Semi-flexible foam polymer used in packaging

Claim 2

A semi-flexible foam polymer having a density of from about 0.35 to about 1 pound per cubic foot, said polymer being prepared from a reaction mixture having an over-all index of about 20 to about 70, wherein said reaction mixture comprises: (a) a polymeric polyisocyanate having an average functionality of about 2 to about 3.5; (b) a polyether polyol having 2-4 hydroxy groups and a molecular weight from about 500 to about 3,000, said polyether polyol being employed in a proportion of about 10 to about 70 parts per every 100 parts by weight of total polyisocyanate in said reaction mixture; (c) a foaming agent which consists essentially of water and is substantially free of fluorinated hydrocarbon compounds, said foaming agent being employed in a proportion of about 7 to about 30 parts per every 100 parts of total polyisocyanate in said reaction mixture; (d) an amine catalyst; and (e) a silicon-based surfactant.

Claim 3

The semi-flexible foam polymer of claim 1, wherein said reaction mixture further comprises a supplemental polyol having 3-8 hydroxy groups and a hydroxyl number of about 300-700.

Claim 4

The semi-flexible foam polymer of claim 1, wherein said polyether polyol is an oxypropylated then oxyethylated diol or triol.

Claim 5

The semi-flexible foam polymer of claim 1, wherein: (a) said polyether polyol is an oxypropylated then oxyethylated triol; and (b) said amine catalyst is a tertiary amine.

Claim 6

The semi-flexible foam polymer of claim 4, wherein per every 100 parts by weight of total polyisocyanate in said reaction mixture, there are employed: (a) about 20 to about 50 parts of said polyether polyol; (b) about 12 to about 20 parts of said foaming agent; and (c) about 0.2 to about 8 parts of said silicon-based surfactant.

Claim 7

The semi-flexible foam polymer of claim 5, wherein said reaction mixture further comprises a supplemental polyol having 4-6 hydroxy groups and a hydroxyl number of about 400-600.

Claim 8

The semi-flexible foam polymer of claim 6, wherein said polymeric polyisocyanate is polymethylene polyphenylisocyanate and has a functionality of about 2.2-3.0.

Claim 9

A semi-flexible foam polymer having a density of from about 0.35 to about 0.5 pound per cubic foot, said polymer being prepared from a reaction mixture having an over-all index of about 30 to about 50, wherein reaction mixture comprises: (a) polymethylene polyphenylisocyanate having a functionality of about 2.4-2.8; (b) an oxypropylated then oxyethylated triol having a molecular weight of about 800-2,000, said triol being employed in a proportion of about 20 to about 50 parts per every 100 parts by weight of total polyisocyanate in said reaction mixture; (c) a foaming agent which consists essentially of water and is substantially free of fluorinated hydrocarbon compounds, said foaming agent being employed in a proportion of about 12 to about 20 parts per every 100 parts by weight of total polyisocyanate in said reaction mixture; (d) a catalytic proportion of a tertiary amine catalyst; and (e) a non-hydroxyzable silicon-based surfactant in a proportion of about 0.4 to about 4 parts per every 100 parts by weight of total polyisocyanate in said reaction mixture.

Claim 10

A semi-flexible foam polymer having a density of from about 0.35 to about 0.5 pound per cubic foot, said polymer being prepared from a reaction mixture having an over-all index of about 30 to about 50, wherein reaction mixture comprises: (a) polymethylene polyphenylisocyanate having a functionality of about 2.4-2.8; (b) an oxypropylated then oxyethylated triol having a molecular weight of about 800-2,000, said triol being employed in a proportion of about 20 to about 50 parts per every 100 parts by weight of total polyisocyanate in said reaction mixture; (c) a foaming agent which consists essentially of water and is substantially free of fluorinated hydrocarbon compounds, said foaming agent being employed in a proportion of about 12 to about 20 parts per every 100 parts by weight of total polyisocyanate in said reaction mixture; (d) a catalytic proportion of a tertiary amine catalyst; and (e) a non-hydroxyzable silicon-based surfactant in a proportion of about 0.4 to about 4 parts per every 100 parts by weight of total polyisocyanate in said reaction mixture.

Claim 11

The semi-flexible foam polymer of claim 8, wherein said reaction mixture further comprises a supplemental polyol having a hydroxyl number of about 400-600 and which is the product of reacting alkylene oxide having 2-4 carbon atoms with a mixture of sucrose and an alkanolamine.