SILICONE SURFACTANT FOR MAKING FLEXIBLE FOAMS
A polyurethane foam-forming composition having a surfactant with the formula R 1 3 Si(OSiR 2 G)xOSiR 3 3 , where each R 1 , R 2 , and R 3 is independently an alkyl radical having from 1 to 10 carbon atoms; G is a group having the formula —R 4 (OR 5 ) y A, where R 4 is a divalent alkyl radical having from 2 to 4 carbon atoms, R 5 is ethylene or propylene, A is a hydroxyl group, and x is an number from 1 to 5, and y is an number from 0 to 10 is provided which can be used to form polyurethane foams having a large open cell concentration, improved dry and wet compression sets, and low fugitive emissions.
1 . A polyurethane foam-forming composition comprising:
(a) a polyol;
(b) a polyisocyanate;
(c) a catalyst;
(d) a surfactant having Formula (1):
R 13 Si(OSiR 2 G)xOSiR 3 3 (1),
wherein:
each occurrence of R 1 , R 2 , and R 3 is independently an alkyl radical having from 1 to 10 carbon atoms;
G is an organic group having Formula (2):
—R 4 (OR 5 ) y A (2),
where R 4 is a divalent alkyl radical having from 2 to 4 carbon atoms; R 5 is ethylene or propylene; A is a hydroxyl group; and the subscript x is a number ranging from 1 to 5; and the subscript y is a number ranging from 0 to 10; and, optionally,
(e) at least one other component selected from the group consisting of a chain extender, a crosslinker, a filler, a reinforcement, a pigment, a tint, a dye, a colorant, a flame retardant, an antioxidant, an antiozonant, a UV stabilizer, an anti-static agent, a biocide and a biostat.
2 . The polyurethane foam-forming composition of claim 1 , wherein R 1 , R 2 , and R 3 are each a methyl radical.
3 . The polyurethane foam-forming composition of claim 1 , wherein R 5 is ethylene.
4 . The polyurethane foam-forming composition of claim 1 , wherein R 5 is propylene.
5 . The polyurethane foam-forming composition of claim 1 , wherein y is greater than 1, and the surfactant comprises at least one (OR 5 ) y group where R 5 is ethylene, and at least one (OR 5 ) y group where R 5 is propylene.
6 . The polyurethane foam-forming composition of claim 1 , wherein the surfactant has a weight average molecular weight of about 2000 or less.
7 . The polyurethane foam-forming composition of claim 1 , wherein the surfactant has a weight average molecular weight of from about 200 to about 2000.
8 . The polyurethane foam-forming composition of claim 1 , wherein the surfactant has a weight average molecular weight of from about 200 to about 1000.
9 . The polyurethane foam-forming composition of claim 1 , wherein the surfactant is of the formula Me 3 Si(OSiMeG) 1 OSiMe 3 .
10 . The polyurethane foam-forming composition of claim 1 , wherein the G group is derived from CH 2 ═CHCH 2 OH; CH 2 ═CHCH 2 (OCH 2 CH 2 ) y OH; CH 2 ═CHCH 2 (OCH 2 CHCH 3 )OH, or a combination of two or more thereof, where y is 1-10.
11 . The polyurethane foam-forming composition of claim 1 , wherein the surfactant (d) is present in an amount of from about 0.01 to about 10 pphp.
12 . The polyurethane foam-forming composition of claim 1 , wherein the surfactant (d) is present in an amount of from about 0.1 to about 7.5 pphp.
13 . The polyurethane foam-forming composition of claim 1 , wherein the surfactant (d) is present in an amount of from about 0.20 to about 5 pphp.
14 . A polyurethane foam prepared from the composition of claim 1 .
15 . The polyurethane foam of claim 14 having a siloxane VOC and FOG emission of about 50 ppm or less.
16 . The polyurethane foam of claim 14 having a siloxane VOC and FOG emission of about 25 ppm or less.
17 . The polyurethane foam of claim 14 having a silxoane VOC and FOG emission of about 10 ppm or less.
18 . The polyurethane foam of claim 14 having a silxoane VOC and FOG emission of about 5 ppm or less.
19 . A method of preparing a flexible polyurethane foam comprising reacting a polyisocyanate with a polyol in the presence of a urethane catalyst and a surfactant, the surfactant having the formula R 1 3 Si(OSiR 2 G)xOSiR 3 3 , where each R 1 , R 2 , and R 3 is independently an alkyl radical having from 1 to 10 carbon atoms; G is a group having the formula —R 4 (OR 5 ) y A, where R 4 is a divalent alkyl radical having from 2 to 4 carbon atoms, R 5 is ethylene or propylene, and A is a hydroxyl group; and x is from 1 to 5; and y is from 0 to 10.
20 . The method of claim 19 , wherein R 1 , R 2 , and R 3 are each a methyl radical.
21 . The method of claim 19 , wherein R 5 is ethylene.
22 . The method of claim 19 , wherein R 5 is propylene.
23 . The method of claim 19 , wherein y is greater than 1, and the surfactant (d) comprises at least one (OR 5 ) y group where R 5 is ethylene, and at least one (OR 5 ) y group where R 5 is propylene.
24 . The method of claim 19 , wherein the surfactant (d) has a molecular weight of about 2000 or less.
25 . The method of claim 19 , wherein the surfactant (d) has a molecular weight of from about 200 to about 1000.
26 . The method of claim 19 , wherein the surfactant (d) is present in an amount of from about 0.01 to about 10 pphp.