Polyurethane foam production process, pre-mix, formulation, and product
Disclosed are a process of producing a polyurethane foam product, a polyurethane foam product pre-mix, polyurethane foam product formulation, and a polyurethane foam product. The process of producing the polyurethane foam product includes contacting a halohydrin component with a polyurethane foam product pre-mix. The polyurethane foam product pre-mix includes the halohydrin component. The polyurethane foam product formulation includes a polyol component, an isocyanate component, and a halohydrin component. The polyurethane foam product is formed by the pre-mix having the halohydrin component.
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, 3-bromo-1-propanol, 1-chloro-5-pentanol, and combinations thereof; wherein the polyurethane foam product pre-mix comprises a tertiary amine catalyst component, a silicon surfactant that is devoid of acyl groups and a blowing agent consisting of water; and wherein the silicon surfactant is selected from the group consisting of polyalkylsiloxane; polyoxyalkylene polyol-modified dimethylpolysiloxane; alkylene glycol-modified dimethylpolysiloxane; or a combination thereof.
2. The process of claim 1 , wherein the process further comprises contacting the polyurethane foam product pre-mix and halohydrin component with an isocyanate component.
3. The process of claim 1 , wherein the polyurethane foam product pre-mix further comprises a metal complex.
4. The process of claim 3 , wherein the metal complex comprises dimethyltin dilaureate.
5. The process of claim 1 , wherein the polyurethane foam product pre-mix is devoid of any metal complex.
6. The process of claim 1 , wherein the tertiary amine catalyst component comprises diazobicyclooctane (triethylenediamine).
7. The process of claim 1 , wherein the polyurethane foam product pre-mix further comprises an auxiliary blowing catalyst component.
8. The process of claim 7 , wherein the auxiliary blowing catalyst component comprises bis-dimethylaminoethyl ether.
9. 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.
10. The process of claim 1 , wherein the polyurethane foam product produced by the process has a humid aged elongation of greater than about 80%.
11. 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.
12. The process of claim 1 wherein the polyurethane foam product pre-mix further comprises a polyol component; and
an isocyanate component.
13. 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.
14. The process of claim 13 wherein the polyurethane foam product pre-mix further comprises at least one tertiary amine catalyst blocked with at least one acid.
15. The process of claim 14 wherein the polyurethane foam product pre-mix further comprises at least one organic tin catalyst.
16. The process of claim 15 wherein the polyurethane foam product pre-mix further comprises at least one polyol and at least one crosslinker.