A New Type of Polyurethane Memory Foam


 Number/Link:WO 2014/058857

Applicant/Assignee: BASF

Publication date: 17-04-2014

Gist”: Using TDI, two high MW and high EO polyether triols, hydrolizable PDMS and DELA results in a flexible foam with a low Tg ánd a low resilience.

Why it is interesting: While viscoelastic or “memory” foams are popular in the furniture industry they are currently not used in e.g. car seats because of their limited use temperature. Typically these foams become too stiff at lowish temperatures and often too soft and resilient at higher temperatures. The current invention is about viscoelastic foams which are useful for transport applications because they show constant properties over a wide temperature range. This is accomplished by reacting TDI with a (about) 4000 MW,  75% EO triol, an EO-capped 6500 MW, 75% EO triol, quite some diethanolamine (DELA), and quite some (2.5 pdw in the examples)  hydrolyzable polydimethylsiloxane copolymer (PDMS), together with water and catalysts. The foams show two Tg’s one at about -20°C and a minor one at about -55°C (probably due to a seperate PDMS phase) which keeps the foams resilient at low temperatures. The -20°C polyether phase is probably mixed with the DELA-TDI phase resulting in a wide transition reaching to over 0°C. This results in a resilience of  about 30% which is quite high for a typical ‘memory’ foam.

Polyurethane "memory foam"

Polyurethane “memory foam”


Improved P.I.P. Foams

Title: Foam Composition and its Uses Thereof

 Number/Link: US2014/079940


Publication date: 20-03-2014 (priority PCT)

Gist”: Use of 4 catalysts:  2 ‘normal’ and 2 ‘delayed action’ are used to formulate pour-in-place foams that resist fabric penetration.

Why it is interesting: “Pour in place” or “in situ” foaming is a technique where a flexible foam-forming mixture is poured directly onto fabric to (typically) produce car seats. The fabrics used are often laminated with a thermoplastic film or a layer of polyester PU foam to prevent penetration of the foaming mixtures.  These liners however impair breathability and therefore comfort. The current invention should allow use of liner-free fabrics without strike through. Four different catalysts are used:  a normal gelling catalyst, a normal blowing catalyst a delayed action gelling catalyst and a delayed action blowing catalyst. The delayed action catalysts are conventional amine catalysts reacted with a suitable acid like lactic acid and become active at a temperature of around 50°C. When poured on a fabric-lined and heated mould, a flexible foam mixture formulated with these catalysts should gel imediately and not penetrate the fabric.

Pour-in-place technique:  2: mould, 3 fabric, 7 foam forming mixture.

Pour-in-place technique: 2: mould, 3 fabric, 7 foam forming mixture.

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