Composition containing polyester, organic polyisocyanate, tertiary amine salt and alkali metal carbonate and process of preparing foam therefrom

Claim 1

IN A METHOD FOR PRODUCING FOAMED PRODUCTS THROUGH SUBSTANTIALLY CONCURRENT POLYMERIZATION AND FOAMING REACTIONS BETWEEN AN ORGANIC POLYSOCYANATE AND A POLYESTER, THE STEPS OF, MIXING AT ROOM TEMPERATURE FROM 16 TO 25 PARTS BY WEIGHT OF AN ORGANIC POLYISOCYANATE WITH 100 PARTS BY WEIGHT OF A POLYESTER WHICH IS A REACTION PRODUCT OF A DICARBOXYLIC ACID AND A POLYHYDRIC ALCOHOL HAVING AN ACID NUMBER NOT OVER 5 AND A HYDOXYL NUMBER NOT LESS THAN 60 TOGETHER WITH FROM 3 TO 7 PARTS BY WEIGHT OF AN ANHYDROUS CATALYST SOURCE COMPOUND TAKEN FROM THE CLASS CONSISTING OF N-PHENYL, N-METHYL AND NETHYL MORPHOLINE HYDROCHLORIDE, TOGETHER WITH 4 TO 8 PARTS BY WEIGHT OF AN ALKALI METAL CARBONATE HYDRATE, HEATING SAID MIXTURE TO A TEMPERATURE ABOVE ROOM TEMPERATURE AND NOT IN EXCESS OF 250*F. FOR A TIME SUFFICIENT TO CAUSE THE MORPHOLINE HYDROCHLORIDE TO LIBERATE ITS HYDROCHLORIC ACID AND SUBSEQUENTLY FOR THE RESIDUAL CATALYTIC MORPHOLINE COMPOUND TO INITIATE THE POLYMERIZATION REACTION BETWEEN THE POLYISOCYANATE AND THE POLYESTER, AND TO SUBSTANTIALLY CONCURRENTLY CAUSE THE HYDRATED CARBONATE TO RELEASE WATER OF HYDRATION TO CAUSE THE FOAMING REACTION TO PROGRESS AND SIMULTANEOUSLY NEUTRALIZE AT LEAST A PORTION OF SAID LIBERATED HYDROCHLORIC ACID.