8, b=40 to 150, c=2 to 30, d=0 to 8, e=0 to 3, where: a+b+c+d+e>48 R.sup.1=Me or R.sup.2 R.sup.2=polyethers of the general formula (c), ##STR00015## where f=0-3, g=3 to 70, h=0 to 80, where g+h>0 R.sup.3=OH, methyl, acetyl or butyl and where
[R.sup.4Me.sub.2SiO.sub.1/2].sub.i[Me.sub.2SiO.sub.2/2].sub.j[R.sup.5MeSiO.sub.2/2].sub.k[MeSiO.sub.3/2].sub.l[SiO.sub.4/2].sub.m  Formula (1b) with i=2 to 8, j=0 to 18, k=0 to 15, l=0 to 8, m=0 to 3, where: i+j+k+l+m<20 R.sup.4=Me or R.sup.5 R.sup.5=polyethers of the general formula (d), or alkyl C.sub.3 to C.sub.15, ##STR00016## where n=0-3, o=0 to 25, p=0 to 25, where o+p>0 R.sup.6=OH, methyl, acetyl or butyl.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0241] FIG. 1 the result of the rolling test for silicone additive 1 is plotted against the porosity.

[0242] FIG. 2 the result of the rolling test for silicone additive 2 is plotted against the porosity.

[0243] FIG. 3 the result of the rolling test for silicone additive 3 is plotted against the porosity.

[0244] For this purpose, in the figures FIG. 1 to FIG. 3, the result of the rolling test is plotted against porosity. In each case, the values for the reference (hot-cure flexible PU foam with foam stabilizer 1 only) and reference+1 part silicone additive are plotted. In order to obtain hot-cure flexible PU foams having different porosity, the same foaming operations were repeated on different days, the amount of stabilizer was varied and the amount of tin catalyst (Kosmos 29) was altered. Particularly the variation of the tin catalyst shows the desirably broad spectrum of porosity values.

[0245] It is found that significant dependence of the result of the rolling test on porosity is observed for the reference foams. Non-inventive foams having porosities up to 2.3 scfm are generally very poor in the rolling test. Conversely, non-inventive hot-cure flexible PU foams are very good in the rolling test when they are very open (scfm>4.5). Most of the industrial hot-cure flexible PU foams, however, are between 1.5 and 4.5 scfm. Within this range, significantly improved results have surprisingly been found for all foams according to the invention in the rolling test. There is generally a certain degree of scatter in the values since both the measurement of porosity and the measurement of the results of the rolling test are subject to variations. Nevertheless, a significant improvement can be discerned.

[0246] As can be seen, the inventive combination of a compound of formula (1a) with a compound of the formula (1b) shows significant advantages in the rolling deformation test on hot-cure flexible PU foams compared to the sole use of a single high molecular weight silicone component as foam stabilizer. The recovery of the original shape of the test specimens after rolling deformation was improved to a quite crucial degree. The use of exclusively low molecular weight silicone additives (compounds of the formula (1b)) leads to collapse in hot-cure flexible PU foam formulations. Combinations of a high molecular weight foam stabilizer (compounds of the formula (1a)) and low molecular weight silicone components (compounds of the formula (1b)) still show sufficient stabilization (settling of less than 2.0 cm), unchanged cell counts (14 to 15 cells per cm) and distinct advantages in the rolling test.

[0247] The hot-cure 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 are slightly increased when silicone additive 1 is added (from 40 g/m.sup.3, cf. Table 8, to 130 μg/m.sup.3, cf. Table 9), but are nevertheless still well below the typical limits for TVOC of 500 μg/m.sup.3. The silicone additive 1 is thus also highly suitable for use in low-emissions formulations.

[0248] The overall advantageousness of the invention has also been confirmed in the case of viscoelastic flexible foams.

TABLE-US-00008 TABLE 8 VOC tests according to DIN EN ISO 16000-9: 2008- 04: (reference hot-cure PU flexible foam) Sample name: Reference Instrument: 7890/5975C Sample volume: 2.0001 Mass of standard: 0.396 μg Area of standard: 129693683 Concentration Retention time equivalent to [min] Area toluene 4.6 510950 <1 μg/m.sup.3 5.1 593475 <1 μg/m.sup.3 5.9 534225 <1 μg/m.sup.3 6.4 957326 1 μg/m.sup.3 dimethylsilanediol 22.1 3381605 5 μg/m.sup.3 ethylhexanoic acid 23.5 2598228 4 μg/m.sup.3 cyclic siloxane D5 25.4 940103 1 μg/m.sup.3 29.0 8728324 13 μg/m.sup.3 branched alkanes 29.4 4122469 6 μg/m.sup.3 branched alkanes 29.6 3680639 6 μg/m.sup.3 branched alkanes 29.7 2462516 4 μg/m.sup.3 branched alkanes 41.3 542066 <1 μg/m.sup.3 Total (TVOC) 40 μg/m.sup.3 Siloxane emissions (total) 5 μg/m.sup.3

TABLE-US-00009 TABLE 9 VOC tests according to DIN EN ISO 16000-9: 2008-04: (reference hot-cure PU flexible foam + 1.0 part silicone additive 1) Sample name: Reference + silicone additive 1 Instrument: 7890/5975C Sample volume: 2.0001 Mass of standard: 0.396 μg Area of standard: 117796486 Concentration Retention time equivalent to [min] Area toluene 4.3 1241210 2 μg/m.sup.3 4.4 904874 2 μg/m.sup.3 4.6 813896 1 μg/m.sup.3 5.1 803280 1 μg/m.sup.3 6.0 1775599 3 μg/m.sup.3 benzene 6.5 1756844 3 μg/m.sup.3 dimethylsilanediol 8.8 2026275 3 μg/m.sup.3 17.3 1528105 3 μg/m.sup.3 cyclic siloxane D4 20.3 1676694 3 μg/m.sup.3 linear siloxane N4 22.1 3887341 7 μg/m.sup.3 ethylhexanoic acid 23.5 6367115 11 μg/m.sup.3 cyclic siloxane D5 26.5 8835334 15 μg/m.sup.3 linear siloxane N5 29.0 11993451 20 μg/m.sup.3 branched alkanes 29.4 5008151 8 μg/m.sup.3 branched alkanes 29.6 4203748 7 μg/m.sup.3 branched alkanes 29.7 2903703 5 μg/m.sup.3 branched alkanes 31.2 3916492 7 μg/m.sup.3 linear siloxane N6 34.3 2291055 4 μg/m.sup.3 linear siloxane N7 36.5 7455648 13 μg/m.sup.3 linear siloxane N8 38.4 4932388 8 μg/m.sup.3 linear siloxane N9 42.1 1213236 2 μg/m.sup.3 Total 130 μg/m.sup.3 (TVOC) Siloxane 67 μg/m.sup.3 emissions (total)