US 12,351,675 B2
Soft, washable polyurethane foam with slow recovery time
David Foix Tajuelo, Horgen (CH); Anja Arlt, Horgen (CH); Lucie Porcelli, Richterswil (CH); and Paul A. Cookson, Schindellegi (CH)
Assigned to DOW GLOBAL TECHNOLOGIES LLC, Midland, MI (US)
Appl. No. 17/787,781
Filed by Dow Global Technologies LLC, Midland, MI (US)
PCT Filed Jan. 4, 2021, PCT No. PCT/US2021/012033
§ 371(c)(1), (2) Date Jun. 21, 2022,
PCT Pub. No. WO2021/141841, PCT Pub. Date Jul. 15, 2021.
Claims priority of provisional application 62/957,349, filed on Jan. 6, 2020.
Prior Publication US 2023/0080960 A1, Mar. 16, 2023
Int. Cl. C08G 18/08 (2006.01); C08G 18/10 (2006.01); C08G 18/12 (2006.01); C08G 18/28 (2006.01); C08G 18/30 (2006.01); C08G 18/48 (2006.01); C08G 18/76 (2006.01); C08G 101/00 (2006.01)
CPC C08G 18/14 (2013.01) [C08G 18/12 (2013.01); C08G 18/302 (2013.01); C08G 18/4808 (2013.01); C08G 18/4816 (2013.01); C08G 18/4837 (2013.01); C08G 2101/00 (2013.01); C08G 2110/0008 (2021.01); C08G 2110/0083 (2021.01); C08G 2280/00 (2013.01)] 11 Claims
 
1. A polyurethane foam produced in a process comprising the steps of A) combining ingredients that comprise isocyanate-reactive components, a polyisocyanate component, at least one foam stabilizing surfactant and at least one urethane and/or urea catalyst at an isocyanate index of 65 to 95 to form a reaction mixture, and B) curing the reaction mixture to form the polyurethane foam,
wherein the isocyanate-reactive components comprise;
a-1) one or more first polyether polyols having a hydroxyl number of 112 to 280 mg KOH/g, a nominal hydroxyl functionality of 2 to 4 and an oxyethylene content of 45 to 70% by weight, in an amount of 40 to 60 weight-%, based on the total weight of all isocyanate-reactive components in the reaction mixture;
a-2) one or more second polyether polyols having a hydroxyl number of 20 to 70 mg KOH/g, a nominal hydroxyl functionality of 2 to 4 and an oxyethylene content of 0 to 25% by weight, in an amount of 0 to 25 weight-%, based on the total weight of all isocyanate-reactive components in the reaction mixture;
a-3) one or more third polyether polyols having a hydroxyl number of 112 to 280 mg KOH/g, a nominal hydroxyl functionality of 2 to 4 and an oxyethylene content of 0 to 25% by weight, in an amount of 5 to 25 weight-%, based on the total weight of all isocyanate-reactive components in the reaction mixture; and
a-4) one or more polyether monols having a hydroxyl number of 50 to 200 mg KOH/g, a number average molecular weight of up to 1000 and an oxyethylene content of at least 40% by weight, in an amount of 3 to 12 weight-%, based on the total weight of all isocyanate-reactive components in the reaction mixture; and
a-5) water, in an amount of 2 to 6 weight-%, based on the total weight of all isocyanate-reactive components in the reaction mixture;
and further wherein i) a-1), a-2), a-3), a-4) and a-5) together constitute at least 95% of the weight of the isocyanate-reactive components in the reaction mixture and ii) the isocyanate-reactive components include one or more fourth polyether polyols having a hydroxyl number of at most 56 mgKOH/g and a nominal hydroxyl functionality of 2 or greater, in an amount of 0 to 2 weight-%, based on the total weight of all isocyanate-reactive components in the reaction mixture;
and further wherein the polyisocyanate component is a quasi-prepolymer of diphenylmethane diisocyanate and a polyether polyol having a hydroxyl number of 15 to 56 mg KOH/g, a nominal hydroxyl functionality of 2 to 4 and an oxyethylene content of at least 70% by weight, the quasi-prepolymer having an isocyanate content of 25 to 31% by weight.