AU622408B2 - Creation of Inventions and Patents with Artificial Intelligence

AU622408B2 – Rapid cure of polyurethane foam with ammonium containing materials
– Google Patents

AU622408B2 – Rapid cure of polyurethane foam with ammonium containing materials
– Google Patents
Rapid cure of polyurethane foam with ammonium containing materials

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Publication number
AU622408B2

AU622408B2
AU19421/88A
AU1942188A
AU622408B2
AU 622408 B2
AU622408 B2
AU 622408B2
AU 19421/88 A
AU19421/88 A
AU 19421/88A
AU 1942188 A
AU1942188 A
AU 1942188A
AU 622408 B2
AU622408 B2
AU 622408B2
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AU
Australia
Prior art keywords
foam
ammonia containing
ammonia
containing material
parts
Prior art date
1987-05-21
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AU19421/88A
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AU1942188A
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Inventor
Gregory Wayne Howard
Ronald Lance Murph
Michael Anthony Ricciardi
Fred Norman Teumac
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Foamex LP

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Foamex LP
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1987-05-21
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1988-05-19
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1992-04-09

1988-05-19
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1988-12-21
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patent/AU1942188A/en

1992-01-23
Assigned to FOAMEX L.P.
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FOAMEX L.P.
Alteration of Name(s) of Applicant(s) under S113
Assignors: REEVES BROTHERS INC.

1992-04-09
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1992-04-09
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patent/AU622408B2/en

2008-05-19
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Classifications

C—CHEMISTRY; METALLURGY

C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON

C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS

C08G18/00—Polymeric products of isocyanates or isothiocyanates

C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen

C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen

C08G18/2805—Compounds having only one group containing active hydrogen

C08G18/285—Nitrogen containing compounds

C08G18/2865—Compounds having only one primary or secondary amino group; Ammonia

C—CHEMISTRY; METALLURGY

C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON

C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS

C08G2110/00—Foam properties

C08G2110/0008—Foam properties flexible

C—CHEMISTRY; METALLURGY

C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON

C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS

C08G2110/00—Foam properties

C08G2110/0083—Foam properties prepared using water as the sole blowing agent

Abstract

Methods for rapidly curing flexible polyether-derived foam in situ by adding to the foam forming composition an ammonia containing material having a decomposition temperature below the temperature of the highest reaction exotherm of the foam-forming composition and decomposing the ammonia containing material by exposure to the heat of the exotherm produced by reaction of the foam-forming components to release ammonia to cure the foam by contact therewith.

Description

64 “C ~ir 9 AU-AI-19421/88 S’PCT WORLD INTELLECTUAL PROPERTY ORGANIZATION V T A International Bureau INTERNATIONAL APPLICATI P IS E E ENT COOPERATION TREATY (PCT) (51) International Patent Classification 4 (11) International Publication Number: WO 88/ 09352 C08G 18/30 Al (43) International Publication Date: I December 1988 (01.12.88) (21) International Application Number: PCT/US88/01729 (22) International Filing Date: (31) Priority Application Number: (32) Priority Date: (33) Priority Country: 19 May 1988 (19.05.88) 052,815 21 May 1987 (21.05.87)
US
(74) Agent: LAWRENCE, Stanton, III; Pennie Edmonds, 1155 Avenue of the Americas, New York, NY 10036 (US).
(81) Designated States: AT (European patent), AU, BE (European patent), BR, CH (European patent), DE (European patent), FR (European patent), GB (European patent), IT (European patent), JP, KR, LU (European patent), NL (European patent), SE (European paeat— -LI (71) SECTION 113 DIRECTION SEE FOLIO (72) NAME DIRECTED Charlotte, NC 28213 (US).
SA’
2 *2jl-i F e*l~~n -r J AUSTRALi-AN 2 1 DEC 1988 PATENT OFFICE (54) Title: RAPID CURE OF POLYURETHANE FOAM WITH AMMONIUM CONTAINING MATERIALS (57) Abstract Methods for rapidly curing flexible polyether-derived foam in situ by adding to the foam forming composition an ammonia containing material having a decomposition temperature below the temperature of the highest reaction exotherm of the foam-forming composition and decomposing the ammonia containing material by exposure to the heat of the exotherm produced by reaction of the foam-forming components to release ammonia to cure the foam by contact therewith.
‘WO 88/09352 PCT/US88/01729 -1- RAPID CURE OF POLYURETHANE FOAM WITH AMMONIUM CONTAINING ,MA’RIALS Technical Field The invention relates to a method for rapidly curing polyurethane foam wherein ammonia is released from ammonia containing materials which at least partially decompose when exposed to the heat generated by reaction of the foam forming components.
Background Art Polyurethane foam is prepared commercially in the form of large blocks that are subsequently cut into the desired shape for use in the manufacture of various articles that require a foam padding. It is well known that polyurethane foam requires time to cure and develop its full physical properties. In typical polyurethane foam formulations, a polyhydroxy material (“polyol”), water and an organic isocyanate compound are reacted in the presence of catalysts or other additives. Much of the time, a small percentage of terminal isocyanate groups are left unreacted in the foam structure. If the foam is distorted or compressed in this condition, it fails to recover its original dimensions when the distorted or compressive force is released. Normally, the terminal isocyanate groups that are left unreacted in the foam structure will react with the residual water in the foam structure or with the water vapor in the atmosphere over a period of several hours or days, and the foam will ultimately 3 achieve its full physical properties.
As pointed out in the Encyclopedia of Polymer in the section on Polyurethanes, polyethers are commercially I! r WO 88/09352 PCT/US88/,01729 -2the most important of the polyols used to prepare polyurethanes. At the present time most of the polyethers used in the production of flexible polyurethane foams are derived from propylene oxide and ethylene oxide. In this preparation, propylene oxide is reacted with glycerol in the presence of a basic catalyst to form a poly(oxypropylene) homopolymer which is further reacted with ethylene oxide to form a block copolymer.
Post-curing of polyether derived foam by exposure to a mixture of water vapor and gaseous ammonia, primary -or secondary amines at temperatures of about 50 to 150’F for a period of at least one minute is disclosed in U.S. Patent No.
4,537,912. While this process effectively and rapidly cures the foam, it constitutes an additional step beyond those normally used in the foam manufacturing process. This process also requires storage of the foam prior to the postcuring treatment. It is more desirable to cure the foam as it is manufactured to reduce or even eliminate such storage time and to prepare a fully cured foam material which can be immediately shipped to the end users after cutting to the desired shapes. The present invention provides one solution to this problem in that a one-step foaming and curing process is disclosed herein. This process achieves a rapid and full post cure of the foam so that the foam will exhibit low compression set values as measured by ASTM standard test D-3574 (Constant Deflection Compression Set Test), with the p’ elimination of post curing steps.
Summary of the Invention The present invention relates to a method for the rapid curing of flexible polyether-derived foam without adversely affecting the resulting physical properties of the foam.
This method includes the steps of adding to a foam forming composition of a polyether polyol, an organic isocyanate i wo 88/09352 PCT/US88/0 1729 -3compound and water, an ammonia containing material having a decomposition temperature below the temperature of the highest reaction exotherm of the foam-forming composition; forming the foam by reaction of the foam-forming components thereby generating heat; and at least partially decomposing the ammonia containing material by exposure to the generates heat to release ammonia to cure the foam by contact therewith.
The ammonia containing material can be an ammonium salt, an encapsulated ammonia containing material, or certain ammonia containing zeolites, each of which are relatively insoluble in the polyol and preferably have a decomposition temperature of at least about 225°F and up to about 300°F.
Alternately, other ammonia containing compounds which have a higher solubility in the polyol or which have lower decomposition temperatures can be encapsulated so that the compound is prevented from affecting the reaction mixture until the heat generated by the exotherm breaks through the encapsulation and allows the ammonia to be generated at the appropriate time during the manufacturing process to cure the foam.
t. Detailed Description of the Preferred Embodiments ii -‘Ammonia and, alternatively, primary and secondary amines, with or without the presence of moisture or moisture vapor, are effective in causing the completion of cure of any active chemical components which remain in the foam after the foam forming reactions. Ammonia would, however, also interfere with the complex reactions that occur during the initial production of foam, and for this reason cannot simply be added to the foam forming components. This invention provides new and different methods for releasing ammonia in the foam during the foam forming process but after the initial foam forming reactions have occurred.
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‘4 I i WO 88/09352 PCT/US88/,01729 -4- The term “polyether polyurethane” as used throughout this application refers to polyurethanes derived by polyether polyols. This class would include the poly(oxytetramethylene) glycols which are prepared by the polymerization of tetrahydrofuran. Poly(oxypropylene) triols are another important group of polyethers used in the manufacture of polyurethanes which are included in this class. These triols are prepared by the same general reactions as poly(oxypropylene) glycols. The polyurethanes derived from polyesters do not normally present post-curing problems and thus do not form part of this invention.
The term “organic isocyanate compound” is used to describe the isocyanate or polyisocyanate compounds that are suitable for use in this invention. Such organic isocyanate compounds include aromatic, aliphatic, and cycloaliphatic polyisocyanates and combinations thereof. Representative of these types are the diisocyanates such as m-phenylene diisocyanate, 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, mixtures of 2,4- and 2,6-toluene diisocyanate, hexamethylene diisocyanate, tetramethylene diisocyanate, cyclohexane-1,4-diisocyanate, hexahydrotoluene diisocyanate (and isomers), naphthalene- l-methoxyphenyl-2,4-diisocyanate, 4,4′-diphenylmethane diisocyanate, 4,4′-biphenylene diisocyanate, 3,3-dimethoxy- 4,4′-biphenyl diisocyanate, 3,3′-dimethoxy-4,4′-biphenyl diisocyanate, 3,3′-dimethyl-4,4′-biphenyl diisocyanate and 3,3′ -dimethyldiphenylmethane-4,4′-diisocyanate; the triisocyanates such as 4,4′,4″-triphenylmethane triisocyanate, and toluene 2,4,6-triisocyanate; and the tetraisocyanates such as 4,4′-dimethyldiphenylmethane-2,2’and polymeric polyisocyanates such as polymethylene polyphenylene polyisocyanate. Especially useful due to their availability and properties are toluene WO 88/09352 PCT/US88/01729 diisocyanate, 4,4’-diphenylmethane diisocyanate and polymethylene polyphenylene polyisocyanate.
Crude polyisocyanates may also be used in the compositions of the present invention, such as crude toluene diisocyanate obtained by the phosgenation of a mixture of toluene diamines or crude diphenylmethane isocyanate obtained by the phosgenation of crude diphenylmethane diamine. The preferred crude isocyanates are disclosed in U.S. Pat. No.
3,215,652.
The polyurethane foams employed in the present invention are generally prepared by the reaction of the polyether polyol with the organic isocyanate compound in the presence of a blowing agent such as water and, optionally, in the presence of additional polyhydroxyl-containing components, chain-extending agents, catalysts, surface-active agents, stabilizers, dyes, fillers and pigments. The preparation of cellular polyurethane plastic foam is well known in the art.
Corresponding quantities of excess isocyanate compound are used to react with a blowing agent, generally water.
It is also possible to proceed with the preparation of the polyurethane plastics by a prepolymer technique wherein an excess of the organic isocyanate compound is reacted in a first step with the polyol of the present invention to prepare a prepolymer having free isocyanate groups which is then reacted in a second step with water and/or additional polyols to prepare a foam. Alternatively, the components may be reacted in a single working step commonly known as the “one-shot” technique of preparing polyurethanes.
After the initial formation of the foam, an exotherm is generated due to the reaction of the foam forming components.
WO 88/09352 PCT/US88,/01729 -6- The temperature of the exotherm usually ranges from about 225 to 350*F. Thus, the invention resides in the discovery that ammonia containing compounds or materials which decompose at the temperatures generated by the reaction exotherm enable ammonia to be released in the foam after the initial foam forming reactions have occurred so as to cure the foam in situ.
It is known from U.S. Pat. No. 4,537,912 that the presence of moisture with ammonia or amines causes the curing of the foam to occur very rapidly. In the current invention, the ammonia is supplied by the ammonia containing compounds and the foam gains sufficient moisture from the formulation and/or atmosphere, particularly on days of high relative humidity, to achieve this rapid cure. When the relative humidity is very low, moisture generating salts can be added along with the ammonia containing compounds to the foam forming components to release both moisture and ammonia by exposure to the exotherm temperature.
By binding or preventing the release of ammonia until the exotherm, the foam forming reaction proceeds without interruption. The ammonia can be bound by a number of methods. One way is to utilize ammonia containing compounds i 25 which are relatively insoluble in the polyol and which preferably have a decomposition temperature above 225’F and up to about 300*F. Compounds having a decomposition temperature between 275 and 300’F are most advantageous.
Such compounds include ammonium orthophosphate, monohydrogen (decomposition temperature 300’F), ammonium citrate (277’F), and ammonium oxalate (285*F). Also, a number of ammonium polyphosphates are suitable: these compounds are fully described in U.S. Patent No. 4,515,632, the content of which is expressly incorporated by reference herein. Of all these compounds, the ammonium polyphosphates are preferred because they are relatively insoluble in the polyol and the mixture 4) WO 88/09352 PCT/US88/01729 -7of foam forming components. Such water-insoluble ammonium polyphosphates are disclosed in U.S. Patent No. 4,511,546, the content of which is expressly incorporated by reference ‘herein.
Compounds which have lower decomposition temperatures between 175 and 225″F) or which are soluble in the polyol or the mixture of foam forming components have been found to interfere with the foam-forming reaction because the ammonia is released too early. Although the solubility of such compounds in various polyether polyols is not known, it appears that the polyol solubility parallels that of the compound in water. Therefore, ammonia containing compounds which are completely water soluble, by themselves, are not suitable for use in the invention. Other ammonium compounds having a lower degree of solubility in water can be routinely tested to determine if they provide suitable performance in the process of this invention. Generally, those which are relatively insoluble in water should provide satisfactory results.
In order to utilize the relatively water-soluble ammonia containing compounds, an encapsulating resin material that decomposes or breaks down at the exotherm temperatures is used, so that ammonia containing compounds are not exposed until the exotherm is achieved to then release the ammonia and cure the foam. Suitable compounds for encapsulation include ammonium carbonates, carbamates, phosphates, J’ phosphonates and the like. Specific examples of these compounds are well know in the art and would include, for example, those described in U.S. Patent No. 4,066,578, the content of which is expressly incorporated by reference herein. A commercial ammonium polyphosphate product of Monsanto, PHOSCHEK P-30, when encapsulated with a suitable resin, is another example of this type compound. The water- I soluble ammonium salts of various organic acids, when encapsulated, are also useful in the process of this inventi6m.-, WO 88/09352 PCT/US88/0 1729 -8- A number of commercial products based on encapsulated ammonium polyphosphates are available from Hoechst under the tradename EXOLIT: these compounds are described in U.S.
Patent No. 4,467,056, the content of which is also expressly incorporated by reference herein. The solubility of the polyphosphates is reduced by the encapsulation by an epoxy or melamine-formaldehyde resin. These resins are also suitable for encapsulation of the other low decomposition temperature ammonia containing compounds described above. Specifically, EXOLIT 422, 455 and 462 are preferred for use in the proces- .ses of the present invention.
A further clrss of suitable materials includes the ammonia containing zeolites. The P.Q. Corporation, Valley Forge, PA, markets a product known as NH4NaA Zeolite, which has no free ammonia at room temperature, but which loses percent by weight at 300*F due to ammonia and water release.
Although the use of a single ammonia containing material is preferred from the standpoint of simplicity of formulation, mixtures of two or more of the same type or of different types also are suitable in achieving the results of the invention, and such mixtures are included in the scope of this invention.
As noted above, for periods reative the addition of a source of moisture may be desiae. Such sources include: water, steam, microenc ated water, or other water generating compound.s- so, the zeolite materials described-above ease water during exposure to the exother tempe ures, and are preferred for use under low humid conditions.
LI 1 i i -I -88- The amount of ammonia containing material or ammonia containing zeolite used in the process of the present invention is preferably between about 1 and 3 parts by weight of 100 parts polyol; more preferably between about 1.5 and 2 parts by weight of 100 parts polyol.
As noted above, for periods of low relative humidity, the addition of a source of moisture may be desirable. Such sources include: water, steam, microencapsulated water, or other water generating compounds. Also, the zeolite materials described above release water during exposure to the exotherm temperatures, and are preferred for use under low humidity conditions.
S
39 WO 88/09352 PCT/US88/01729 i -9- With the exception of the zeolite materials, these ammonia containing compounds also have some utility as flame retardant additives for the foam. Therefore, it may be possible to reduce the amounts of other flame retardant Sadditives when these compounds are used, thus providing an additional advantage for foam produced by these processes.
Other additives which may be incorporated into to these form foaming compositions are well known to those skilled in the art, and would include, for example, catalysts, chain extending agents, surfactants or surface active agents, and/or flame retardant additives.
Suitable flame retardants for use in the composition of the invention include those which are conventionally used in the art of making flexible, flame retardant polyurethane foams, such as tri-esters of phosphoric acid, halogenated triesters of phosphoric acid, halogenated hydrocarbons, and the like.
Specific examples of such suitable flame retardants are: tris(1,3-dichloropropyl)phosphate, tris(2,3-dibromopropyl)phosphate, 2,2-bis(chloromethyl)-l,3 propylene bis[di(2chloroethyl)phosphate], tris(2-chloroethyl)phosphate, tris(2-chloroprophyl)phosphate, bis(dichloropropyl) tribromoneopentyl phosphate, tetrakis(2-chloroethyl) ethylene diphosphate (sold by Olin Chemicals as THERMOLIN*101), FYROL* EFF(oligomeric chloroalkyl phosphate, sold by Stauffer Chemical tricresyl phosphate, cresyl diphenyl phosphate, chlorinated paraffin, and brominated paraffin, Halogenated phosphates are generally preferred as flame retardant additives in polyether polyurethane foams of the invention, especially tris(l,3-dichloropropyl)phosphate, tris(2-chloroethyl)phosphate, FYROL* EFF, and tetrakis(2chloroethyl)ethylene diphosphate, with the first and lastnamed being particularly preferred.
I
WO 88/09352 PCT/US88/01729 I Although a single flame retardant is preferred from the standpoint of simplicity of formulation, mixtures of two or more of the same type or of different types may be found to give improved performance in some cases, and such mixtures be included in the foams of this invention. The amount of flame retardant additive or mixture can be varied over a wide range, from about 8 to about 60 parts by weight per 100 parts by weight of polyol in the foam forming compositon. It is preferred to use from about 8 to about 20 parts by weight.
Chain-extending agents which may be employed in the preparation of the polyurethane foams of the invention include those compounds having at least two functional groups bearing active hydrogen atoms such as water, hydrazine, primary and secondary diamines, amino alcohols, amino acids, hydroxy acids, glycols, or mixtures thereof. A preferred group of chain-extending agents includes water, ethylene glycol, 1,4-butanediol and primary and secondary diamines which react more readily with the prepolymer than does water such as phenylene diamine, 1,4-cyclohexane-bis-(methylamine), ethylenediamine, diethylenetriamine, N-(2-hydroxypropyl) ethylenediamine, N’N-di(2-dydroxypropyl)ethylenediamine, piperazine, and 2-methylpiperazine.
Any suitable catalyst or combination of catalysts may be Sused including tertiary amines such as, for example, triethy- “lenediamine, N-methylmorpholine, N-ethylmorpholine, diethylethanolamine, N-cocomorpholine, l-methyl-4-dimethylaminoethylpiperazine, 3-methoxypropyldimethylamine, N,N,N’trimethylisopropyl propylenediamine, 3-diethylaminopropyldiethylamine, dimethylbenzylamine, and the like. Other suitable catalysts include, for example, stannous octoate, stannous chloride, dibutyltin di-2-ethyl hexanoate, stannous oxide, as well as other organometallic compounds such as are disclosed in U.S. Pat. No. 2,846,408.
y SWO 88/09352 PCT/US88/01729 A surfactant or surface-active agent is generally necessary for production of high grade polyurethane foam according to the present invention, since in the absence of same, the foams may collapse or contain very large uneven Scells. Numerous surface-active agents have been found satisfactory, with nonionic surface active agents being preferred. Of these, the well-known silicones have been found to be particularly advantageous. Other surface-active agents which are operative, include polyethylene glycol ethers of long chain alcohols, tertiary amine or alkanolamine salts of long chain alkyl acid sulfate esters, alkyl sulfonic esters, and alkyl arylsulfonic acids.
Examples The scope of the invention is further described in connection with the following examples which are set forth for the sole purpose of illustrating the preferred embodiments of the invention and which are not to be construed as limiting the scope of the invention in any manner. In these examples, all parts given are by weight unless otherwise specified, while the density values are reported in pounds per cubic feet, the porosity values in cubic decimeters per second and the compression set values in percent recovery as defined in ASTM D-3574.
Example 1: (Comparative) Control samples A through H were prepared from the following formulation: Component parts by weight polyether polyol* (3000 mw) 100.00 toluene diisocyanate (80/20) 51.70 water 4.20 stannous octoate catalyst 0.32 silicone surfactant 1.10 ij 1 s- WO 88/09352 PCTIUS88/p0729 -12- Component amine catalyst conventional fire retardant additives *Polyol 3010 from Dow Chemical Foam samples were prepared *properties were measured: parts by weight 0.40 8.21 at 70’F, and the following Property A B Density 1.56 1.57 Porosity 2.5 3.1 Compression 82.6 84.1 Set C D E F G H Average 1.52 3.5 85.6 1.54 3.3 85.5 1.52 3.5 81.7 1.54 3.3 85.8 1.48 3.6 82 1.54 1.53 3.3 3.3 85.8 84.1 Ex!ples 2-5: To the control formulation of Example 1, 1.8 and 2.0 parts of ammonium orthophosphate, monohydrogen were added to prepare the foam samples of Examples 2 through 5, respectively. These samples were also prepared at 70*F, and the following properties were measured. The result for Example 2 are the average of two tests, while the results for Example 3 are the average of three tests.
Example 3 Property Density Porosity Compression Set 1.56 3.4 8.03 1.55 3.6 7.5 1.58 3.6 5.6 1.62 3.1 9.4 Examples 6-8: To the control formulat.on of Example 1, and 2.0 parts of NH4NaA Zeolite were added to prepare the foam samples of Examples 6, 7 and 8, respectively. These samples were prepared at 70*F as in the preceding examples, and the following properties were measured: sf WO 88/09352 Density 3 Porosity Compression Set Examples 9-11: To the c and 2.0 parts of Exc foam samples of Examples samples were also prepal ties were measured. ThE average of two samples.
Property Density Porosity Compression Set In each of the precedinc determined from the mid I measured at 4.5 hours al samples were wrapped wh: Example 12: (Comparati’ Q) were prepared from t PCT/US88/01729 13- 6 52 i.2 7.4 Example 7 1.53 2.2 5.6 1.53 8.7 :ontrol formulation of Example 1, olit 462 were added to prepare the s 9, 10 and 11, respectively. These red at 70″F and the following propere results for Example 10 are an L.43 3.6 5.6 Example 10 1.48 4.0 5.8 11 1.46 3.1 7.3 g examples, the properties were dle section of the foam sample when fter foam formation. Also, the ile aging.
ve) Nine control samples (I through he following formulation: Component polyether polyol* (3000 mw) toluene diisocyanate (80/20) water stannous octoate catalyst silicone surfactant Parts by Weight 100.0 49.7 0.27 WO 88/09352 PCT/US88/01729 j-14- Component Parts by Weight amine catalyst 0.35 conventional fire 8.2 retardant additives *Polyol 3010 from Dow Chemical Foam samples were prepared at ambient temperature (i.e, 74-78F), and the following properties were measured: Property I J K L M 1 0 P Q Average Density 1.62 1.63 1.61 1.55 1.58 1.61 1.62 1.57 1.60 1.60 Porosity 5.2 4.6 4.8 4.4 3.7 3.6 3.1 4.6 3.9 4.2 Compression 87.8 87.4 86.3 81.7 86.6 82.4 87.4 85.9 84.3 85.5 These properties were determined from the middle section of foam samples which ware wrapped while aging. Foam I properties were determined 3 hours after foam formation; foams J and K at 4 hours, and the remaining foams at hours.
Examples 13-15: To thu control formulation of Example 12, 1.8 parts of ammonium tartrate were added to prepare the foam of Examples 13-15. These samples were prepared at 75, 74 and 78°F, respectively, and the following properties were measured.
Example Property 13 14 15 Avg.
Density 1.66 1.62 1.62 1.64 Porosity 5.6 5.1 5.1 5.3 Compression Set 6.3 6.7 8.7 7.2 The properties of the foam of Example 13 were measured 3 hours after foam formation, while the properties of the foams of Examples 14 and 15 were measured at 4 hours.
WO 88/09352 PCT/US88/01729 i Examples 16-18: To the control formulation of Example 12, 1.8 parts of ammonium citrate were added to prepare the foams of Examples 16-18. These samples were prepared at 76, 76 and respectively, as in the preceding examples, and the following properties were measured 2.5 hours after foam formation.
Example Property 16 17 18 Avg.
Density 1.55 1.62 1.59 1.59 Porosity 3.8 4.9 4.2 4,3 Compression Set 8.1 9.’5 10.2 9.3 Examples 19-21: To the control formulation of Example 12, 1.8, parts of ammonium oxalate were added to prepare the foams of Examples 19-21. These samples were prepared at 76, 76 and 75*F, respectively, as in the preceding examples, and the following properties were measured 2.5 hours after foam formation.
Example Property 19 20 21 Avg.
Density 1.57 1.58 1.57 1.57 Porosity 1.9 3.2 2.6 2.6 Compression Set 10.4 9.8 9.9 10.0 Examples 22-24: To the control formulation of Example 12, 1.8 parts of ammonium succinate were added to prepare the foams of Examples 22-24. These samples were prepared at 74 and 78*F, respectively, as in the preceding examples, and the following properties were measured.
i _._iii.l WO 88/09352 PCT/US88/91729 -16- Example Property 22 23 24 Avg.
Density 1.64 1.60 1.60 1.61 Porosity 3.7 4.6 4.3 4.2 Compression Set 11.9 6.7 10.1 9.6 The properties of the foam of Example 22 were ieasured 3 hours after foam formation, while the properties of the foams of Examples 23 and 24 were measured at 4 hours.
Examples 25-27: To the control formulation of Example 12, 1.8 parts of Exolit 455 were added to prepare the foams of Examples 25-27. These samples were prepared at 76, 76 and 75’F, respectively, and the following properties were measured 2.5 hours after foam formation.
Example Property 25 26 27 Avg.
Density 1.54 1.54 1.59 1.56 Porosity 5.1 3.9 4.6 4.2 Compression Set 4.4 4.3 5.6 4.7 These examples illustrate the improvement in the compression set of the foam by the addition of the ammonia containing compounds compared to the control samples.
While it is apparent that the invention herein disclosed is well calculated to fulfill the objects above stated, it will be appreciated that numerous modifications and embodiments may be devised by those skilled in the art, and it is intended that the appended claims over all such modifications and embodiments as fall within the true spirit and scope of the present invention.

Claims (22)

1. A method for the rapid cure of flexible polyether- derived polyurethane foam without adversely affecting the resultant physical properties of said foam, which method comprises: adding to a foam forming composition comprising a polyether polyol, an organic isocyanate compound, and water, an ammonia containing material having a decomposition temperature below the temperature of the highest reaction exotherm of the foam-forming composition; forming the foam by reaction of the form-foaming components and thereby generating heat; and at least partially decomposing said ammonia containing material by exposure to said heat to release ammonia to cure the foam by contact therewith.

2. The method of claim 1 wherein the ammonia containing material is a compound having a decomposition temperature above 225°F.

3. The method of claim 2 wherein the ammonia containing material is a compound having a decomposition temperature below 300’F.

4. The method of sc-l-wherein the ammonia containing material is relatively insoluble in water.

The method of claim 4 wherein the ammonia containing material is an ammonium salt of an organic acid. v/ G/f- “.0 o W WO 88/09352 PCT/US88/91729 -18-

6. The method of claim 5 wherein the ammonia containing material is at least partially soluble in water but is encapsulated to delay the decomposition of the compound until the reaction exotherm occurs.

7. The method of claim 1 wherein the ammonia containing material has a decomposition temperature between about 175 and 225*F, but is encapsulated to delay the decomposition of the compound until the reaction exotherm occurs. c oe o c\QA,,

8. The method of eti\~ w wherein the amount of ammonia containing material is sufficient to generate an amount of ammonia which cures substantially all the foam.

9. The method of claim 8 wherein the amount of ammonia containing material is between about 1 and 3 parts by weight of 100 parts polyol.

The method of claim 9 wherein the amount of ammonia containing material is between about 1.5 and 2 parts by weight of 100 parts poyol.

11. The method of claim 1 wherein the ammonia containing compound is an ammonia containing zeolite.

12. A method for the rapid cure of flexible polyether- derived polyurethane foam without adversely affecting the resultant physical properties of said foam, which method comprises: adding to a foam-forming composition comprising a polyether polyol, an organic isocyanate compound, and water, an encapsulated ammonia containing material; forming the foam by reaction of the foam-forming S components and thereby generating heat; and V U WO 88/09352 PCT/US88/01729 -19- at least partially decomposing said ammonia containing material by exposure to said heat to break through said encapsulation to release ammonia to cure the foam by contact therewith.

13. The method of claim 12 wherein the amount of ammonia containing material is sufficient to generate an amount of ammonia which cures substantially all the foam.

14. The method of claim 13 wherein the amount of ammonia containing material is between about 1 and 3 parts by weight of 100 parts polyol.

The method of claim 14 wherein the amount of ammonia containing material is between about 1.5 and 2 parts by weight of 100 parts polyol.

16. The method of c1i-4= f wherein the encapsulated ammonia containing compound is a water soluble ammonium salt of an organic acid.

17. The method of claim 16 wherein the encapsulation is by an epoxy or melamine-formaldehyde resin.

18. A method for the rapid cure of flexible polyether- derived polyurethane foam without adversely affecting the compression set of said foam, which method comprises: adding an ammonia containing zeolite to a foam- forming composition comprising a polyether polyol, an organic isocyanate compound, and water; forming the foam by reaction of the foam-forming components and thereby generating heat; and at least partially decomposing the ammonia containing zeolite by exposure to said heat to release ammonia to cure the foam by contact therewith. 2$

19. The method of claim 18 wherein the amount of ammonia containing zeolite is sufficient to generate an amount of ammonia which cures substantially all the foam.

20. The method of claim 18 wherein the amount of ammonia containing zeolite is between about 1 and 3 parts by weight of 100 parts polyol.

21. The method of claim 18 wherein the amount of ammonia containing zeloite is between about 1.5 and 2 parts by weight of 100 parts polyol. 20 eo 25O o 20

22. The method of claim 1 substantially as hereinbefore described with reference to the examples. DATED: 30 JANUARY 1992 PHILLIPS ORMONDE FITZPATRICK Attorneys for: FOAMEX L.P. UD&IP A^^ 5735j ‘K 4 :7 INTERNATIONAL SEARCH REPORT International Application No. 8r 8/01729 I. CLASSIFICATION OF SUBJECT MATTER (il several classification symbols apply, indicate all) 6 According to International Patent Classification (IPC) or to both National Classification and IPC IPC.(4) C08G, 18/30; US CL. 521/107 II. FIELDS SEARCHED Minimum Documentation Searched 7 Classification System Classification Symbols U.S. 521/107, 110, 122, 128, 137 Documentation Searched other than Minimum Documentation to the Extent that such Documents are Included in the Fields Searched 8 I- II. DOCUMENTS CONSIDERED TO BE RELEVANT 9 Category Citation of Document, “i with indication, where appropriate, of the relevant passages 12 Relevant to Claim No. i 3 A US, A, 4,467,056 (STAENDEKE ET AL) 21 AUGUST 1-21 1984 A US, A, 4,066,578 (MURCH ET AL) 03 JANUARY 1-21 1978 A US, A, 4,230,822(MURCH ET. AL) 28 OCTOBER 1-21 1980 SSpecial categories of cited documents: ‘i later document published after the international filing date document definingthe general state the art hich is not or priority date and not in conict with the application but document defining the general stale o the art cited to understand the principle or theory underlying the considered to be of particular relevance invention earlier document but published on or alter the international document of particular relevance; the claimed invention filing date cannot be considered novel or carnot be considered to document which may throw doubts on priority claim(s) or involve an inventive step which is cited to establish the publication date of another document of particular relevance, the claimed invention citation or other special reason (as specified) cannot be considered to involve an inventive step when the document referring to an oral disclosure, use, exhibition or document is combined with one or more other such docu- other means ments, such combination being obvious to a person skilled document published prior to the international filing date but in the art, later than the priority date claimed document member of the same patent family IV. CERTIFICATION Date of the Actual Completion of the International Search Date of Mailing of this International Search Report 27 JUNE 1988 1 8 AUG 1988 International Searching Authority Sin Auhor ed Officer -ISA/U s.A. ACQUAH Form PCTlSAf210 (scond sheet) (Rev.11.87)

AU19421/88A
1987-05-21
1988-05-19
Rapid cure of polyurethane foam with ammonium containing materials

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Applications Claiming Priority (2)

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US07/052,815

US4818775A
(en)

1987-05-21
1987-05-21
Rapid cure of polyurethane foam with ammonium containing materials

US052815

1987-05-21

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AU1942188A

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1988-12-21

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AU622408B2
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1992-04-09

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AU19421/88A
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1987-05-21
1988-05-19
Rapid cure of polyurethane foam with ammonium containing materials

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US4818775A
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EP0394246B1
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JP
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AU622408B2
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BR
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BR8807512A
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CA
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CA1303792C
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DE
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DE3853722T2
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MX
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MX165684B
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1989-10-20
1991-04-25
Bayer Ag

METHOD FOR THE PRODUCTION OF FORM BODIES OF POLYURETHANE FOAMS AND THE FORMKOERPER OBTAINED BY THIS METHOD

DE4003230A1
(en)

1990-02-03
1991-08-08
Hoechst Ag
Self-extinguishing polyurethane prods. partic. foams – contain mixt. of ammonium poly:phosphate with bis-triazinyl-piperazine or hydroxyalkyl isocyanurate or amino-triazine-aldehyde

US5188792A
(en)

1992-02-10
1993-02-23
Trinity American Corp.
Post treatment of polyurethane foam

CA2101613A1
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1992-08-14
1994-02-15
Siusun K. Leung
Flexible polyurethane foams using chlorinated alkanes

CN110790883B
(en)

2019-11-15
2021-11-23
上海东大聚氨酯有限公司
Low-heat-release combined polyether, polyurethane raw material composition, polyurethane foam and preparation method thereof

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