Self sealable thermoplastic polyurethane foamed articles and method for forming same

Patent metadata

Field	Value
Publication number	US-2016289409-A1
Application number	US-201415037870-A
Country	US
Kind code	A1
Filing date	Nov 19, 2014
Priority date	Nov 20, 2013
Publication date	Oct 6, 2016
Grant date	—

Abstract

A thermoplastic polyurethane foamed article has a density ranging from 0.3 to 0.8 g/cm3 measured at 25° C. and is self sealable in accordance with Section 7.9 of ASTM D1970/D1970M-11. The thermoplastic polyurethane foamed article is formed by melting and foaming a thermoplastic polyurethane composition having a durometer hardness ranging from 30A to 75D in the presence of a blowing agent.

First claim

1 . A thermoplastic polyurethane foamed article comprising:
a thermoplastic polyurethane composition having a durometer hardness ranging from a Shore A hardness of 30 to a Shore D hardness of 75 foamed in the presence of a blowing agent, wherein the thermoplastic polyurethane foamed article has a density ranging from 0.3 to 0.8 g/cm 3 measured at 25° C. and is self sealable in accordance with Section 7.9 of ASTM D1970/D1970M-11.

2 . The thermoplastic polyurethane foamed article according to claim 1 , wherein the thermoplastic polyurethane composition has a durometer hardness ranging from a Shore A hardness of 50 to a Shore D hardness of 60.

3 . The thermoplastic polyurethane foamed article according to claim 1 , further comprising a melt strength enhancer present in an amount from 0.1 to 5% of the total combined weight of the thermoplastic polyurethane composition and melt strength enhancer.

4 . The thermoplastic polyurethane foamed article according to claim 3 , wherein the melt strength enhancer comprises an epoxy-functional styrene acrylic copolymer.

5 . The thermoplastic polyurethane foamed article according to claim 1 , wherein the thermoplastic polyurethane composition comprises the reaction product of an isocyanate, a polyol and a chain extender.

6 . The thermoplastic polyurethane foamed article according to claim 1 , wherein the thermoplastic polyurethane composition comprises the reaction product of an isocyanate, a chain extender, and a polyol selected from a polyether polyol, a polyester polyol, a caprolactone, and combinations thereof

7 . The thermoplastic polyurethane foamed article according to claim 5 , wherein the chain extender comprises a diol.

8 . An underlayment for roofing or flooring, the underlayment comprising the thermoplastic polyurethane foamed article according to claim 1 , and having a thickness ranging from 0.6 mm to 2.0 mm and a weight per square foot ranging from 0.037 to 0.328 pounds per square foot.

9 . A method for forming a foamed thermoplastic polyurethane article that is self sealable in accordance with Section 7.9 of ASTM D1970/D1970M-11, the method comprising:
providing a thermoplastic polyurethane composition having a durometer hardness ranging from a Shore A hardness of 30 to a Shore D hardness of 75 and a blowing agent; melting the thermoplastic polyurethane composition in the presence of the blowing agent; and foaming the melted thermoplastic polyurethane composition in the presence of the blowing agent to form the foamed thermoplastic polyurethane article having a density ranging from 0.3 to 0.8 g/cm 3 measured at 25° C.

10 . The method according to claim 9 , wherein foaming the melted thermoplastic polyurethane composition comprises depressurizing the melted thermoplastic polyurethane composition.

11 . The method according to claim 9 , wherein melting the thermoplastic polyurethane composition in the presence of the blowing agent comprises:
introducing the provided thermoplastic polyurethane composition and blowing agent into an extruder; and heating the thermoplastic polyurethane composition to a temperature sufficient to melt the thermoplastic polyurethane composition.

12 . The method according to claim 9 , wherein foaming the melted thermoplastic polyurethane composition in the presence of the blowing agent comprises injecting the melted thermoplastic polyurethane composition into a mold cavity from the extruder.

13 . The method according to claim 9 , wherein foaming the melted thermoplastic polyurethane composition in the presence of the blowing agent comprises releasing the melted thermoplastic material through a die opening in the extruder and onto a conveyor in a continuous process.

14 . The method according to claim 9 , further comprising introducing a melt strength enhancer to the provided thermoplastic polyurethane composition present in an amount from 0.1 to 5% of the total combined weight of the thermoplastic polyurethane composition and the melt strength enhancer.

15 . The method according to claim 9 , further comprising curing the foamed thermoplastic polyurethane article.

16 . The thermoplastic polyurethane foamed article according to claim 2 , further comprising a melt strength enhancer present in an amount from 0.1 to 5% of the total combined weight of the thermoplastic polyurethane composition and melt strength enhancer, wherein the melt strength enhancer comprises an epoxy-functional styrene acrylic copolymer.

Assignees

• Basf Se

Inventors

• Kujawski Mark
• Adams Daniel A
• Kaffarani Samer
• Manitiu Mihai
• Martin Brad
• Scholz Guenter
• Pham Hung Manh

Classifications

• C08J9/00 Primary

  Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof (mechanical aspects of shaping of plastics or substances in a plastic state for the production of porous or cellular articles B29C) · CPC title

• E04C2/205

  of foamed plastics, or of plastics and foamed plastics, optionally reinforced · CPC title

• E04F15/20

  for sound insulation · CPC title

• E04B1/88

  Insulating elements for both heat and sound · CPC title

• C08G18/42

  Polycondensates having carboxylic or carbonic ester groups in the main chain · CPC title