US4241131A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Moldable polyurethane foam-backed fabrics
Assignee: Bayer Corp
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Filing: 1978-05-24
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Granted: 1980-12-23
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Expires: 1998-05-24
Abstract
Abstract The invention relates to a process wherein A a heat curable froth or foamable mixture of polyurethane reaction components is applied to the back of a fabric, B the coated fabric is heated to form a gelled, tack-free and storable foam-backed fabric and C the fabric is shaped and cured using a hot molding process. The polyurethane formulation contains a hydroxy functional ester of an acrylic or alkyl acrylic acid and a free radical initiator.
Inventors
- 👤 Robert J. Bailey
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-30 17:31
CPC Classifications
C; C08; C08J; C08J9/00; C08J9/0061; C08G; C08G18/00; C08G18/06; C08G18/28; C08G18/67; C08G18/671; C08G18/672; C08J9/0014; C08J9/0023; D; D06; D06N; D06N3/00; D06N3/12; D06N3/14; D06N3/142; D06N3/144; D06N7/00; D06N7/0063; D06N7/0071; D06N7/0086; C08J2375/00; C08J2375/04; C08J2433/00; D06N2203/00; D06N2203/06; D06N2203/068; D06N2205/00; D06N2205/04; D06N2207/00; D06N2207/08; D06N2207/12; D06N2207/123; Y; Y10; Y10T; Y10T428/00; Y10T428/249921; Y10T428/249953; Y10T442/00; Y10T442/60; Y10T442/647; Y10T442/652
Claims Analysis
Total Claims: 14
Claim 1
Independent Claim
172 words
A process for preparing a molded, polyurethane foam-backed fabric comprising the steps of: (A) applying a foamable mixture or froth of polyurethane reaction components to the back of a fabric, said reaction components consisting essentially of: (1) a polyisocyanate; (2) an organic compound containing at least two hydrogen atoms capable of reacting with isocyanate groups, having a molecular weight of between 400 and 16,000 and containing essentially no ethylenically unsaturated groups; (3) hydroxyl containing esters of acrylic and alkyl acrylic acids; (4) a free radical initiator; (5) a heat activated catalyst for the reaction between components (1) and (2); (6) a blowing agent, or inert gas for frothing; (7) a surface active agent for foam stability; (B) heating the coated fabric for from 15 seconds to 10 minutes at a temperature of from about 80° to about 250° F. to allow the polyurethane reaction to proceed to produce a fully foamed, gelled, tack-free polyurethane foam; and (C) thereafter molding the resultant foam-backed fabric by a hot-molding process to produce a complex shape.
Claim 2
Dependent Claim
172 words
A process for preparing a molded, polyurethane foam-backed fabric comprising the steps of: (A) applying a foamable mixture or froth of polyurethane reaction components to the back of a fabric, said reaction components consisting essentially of: (1) a polyisocyanate; (2) an organic compound containing at least two hydrogen atoms capable of reacting with isocyanate groups, having a molecular weight of between 400 and 16,000 and containing essentially no ethylenically unsaturated groups; (3) hydroxyl containing esters of acrylic and alkyl acrylic acids; (4) a free radical initiator; (5) a heat activated catalyst for the reaction between components (1) and (2); (6) a blowing agent, or inert gas for frothing; (7) a surface active agent for foam stability; (B) heating the coated fabric for from 15 seconds to 10 minutes at a temperature of from about 80° to about 250° F. to allow the polyurethane reaction to proceed to produce a fully foamed, gelled, tack-free polyurethane foam; and (C) thereafter molding the resultant foam-backed fabric by a hot-molding process to produce a complex shape.
Claim 3
Dependent Claim
48 words
The process of claim 1 wherein Step (C) comprises placing the fabric in a heated mold where at least the polyurethane side is subjected to temperatures of from 200° to 350° F. and a pressure of from 0.1 to 20 psi for from 15 seconds to 5 minutes.
Claim 4
Dependent Claim
40 words
The process of claim 1 wherein Step (C) comprises heating the fabric to a temperature of from 200° to 350° F. and then shaping the heated carpet in an unheated mold at a pressure of from 0.1 to 20 psi.
Claim 5
Dependent Claim
22 words
The process of claim 3, wherein the fabric is laid flat and heated by forced heated air, infrared radiation or microwave radiation.
Claim 6
Dependent Claim
66 words
The process of claim 1 wherein component (3) is represented by the formula ##STR7## wherein R 1 is an x+y valent, optionally branched C 1 -C 18 alkylene, arylene or aralkylene group R 2 is H or C 1 -C 18 alkyl x & y are integers which may be the same or different and represent 1-8, with the proviso that x+y does not exceed 8.
Claim 7
Dependent Claim
29 words
The process of claim 5 wherein x and y are each 1, R 1 is a C 1 to C 4 alkylene and R 2 is H or methyl.
Claim 8
Dependent Claim
156 words
The process of claim 1 wherein said reaction components comprise Component (1): in an amount such that the isocyanate index is from 100 to 200; 100 parts by weight of Component (2); of from 0.5 to 50 parts by weight of Component (3); from 0.01 to 1 part by weight of Component (4), said Component (4) being a thermally activated free radical initiator which has a half life of less than 1 minute at the molding temperature of Step (C); from 0.05 to 1 part by weight of Component (5); and further comprising (8) from 0 to 30 parts by weight of a chain extender; (9) from 0 to 50 parts by weight of a compound containing at least one ethylenically unsaturated group and a hydroxyl group and being different than Component (3); and (10) from 0 to 500 parts by weight of an inorganic filler based on the total weight of Components (2) to (9).
Claim 9
Dependent Claim
80 words
The process of claim 7 wherein the isocyanate index is from 125-150; and Component (3) is used in amounts of from 5 to 20 parts; Component (8) is used in amounts of from 0.5 to 30 parts; Component (9) is used in amounts of from 8 to 15 parts; and Component (10) is used in amounts of from 300 to 500 parts; the amounts of Components (3), (8), (9) and (10) being per 100 parts by weight of Component (2).
Claim 10
Dependent Claim
25 words
The process of claim 8 wherein from 8 to 15 parts of hydroxyfunctional acrylate and from 5 to 15 parts of chain extender is used.
Claim 11
Dependent Claim
14 words
The process of claim 9 wherein the acrylate is 2-hydroxyethyl acrylate or 2-hydroxypropyl acrylate.
Claim 12
Dependent Claim
19 words
The process of claim 1 wherein Component (1) and all of Component (3) are prereacted to form a preadduct.
Claim 13
Dependent Claim
8 words
The product of the process of claim 1.
Claim 14
Dependent Claim
8 words
The product of the process of claim 8.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1983-12-23 | 1984-06-23 | 1984-12-23 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1987-12-23 | 1988-06-23 | 1988-12-23 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1991-12-23 | 1992-06-23 | 1992-12-23 | $7700.00 | Window Closed / Lapsed |