Novel process for making polyurethane products which require reduced crushing in preventing said products from substantially shrinking or changing dimensionally upon cooling

Claim 2

A process for making molded high resilience polyurethane cellular products which require reduced crushing in preventing said products from substantially shrinking or changing dimensionally upon cooling comprising: (a) introducing a liquid foamable polyurethane reaction mixture into a mold adopted to expose the mixture to atmospheric pressure during the curing of said product and said mold adapted to be closed; (b) closing said mold; (c) permitting said reaction mixture to expand into contact with the confines of the mold to form a curing molded polyurethane cellular product containing cells having cell walls of curing polyurethane and pressurized expansion gases contained within and supporting said cell walls; (d) exposing said curing product to atmospheric pressure while in contact with the confines of the mold at a time when said cell walls of said curing polyurethane cellular product have cured sufficiently to develop sufficient strength to partially resist bursting by the pressure of said expansion gases contained within said cell walls upon exposure to atmospheric pressure, but before said cell walls have cured sufficiently to develop sufficient strength so that exposure to atmospheric pressure does not result in a reduction of the crushing force necessary to prevent said products from substantially shrinking or changing dimensionally; (e) allowing said curing polyurethane product to continue to cool and cure in said mold until it has developed sufficient strength to be removed from the mold without permanently distorting its shape; (f) removing said product from said mold; and (g) crushing said product to prevent shrinkage or dimensional change.

Claim 3

A process for making molded high resilience polyurethane cellular products which require reduced crushing in preventing said product from substantially shrinking or changing dimensionally upon cooling comprising: (a) introducing a liquid foamable polyurethane reaction mixture into a mold adopted to expose the mixture to atmospheric pressure during the curing of said product and said mold adapted to be closed; (b) closing said mold; (c) permitting said reaction mixture to expand into contact with the confines of the mold to form a curing molded polyurethane cellular product containing cells having cell walls of curing polyurethane and pressurized expansion gases contained within and supporting said cell walls; (d) exposing said curing product to atmospheric pressure while in contact with the confines of the mold at a time when said cell walls of said curing polyurethane cellular product have cured sufficiently to develop sufficient strength to partially resist bursting by the pressure of said expansion gases contained within said walls upon exposure to atmospheric pressure, but before said cell walls have cured sufficiently to develop sufficient strength so that exposure to atmospheric pressure does not result in a reduction of crushing force of at least 25% in a regular demold system in the crushing step necessary to prevent said products from substantially shrinking or changing dimentionally; (e) allowing said curing polyurethane product to continue to cool and cure in said mold until it has developed sufficient strength to be removed from the mold without permanently distorting its shape; (f) removing said product from said mold; and (g) crushing said product to prevent shrinkage or dimensional change.

Claim 4

A process for making molded high resilience polyurethane cellular products which require reduced crushing in preventing said product from substantially shrinking or changing dimensionally upon cooling comprising: (a) introducing a liquid foamable polyurethane reaction mixture into a mold adopted to expose the mixture to atmospheric pressure during the curing of said product and said mold adapted to be closed; (b) closing said mold; (c) permitting said reaction mixture to expand into contact with the confines of the mold to form a curing molded polyurethane cellular product containing cells having cell walls of curing polyurethane and pressurized expansion gases contained within and supporting said cell walls; (d) exposing said curing product to atmospheric pressure while in contact with the confines of the mold at a time when said cell walls of said curing polyurethane cellular product have cured sufficiently to develop sufficient strength to partially resist bursting by the pressure of said expansion gases contained within said walls upon exposure to atmospheric pressure, but before said cell walls have cured sufficiently to develop sufficient strength so that exposure to atmospheric pressure does not result in a reduction of crushing force of at least 25% in a regular demold system in the crushing step necessary to prevent said products from substantially shrinking or changing dimentionally; (e) allowing said curing polyurethane product to continue to cool and cure in said mold until it has developed sufficient strength to be removed from the mold without permanently distorting its shape; (f) removing said product from said mold; and (g) crushing said product to prevent shrinkage or dimensional change.

Claim 5

The process according to claim 1 wherein the molded high resilience polyurethane cellular products are made from highly reactive polyurethane reaction mixtures characteristic of rapld demold systems.

Claim 6

The process according to claim 1 wherein the force to crush the molded high resilience polyurethane cellular products is reduced from 10% to 90%.

Claim 7

The process according to claim 2 wherein the force to crush the molded high resilience polyurethane cellular products is reduced from 25% to 90%.

Claim 8

The process according to claim 1 wherein a vacuum is used to increase the pressure differential between internal cell gases and the pressure outside the mold.

Claim 9

The process according to claim 2 wherein a vacuum is used to increase the pressure differential between internal cell gases and the pressure outside the mold.

Claim 10

The process according to claim 1 wherein a silicone surfactant is employed in an amount up to 6.0 parts by weight of the total system.

Claim 11

The process according to claim 2 wherein a silicone surfactant is employed in an amount up to parts by weight of the total system.