Polyurethane foam production process, pre-mix formulation, and product

1. A process of producing a flexible polyurethane foam product, the process comprising contacting a halohydrin component with a polyurethane foam product pre-mix;

wherein the halohydrin component comprises a halohydrin compound selected from the group consisting of 3-chloro-1-propanol, 6-chloro-1-hexanol, 2-(2-chloroethoxy) ethanol, 1 chloro-2-propanol, 3-bromo-1-propanol, chlorobutanol, ethylene chlorhydrin, 1-chloro-5-pentanol, 1-chloro-2,3-propanediol, and combinations thereof;

wherein the halohydrin component is present in an amount between about 0.5 pphp and about 1.0 pphp;

wherein the polyurethane foam product pre-mix comprises a silicon surfactant that is devoid of acyl groups and a blowing agent consisting of water; and wherein the silicon surfactant is present in an amount of about 0.7 pphp to about 5 pphp.

2. The process of claim 1 , wherein the polyurethane foam product pre-mix further comprises a non-fugitive tertiary amine catalyst composition.

3. The process of claim 1 , wherein the process further comprises contacting the polyurethane foam product pre-mix and halohydrin component with an isocyanate component.

4. The process of claim 1 , wherein the silicon surfactant is selected from the group consisting of polyalkylsiloxane, polyoxyalkylene, polyol-modified dimethylpolysiloxane, alkylene glycol-modified dimethylpolysiloxane, or a combination thereof.

5. The process of claim 1 , wherein the polyurethane foam product pre-mix further comprises a metal complex.

6. The process of claim 5 , wherein the metal complex comprises dimethyltin dilaureate.

7. The process of claim 1 , wherein the polyurethane foam product pre-mix is devoid of any metal complex.

8. The process of claim 1 , wherein the polyurethane foam product pre-mix further comprises a tertiary amine catalyst component.

9. The process of claim 8 , wherein the tertiary amine catalyst component comprises diazobicyclooctane (triethylenediamine).

10. The process of claim 1 , wherein the polyurethane foam product pre-mix is devoid of any tertiary amine catalyst components.

11. The process of claim 1 , wherein the polyurethane foam product pre-mix further comprises an auxiliary blowing catalyst component.

12. The process of claim 11 , wherein the auxiliary blowing catalyst component comprises bis-dimethylaminoethyl ether.

13. The process of claim 1 wherein the polyurethane foam product produced by the process has a humid aged tensile strength of greater than about 80 kPa.

14. The process of claim 1 wherein the polyurethane foam product produced by the process has a humid aged elongation of greater than about 80%.

15. The process of claim 1 wherein the polyurethane foam product produced by the process has a humid aged 50% compression set of less than about 18.

16. The process of claim 1 wherein the polyurethane foam product pre-mix further comprises

a polyol component; and

an isocyanate component.

17. The process of claim 1 wherein the halohydrin component comprises at least one halohydrin, and the polyurethane foam product pre-mix comprises at least one silicone surfactant and at least one glycol carrier.

18. The process of claim 17 wherein the polyurethane foam product pre-mix further comprises at least one tertiary amine catalyst blocked with at least one acid.

19. The process of claim 18 wherein the polyurethane foam product pre-mix further comprises at least one organic tin catalyst.

20. The process of claim 19 wherein the polyurethane foam product pre-mix further comprises at least one polyol and at least one crosslinker.