Composition for manufacturing polyurethane foam and molded article thereof

Patent metadata

Field	Value
Publication number	US-2017292003-A1
Application number	US-201615283191-A
Country	US
Kind code	A1
Filing date	Sep 30, 2016
Priority date	Apr 7, 2016
Publication date	Oct 12, 2017
Grant date	—

Abstract

Disclosed are a polyurethane composition, a molded article, and a vehicle comprising the polyurethane composition or the molded article. The polyurethane composition comprises a polyol composition (A) in which polyether polyol (a1) and polymer polyol (a2) are mixed at a predetermined amount, an isocyanate composition (B) obtainable by polymerizing polyether polyol (b2) and an isocyanate composition (b1) that comprises i) methylene diphenyl isocyanate (M-MDI) and ii) polymethylene diphenyl isocyanate (P-MDI). As such, the molded article such as a vehicle seat pad can be manufactured with improved static and dynamic comfort.

First claim

What is claimed is:

1 . A composition for manufacturing a polyurethane foam, comprising:
an amount of 100 parts by weight of a polyol composition (A), an isocyanate composition (B) wherein the isocyanate composition (B) is obtainable by steps comprising polymerizing 1) an amount of about 1 to 5 parts by weight of polyether polyol (b2) with respect to 100 parts by weight of the polyol composition (A) and 2) an isocyanate composition (b1) that comprises i) an amount of about 15 to 40 parts by weight of methylene diphenyl isocyanate (M-MDI) with respect to 100 parts by weight of the polyol composition (A) and ii) an amount of about 8 to 21 parts by weight of polymethylene diphenyl isocyanate (P-MDI) with respect to 100 parts by weight of the polyol composition (A).

2 . The composition of claim 1 , further comprising:
one or more additives selected from the group consisting of a cross-linking agent (C), a catalyst (D), a foam stabilizer (E), and a foaming agent (F), wherein the composition further comprises an amount of about 0.01 to 10 parts by weight of the cross-linking agent (C), an amount of about 0.01 to 3 parts by weight of the catalyst (D), an amount of about 0.01 to 3 parts by weight of the foam stabilizer (E), and an amount of about 1 to 5 parts by weight of the foaming agent (F), with respect to 100 parts by weight of the polyol composition (A).

3 . The composition of claim 1 , wherein the methylene diphenyl isocyanate (M-MDI) has an NCO content of about 30 to 35 wt % based on the total weight of the methylene diphenyl isocyanate.

4 . The composition of claim 1 , wherein the polymethylene diphenyl isocyanate (P-MDI) has a weight average molecular weight in a range of about 370 to 390 g/mol and an NCO content of about 25 to 35 wt % based on the total weight of the polymethylene diphenyl isocyanate.

5 . The composition of claim 1 , wherein the polyol composition (A) comprises:
an amount of about 60 to 99 wt % of polyether polyol (a1); and an amount of about 1 to 40 wt % of a grafted polymer polyol (a2′) in which one or more monomers selected from the group consisting of acrylonitrile and styrene are grafted to a polyether polyol having a weight average molecular weight of 5,000 to 8,000 g/mol and a value of OH of 20 to 35 mg KOH/g, based on the total weight of the polyol composition (A), wherein the polyether polyol (a1) is obtainable by steps comprising polymerizing propylene oxide (PO) and ethylene oxide (EO), and has a weight average molecular weight of about 6,000 to 8,000 g/mol and a value of OH of about 20 to 30 mg KOH/g.

6 . The composition of claim 1 , wherein the polyol composition (A) comprises:
an amount of about 60 to 99 wt % of polyether polyol (a1); and an amount of 1 to 40 wt % of a mixture (a2″) comprising one or more monomers selected from the group consisting of acrylonitrile and styrene dispersed in a polyether polyol having a weight average molecular weight of 5,000 to 8,000 g/mol and a value of OH of 20 to 35 mg KOH/g, with all the wt % based on the total weight of the polyol composition (A), wherein the polyether polyol (a1) is obtainable by steps comprising polymerizing propylene oxide (PO) and ethylene oxide (EO), and has a weight average molecular weight of about 6,000 to 8,000 g/mol and a value of OH of 20 to 30 mg KOH/g.

7 . The composition of claim 5 , wherein the polyether polyol (a1) comprises an amount of about 10 to 20 wt % of ethylene oxide (EO) and an amount of about 80 to 90 wt % of propylene oxide (PO), all the wt % based on the total weight of the polyether polyol (a1).

8 . The composition of claim 6 , wherein the polyether polyol (a1) comprises an amount of about 10 to 20 wt % of ethylene oxide (EO) and an amount of about 80 to 90 wt % of propylene oxide (PO), all the wt % based on the total weight of the polyether polyol (a1).

9 . The composition of claim 1 , wherein the polyether polyol (b2) is obtainable by steps comprising polymerizing propylene oxide and ethylene oxide, and has a weight average molecular weight of about 3,000 to 8,000 g/mol and a value of OH of about 20 to 60 mg KOH/g.

10 . A molded article of a vehicle seat pad comprising a composition of claim 1 .

11 . A vehicle comprising a composition of claim 1 .

12 . A composition for manufacturing a polyurethane foam, comprising:
an amount of 100 parts by weight of a polyol composition (A), an isocyanate composition (B) wherein the isocyanate composition (B) comprises: 1) an amount of about 1 to 5 parts by weight of polyether polyol (b2) with respect to 100 parts by weight of the polyol composition (A) and 2) an isocyanate composition (b1) comprising, i) an amount of about 15 to 40 parts by weight of methylene diphenyl isocyanate (M-MDI) with respect to 100 parts by weight of the polyol composition (A) and ii) an amount of about 8 to 21 parts by weight of polymethylene diphenyl isocyanate (P-MDI) with respect to 100 parts by weight of the polyol composition (A).

13 . The composition of claim 12 , further comprising:
one or more additives selected from the group consisting of a cross-linking agent (C), a catalyst (D), a foam stabilizer (E), and a foaming agent (F), wherein the composition further comprises an amount of about 0.01 to 10 parts by weight of the cross-linking agent (C), an amount of about 0.01 to 3 parts by weight of the catalyst (D), an amount of about 0.01 to 3 parts by weight of the foam stabilizer (E), and an amount of about 1 to 5 parts by weight of the foaming agent (F), with respect to 100 parts by weight of the polyol composition (A).

14 . The composition of claim 12 , wherein the methylene diphenyl isocyanate (M-MDI) has an NCO content of about 30 to 35 wt % based on the total weight of the methylene diphenyl isocyanate.

15 . The composition of claim 12 , wherein the polymethylene diphenyl isocyanate (P-MDI) has a weight average molecular weight in a range of about 370 to 390 g/mol and an NCO content of about 25 to 35 wt % based on the total weight of the polymethylene diphenyl isocyanate.

16 . The composition of claim 12 , wherein the polyol composition (A) comprises:
an amount of about 60 to 99 wt % of polyether polyol (a1); and an amount of about 1 to 40 wt % of a grafted polymer polyol (a2′) in which one or more monomers selected from the group consisting of acrylonitrile and styrene are grafted to a polyether polyol having a weight average molecular weight of 5,000 to 8,000 g/mol and a value of OH of 20 to 35 mg KOH/g, based on the total weight of the polyol composition (A), wherein the polyether polyol (a1) comprises propylene oxide (PO) and ethylene oxide (EO), and has a weight average molecular weight of about 6,000 to 8,000 g/mol and a value of OH of about 20 to 30 mg KOH/g.

17 . The composition of claim 12 , wherein the polyol composition (A) comprises:
an amount of about 60 to 99 wt % of polyether polyol (a1); and an amount of 1 to 40 wt % of a mixture (a2″) comprising one or more monomers selected from the group consisting of acrylonitrile and styrene dispersed in a polyether polyol having a weight average molecular weight of 5,000 to 8,000 g/mol and a value of OH of 20 to 35 mg KOH/g, with all the wt % based on the total weight of the polyol composition (A), wherein the polyether polyol (a1) comprises propylene oxide (PO) and ethylene oxide (EO), and has a weight average molecular weight of about 6,000 to 8,000 g/mol and a value of OH of 20 to 30 mg KOH/g.

18 . The composition of claim 17 , wherein the polyether polyol (a1) comprises an amount of abo

Assignees

• Hyundai Motor Co Ltd
• Kia Motors Corp

Inventors

• Lee Sung Hyun
• Choi Kwon Yong
• Lee Dong Uk
• Lim Byung Guk
• Jung Soon Joon
• Lee Il Gon
• Park Jae Beom

Classifications

• C08G18/632 Primary

  onto polyethers · CPC title

• C08J2203/10

  Water or water-releasing compounds · CPC title

• C08G18/7621

  being toluene diisocyanate including isomer mixtures · CPC title

• C08J9/125 Primary

  Water, e.g. hydrated salts · CPC title

• C08G18/12

  using two or more compounds having active hydrogen in the first polymerisation step · CPC title