Process for preparing flexible polyurethane foams

Claim 2

A process for preparing flexible polyurethane foam having a modulus of at least about 2.3 which comprises subjecting to foaming conditions, a composition comprising: A 1. from about 50 to 100 parts by weight of a primary, hydroxyl-containing polyether triol having an average hydroxyl equivalent weight of from about 900 to about 2500, 2. from 0 to about 50 parts by weight of a polyol selected from a diol, a triol, a polymer-containing diol, a polymer-containing triol or mixtures thereof wherein said diols and triols have an average hydroxyl equivalent weight of from about 500 to about 2500 and said polymer has an average molecular weight of at least about 5000; B. an organic polyisocyanate consisting of 1. from about 50% to 100% by weight of 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, NCO-containing prepolymers thereof, and 2. from 0 to about 50% by weight of an organic polyisocyanate having an average NCO functionality of at least 2; C. from about 1.0 to about 5 parts by weight of water per 100 parts by weight of Component (A); D. from about 0 to about 20 parts of a low boiling auxiliary blowing agent per 100 parts by weight of Component (A); E. from about 0.1 to about 10 parts per 100 parts by weight of Component (A) of a crosslinker composition consisting essentially of

Claim 3

from 5 to 100 percent by weight of compounds or mixtures of compounds represented by the formula ##STR15## wherein A is represented by the group ##STR16## each R, R 1 and R 2 are independently hydrogen or an alkyl group having from 1 to about 4 carbon atoms, x has a value from zero to about 4; y has a value of 1 or 2; z has a value of zero or 1, and when y is 2, z is zero and the sum of y and z is 2, as a primary crosslinker component, and 2.

Claim 4

from 5 to 100 percent by weight of compounds or mixtures of compounds represented by the formula ##STR15## wherein A is represented by the group ##STR16## each R, R 1 and R 2 are independently hydrogen or an alkyl group having from 1 to about 4 carbon atoms, x has a value from zero to about 4; y has a value of 1 or 2; z has a value of zero or 1, and when y is 2, z is zero and the sum of y and z is 2, as a primary crosslinker component, and 2.

Claim 5

from 0 to about 95 percent by weight of an auxiliary crosslinker component; F. from about 0.5 to about 4 parts by weight per 100 parts by weight of Component (A) of a catalyst for the urethane reaction; G. from abut 0.005 to about 2.5 parts by weight per 100 parts by weight of Component (A) of a silicone oil cell control agent; and wherein Components (A), (B), (C) and (E) are present in quantities so as to provide an NCO:active hydrogen equivalent ratio of from about

Claim 6

from 0 to about 95 percent by weight of an auxiliary crosslinker component; F. from about 0.5 to about 4 parts by weight per 100 parts by weight of Component (A) of a catalyst for the urethane reaction; G. from abut 0.005 to about 2.5 parts by weight per 100 parts by weight of Component (A) of a silicone oil cell control agent; and wherein Components (A), (B), (C) and (E) are present in quantities so as to provide an NCO:active hydrogen equivalent ratio of from about

Claim 7

8:1.0 to about 1.3:1.0. 2. The process of claim 1 wherein Components (A), (B) and (E) are employed in quantities so as to provide an NCO: active hydrogen equivalent ratio of from about 0.9:1 to about 1.1:1, and Component (E) is present in quantities of from about 1 to about 5 parts by weight per 100 parts by weight of Component (A) and wherein Component (A) comprises from 50-100 parts of (1) and 0-50 parts by weight of (2).

Claim 8

The process of claim 2 wherein Component (E-1) is present in quantities of from about 75 to about 100 percent and Component (E-2) is present in from about 0 to about 25 percent.

Claim 9

The process of claim 3 wherein Component (E) consists of 100 percent of Component (E-1).

Claim 10

The process of claim 4 wherein Component (A-1) is a glycerine initiated polyether polyol.

Claim 11

The process of claim 5 wherein Component (A=2) is absent from the composition.

Claim 12

The process of claim 2 wherein the silicone oil cell control agent, Component G, is a block compolymer of two or more alkylene oxides contaning siloxane groups.

Claim 13

The process of claim 4 wherein Component (E-1) is menthanediamine or isophorone diamine or mixtures thereof.

Claim 14

The process of claim 8 wherein Component (E) is isophorone diamine and is employed in quantities of from about 0.1 to about 2 parts per 100 parts of Component (A).

Claim 15

The process of claim 9 wherein Component (E) is employed in quantities of from about 0.35 to about 1.35 parts per 100 parts of Component (A).

Claim 16

The process of claim 8 wherein menthanediamine is employed as Component (E) in quantities of from about 0.3 to about 3 parts per 100 parts of Component (A).

Claim 17

The process of claim 11 wherein Component (E) is employed in quantities of from 1.25 to about 2.25 parts per 100 parts of Component (A).

Claim 18

A super-soft flexible polyurethane foa characterized by a modulus of at least about 2.3 and 25% ILD value of <5lbs (2.27 kg).

Claim 19

A super-soft flexible polyurethane foa characterized by a modulus of at least about 2.3 and 25% ILD value of <5lbs (2.27 kg).

Claim 20

A process for preparing super-soft flexible polyurethane foams having a modulus of at least about 2.3 and a 25% ILD values of <20lbs (9.07 kg) which process comprises: A. a polyol component comprising 1. a diol having an equivalent weight of from about 500 to about 2000 and an ethylene oxide content of from about 0 to about 50% by weight; 2. a triol having an equivalent weight of from about 500 to about 2000 and an ethylene oxide residue content of from about 0 to about 50% by weight; wherein the ratio of hydroxyl equivalents of (1):(2) is from about 0.11:1 to about 1.1:1; B. an organic polyisocyanate; C. from about 1 to about 4 parts of water per 100 parts by weight of Component (A); D. from about 5 to about 40 parts of a low boiling auxiliary blowing agent per 100 parts by weight of Component (A); E. from about 0.1 to about 3 parts per 100 parts by weight of Component (A) of a crosslinker selected from the group consisting of compounds or mixtures of compounds represented by the formula ##STR17## wherein A is represented by the group ##STR18## each R, R 1 and R 2 are independently hydrogen or an alkyl group having from 1 to about 4 carbon atoms x has a value from zero to about 4; y has a value of 1 or 2; z has a value of zero or 1, and when y is 2, z is zero and the sum of y and z is 2; F. from about 0.2 to about 3 parts of a catalyst for urethane formation per 100 parts by weight of Component (A); G. from about 0.2 to about 3 parts of a silicone oil cell control agent per 100 parts by weight of Component (A); and wherein Components (A), (B), (C) and (D) are present in quantities so as to provide an NCO:active hydrogen ratio of from about 0.9:1 to about 1.2:1.

Claim 21

A process for preparing super-soft flexible polyurethane foams having a modulus of at least about 2.3 and a 25% ILD values of <20lbs (9.07 kg) which process comprises: A. a polyol component comprising 1. a diol having an equivalent weight of from about 500 to about 2000 and an ethylene oxide content of from about 0 to about 50% by weight; 2. a triol having an equivalent weight of from about 500 to about 2000 and an ethylene oxide residue content of from about 0 to about 50% by weight; wherein the ratio of hydroxyl equivalents of (1):(2) is from about 0.11:1 to about 1.1:1; B. an organic polyisocyanate; C. from about 1 to about 4 parts of water per 100 parts by weight of Component (A); D. from about 5 to about 40 parts of a low boiling auxiliary blowing agent per 100 parts by weight of Component (A); E. from about 0.1 to about 3 parts per 100 parts by weight of Component (A) of a crosslinker selected from the group consisting of compounds or mixtures of compounds represented by the formula ##STR17## wherein A is represented by the group ##STR18## each R, R 1 and R 2 are independently hydrogen or an alkyl group having from 1 to about 4 carbon atoms x has a value from zero to about 4; y has a value of 1 or 2; z has a value of zero or 1, and when y is 2, z is zero and the sum of y and z is 2; F. from about 0.2 to about 3 parts of a catalyst for urethane formation per 100 parts by weight of Component (A); G. from about 0.2 to about 3 parts of a silicone oil cell control agent per 100 parts by weight of Component (A); and wherein Components (A), (B), (C) and (D) are present in quantities so as to provide an NCO:active hydrogen ratio of from about 0.9:1 to about 1.2:1.

Claim 22

The process of claim 14 wherein Component (E) is selected from isophorone diamine, menthane diamine and mixtures thereof.

Claim 23

The process of claim 15 wherein Component (A-1) and (A-2) have OH equivalent weights of from about 900 to about 1200; the ratio of hydroxyl equivalents of (A-1):(A-2) is from about 0.17:1 to about 0.42:1, Component (C) is present in quantities of from about 2 to about 3 parts per 100 parts of Component (A); Component (D) is present in quantities of from about 15 to about 30 parts per 100 parts of Component (A); Component (E) is present in quantities of from about 0.4 to about 1.5 parts per 100 parts of Component (A), Component (G) is present in quantities of from that 0.5 to about 2.0 and the NCO:active hydrogen ratio of Components (A), (B), (C) and (D) is from about 0.95:1 to about 1.1:1.

Claim 24

The process of claim 16 wherein at least one of Components (A-1) and (A-2) contains from about 7% to about 20% ethylene oxide residue by weight.

Claim 25

The process of claim 17 wherein Component (A-2) contains from about 7% to about 20% ethylene oxide residue by weight.

Claim 26

The process of claim 18 wherein Component (A-1) is a polyoxypropylene glycol having an average OH equivalent weight of about 1000 and Component (A-2) is a glycerine initiated polyoxypropylene glycol end capped with about 10% ethylene oxide by weight and having an OH equivalent weight of about 1000.

Claim 27

The process of claim 19 wherein Component (D) is trichloromonofuoromethane.

Claim 28

The process of claim 20 wherein Component (B) is an 80/20 mixture of 2,4-/2,6-toluene diisocyanate.

Claim 29

The process of claim 21 wherein Component (E) is isophorone diamine.