Mechanically frothed and chemically blown polyurethane foam
First Claim
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1. A process for preparing a polyurethane foam pad for use as either an attached carpet cushion or a detached carpet underlay, said process comprising admixing a polyurethane formulation under reaction conditions such that said polyurethane formulation is both frothed and chemically blown, said polyurethane formulation comprising:
- a) at least one isocyanate-reactive material having an average equivalent weight of about 1,000 to about 5,000;
b) from about 0.5 to about 3 parts water per hundred parts of said at least one isocyanate-reactive material;
c) from about 0.01 to about 3.5 parts urethane catalyst per hundred parts of said at least one isocyanate-reactive material;
d) from about 1 to about 2 parts surfactant per hundred parts of said at least one isocyanate-reactive material; and
e) an isocyanate-based prepolymer prepared by reaction of an isocyanate with a polyol having a molecular weight of up to about 800.
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Abstract
The present invention is a low density polyurethane foam cushion useful as an attached carpet cushion or as a detached carpet underlay. The low density foams of the present invention are prepared by a process wherein a polyurethane foam formulation is blown by both mechanical and chemical processes.
20 Citations
23 Claims
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1. A process for preparing a polyurethane foam pad for use as either an attached carpet cushion or a detached carpet underlay, said process comprising admixing a polyurethane formulation under reaction conditions such that said polyurethane formulation is both frothed and chemically blown, said polyurethane formulation comprising:
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a) at least one isocyanate-reactive material having an average equivalent weight of about 1,000 to about 5,000;
b) from about 0.5 to about 3 parts water per hundred parts of said at least one isocyanate-reactive material;
c) from about 0.01 to about 3.5 parts urethane catalyst per hundred parts of said at least one isocyanate-reactive material;
d) from about 1 to about 2 parts surfactant per hundred parts of said at least one isocyanate-reactive material; and
e) an isocyanate-based prepolymer prepared by reaction of an isocyanate with a polyol having a molecular weight of up to about 800. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23)
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Specification