Flexible Foams with Enlarged Cell Size

Title: PUR FOAM WITH ENLARGED CELL STRUCTURE

 Number/Link: WO2014/170198 (German)

Applicant/Assignee: Evonik

Publication date: 23-10-2014

Gist”: The cell size of PU flexible foam is enlarged by using microcrystalline wax.

Why it is interesting: Enlarging the cell size of flexible foams can improve comfort properties by enhancing ‘breathabibility’, that is by enhancing airflow and moisture- and heat transport.  According to this invention the cell size of flex foams can be increased without affecting foam density or hardness by using a specific type of wax.  The wax (preferably) is a microcrystalline wax (as opposed to a paraffinic wax) with a congealing temperature of between 60 and 75°C.  The wax is used as a dispersion in a solvent (e.g. a sorbitan ester)  in an amount of about 0.05 to 2.0 php.

Cell structure of a flexible polyurethane foam.

Cell structure of a flexible polyurethane foam.

Classic PU Patent of the Month: Scott Paper Co. on Reticulated Polyurethane Foams (1964)

Title: Reticulated polyurethane foams and process for their production

 Number/Link: US3171820

Applicant/Assignee: Scott Paper Co.

Publication date: 2-03-1965

Gist”: PU foams are reticulated by hydrolysis or explosion.

Why it is interesting:   Reticulated foams are foams from which the membranes have been removed so that only a three dimensional network of strands or ‘struts’ remains. These materials are commercially available in different grades of stiffness and porosity and are useful in applications such as filtering, sound absorbing, padding and the like. The current invention – filed in 1964 but a ‘continuation’ of an application filed in 1956- teaches the two processes to reticulate PU foam still in use today. The first process uses an aqueous NaOH solution to hydrolyse the cell membranes, in the second process a foam block is brought in an autoclave together with an explosive gas mixture (e.g. a mixture of oxigen and acetylene) which is then made to explode using a spark plug. When executed correctly the explosion removes all cell membranes leaving the struts intact. ‘Explosive recticulation’ is one of my all-time favorite PU inventions: simple, yet very effective and very courageous. In the current culture of hyper-safety where employees have to report paper-cuts, inventions like this are no longer possible.

Recticulate polyurethane foam

A recticulated polyurethane foam

Classic PU Patent of the Month: The First SMPUs (1988)

Title: Shape memory polymer foam.  – and – Shape memory polyurethane elastomer molded article.

 Number/Link: EP0361418 and EP0361419

Applicant/Assignee: Mitsubishi Heavy Industries

Publication date: 27-09-1989

Gist”: The first shape memory polyurethane foams and elastomers

Why it is interesting: Shape memory polymers are so-called “smart materials” that remain in a deformed shape until a trigger (usually an increase in temperature) makes them return to their original  (“memorized”) shape. In the 1980s these materials were more of a curiosity, only used in some niche applications such as heat shrinkable tubing. Currently however a lot of academic and industrial research is done on these materials, mostly driven by medical applications (e.g. stents, orthopedic casts, self-tightening sutures etc). And not surprisingly a lot of current SMPs are based on polyurethanes (SMPUs).  Interest in shape memory materials was stimulated significantly by the invention of the first SMPUs by Mitsubishi H.I. Ltd. They filed two patents covering both shape memory foams and elastomers. The first SMPUs were based on a di-isocyanate like 4,4′-MDI, a diol like PPG700 and a chain extender like bisphenol-A, and were formulated over a range of Tg’s. The foamed materials were blown with a physical blowing agent (i.e. not water) so that all materials can be considered thermoplastics.

SMP transition from temporary shape (spiral) to permanent shape (rod).  (Angew. Chem. Int. Ed. 2002, 41, 2034 ± 2057)

SMP transition from temporary shape (spiral) to permanent shape (rod). (Angew. Chem. Int. Ed. 2002, 41, 2034 ± 2057)

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