Process for producing flexible polyurethane foam and apparatus for producing flexible polyurethane foams
First Claim
1. A process for producing various kinds of flexible polyurethane foams with different properties, comprising:
- bringing at least a polyol, a polyisocyanate and a blowing agent to contact with each other by employing single production apparatus, wherein the polyisocyanate contains tolylene diisocyanate, and the polyol consists essentially of two or three types of polyols, at least two of these two or three types of polyols being selected from the group consisting of;
three types of polyoxyalkylene polyether polyols having an overall degree of unsaturation of less than 0.06 meq/g and three types of polymer polyols obtained from polyoxyalkylene polyether polyols having an overall degree of unsaturation of less than 0.06 meq/g;
and wherein at least the polyisocyanate, the polyol and the blowing agent are mixed by employing a multimixing head (multicomponent head) equipped with at least three feed openings, and the mixing ratio of the two or three types of polyols, polyisocyanate and blowing agent varied to attain various changes of the values of the properties, thus flexible polyurethane foams with desired properties being obtainable.
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Abstract
A process for producing various kinds of flexible polyurethane foams with different properties, comprising: bringing at least a polyol, a polyisocyanate and a blowing agent to contact with each other by employing a single production apparatus, wherein the polyisocyanate contains tolylene diisocyanate, and the polyol consists essentially of two or three types of polyols, at least two of these two or three types of polyols being selected from the group consisting of three types of polyoxyalkylene polyether polyols having an overall degree of unsaturation of less than 0.06 meq/g and three types of polymer polyols obtained from polyoxyalkylene polyether polyols having an overall degree of unsaturation of less than 0.06 meq/g; and wherein the two or three types of polyols, the polyisocyanate and the blowing agent are mixed at a mixing ratio varied to attain various changes of the values of the properties, thus flexible polyurethane foams with desired properties being obtainable. In particular, the use of a polyisocyanate containing tolylene diisocyanate in an amount of 20% by weight or more enables to change a core density of the flexible polyurethane foam in the range of 20 to 70 kg/m3 and to change a 25% ILD hardness of the flexible polyurethane foam in the range of 50 to 400 N/314 cm2.
In the process for producing flexible polyurethane foams of the present invention, various kinds of flexible polyurethane foams having a wide range of values of properties such as hardness, density and impact resilience so as to meet requirements of a wide range of values of properties can be produced from essentially two or three types of polyols by employing a single production apparatus in a simple manner.
25 Citations
28 Claims
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1. A process for producing various kinds of flexible polyurethane foams with different properties, comprising:
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bringing at least a polyol, a polyisocyanate and a blowing agent to contact with each other by employing single production apparatus, wherein the polyisocyanate contains tolylene diisocyanate, and the polyol consists essentially of two or three types of polyols, at least two of these two or three types of polyols being selected from the group consisting of;
three types of polyoxyalkylene polyether polyols having an overall degree of unsaturation of less than 0.06 meq/g and three types of polymer polyols obtained from polyoxyalkylene polyether polyols having an overall degree of unsaturation of less than 0.06 meq/g;
and wherein at least the polyisocyanate, the polyol and the blowing agent are mixed by employing a multimixing head (multicomponent head) equipped with at least three feed openings, and the mixing ratio of the two or three types of polyols, polyisocyanate and blowing agent varied to attain various changes of the values of the properties, thus flexible polyurethane foams with desired properties being obtainable. - View Dependent Claims (3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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2. A process for producing various kinds of flexible polyurethane foams with different properties, comprising:
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bringing at least a polyol, a polyisocyanate and a blowing agent to contact with each other by employing a single production apparatus, wherein the polyisocyanate contains tolylene diisocyanate in an amount of 20% by weight or more, and the polyol consists essentially of two or three types of polyols, at least two of these two or three types of polyols being selected from the group consisting of;
three types of polyoxyalkylene polyether polyols having an overall degree of unsaturation of less than 0.06 meq/g and three types of polymer polyols obtained from polyoxyalkylene polyether polyols having an overall degree of unsaturation of less than 0.06 meq/g;
and wherein the two or three types of polyols, the polyisocyanate and the blowing agent are mixed at a mixing ratio varied to attain changing of a core density of the flexible polyurethane foam in the range of 20 to 70 kg/m3 and changing of a 25% ILD hardness of the flexible polyurethane foam within the range of 50 to 400 N/314 cm2, thus flexible polyurethane foams having a spectral peak, measured by an infrared spectrophotometer, in the range of 1645 to 1700 cm−
1 being obtainable.
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15. An apparatus for producing various kinds of flexible polyurethane foams with different properties, comprising:
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at least one feed opening for feeding a polyisocyanate and one or a plurality of feed openings for feeding essentially two or three types of polyols, wherein the polyisocyanate contains tolylene diisocyanate, and the polyols consist essentially of two or three types of polyols, at least two of these two or three types of polyols being selected from the group consisting of;
three types of polyoxyalkylene polyether polyols having an overall degree of unsaturation of less than 0.06 meq/g and three types of polymer polyols obtained from polyoxyalkylene polyether polyols having an overall degree of unsaturation of less than 0.06 meq/g;
and wherein at least the polyisocyanate, the polyols and a blowing agent can be mixed by employing a multimixing head (multicomponent head) equipped with at least three feed openings, and the mixing ratio of the two or three types of polyols, polyisocyanate and blowing agent is varied to attain various changes of the values of the properties, thus flexible polyurethane foams with desired properties being obtainable. - View Dependent Claims (17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28)
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16. An apparatus for producing various kinds of flexible polyurethane foams with different properties, comprising:
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at least one feed opening for feeding a polyisocyanate and one or a plurality of feed openings for feeding essentially two or three types of polyols, wherein the polyisocyanate contains tolylene diisocyanate in an amount of 20% by weight or more, and the polyols consist essentially of two or three types of polyols, at least two of these two or three types of polyols being selected from the group consisting of;
three types of polyoxyalkylene polyether polyols having an overall degree of unsaturation of less than 0.06 meq/g and three types of polymer polyols obtained from polyoxyalkylene polyether polyols having an overall degree of unsaturation of less than 0.06 meq/g;
and wherein the two or three types of polyols, the polyisocyanate and a blowing agent can be mixed at a mixing ratio varied to attain changing of a core density of the flexible polyurethane foam in the range of 20 to 70 kg/m3 and changing of a 25% ILD hardness of the flexible polyurethane foam within the range of 50 to 400 N/314 cm2, thus flexible polyurethane foams having a spectral peak, measured by an infrared spectrophotometer, in the range of 1645 to 1700 cm−
1 being obtainable.
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Specification