Static dissipative polyurethane foams

• US 7,005,458 B2
• Filed: 06/20/2003
• Issued: 02/28/2006
• Est. Priority Date: 06/20/2003
• Status: Active Grant

• Current Assignee: FXI, Inc. (FXI Holdings Incorporated)
• Original Assignee: Foamex LP (FXI Holdings Incorporated)
• Inventors: Lovette, Joseph W.
• Primary Examiner(s): Cooney, John M.
• Application Number:
  US10/601,088
• Publication Number:
  US 20040259966A1
• Time in Patent Office: 984 Days
• Field of Search: 521/99, 521/123, 521/130, 521/134, 521/137, 521/170, 521/172, 521/173, 521/174
• US Class Current: 521/174
• CPC Class Codes: C08G 18/4072 Mixtures of compounds of group C08G18/63 with other macromolecular compounds
• CPC Class Codes: C08G 18/632 onto polyethers
• CPC Class Codes: C08G 2110/0008 flexible
• CPC Class Codes: C08G 2110/0058 ≥50 and <150kg/m3
• CPC Class Codes: C08G 2110/0083 prepared using water as the sole blowing agent
• CPC Class Codes: C08J 2375/04 Polyurethanes
• CPC Class Codes: C08J 9/0004 Use of compounding ingredients, the chemical constitution of which is unknown, broadly defined, or irrelevant
• CPC Class Codes: G03G 2215/0634 Developing device
• CPC Class Codes: G03G 2215/16 Transferring device, details

Abstract

A static dissipative flexible polyurethane foam is formed under free rise expansion conditions from a polyether graft polyol and an isocyanate, wherein one or more anti-static additives are incorporated into the reaction mix in an amount from 0.10 to 20 parts by weight. Water is added in an amount of from 0.2 to 1.0 parts per weight. Upon curing, the foam has a density in the range of 6 to 20 pounds per cubic foot, a surface resistivity below 1×10¹¹ ohms/square, and a pore size in the range of 100 to 250 pores per inch. The foam may be fabricated (cut or shaped) to form a shaped article, such as a roller, a clean room wipe, a cosmetic applicator or a packaging element.

Claims

1. A method for making a flexible polyurethane foam, comprising:

mixing at a mix head to react (i) a polyether graft polyol or a polyether graft polyol mixed with an ester polyol and/or a polyether polyol, wherein said polyol or combination of polyols has a number average molecular weight of from about 500 to about 8000, with (ii) an isocyanate selected from the group consisting of diphenylmethane 4,4′

diisocyanate, diphenyl methane 2,2′

diisocyanate, diphenylmethmne 2,4′

diisocyanate, toluene diisocyanate, higher molecular weight isocyanate oligomers, and mixtures thereof, with an isocyanate index in the range of 95 to 110 to form a reaction mix;

incorporating into the reaction mix water in an amount from 0.2 to 1.0 parts by weight per hundred parts polyol;

further incorporating into the reaction mix one or more anti-static additives in an amount from 0.1 to 20 parts by weight per hundred parts polyol, to form a foam-forming mixture; and

presenting the foam-forming mixture to an open container or a moving conveyor to permit free rise expansion of the polyurethane foam;

wherein, upon curing, the polyurethane foam has a density in the range of 6 to 20 pounds per cubic foot, a surface resistivity below 1×

10¹¹ ohms/square as determined at 12% relative humidity and 23°

C., and a pore size in the range of 100 to 250 pores per inch.

2. The method of claim 1, wherein the anti-static additive is selected from the group consisting of:

quarternary ammonium compounds, metallic salts, complexes of metallic salts with polyhydric alcohols and their derivatives, complexes of metallic salts with mono-ols, hexahalogenated ionic compounds, and carbon black.

3. The method of claim 1, wherein the graft polyol comprises at least 20 parts by weight per hundred parts of the polyol component of the reaction mix.

4. The method of claim 1, further comprising incorporating into the reaction mix at the mix head a cross-linking agent selected from the group consisting of diethanolamine (DEOA), ethylene glycol (EG), diethylene glycol (DEG), triethylene glycol (TEG), propylene glycol (PG), dipropylene glycol (DPG), 1,4 butanediol (BDO), and mixtures thereof, and in an amount from 0 to 25 parts by weight per hundred parts polyol.

5. The method of claim 1, wherein the surface resistivity of the polyurethane foam is from 1×

10⁷ ohms/square to 1×

10⁷ ohms/square as determined at 12% relative humidity and 23°

C.

6. The method of claim 1, wherein the density of the polyurethane foam as from 7 to 9 pounds per cubic foot.

7. The method of claim 1, wherein the isocyanate is diphenylmethane 4,4′

diisocyanate or diphenylmethmne 2,2′

diisocyanate or diphenylmethane 2,4′

diisocyanate, or mixtures thereof.

16. A polyurethane foam produced by the method of claim 1.

8. A method for making a shaped polyurethane foam part, comprising:

mixing at a mix head to react (i) a polyether graft polyol or polyol mixed with ester polyol and/or a polyether polyol, wherein said polyol or combination of polyols has a number average molecular weight of from about 500 to about 8000, with (ii) an isocyanate selected from the group consisting of diphenyl 4,4′

diisocyanate, diphenylmethane 2,2′

diisocyanate, diphenylmethane 2, 4′

diisocyanate, toluene diisocyanate, higher molecular weight isocyanate oligomers, and mixtures thereof, to form a reaction mix;

incorporating into the reaction mix water in an amount from 0.2 to 1.0 parts by weight per hundred parts polyol;

further incorporating into the reaction mix one or more anti-static additives in an amount from 0.1 to 20 parts by weight per hundred parts polyol, to form a foam-forming mixture;

presenting the foam-forming mixture to an open container or a moving conveyor to permit free rise expansion of the polyurethane foam, wherein, upon curing, the polyurethane foam has a density in the range of 6 to 20 pounds per cubic foot, a surface resistivity below 1×

10¹¹ ohms/square as determined at 12% relative humidity and 23°

C., and a pore size in the range of 100 to 250 pores per inch.; and

fabricating the polyurethane foam into the shaped polyurethane foam part.

9. The method of claim 8, wherein the anti-static additive is selected from the group consisting of:

quarternary ammonium compounds, metallic salts, complexes of metallic salts with polyhydric alcohols and their derivatives, complexes of metallic salts with mono-ols, hexahalogenated ionic compounds, and carbon black.

10. The method of claim 8, wherein the graft polyol comprises at least 20 parts by weight per hundred parts of the polyol component of the reaction mix.

11. The method of claim 8, further comprising incorporating into the reaction mix a cross-linking agent selected from the group consisting of:

diethanolamine (DEOA), ethylene glycol (EG), diethylene glycol (DEG), triethylene glycol (TEG), propylene glycol (PG), dipropylene glycol (DPG), 1,4 butanediol (BDO), and mixtures thereof, and in an amount from 0 to 25 parts by weight per hundred parts polyol.

12. The method of claim 8, wherein the surface resistivity of the polyurethane foam is from 1×

10⁷ ohms/square to 1×

10⁹ ohms/square as determined at 12% relative humidity and 23°

C.

13. The method of claim 8, wherein the density of the polyurethane foam is from 7 to 9 pounds per cubic foot.

14. The method of claim 8, wherein the isocyanate is diphenylmethane 4,4′

diisocyanate or diphenylmethane 2,2′

diisocyanate or diphenylmethane 2,4′

diisocyanate, or mixtures thereof.

15. The method of claim 8, wherein fabricating comprises one or more of grinding, slicing, die-cutting, machining, peeling, convoluting, laser cutting, water pressure cutting or otherwise shaping by cutting.

17. A polyurethane foam part produced by the method of claim 8.