US4338407A — Stabilization of high resilience polyurethane foam

Claim 1

Independent Claim 170 words

In a process for preparing a high resilience polyurethane foam from a reaction mixture comprising: (a) a polyether polyol having a molecular weight of at least about 1,500, a polyhydroxy alcohol nucleus having a functionality from about 2 to about 8, polyoxyalkylene chain segments attached to said nucleus, and a ratio of primary to secondary hydroxyl end groups ranging from about 1.5:1 to about 5.5:1; (b) an organic polyisocyanate; (c) a foaming agent; and (d) a reaction catalyst; said process including the steps of: including in said reaction mixture a polyol containing a proportion of an effectively dispersed finely divided solid particulate material, said particulate material having, prior to dispersion in said polyol, an average primary particle size of about 0.007 to about 10 microns and a pH ranging from about 3 to about 5, and further having, in dispersion in said polyol, an effective maximum particle size of less than about 75 microns; and adding to said reaction mixture an effective proportion of 1,4-cyclohexanedimethanol to stabilize said reaction mixture.

Claim 2

Dependent Claim 170 words

In a process for preparing a high resilience polyurethane foam from a reaction mixture comprising: (a) a polyether polyol having a molecular weight of at least about 1,500, a polyhydroxy alcohol nucleus having a functionality from about 2 to about 8, polyoxyalkylene chain segments attached to said nucleus, and a ratio of primary to secondary hydroxyl end groups ranging from about 1.5:1 to about 5.5:1; (b) an organic polyisocyanate; (c) a foaming agent; and (d) a reaction catalyst; said process including the steps of: including in said reaction mixture a polyol containing a proportion of an effectively dispersed finely divided solid particulate material, said particulate material having, prior to dispersion in said polyol, an average primary particle size of about 0.007 to about 10 microns and a pH ranging from about 3 to about 5, and further having, in dispersion in said polyol, an effective maximum particle size of less than about 75 microns; and adding to said reaction mixture an effective proportion of 1,4-cyclohexanedimethanol to stabilize said reaction mixture.

Claim 3

Dependent Claim 24 words

The process of claim 1 wherein said particulate material is dispersed to an effective particle size in dispersion of less than about 50 microns.

Claim 4

Dependent Claim 24 words

The process of claim 2 wherein said particulate material is dispersed to an effective particle size in dispersion of less than about 25 microns.

Claim 5

Dependent Claim 29 words

The process of claim 1 wherein said particulate material is added in a proportion ranging from about 0.1 to about 5.0 percent, by weight, based on polyether polyol weight.

Claim 6

Dependent Claim 16 words

The process of claim 4 wherein said proportion ranges from about 0.25 to about 1.0 percent.

Claim 7

Dependent Claim 31 words

The process of claim 1 wherein said 1,4-cyclohexanedimethanol is added in a stabilizing amount ranging from about 0.5 to about 10 parts per 100 parts by weight of said polyether polyol.

Claim 8

Dependent Claim 17 words

The process of claim 6 wherein said stabilizing amount ranges from about 0.5 to about 5 parts.

Claim 9

Dependent Claim 40 words

The process of claim 1 wherein said finely divided solid particulate material is selected from the group consisting of non-metal oxides, metal oxides, metal silicates, metal salts, solid organic polymers, solid inorganic polymers, graphite, carbon, organic pigments, and mixtures thereof.

Claim 10

Dependent Claim 26 words

The process of claim 8 wherein said particulate material is selected from the group consisting of synthetic silicon dioxide, titanium dioxide, aluminum oxide, and mixtures thereof.

Claim 11

Dependent Claim 14 words

The process of claim 9 wherein said particulate material is a synthetic amorphous silica.

Claim 12

Dependent Claim 15 words

The process of claim 10 wherein said particulate material is a synthetic hydrophobic amorphous silica.

Claim 13

Dependent Claim 41 words

The process of claim 8 wherein, prior to dispersion into said polyol, said particulate material has a surface area of about 50 to about 400 m 2 /g, and a bulk density of about 1 to about 10 lbs./ft. 3 .

Claim 14

Dependent Claim 37 words

The process of claim 1 wherein said polyether polyol reactant has a molecular weight of about 4,000 to about 7,000, and a ratio of primary to secondary hydroxyl end groups ranging from about 2:1 to about 5:1.

Claim 15

Dependent Claim 40 words

The process of claim 11 wherein said polyether polyol reactant is a triol having a molecular weight of about 4,500 to about 6,600, and a ratio of primary to secondary hydroxyl end groups ranging from about 3:1 to about 4.5:1.

Claim 16

Dependent Claim 77 words

The process of claim 13 including about 0.1 to about 5.0 percent of said particulate material selected from silicon dioxide, titanium dioxide, aluminum oxide, and mixtures thereof, said particulate material having a surface area of about 50 to about 400 m 2 /g, and a bulk density of about 1 to about 10 lbs./ft. 3 , and being dispersed to an effective maximum particle size in dispersion in the range of about 10 to about 20 microns.

Claim 17

Dependent Claim 11 words

A polyurethane foam prepared according to the process of claim 1.

Claim 18

Dependent Claim 11 words

A polyurethane foam prepared according to the process of claim 11.

Claim 19

Dependent Claim 11 words

A polyurethane foam prepared according to the process of claim 12.

Claim 20

Dependent Claim 11 words

A polyurethane foam prepared according to the process of claim 15.

Claim 21

Dependent Claim 159 words

A two-part reaction formulation for use in preparing a high resilience polyurethane foam, comprising: an "A" part which includes an organic polyisocyanate; and a "B" part which includes: a polyether polyol having a molecular weight of at least about 1,500, a polyhydroxy alcohol nucleus having a functionality from about 2 to about 8, polyoxyalkylene chain segments attached to said nucleus, and a ratio of primary to secondary hydroxyl end groups ranging from about 1.5:1 to about 5.5:1, said polyol containing a proportion of an effectively dispersed finely divided solid particulate material, said particulate material having, prior to dispersion in said polyol, an average primary particle size of about 0.007 to about 10 microns and a pH ranging from about 3 to about 5, and further having, in dispersion in said polyol, an effective maximum particle size of less than about 75 microns; a foaming agent; a reaction catalyst; and an effective proportion of 1,4-cyclohexanedimethanol to stabilize said reaction mixture.

Claim 22

Dependent Claim 159 words

A two-part reaction formulation for use in preparing a high resilience polyurethane foam, comprising: an "A" part which includes an organic polyisocyanate; and a "B" part which includes: a polyether polyol having a molecular weight of at least about 1,500, a polyhydroxy alcohol nucleus having a functionality from about 2 to about 8, polyoxyalkylene chain segments attached to said nucleus, and a ratio of primary to secondary hydroxyl end groups ranging from about 1.5:1 to about 5.5:1, said polyol containing a proportion of an effectively dispersed finely divided solid particulate material, said particulate material having, prior to dispersion in said polyol, an average primary particle size of about 0.007 to about 10 microns and a pH ranging from about 3 to about 5, and further having, in dispersion in said polyol, an effective maximum particle size of less than about 75 microns; a foaming agent; a reaction catalyst; and an effective proportion of 1,4-cyclohexanedimethanol to stabilize said reaction mixture.

Claim 23

Dependent Claim 24 words

The formulation of claim 20 wherein said particulate material is dispersed to an effective particle size in dispersion of less than about 50 microns.

Claim 24

Dependent Claim 24 words

The formulation of claim 21 wherein said particulate material is dispersed to an effective particle size in dispersion of less than about 25 microns.

Claim 25

Dependent Claim 31 words

The formulation of claim 20 wherein said 1,4-cyclohexanedimethanol is added in a stabilizing amount ranging from about 0.5 to about 10 parts per 100 parts by weight of said polyether polyol.

Claim 26

Dependent Claim 17 words

The formulation of claim 23 wherein said stabilizing amount ranges from about 0.5 to about 5 parts.

Claim 27

Dependent Claim 40 words

The formulation of claim 20 wherein said finely divided solid particulate material is selected from the group consisting of non-metal oxides, metal oxides, metal silicates, metal salts, solid organic polymers, solid inorganic polymers, graphite, carbon, organic pigments, and mixtures thereof.

Claim 28

Dependent Claim 26 words

The formulation of claim 25 wherein said particulate material is selected from the group consisting of synthetic silicon dioxide, titanium dioxide, aluminum oxide, and mixtures thereof.

Claim 29

Dependent Claim 14 words

The formulation of claim 26 wherein said particulate material is a synthetic amorphous silica.

Claim 30

Dependent Claim 15 words

The formulation of claim 27 wherein said particulate material is a synthetic hydrophobic amorphous silica.

Claim 31

Dependent Claim 62 words

The formulation of claim 28 wherein said particulate material has, prior to dispersion in said polyol, a surface area of about 50 to about 400 m 2 /g, and a bulk density of about 1 to about 10 lbs./ft. 3 , and further has, in dispersion in said polyol, an effective maximum particle size ranging from about 10 to about 20 microns.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1985-07-05	1986-01-04	1986-07-06	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1989-07-05	1990-01-04	1990-07-06	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1993-07-05	1994-01-04	1994-07-06	$7700.00	Window Closed / Lapsed

Stabilization of high resilience polyurethane foam

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