Compression set

Patent metadata

Field	Value
Publication number	US-12082704-B2
Application number	US-202017070254-A
Country	US
Kind code	B2
Filing date	Oct 14, 2020
Priority date	Nov 7, 2019
Publication date	Sep 10, 2024
Grant date	Sep 10, 2024

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.

First claim

The invention claimed is:

1. A shaped hot-cure flexible polyurethane foam article, wherein the hot-cure flexible PU foam is 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,
where:
[R 1 Me 2 SiO 1/2 ] a [Me 2 SiO 2/2 ] b [R 2 MeSiO 2/2 ] c [MeSiO 3/2 ] d [SiO 4/2 ] 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 1 =Me or R 2
R 2 =identical or different polyethers obtained from the polymerization of ethylene oxide, propylene oxide and/or other alkylene oxides

and where
[R 4 Me 2 SiO 1/2 ] i [Me 2 SiO 2/2 ] j [R 5 MeSiO 2/2 ] k [MeSiO 3/2 ] l [SiO 4/2 ] 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 4 =Me or R 5
R 5 =identical or different polyethers obtained from the polymerization of ethylene oxide, propylene oxide and/or other alkylene oxides,
wherein the finished polyurethane foam comprises 0.1% to 5% by weight of the at least one compound having the formula (1a) and comprises 0.1% to 5% by weight of the at least one compound of formula (1b),
and wherein the finished polyurethane foam comprises the at least one compound having the formula (1a) and the at least one compound of formula (1b) in a total amount of about 1.45% to 10.0% by weight.

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 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 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 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 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%, and kept in compressed form by 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 a vacuum-packed state, and is a roll-up mattress.

10. The shaped hot-cure flexible polyurethane foam article according to claim 1 , wherein the at least one polyol component comprises recycled polyols.

11. The shaped hot-cure flexible polyurethane foam article 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 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, comprising:
(a) in a first step providing a shaped hot-cure flexible polyurethane foam article as defined in claim 1 ,
(b) in optional subsequent steps the shaped hot-cure flexible polyurethane foam article obtained is subjected to further processing,
(c) and wherein in a final step the shaped hot-cure flexible polyurethane foam article is compressed by at least 20%, based on its starting volume, and optionally vacuum-packed and kept in compressed form by auxiliary means, and sent for storage and/or transport,

wherein the hot-cure flexible polyurethane foam has a porosity of 1 to 6 scfm.

13. A process for producing hot-cure flexible polyurethane foam having a porosity of 1 to 6 scfm,
comprising reacting 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 1 Me 2 SiO 1/2 ] a [Me 2 SiO 2/2 ] b [R 2 MeSiO 2/2 ] c [MeSiO 3/2 ] d [SiO 4/2 ] 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 1 =Me or R 2
R 2 =polyethers of the general formula (c),

where
f=0-6,
g=0 to 150,
h=0 to 150,
where
g+h>0
R 3 ═OH, alkyl or acetyl,

and where
[R 4 Me 2 SiO 1/2 ] i [Me 2 SiO 2/2 ] j [R 5 MeSiO 2/2 ] k [MeSiO 3/2 ] l [SiO 4/2 ] 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 4 =Me or R 5
R 5 =polyethers of the general formula (d), or alkyl C 3 to C 15 ,

where
n=0-6,
o=0 to 100,
p=0 to 100,
where
o+p>0
R 6 ═OH, alkyl or acetyl,
wherein the finished polyurethane foam comprises the at least one compound having the formula (1a) and the at least one compound of formula (1b) in a total amount of about 1.45% to 10.0% by weight.

14. The shaped hot-cure flexible polyurethane foam article according to claim 8 , which is a mattress 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.

15. A mixture comprising at least one compound of the formula (1b) and at least one compound of the formula (1a), and optionally glycols, polyethers, organic esters and/or other solvents suitable, for the purposes of flexible polyurethane foam production, wherein
[R 1 Me 2 SiO 1/2 ] a [Me 2 SiO 2/2 ] b [R 2 MeSiO 2/2 ] c [MeSiO 3/2 ] d [SiO 4/2 ] 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 1 =Me or R 2
R 2 =identical or different polyethers obtained from the polymerizatio

Assignees

• Evonik Operations Gmbh

Inventors

• Landers Rüdiger
• Hermann Daniela
• Wessely Isabelle Denise
• Ferenz Michael
• Ziegler Rainer

Classifications

• C08G18/5045

  containing urethane groups · CPC title

• C08G2110/0008

  flexible · CPC title

• C08G2110/0041

  having specified density · CPC title

• C08G2110/0083

  prepared using water as the sole blowing agent · CPC title

• C08G18/4829

  Polyethers containing at least three hydroxy groups (C08G18/4833 - C08G18/5096 take precedence) · CPC title