High-resiliency polyurethane foam

Abstract

A high-resiliency polyurethane foam comprises the reaction product of an isocyanate and an isocyanate-reactive component. The isocyanate-reactive component comprises a first polyether polyol in an amount of greater than about 5 parts by weight and a second polyether polyol in an amount of less than about 80 parts by weight, with parts by weight based on the total weight of the isocyanate-reactive component. The high-resiliency polyurethane foam has a resilience of about 45 to about 70% when tested in accordance with ASTM D3574-11. A method of forming a high-resiliency polyurethane foam includes the steps of providing the isocyanate and the isocyanate-reactive component and reacting the isocyanate and the isocyanate-reactive component.

Claims

1. A high-resiliency polyurethane foam comprising a reaction product of: (A) an isocyanate; and (B) an isocyanate-reactive component comprising: i) a first polyether polyol containing alkyleneoxy units having a weight-average molecular weight of from about 4,000 to about 6,000 g/mol, a hydroxyl number of about 25 to about 35 mg KOH/g, and present in an amount of greater than about 5 to about 30 parts by weight based on the total weight of said isocyanate-reactive component, said first polyether polyol comprising: a) from about 3.5 to about 25 parts by weight ethyleneoxy units, based on the total weight of alkyleneoxy units used to form said first polyether polyol; and b) greater than about 95% propyleneoxy end caps based on a total number of end caps present in said first polyether polyol wherein said end caps comprise from about 3.5 to about 20 parts by weight propyleneoxy units based on the total weight of alkyleneoxy units used to form said first polyether polyol; and ii) a second polyether polyol, different from said first polyether polyol, having a weight-average molecular weight of from about 2,000 to about 6,000 g/mol and present in an amount of less than about 80 parts by weight based on the total weight of the isocyanate-reactive component, said second polyether polyol comprising about 100% ethyleneoxy end caps based on a total number of end caps present in said second polyether polyol and greater than about 25 parts by weight ethyleneoxy units based on the total weight of the second polyether polyol; iii) a graft polyol; wherein said high-resiliency polyurethane foam has a density of from about 1.5 to about 10 pcf and a resilience of about 45 to about 70% when tested in accordance with ASTM D3574-11.

2. A high-resiliency polyurethane foam as set forth in claim 1 wherein said first polyether polyol comprises from about 5 to about 15 parts by weight ethyleneoxy units, based on the total weight of alkyleneoxy units used to form said first polyether polyol.

3. A high-resiliency polyurethane foam as set forth in claim 1 wherein said first polyether polyol comprises greater than about 99% propyleneoxy end caps based on a total number of end caps present in said first polyether polyol.

4. A high-resiliency polyurethane foam as set forth in claim 1 wherein said first polyether polyol comprises about 100% propyleneoxy end caps based on a total number of end caps present in said first polyether polyol.

5. A high-resiliency polyurethane foam as set forth in claim 1 wherein said end caps of said first polyether polyol comprise from about 5 to about 15 parts by weight propyleneoxy units, based on the total weight of alkyleneoxy units used to form said first polyether polyol.

6. A high-resiliency polyurethane foam as set forth in claim 4 wherein said first polyether polyol is a heteric polyether polyol capped with propyleneoxy end caps.

7. A high-resiliency polyurethane foam as set forth in claim 1 wherein said first polyol is present in said isocyanate-reactive component in an amount of from about 10 to about 35 parts by weight based on the total weight of said isocyanate-reactive component.

8. A high-resiliency polyurethane foam as set forth in claim 1 wherein said second polyether polyol has a weight-average molecular weight of from about 4,000 to about 6,000 g/mol.

9. A high-resiliency polyurethane foam as set forth in claim 1 wherein said second polyether polyol is present in said isocyanate-reactive component in an amount of less than about 60 parts by weight based on the total weight of said isocyanate-reactive component.

10. A high-resiliency polyurethane foam as set forth in claim 1 wherein said first polyether polyol and said second polyether polyol are present in said isocyanate-reactive component in a weight ratio of from about 1:10 to about 1:2.

11. A high-resiliency polyurethane foam as set forth in claim 1 wherein the graft polyol includes co-polymerized styrene and acrylonitrile.

12. A high-resiliency polyurethane foam as set forth in claim 11 wherein said graft polyol is present in said isocyanate-reactive component in an amount of from about 20 to about 40 parts by weight based on the total weight of said isocyanate-reactive component.

13. A high-resiliency polyurethane foam as set forth in claim 1 wherein said isocyanate comprises toluene diisocyanate.

14. A high-resiliency polyurethane foam as set forth in claim 1 wherein said isocyanate comprises diphenylmethane diisocyanate and/or polymeric diphenylmethane diisocyanate.

15. A high-resiliency polyurethane foam as set forth in claim 1 having a support factor of greater than 2 when tested in accordance with ASTM D3574.

16. A high-resiliency polyurethane foam as set forth in claim 1 having a resilience of about 48 to about 60% when tested in accordance with ASTM D3574-11.

17. A method of forming a high-resiliency polyurethane foam comprising the steps of: providing an isocyanate; providing an isocyanate-reactive component comprising: i) a first polyether polyol containing alkyleneoxy units having a weight-average molecular weight of from about 4,000 to about 6,000 g/mol, a hydroxyl number of about 25 to about 35 mg KOH/g, and present in an amount of greater than about 5 to about 30 parts by weight based on the total weight of said isocyanate-reactive component, said first polyether polyol comprising: a) from about 3.5 to about 25 parts by weight ethyleneoxy units, based on the total weight of alkyleneoxy units used to form said first polyether polyol; and b) greater than about 95% propyleneoxy end caps based on a total number of end caps present in said first polyether polyol wherein said end caps comprise from about 3.5 to about 20 parts by weight propyleneoxy units based on the total weight of alkyleneoxy units used to form said first polyether polyol; and ii) a second polyether polyol, different from said first polyether polyol, having a weight-average molecular weight of from about 2,000 to about 6,000 g/mol and present in an amount of less than about 80 parts by weight based on the total weight of the isocyanate-reactive component, said second polyether polyol comprising about 100% ethyleneoxy end caps based on a total number of end caps present in said second polyether polyol and greater than about 25 parts by weight ethyleneoxy units based on the total weight of the second polyether polyol; iii) a graft polyol; reacting the isocyanate and the isocyanate-reactive component to form the high-resiliency polyurethane foam; wherein said high-resiliency polyurethane foam has a density of from about 1.5 to about 10 pcf and a resilience of about 45 to about 70% when tested in accordance with ASTM D3574-11.

18. A method as set forth in claim 17 wherein the first polyol is present in the isocyanate-reactive component in an amount of from about 15 to about 30 parts by weight and/or the second polyether polyol is present in the isocyanate-reactive component in an amount of less than about 60 parts by weight, with all parts by weight based on the total weight of the isocyanate-reactive component.

19. A method as set forth in claim 18 wherein the isocyanate and the first and the second polyether polyols are reacted at an isocyanate index of from about 80 to about 120.

Description

EXAMPLES

(1) Examples of HR polyurethane foams are formed with Polyols A through J, which are set forth and described in Table 1 below. Comparative Examples of HR polyurethane foams are formed with Polyols C-A, C-B, and C-C, which are also set forth and described in Table 1 below. The molded HR polyurethane foams set forth and described in Tables 2 and 3 further below utilize relatively high molecular weight PO-capped polyols set forth in Table 1 below in lieu of EO-capped polyols, which are required to produce HR polyurethane foam.

(2) TABLE-US-00001 TABLE 1 (Exemplary First Polyols) Mol. Hydroxyl Polyol End Weight % Number ID Initiator Cap Funct. (g/mol) EO (mg KOH/g) A GLY.sup.1 PO 3.0 5000 9 34.1 B GLY PO 3.0 5000 25 32.4 C GLY/DPG.sup.2 PO 2.6 5000 9 31.3 D GLY/DPG PO 2.6 5500 25 29.3 E GLY/DPG PO 2.6 5500 9 29.8 F GLY/DPG PO 2.6 5500 7 29.9 G GLY/DPG PO 2.6 5500 5 28.4 H GLY/DPG PO 2.6 5500 3.5 27.9 I GLY/DPG PO 2.6 5500 0 28.3 J TMP.sup.3/DPG PO 2.6 5500 7 27.6 C-A GLY PO 3.0 3000 10 56 C-B GLY PO/EO 3.0 3000 25 56 C-C GLY PO 3.0 3000 7 56 .sup.1Glycerin .sup.2Dipropyleneglycol .sup.3Trimethylpropane

(3) Referring now to Tables 2 and 3, Examples 1 through 10 are described. Examples 1 through 10 are HR polyurethane foams formed in accordance with the instant disclosure. The amount and type of each component used to form each Example is indicated in Tables 2 and 3 with all values in parts by weight, based on 100 parts by weight of the Isocyanate-reactive Component.

(4) TABLE-US-00002 TABLE 2 Ex. Ex. Ex. Ex. Ex. Ex. Ex. Ex. Ex. Ex. Component 1a 1b 2a 2b 3a 3b 4a 4b 5a 5b Isocyanate-reactive Component Polyol A 5 20 Polyol B 5 20 Polyol C 5 25 Polyol D 5 20 Polyol E 5 30 Polyol K 73 58 73 58 73 58 73 58 73 58 (Second Polyol) Polyol L 22 22 22 22 22 22 22 22 22 22 (Graft Polyol) Catalyst A 1.40 1.40 1.40 1.40 1.40 1.40 1.40 1.40 1.40 1.40 Catalyst B 0.32 0.32 0.32 0.32 0.32 0.32 0.32 0.32 0.32 0.32 Catalyst C 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 Water 4.07 4.07 4.07 4.07 4.07 4.07 4.07 4.07 4.07 4.07 Surfactant 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 A Isocyanate TDI Index 100 100 100 100 100 100 100 100 100 100

(5) Polyols A through E are described in Table 1.

(6) Polyol K is an EO-end capped polyol.

(7) Polyol L is a graft polyol.

(8) Catalyst A is Diethanol amine.

(9) Catalyst B is a solution of 33% by weight triethylenediamine and 67% by weight dipropylene glycol.

(10) Catalyst C is 70% bis(2-Dimethylaminoethyl) ether diluted with 30% dipropylene glycol.

(11) Surfactant A is a silicone glycol copolymer.

(12) Isocyanate is toluene diisocyanate (TDI).

(13) TABLE-US-00003 TABLE 3 Ex. Ex. Ex. Ex. Ex. Ex. Ex. Ex. Ex. Ex. Component 6a 6b 7a 7b 8a 8b 9a 9b 10a 10b HR Isocyanate-reactive Component Polyol F 5 20 Polyol G 5 20 Polyol H 5 20 Polyol I 5 20 Polyol J 5 20 Polyol K 73 58 73 58 73 58 73 58 73 58 (Second Polyol) Polyol L 22 22 22 22 22 22 22 22 22 22 (Graft Polyol) Catalyst A 1.40 1.40 1.40 1.40 1.40 1.40 1.40 1.40 1.40 1.40 Catalyst B 0.32 0.32 0.32 0.32 0.32 0.32 0.32 0.32 0.32 0.32 Catalyst C 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.8 0.08 Water 4.07 4.07 4.07 4.07 4.07 4.07 4.07 4.07 4.07 4.07 Surfactant 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 A Isocyanate TDI Index 100 100 100 100 100 100 100 100 100 100

(14) All of the components in Table 3 are described in Table 1 and in reference to Table 2.

(15) Referring now to Table 4, Comparative Examples 1 and 2 are described. Comparative Examples 1 and 2 are HR polyurethane foams which are not formed in accordance with the instant disclosure, and are included for comparative purposes. The amount and type of each component used to form these comparative examples is indicated in Table 4 with all values in parts by weight, based on 100 parts by weight of the Isocyanate-reactive Component.

(16) TABLE-US-00004 TABLE 4 Comp. Comp. Component Ex. 1 Ex. 2 Ex. 6b Isocyanate-reactive Component Polyol I 20 Polyol C-A 5 Polyol K 73 78 58 (Second Polyol) Polyol L 22 22 22 (Graft Polyol) Catalyst A 1.40 1.40 1.40 Catalyst B 0.32 0.32 0.32 Catalyst C 0.08 0.08 0.08 Water 4.07 4.07 4.07 Surfactant A 1.00 1.00 1.00 Isocyanate TDI Index 100 100 100

(17) Examples 1 through 10 and Comparative Examples 1 and 2 are tested for density (g/cm.sup.3), tensile strength (PSI), elongation (%), tear graves (ppi), IFD (%), and resilience (%) (all key performance properties for HR polyurethane foam). Surprisingly, when Polyol K, which is EO-end capped, is partially displaced with Polyols A-1, which are higher molecular weight polyether polyols having PO/EO-heteric chains and PO end caps, in the HR Isocyanate-reactive Component, Polyols A-I could be utilized in the HR Isocyanate-reactive Component at a loading of up to 30% by weight, based on 100 parts by weight of the HR Isocyanate-reactive Component without negatively impacting the performance properties of the HR polyurethane foams formed therefrom. However, when Polyol K, which is EO-end capped, is partially displaced with comparative polyols C-A, C-B, and C-C, which are lower molecular weight polyether polyols having PO/EO-heteric chains and PO end caps, in an HR Isocyanate-reactive Component, these comparative polyols could only be utilized in the HR Isocyanate-reactive Component at a loading of up to 5% by weight, based on 100 parts by weight of the HR Isocyanate-reactive Component without sacrificing performance properties in the HR polyurethane foams formed therefrom.

(18) For example, Table 5 sets forth the performance properties of HR Polyurethane Example 6b which is formed with an HR Isocyanate-reactive Component including Polyol F in an amount of 20% by weight, based on 100 parts by weight of the HR Isocyanate-reactive Component (20% of Polyol K is displaced). Table 5 also sets forth the performance properties of Comparative Examples 1 and 2. Comparative Example 1 is formed with an HR Isocyanate-reactive Component including Polyol C-A in an amount of just 5% by weight, based on 100 parts by weight of the HR Isocyanate-reactive Component (only 5% of Polyol K is displaced). Comparative Example 2 is formed with an HR Isocyanate-reactive Component including 78% Polyol K, based on 100 parts by weight of the HR Isocyanate-reactive Component (none of the Polyol K is displaced). Example 6b of Table 5 demonstrates that Polyol K, which is EO-end capped, can be partially displaced with 20% Polyol F, which is relatively high molecular weight (5500 g/mol) and PO-end capped, to form molded HR foam which exhibits excellent performance properties. In contrast. Comparative Example 1 demonstrates that no more than 5% of Polyol K can be replaced with polyol C-A (3000 g/mol) to form molded HR foam which exhibits excellent performance properties. Comparative Example 2 is a control example HR polyurethane foam which exhibits excellent performance properties.

(19) TABLE-US-00005 TABLE 5 HR Polyure- HR Polyure- HR Polyure- thane Foam thane Foam thane Foam Ex. 6b Comp. Ex. 1 Comp. Ex. 2 Notes 20% Polyol 5% Polyol 0% Polyol F and 58% C-A and 73% F and 78% Polyol K Polyol K Polyol K Density, PCF 1.8 1.9 1.8 ASTM D1622 Tensile, PSI 18 16 17 ASTM D3574-11 Elongation, % 89 79 88 ASTM D3574-11 Tear, ppi 3.2 3.3 3.4 ASTM D3574-11 IFD, LBS/50 SQ. IN. (4 INCH) ASTM D3574-11 SI1 25% IFD, 28 28 29 % Loss SI1 65% IFD, 77 79 76 % Loss Resilience ASTM D3574-11 Resilience, % 52 50 52 Resilience, % 26 26 25 50% Humidity Aged

(20) Further, with respect to slab HR polyurethane foam systems (as opposed to molded HR polyurethane foam systems which are described in the Examples above), a first polyol (as is set forth in Table 1 above) can be utilized in an HR Isocyanate-reactive Component to replace Polyol K, which is EO-end capped. The first polyol is a relatively high molecular weight PO-end capped polyol, examples of which are described in Table 1. Referring now to Table 6, when Polyol K is partially displaced with the relatively high molecular weight PO-end capped polyols (the first polyol), a wider processing window for tin catalysts is generally observed.

(21) TABLE-US-00006 TABLE 6 Amount of Polyol K Amount of Polyol K Required to Make an HR Typically Required Polyurethane Foam to Make an HR According to the Titanium Exam- Polyurethane Foam Subject Invention Catalyst ple (% by weight) (% by weight) Range A 45 19 + B 26 6 C 34 24 ++ D 14 E 26 19 ++ F 41 27 +++ G H 34 6 ++ I 41 6 + J 34 19 ++ C-A 51 6 C-B 64 6 C-C 58 13 +

(22) In Table 6 above, the first column represents the amount of polyol K typically required to make an HR foam having adequate physical properties. The second column represents the amount of polyol K required to make the HR polyurethane foam having adequate physical properties of the subject invention. The third column represents a range of tin catalyst that can be used with the amount of polyol K set forth in the second column to make an HR polyurethane in accordance with the subject invention. More specifically, + represents a wider range of tin catalyst which can be used to obtain an HR polyurethane foam having adequate physical properties while a represents a more narrow range of tin catalyst which can be used to obtain an HR polyurethane foam having adequate physical properties. The wider the range of tin catalyst that can be used, the more robust the method of making the HR polyurethane foam. As such, a + is positive, and a is negative. Generally, the HR polyurethane foam of the subject invention can be made with non-EO capped polyol (less EO-capped polyol, i.e. Polyol K) and with greater variances in the amount of tin catalyst used.

(23) It is to be understood that the appended claims are not limited to express any particular compounds, compositions, or methods described in the detailed description, which may vary between particular embodiments which fall within the scope of the appended claims. With respect to any Markush groups relied upon herein for describing particular features or aspects of various embodiments, it is to be appreciated that different, special, and/or unexpected results may be obtained from each member of the respective Markush group independent from all other Markush members. Each member of a Markush group may be relied upon individually and or in combination and provides adequate support for specific embodiments within the scope of the appended claims.

(24) It is also to be understood that any ranges and subranges relied upon in describing various embodiments of the instant disclosure independently and collectively fall within the scope of the appended claims, and are understood to describe and contemplate all ranges including whole and/or fractional values therein, even if such values are not expressly written herein. One of skill in the art readily recognizes that the enumerated ranges and subranges sufficiently describe and enable various embodiments of the instant disclosure, and such ranges and subranges may be further delineated into relevant halves, thirds, quarters, fifths, and so on. As just one example, a range of from 0.1 to 0.9 may be further delineated into a lower third, i.e., from 0.1 to 0.3, a middle third, i.e., from 0.4 to 0.6, and an upper third, i.e., from 0.7 to 0.9, which individually and collectively are within the scope of the appended claims, and may be relied upon individually and/or collectively and provide adequate support for specific embodiments within the scope of the appended claims. In addition, with respect to the language which defines or modifies a range, such as at least, greater than, less than, no more than, and the like, it is to be understood that such language includes subranges and/or an upper or lower limit. As another example, a range of at least 10 inherently includes a subrange of from at least 10 to 35, a subrange of from at least 10 to 25, a subrange of from 25 to 35, and so on, and each subrange may be relied upon individually and/or collectively and provides adequate support for specific embodiments within the scope of the appended claims. Finally, an individual number within a disclosed range may be relied upon and provides adequate support for specific embodiments within the scope of the appended claims. For example, a range of from 1 to 9 includes various individual integers, such as 3, as well as individual numbers including a decimal point (or fraction), such as 4.1, which may be relied upon and provide adequate support for specific embodiments within the scope of the appended claims.

(25) The instant disclosure has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Obviously, many modifications and variations of the instant disclosure are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the instant disclosure may be practiced otherwise than as specifically described.