Flexible polyurethane foams

Patent metadata

Field	Value
Publication number	US-11945904-B2
Application number	US-201816955962-A
Country	US
Kind code	B2
Filing date	Dec 20, 2018
Priority date	Dec 20, 2017
Publication date	Apr 2, 2024
Grant date	Apr 2, 2024

Abstract

The present invention relates to a process for producing a flexible polyurethane foam thermally recyclable by fusion, and to hybrid materials made of flexible polyurethane foam and compact thermoplastic elastomer and/or expanded thermoplastic polyurethane.

First claim

The invention claimed is:

1. A process for producing a thermally recyclable flexible polyurethane foam having a free density between 30 and 150 g/L, the process comprising reacting a mixture comprising:
a. an isocyanate component having a functionality between 1.9 and 2.2;
b. a polyol component having a functionality between 1.7 and 2.2;
c. a blowing agent; and
d a catalyst,
wherein the polyol component (b) comprises a chain extender, and
wherein the thermally recyclable flexible polyurethane foam has a softening point of less than 150° C.

2. The process of claim 1 , wherein the polyol component (h) is a polyester- or polyetherpolyol having an average molecular weight between 500 g/mol and 12 000 g/mol.

3. A thermally recyclable flexible polyurethane foam obtainable by the process of claim 1 .

4. A hybrid material comprising the thermally recyclable flexible polyurethane foam of claim 3 and a compact thermoplastic elastomer.

5. A hybrid material comprising the thermally recyclable flexible polyurethane foam of claim 3 and a compact thermoplastic polyurethane.

6. The hybrid material of claim 4 , further comprising an expanded thermoplastic polyurethane.

7. The hybrid material of claim 5 , wherein at least 50% by weight of the polyol component (b) used to form the thermally recyclable flexible polyurethane foam and of isocyanate-reactive compounds in the thermoplastic polyurethane and at least 50% by weight of the isocyanate component (a) used to form the thermally recyclable flexible polyurethane foam and of organic isocyanates in the thermoplastic polyurethane are identical.

8. A method of recycling the thermally recyclable flexible polyurethane foam of claim 3 , the method comprising performing fusion of the thermally recyclable flexible polyurethane foam.

9. A method of recycling the hybrid material of claim 4 , the method comprising performing fusion of the hybrid material.

10. A method of producing an item of apparel, jewelry, a jewelry part, an item of sports equipment, a damping material, foam particles, a cleaning article for mobile driving or flying devices, a medical article, a furniture part, a cushion, a cushion part, a mattress, a mattress part, a driving or flying device accessory, a component that absorbs structure-borne and airborne sound, a design element for electrical components and seals, or an article for the agricultural industry and hydroculture substrates,
the method comprising obtaining the thermally recyclable flexible polyurethane foam of claim 3 .

11. A method of producing footwear, the method comprising obtaining the thermally recyclable flexible polyurethane foam of claim 3 .

12. A cushioning element comprising the thermally recyclable flexible polyurethane foam of claim 3 in a heel region, a forefoot region or in a footwear tongue.

13. An insole for footwear, comprising recyclable flexible polyurethane foam of claim 3 .

14. An item of footwear comprising the thermally recyclable flexible polyurethane foam of claim 3 as cushioning in a heel region, forefoot region or in a footwear tongue or as insole.

15. An item of footwear comprising the thermally recyclable flexible polyurethane foam of claim 3 as cushioning in a heel region, forefoot region or in a footwear tongue or as insole and a midsole comprising expanded thermoplastic polyurethane and/or a treadsole, an upper material and/or further footwear part comprising thermoplastic polyurethane.

16. The process of claim 3 , wherein the thermally recyclable flexible polyurethane foam has a free density of 30 to 85 g/L.

17. The process of claim 1 , wherein the thermally recyclable flexible polyurethane foam has a free density of 30 to 85 g/L.

18. The process of claim 1 , wherein the polyol component (b) is a polyester- or polyetherpolyol having an average molecular weight between 1000 g/mol and 6000 g/mol.

19. The process of claim 1 , wherein the thermally recyclable flexible polyurethane foam is an open-cell foam.

20. The process of claim 1 , wherein all of the isocyanate components used have a functionality between 1.9 and 2.2 and all of the polyol components used have a functionality between 1.7 and 2.2.

Assignees

• Basf Se

Inventors

• Jaehnigen Julia
• Loelsberg Wibke
• Mueller Angelika
• Tepe Daniela
• Prissok Frank
• Petrovic Dejan
• Lutter Heinz-Dieter

Classifications

• B29K2105/04

  cellular or porous · CPC title

• B29K2075/00

  Use of {PU, i.e.} polyureas or polyurethanes {or derivatives thereof}, as moulding material · CPC title

• B29B2017/042

  Mixing disintegrated particles or powders with other materials, e.g. with virgin materials · CPC title

• C08G18/797 Primary

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

• A43B1/14

  made of plastics (A43B1/028 takes precedence) · CPC title