Low density polyurethane foam, method of producing, and articles comprising the same
First Claim
1. A method for producing a cured, low density polyurethane foam, the method comprising:
- mechanically frothing a reactive polyurethane-forming composition comprising an isocyanate-containing component, an active hydrogen-containing component reactive with the isocyanate-containing component, a blowing agent comprising water, a surfactant, and catalyst system, wherein the catalyst system provides for a delayed curing of the foam; and
in a continuous process,casting the frothed reactive polyurethane-forming composition onto a moving first carrier;
placing a second carrier on a side of the cast froth opposite the first carrier;
blowing the froth with the second carrier in place; and
curing the blown froth so as to provide a polyurethane foam layer having a compression load deflection at 50% of about 0.003 to about 0.025 MPa, a compression load deflection at 75% of about 0.02 to about 0.40 MPa, a density of about 50 to about 400 kg/m3 and a thickness of about 0.3 to about 13 mm.
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Accused Products
Abstract
A method for producing a cured, low-density polyurethane foam, the method comprises frothing a reactive polyurethane-forming composition comprising an isocyanate-containing component, an active hydrogen-containing component reactive with the isocyanate-containing component, a blowing agent, a surfactant, and catalyst system, wherein the catalyst system provides for a delayed curing of the foam; casting the frothed reactive polyurethane-forming composition onto a first carrier; placing a second carrier on a side of the cast foam opposite the first carrier; blowing the froth with the second carrier in place; and curing the blown froth so as to provide a polyurethane foam layer having a density of about 50 to about 400 kg/m3 and a thickness of about 0.3 to about 13 mm. The foams are useful as sealing members.
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Citations
19 Claims
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1. A method for producing a cured, low density polyurethane foam, the method comprising:
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mechanically frothing a reactive polyurethane-forming composition comprising an isocyanate-containing component, an active hydrogen-containing component reactive with the isocyanate-containing component, a blowing agent comprising water, a surfactant, and catalyst system, wherein the catalyst system provides for a delayed curing of the foam; and in a continuous process, casting the frothed reactive polyurethane-forming composition onto a moving first carrier; placing a second carrier on a side of the cast froth opposite the first carrier; blowing the froth with the second carrier in place; and curing the blown froth so as to provide a polyurethane foam layer having a compression load deflection at 50% of about 0.003 to about 0.025 MPa, a compression load deflection at 75% of about 0.02 to about 0.40 MPa, a density of about 50 to about 400 kg/m3 and a thickness of about 0.3 to about 13 mm. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19)
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Specification