Polyurethane filter foam

Patent metadata

Field	Value
Publication number	US-10077331-B2
Application number	US-201615391555-A
Country	US
Kind code	B2
Filing date	Dec 27, 2016
Priority date	Aug 31, 2016
Publication date	Sep 18, 2018
Grant date	Sep 18, 2018

Abstract

A polyurethane filter foam is provided herein. The polyurethane filter foam may have improved permeability by having both a small cell and a large cell in a range for maximizing the opening property of the foam. In some instance, this is achieved by specifically configuring and foaming a composition of polyether polyol and methylene diphenyl diisocyanate (MDI) to manufacture the polyurethane foam. The polyurethane foam of the present invention can be manufactured without performing a reticulation process.

First claim

What is claimed is:

1. A polyurethane filter foam manufactured by foaming (A) polyether polyol and (B) methylene diphenyl diisocyanate (MDI),
wherein the (A) polyether polyol is a polyol resin mixture comprising (A-1) from about 10 to 40 wt % of difunctional polyether polyol having a hydroxyl value of from about 20 to 100 mgKOH/g; (A-2) from about 10 to 50 wt % of trifunctional polyether polyol having a hydroxyl value of 20 to 100 mgKOH/g; and (A-3) from about 10 to 50 wt % of hexafunctional polyether polyol having a hydroxyl value of 50 to 100 mgKOH/g, wherein percent values of (A-1), (A-2) and (A-3) are based on the total weight of the (A) polyether polyol,
wherein the (B) methylene diphenyl diisocyanate (MDI) is an isocyanate mixture comprising (B-1) from about 10 to 80 wt % of MDI monomers; (B-2) from about 0.1 to 20 wt % of carbodiimide modified MDI having a weight average molecular weight of from about 250 to 350 g/mol, (B-3) from about 10 to 50 wt % of polymeric MDI having a weight average molecular weight of from about 300 to 400 g/mol, and (B-4) from about 0.1 to 50 wt % of MDI prepolymer having a weight average molecular weight of from about 250 to 1,000 g/mol prepared by prepolymerizing the MDI monomers and the polyether polyol,
wherein percent values of (B-1), (B-2) and (B-3) are based on the total weight of the (B) methylene diphenyl diisocyanate, and
wherein apparent density measured by MS257-06 is from about 40 to 65 kg/m3, ILD 25% hardness is from about 10 to 25 kgf/314 cm2, and permeability of air is from about 200 to 500 L/min.

2. The polyurethane filter foam of claim 1 , wherein the (B) methylene diphenyl diisocyanate (MDI) is included with from about 40 to 70 parts by weight based on 100 parts by weight of the (A) polyether polyol.

3. The polyurethane filter foam of claim 1 , wherein the (A-1) difunctional polyether polyol is prepared by adding an ethylene oxide (EO) or propylene oxide (PO) group to a middle or a terminal of a molecular chain.

4. The polyurethane filter foam of claim 1 , wherein the (A-1) difunctional polyether polyol is prepared by adding and polymerizing ethylene oxide (EO), propylene oxide (PO), or both the ethylene oxide (EO) and the propylene oxide (PO) to alkylene glycol selected from dipropylene glycol (DPG), diethylene glycol (DEG) and monoethylene glycol (MEG).

5. The polyurethane filter foam of claim 1 , wherein the (A-2) trifunctional polyether polyol is prepared by adding and polymerizing ethylene oxide (EO), propylene oxide (PO), or both the ethylene oxide (EO) and the propylene oxide (PO) to polyol selected from glycerin and trimethylolpropane.

6. The polyurethane filter foam of claim 1 , wherein the (A-3) hexafunctional polyether polyol is prepared by adding and polymerizing ethylene oxide (EO), propylene oxide (PO), or both the ethylene oxide (EO) and the propylene oxide (PO) to sorbitol.

Assignees

• Hyundai Motor Co Ltd

Inventors

• Lim Byung Guk
• Park Sang Do
• Jeong Dong Woo
• Kang Seok Nam
• Lee Hoon Bok
• Han Kug Hun
• Kim Sang Ho
• Choi Kwon Yong
• Jung Soon Joon
• Lee Sung Hoon
• Kim Mu Young
• Kim Kyung Sam
• Cho Yoo Kon
• Lee Sung Il

Classifications

• C08G2101/0083

  Chemistry & Metallurgy · mapped topic

• B01D39/1676

  of synthetic origin · CPC title

• C08G18/48 Primary

  Polyethers · CPC title

• C08G18/797

  containing carbodiimide and/or uretone-imine groups · CPC title

• C08G18/7671 Primary

  containing only one alkylene bisphenyl group · CPC title