Process for producing a two set size cell structure polyurethane foam

Claim 1

A PROCESS FOR PRODUCING A TWO SET SIZE CELL STRUCTURE IN POLYURETHANE FLEXIBLE FOAM INCLUDING FORMING AND FOAMING A FOAMABLE COMPOSITION OF A POLYESTER CONDENSATION PRODUCT OF DICARBOXYLIC ACID AND DIHYDRIC ALCOHOL, HAVING A HYDROXYL NUMBER OF 35 TO 70, AN ACID NUMBER OF LESS THAN 2, AND AN AVERAGE MOLECULAR WEIGHT OF 1500 TO 2500, AROMATIC DIISOCYANATE, WATER, LIQUID POLYURETHANE FOAM EMULSIFIER, AND LIQUID POLYURETHANE FOAM CATALYST, TO PRODUCE FLEXIBLE POLYESTER POLYURETHANE FOAM, WITH AN AMOUNT INTRODUCED SEPARATELY FROM EACH OTHER OF ABOUT 0.3 TO 1.5% OF EACH BY WEIGHT ON THE TOTAL COMPOSITION OF A TERTIARY AMINE CONTAINING AT LEAST 10 CARBON ATOMS AND A SATURATED FATTY ACID OF AT LEAST 12 CARBON ATOMS, TO GIVE A FOAM COMPRISED OF LARGER CELLS RANDOMLY DISTRIBUTED IN A BACKGROUND MASS OF CELLULAR CELLS, THE LARGER CELLS BEING OVAL IN SHAPE, THE LARGER AS WELL AS THE SMALLER CELLS BEING OF SIMILAR SIZE WITHIN EACH SET, WHEREIN THE FATTY ACID IS DISSOLVED IN A CATALYST N-ETHYLMORPHOLINE FOR THE REACTION.