Polyurethane foam and methods of forming the same
View Patent ↗The subject application relates to polyurethane foam and methods of forming the same. A polyurethane foam may include a polyurethane foam may include a first polyol component, a second polyol component, and a third polyol component. The first polyol component may include at least one component selected from the group of a polyether polyol and a polyester polyol. The second polyol component may include a polyether polyol. The third polyol component may include a grafted polyether polyol. The polyurethane foam may have a density of at least about 100 kg/m 3 and not greater than about 800 kg/m 3 . The polyurethane foam may have an adjusted compression force deflection to density ratio of at least about 0.3.
1 . A polyurethane foam prepared from a reaction mixture, wherein the reaction mixture comprises:
a first polyol component having a molecular mass of at least about 2000 g/mol and not greater than about 5800 g/mol, and comprising at least one component selected from the group of a polyether polyol and a polyester polyol,
a second polyol component comprising a polyether polyol,
a third polyol component comprising a grafted polyether polyol,
wherein the reaction mixture comprises the first polyol component in an amount of at least about 5 wt. % and not greater than about 50 wt. % for a total weight of the reaction mixture,
wherein the reaction mixture comprises the second polyol component in an amount of at least about 7 wt. % for a total weight of the reaction mixture,
wherein the reaction mixture comprises the third polyol component in an amount of at least about 1 wt. % and not greater than about 45 wt. % for a total weight of the reaction mixture,
wherein the polyurethane foam has a glass transition temperature of at least about 10° C.,
wherein the polyurethane foam has a density of at least about 175 kg/m 3 and not greater than about 800 kg/m 3 , and
wherein the polyurethane foam has an adjusted compression force deflection to density ratio of at least about 0.3, where the adjusted compression force deflection to density ratio is equal to CFD70/(D{circumflex over ( )}2.6), where the CFD70 is equal to the compression force deflection of the polyurethane foam in Pa measured at 23° C., 70% compressive strain, and D is equal to the density of the polyurethane foam in kg/m 3 .
2 . The polyurethane foam of claim 1 , wherein the polyurethane foam has an adjusted compression force deflection to density ratio of at least about 0.4.
3 . The polyurethane foam of claim 1 , wherein the polyurethane foam has a glass transition temperature of at least about 10° C. and not greater than about 85° C.
4 . The polyurethane foam of claim 1 , wherein the polyurethane foam has a density of at least about 175 kg/m 3 and not greater than about 790 kg/m 3 .
5 . The polyurethane foam of claim 1 , wherein the polyurethane foam has compression recovery ratio of not greater than about 95.5%.
6 . The polyurethane foam of claim 1 , wherein the first polyol component has an OH number of at least about 20 KOH mg/g and not greater than about 100 KOH mg/g.
7 . The polyurethane foam of claim 1 , wherein the first polyol component has a molecular mass of at least about 2,000 g/mol and not greater than about 3500 g/mol.
8 . The polyurethane foam of claim 1 , wherein the first polyol component has a functionality of at least 2 and not greater than 8.
9 . The polyurethane foam of claim 1 , wherein the reaction mixture comprises the third polyol component in an amount of at least about 1 wt % and not greater than about 28 wt. % for a total weight of the reaction mixture.
10 . The polyurethane foam of claim 1 , wherein the first polyol component is produced by a condensation of polycarboxylic acids with polyhydric alcohols, or by ring-opening polymerization of epoxy compounds in the presence of active hydrogen-containing compounds as initiators and catalysts.
11 . The polyurethane foam of claim 1 , wherein the second polyol component has an OH number of at least about 200 KOH mg/g and not greater than about 800 KOH mg/g.
12 . The polyurethane foam of claim 1 , wherein the second polyol component has a molecular mass of at least about 200 g/mol and not greater than about 2000 g/mol.
13 . The polyurethane foam of claim 1 , wherein the second polyol component has a functionality of at least about 3 and not greater than about 8.
14 . A method of forming a polyurethane foam comprising:
providing a raw material mixture comprising: a raw first polyol component having a molecular mass of at least about 2000 g/mol and not greater than about 5800 g/mol, and comprising at least one component selected from the group of a polyether polyol and a polyester polyol,
a raw second polyol component comprising a polyether polyol,
a raw third polyol component comprising a grafted polyether polyol,
a raw fourth polyol component comprising a polycaprolactone polyol; and
forming the raw material mixture into a polyurethane foam,
wherein the polyurethane foam comprises the raw first polyol component in an amount of at least about 5 wt. % and not greater than about 50 wt. % for a total weight of the raw material mixture,
wherein the polyurethane foam comprises the raw second polyol component in an amount of at least about 7 wt. % for a total weight of the raw material mixture,
wherein the polyurethane foam comprises the raw third polyol component in an amount of at least about 1 wt. % and not greater than about 45 wt. % for a total weight of the raw material mixture,
wherein the polyurethane foam has a glass transition temperature of at least about 10° C.,
wherein the polyurethane foam has a density of at least about 175 kg/m 3 and not greater than about 800 kg/m 3 , and
wherein the polyurethane foam has an adjusted compression force deflection to density ratio of at least about 0.3, where the adjusted compression force deflection to density ratio is equal to CFD70/(D{circumflex over ( )}2.6), where the CFD70 is equal to the compression force deflection of the polyurethane foam in Pa measured at 23° C., 70% compressive strain, and D is equal to the density of the polyurethane foam in kg/m 3 .
15 . The method of claim 14 , wherein the polyurethane foam has an adjusted compression force deflection to density ratio of at least about 0.4 and not greater than about 2.5.
16 . The method of claim 14 , wherein the polyurethane foam has a glass transition temperature of at least about 10° C. and not greater than about 85° C.
17 . The method of claim 14 , wherein the polyurethane foam has a density of at least about 175 kg/m 3 and not greater than about 790 kg/m 3 .
18 . The method of claim 14 , wherein the polyurethane foam has a compression recovery ratio of not less than about 95.5%.
19 . The method of claim 14 , wherein the raw first polyol component has an OH number of at least about 20 KOH mg/g and not greater than about 100 KOH mg/g.