Energy absorbing flexible foams produced in part with a double metal cyanide catalyzed polyol
View Patent ↗Energy absorbing flexible foams can be produced by reacting an isocyanate with a first polyol, prepared at least in part by an active double metal cyanide catalyst and a second polyether polyol is prepared at least in part by a basic or acidic catalyst.
1. A process for preparing an energy absorbing flexible foam comprising reacting
a) an organic polyisocyanate with
b) a polyol blend comprising
i) at least a first and a second polyol, wherein the first polyol is prepared at least in part by an active double metal cyanide catalyst and has an average functionality of about 2 and wherein the second polyol is prepared at least in part by a basic or acidic catalyst and has an average functionality from about 1.0 to about 6.0
ii) a blowing agent, and
iii) at least one catalyst,
wherein the energy absorbing flexible foam has a sound absorption coefficient of about 0.1 at 250 Hz and about 1.0 at 2000 Hz.
2. The process of claim 1 , wherein the polyol blend further comprises a surfactant or other additive.
3. The process of claim 1 , wherein the first and second polyols are polyether polyols.
4. The process of claim 3 , wherein the first polyether polyol has a hydroxyl number of about 28 to about 35.
5. The process of claim 3 , wherein the second polyether polyol has a hydroxyl number of about 28 to about 35.
6. The process of claim 1 , wherein the first polyol has a primary OH content of about 25 to about 50%.
7. The process of claim 1 , wherein the second polyol has a primary OH content of greater than 70%.
8. The process of claim 1 , wherein the first polyol comprises from about 20% to about 80% by weight based on the total weight of the polyol blend.
9. The process of claim 1 , wherein the organic polyisocyanate is a methylene diphenylene polyisocyanate or a toluenediisocyanate.
10. The process of claim 6 , wherein the organic polyisocyanate is a methylene diphenylene polyisocyanate.
11. The process of claim 1 , wherein the foam is produced at an NCO index of between 65 and 105.
12. The process of claim 1 , wherein the blowing agent comprises water.
13. The process of claim 1 , wherein the catalyst(s) is used in an amount of about 0.4 to about 2 wt. % based on the total weight of the polyol blend.
14. An energy absorbing flexible foam comprising the reaction product of:
a) an organic polyisocyanate and
b) a polyol blend comprising
i) at least a first and a second polyol, wherein the first polyol is prepared at least in part by an active double metal cyanide catalyst and has an average functionality of about 2 and wherein the second polyol is prepared at least in part by a basic or acidic catalyst and has an average functionality from about 1.0 to about 6.0
ii) a blowing agent, and
iii) at least one catalyst,
wherein the energy absorbing flexible foam has a sound absorption coefficient of about 0.1 at 250 Hz and about 1.0 at 2000 Hz.
15. The foam of claim 14 , wherein the polyol blend further comprises a surfactant or other additive.
16. The foam of claim 15 , wherein the first and second polyols are polyether polyols.
17. The foam of claim 16 , wherein the first polyether polyol has a hydroxyl number of about 28 to about 35.
18. The foam of claim 14 , wherein the first polyol has a primary OH content of about 0 to about 50%.
19. The foam of claim 14 , wherein the second polyol has a primary OH content of greater than 70%.
20. The foam of claim 14 , wherein the first polyol comprises from about 20% to about 80% by weight based on the total weight of the polyol blend.
21. The foam of claim 14 , wherein the organic polyisocyanate is a methylene diphenylene polyisocyanate or a toluenediisocyanate.
22. The foam of claim 21 , wherein the organic polyisocyanate is a methylene diphenylene polyisocyanate.
23. The foam of claim 21 , wherein the foam is produced at an NCO index of between 65 and 105.
24. The foam of claim 14 , wherein the blowing agent comprises water.
25. The foam of claim 14 , wherein the catalyst(s) is used in an amount of about 0.4 to about 2 wt. % based on the total weight of the polyol blend.