US5120770A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Use of liquid carbon dioxide as a blowing agent in the production of open-cell polyurethane foam
Assignee: Individual
•
Filing: 1989-11-29
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Granted: 1992-06-09
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Expires: 2009-11-29
Abstract
Abstract A process for the production of an open cell polyurethane foam comprises the mixing of the following components at ambient temperatures in a mixing zone: a diisocyanate having a functionality of at least about 2.0, at least one hydrogen donor, at least one surfactant which is effective in forming an open cell polyurethane foam, at least one catalyst, and a blowing agent comprising a gas having a boiling point below approximately -100° F. at atmospheric pressure which preferably comprises carbon dioxide. In addition, the mixture may also optionally contain water. The mixture is subjected to a pressure in said mixing zone which is sufficient to maintain the blowing agent in the liquid state at ambient temperatures. After mixing, the mixture is ejected from the mixing zone to atmospheric pressure, thereby completely and instantaneously vaporizing the blowing agent to provide expansion of the mixture. The resultant foam is then cured at ambient temperatures.
Inventors
- 👤 Earl N. Doyle
- 👤 Scott Carson
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-29 23:11
CPC Classifications
C; C08; C08J; C08J9/00; C08J9/04; C08J9/12; C08J9/127; C08J9/122; C08J9/14; C08J2203/00; C08J2203/14; C08J2203/142; C08J2205/00; C08J2205/04; C08J2205/05; C08J2375/00; C08J2375/04
Claims Analysis
Total Claims: 43
Claim 1
Independent Claim
183 words
A process for the production of an open-cell polyurethane foam in the absence of any substantial post-expansion, said process comprising: (a) mixing the following components at ambient temperatures in a mixing zone, (i) a diisocyanate having a functionality of about 2.0 to about 2.7, (ii) at least one hydrogen donor having a functionality of about 2 to about 4 and which is at least one polyol having a molecular weight of about 2000 to about 6500, (iii) at least one surfactant which is effective in forming an open-cell polyurethane foam, (iv) at least one catalyst, and (v) a blowing agent comprising a gas having a boiling point below approximately -100° F. at atmospheric pressure, the mixture being subjected to a pressure in said mixing zone which is sufficient to maintain said blowing agent in the liquid state at ambient temperatures, said mixture being substantially free of water; (b) ejecting said mixture from said mixing zone to atmospheric pressure, thereby completely and instantaneously vaporizing said blowing agent to provide substantially total expansion of said mixture, and (c) curing the resultant foam at ambient temperatures.
Claim 2
Dependent Claim
183 words
A process for the production of an open-cell polyurethane foam in the absence of any substantial post-expansion, said process comprising: (a) mixing the following components at ambient temperatures in a mixing zone, (i) a diisocyanate having a functionality of about 2.0 to about 2.7, (ii) at least one hydrogen donor having a functionality of about 2 to about 4 and which is at least one polyol having a molecular weight of about 2000 to about 6500, (iii) at least one surfactant which is effective in forming an open-cell polyurethane foam, (iv) at least one catalyst, and (v) a blowing agent comprising a gas having a boiling point below approximately -100° F. at atmospheric pressure, the mixture being subjected to a pressure in said mixing zone which is sufficient to maintain said blowing agent in the liquid state at ambient temperatures, said mixture being substantially free of water; (b) ejecting said mixture from said mixing zone to atmospheric pressure, thereby completely and instantaneously vaporizing said blowing agent to provide substantially total expansion of said mixture, and (c) curing the resultant foam at ambient temperatures.
Claim 3
Dependent Claim
23 words
The process of claim 1 whereby the blowing agent is selected from among carbon dioxide, nitrogen, helium, tetrafluoroethylene, fluoroform, hexafluoroethane, or mixtures thereof.
Claim 4
Dependent Claim
12 words
The process of claim 1 wherein said blowing agent is carbon dioxide.
Claim 5
Dependent Claim
24 words
The process of claim 1 wherein said mixture is subjected in said mixing zone to a pressure of about 300 to about 500 psi.
Claim 6
Dependent Claim
23 words
The process of claim 1 wherein said cured polyurethane foam has a density of about 0.75 to about 12 pounds per cubic feet.
Claim 7
Dependent Claim
17 words
The process of claim 1 wherein each of the components is separately metered into said mixing zone.
Claim 8
Dependent Claim
24 words
The process of claim 1 wherein said diisocyanate and said hydrogen donor are provided in a weight ratio of about 1:1 to about 1:25.
Claim 9
Dependent Claim
28 words
The process of claim 3 wherein said mixtures in said mixing zone comprise greater than about 3 percent by volume of said carbon dioxide in the liquid state.
Claim 10
Dependent Claim
29 words
The process of claim 8 wherein said mixture in said mixing zone comprises about 3 to about 40 percent by volume of said carbon dioxide in the liquid state.
Claim 11
Dependent Claim
29 words
The process according to claim 8 wherein the mixture in said mixing zone comprises about 10 to about 25 percent by volume of the carbon dioxide in liquid state.
Claim 12
Dependent Claim
15 words
The process of claim 1 wherein the catalyst is at least one tertiary amine catalyst.
Claim 13
Dependent Claim
14 words
The process of claim 1 wherein the catalyst is at least one metallic catalyst.
Claim 14
Dependent Claim
19 words
The process according to claim 1 wherein the diisocyanate comprises a pure diisocyanate or a prepolymer having desired-NCO percentage.
Claim 15
Dependent Claim
20 words
The process of claim 1 wherein the surfactant is selected from among a silicone polymer, a diester, or mixtures thereof.
Claim 16
Dependent Claim
22 words
The process according to claim 1 wherein at least two of the components are pre-mixed prior to introduction into the mixing zone.
Claim 17
Dependent Claim
26 words
The process according to claim 1 further including an additional higher boiling point solvent which introduces a controlled minor amount of post expansion into the foam.
Claim 18
Dependent Claim
31 words
The process according to claim 16 wherein the higher boiling point solvent is selected from among methylene chloride, methyl chloride, ethyl chloride, chloroform, chlorofluorocarbons, hydrochlorofluorocarbons, azodicarbonamides, hexane, heptane, or mixtures thereof.
Claim 19
Dependent Claim
33 words
The process according to claim 1 wherein at least a portion of the blowing agent is mixed with one or more of the other components at a point prior to the mixing zone.
Claim 20
Dependent Claim
31 words
The process of claim 1 wherein said blowing agent comprises carbon dioxide, and said diisocynate and said hydrogen donor being provided in a weight ratio of about 1:1 to about 1:25.
Claim 21
Dependent Claim
34 words
The process of claim 19 wherein at least a portion of the carbon dioxide blowing agent is mixed with one or more of the other components at a point prior to the mixing zone.
Claim 22
Dependent Claim
159 words
A process for the production of an open-cell polyurethane foam with varying degrees of post expansion comprising: (a) mixing in a mixing zone the following components at ambient temperatures; (i) a diisocyanate having a functionality of about 2.0 to about 2.7, (ii) at least one hydrogen donor having a functionality of about 2 to about 4 and which is at least one polyol having a molecular weight of about 2000 to about 6500, (iii) at least one surfactant which is effective in forming an open-cell polyurethane foam, (iv) at least one catalyst, (v) a blowing agent comprising a gas having a boiling point below approximately -100° F. at atmospheric pressure, and (vi) water, the mixture being subjected to a pressure in said mixing zone which is sufficient to maintain said blowing agent in the liquid state at ambient temperatures; (b) ejecting said mixture from said mixing zone to atmospheric pressure, and (c) curing the resultant foam at ambient temperatures.
Claim 23
Dependent Claim
159 words
A process for the production of an open-cell polyurethane foam with varying degrees of post expansion comprising: (a) mixing in a mixing zone the following components at ambient temperatures; (i) a diisocyanate having a functionality of about 2.0 to about 2.7, (ii) at least one hydrogen donor having a functionality of about 2 to about 4 and which is at least one polyol having a molecular weight of about 2000 to about 6500, (iii) at least one surfactant which is effective in forming an open-cell polyurethane foam, (iv) at least one catalyst, (v) a blowing agent comprising a gas having a boiling point below approximately -100° F. at atmospheric pressure, and (vi) water, the mixture being subjected to a pressure in said mixing zone which is sufficient to maintain said blowing agent in the liquid state at ambient temperatures; (b) ejecting said mixture from said mixing zone to atmospheric pressure, and (c) curing the resultant foam at ambient temperatures.
Claim 24
Dependent Claim
23 words
The process of claim 21 whereby the blowing agent is selected from among carbon dioxide, nitrogen, helium, tetrafluoroethylene, fluoroform, hexafluoroethane, or mixtures thereof.
Claim 25
Dependent Claim
12 words
The process of claim 21 wherein said blowing agent is carbon dioxide.
Claim 26
Dependent Claim
24 words
The process of claim 21 wherein said mixture is subjected in said mixing zone to a pressure of about 300 to about 5000 psi.
Claim 27
Dependent Claim
22 words
The process of claim 21 wherein said polyurethane foam has a density of about 0.75 to about 12 pounds per cubic feet.
Claim 28
Dependent Claim
17 words
The process of claim 21 wherein each of the components is separately metered into said mixing zone.
Claim 29
Dependent Claim
22 words
The process according to claim 21 wherein at least two of the components are pre-mixed prior to introduction into the mixing zone.
Claim 30
Dependent Claim
33 words
The process according to claim 27 wherein at least a portion of the blowing agent is mixed with one or more of the other components at a point prior to the mixing zone.
Claim 31
Dependent Claim
24 words
The process of claim 21 wherein said diisocyanate and said hydrogen donor are provided in a weight ratio of about 1:1 to about 1:25.
Claim 32
Dependent Claim
28 words
The process of claim 23 wherein said mixtures in said mixing zone comprises greater than about 3 percent by volume of said carbon dioxide in the liquid state.
Claim 33
Dependent Claim
29 words
The process of claim 30 wherein said mixture in said mixing zone comprises about 3 to about 40 percent by volume of said carbon dioxide in the liquid state.
Claim 34
Dependent Claim
15 words
The process of claim 21 wherein the catalyst is at least one tertiary amine catalyst.
Claim 35
Dependent Claim
14 words
The process or claim 21 wherein the catalyst is at least one metallic catalyst.
Claim 36
Dependent Claim
20 words
The process according to claim 21 wherein the diisocyanate comprises a pure diisocyanate or a prepolymer having a desired-NCO percentage.
Claim 37
Dependent Claim
20 words
The process of claims 21 wherein the surfactant is selected from among a silicone polymer, a diester, or mixtures thereof.
Claim 38
Dependent Claim
26 words
The process of claim 21 wherein the water is present in an amount of about 0.25 to about 3 percent by weight of the total formula.
Claim 39
Dependent Claim
26 words
The process according to claim 21 further including an additional higher boiling point solvent which introduces a controlled minor amount of post expansion into the foam.
Claim 40
Dependent Claim
31 words
The process according to claim 37 wherein the higher boiling point solvent is selected from among methylene chloride, methyl chloride, ethyl chloride, chloroform, chlorofluorocarbons, hydrochlorofluorocarbons, azodicarbonamides, hexane, heptane, or mixtures thereof.
Claim 41
Dependent Claim
34 words
The process of claim 21 wherein at least a portion of the carbon dioxide blowing agent is mixed with one or more of the other components at a point prior to the mixing zone.
Claim 42
Dependent Claim
31 words
The process of claim 21 wherein said blowing agent comprises carbon dioxide, and said diisocynate and said hydrogen donor being provided in a weight ratio of about 1:1 to about 1:25.
Claim 43
Dependent Claim
34 words
The process of claim 40 wherein at least a portion of the carbon dioxide blowing agent is mixed with one or more of the other components at a point prior to the mixing zone.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1995-06-09 | 1995-12-09 | 1996-06-09 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1999-06-09 | 1999-12-09 | 2000-06-09 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2003-06-09 | 2003-12-09 | 2004-06-09 | $7700.00 | Window Closed / Lapsed |