Appliance comprising polyurethane foam

• US 8,302,280 B2
• Filed: 01/12/2010
• Issued: 11/06/2012
• Est. Priority Date: 01/12/2010
• Status: Expired due to Fees

• Current Assignee: BASF SE
• Original Assignee: BASF SE
• Inventors: Neff, Raymond A., Carmona, Lucyanne, Phelps, David R.
• Primary Examiner(s): Stinson, Frankie L
• Application Number:
  US12/686,220
• Publication Number:
  US 20110168217A1
• Time in Patent Office: 1,029 Days
• Field of Search: 134/200, 68/3.R
• US Class Current: 29/428
• CPC Class Codes: A47L 15/4209 Insulation arrangements, e.g. for sound damping or heat insulation
• CPC Class Codes: C08G 18/10 Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
• CPC Class Codes: C08G 18/3206 aliphatic
• CPC Class Codes: C08G 18/4816 mixtures of two or more polyetherpolyols having at least three hydroxy groups
• CPC Class Codes: C08G 18/482 Mixtures of polyethers containing at least one polyether containing nitrogen
• CPC Class Codes: C08G 18/6674 with compounds of group C08G18/3203
• CPC Class Codes: C08G 18/6685 with compounds of group C08G18/3225 or polyamines of C08G18/38
• CPC Class Codes: C08G 18/797 containing carbodiimide and/or uretone-imine groups
• CPC Class Codes: C08G 2110/0066 ≥ 150kg/m3
• CPC Class Codes: C08G 2110/0083 prepared using water as the sole blowing agent
• CPC Class Codes: C08G 2115/02 to isocyanurate groups
• CPC Class Codes: C08G 2350/00 Acoustic or vibration damping material
• CPC Class Codes: D06F 39/12 Casings; Tubs
• CPC Class Codes: G10K 11/162 Selection of materials
• CPC Class Codes: Y10T 29/49826 Assembling or joining
• CPC Class Codes: Y10T 428/1376 Foam or porous material containing

Abstract

An appliance includes a housing having top and bottom panels disposed opposite each other and a plurality of walls connected to the top and bottom panels. The top and bottom panels and the plurality of walls define a cavity of the appliance. The housing also has an outermost surface about which a polyurethane foam is disposed. The polyurethane foam reduces noise and vibrations emitted from the appliance during use and has a density of from 20 to 50 pounds per cubic foot (pcf). The polyurethane foam also has a damping factor of at least 0.2 measured at a temperature of from 40° C. to 60° C. Furthermore, the polyurethane foam has a k-factor of less than 2.0 btu-in/hr-ft²-° F. which reduces an amount of energy required to operate the appliance. The appliance is formed by applying the polyurethane foam to at least one of the top panel, bottom panel, and plurality of walls.

Claims

1. A method of forming an appliance comprising a housing having a top panel and a bottom panel that are disposed opposite each other and also having a plurality of walls connected to the top and bottom panels, wherein the top and bottom panels and the plurality of walls define a cavity and wherein the housing has an outermost surface, said method comprising the step of applying a polyurethane foam about at least a portion of the outermost surface wherein the polyurethane foam comprises the reaction product of an isocyanate composition and a resin composition comprising at least one polyol, and has (1) a density of from 20 to 50 pounds per cubic foot as determined according to ASTM D 1622, (2) a damping factor of at least 0.2 measured at a temperature of from 40°

C. to 60°

C. as determined according to ASTM D 4065, and (3) a K-factor of less than 2.0 btu-in/hr-ft²-°

F. as determined according to ASTM C 518.

2. A method as set forth in claim 1 wherein the resin composition comprises from 1 to 2 parts by weight of a polymerization catalyst per 100 parts by weight of the resin composition.

3. A method as set forth in claim 2 wherein the step of applying the polyurethane foam is further defined as applying the polyurethane foam to at least one of the top panel, bottom panel, and plurality of walls before the top panel and bottom panel are connected by the plurality of walls.

4. A method as set forth in claim 3 wherein the polyurethane foam is applied to at least a portion of each of the top and bottom panels and the plurality of walls.

5. A method as set forth in claim 3 wherein the polyurethane foam is applied to at least a portion of each of the top panel and the plurality of walls.

6. A method as set forth in claim 1 wherein the step of applying the polyurethane foam is further defined as applying the polyurethane foam to at least a portion of at least one of the top panel, bottom panel, and plurality of walls after the top panel and bottom panel are connected by the plurality of walls.

7. A method as set forth in claim 6 further wherein the polyurethane foam is applied to at least a portion of each of the top and bottom panels and the plurality of walls.

8. A method as set forth in claim 6 wherein the polyurethane foam is applied to at least a portion of each of the top panel and the plurality of walls.

9. A method as set forth in claim 1 further comprising the step of applying an outermost layer on at least a portion of the polyurethane foam sandwiching the polyurethane foam between the outermost layer and the outermost surface of the housing, wherein the outermost layer has a density that is greater than a density of the polyurethane foam.

10. A method as set forth in claim 9 wherein the outermost layer comprises a polyurethane elastomer, a polyurea elastomer, a polyurethane-polyurea hybrid elastomer, or combinations thereof.

11. A method as set forth in claim 9 wherein the resin composition comprises a diol and a triol, each having a number average molecular weight of less than 1,000 g/mol, and wherein the isocyanate composition comprises an isocyanate prepolymer.

12. A method as set forth in claim 11 wherein the isocyanate composition comprises less than 30 percent by weight of polymeric methylene diphenyl diisocyanate.

13. A method as set forth in claim 12 wherein the polyurethane foam has a glass transition temperature of from 30°

C. to 60°

C. determined according to ASTM D 4065, wherein the density is further defined as from 25 to 35 pounds per cubic foot as determined according to ASTM D 1622, wherein the damping factor is further defined as greater than 0.5 measured at a temperature of from 40°

C. to 60°

C. as determined according to ASTM D 4065, and wherein the appliance is further defined as a dishwasher.

14. A method as set forth in claim 13 wherein the outermost layer comprises a polyurethane-polyurea hybrid elastomer.

15. A method as set forth in claim 11 wherein the polyurethane foam has a glass transition temperature of from 30°

C. to 60°

C. determined according to ASTM D 4065, wherein the density is further defined as from 25 to 35 pounds per cubic foot as determined according to ASTM D 1622, wherein the damping factor is further defined as greater than 0.5 measured at a temperature of from 40°

C. to 60°

C. as determined according to ASTM D 4065, and wherein the appliance is further defined as a dishwasher.

16. A method as set forth in claim 15 wherein the outermost layer comprises a polyurethane-polyurea hybrid elastomer.

17. A method as set forth in claim 9 wherein the outermost layer comprises a polyurethane-polyurea hybrid elastomer.

18. A method as set forth in claim 17 wherein the polyurethane foam has a glass transition temperature of from 30°

C. to 60°

C. determined according to ASTM D 4065, wherein the density is further defined as from 25 to 35 pounds per cubic foot as determined according to ASTM D 1622, wherein the damping factor is further defined as greater than 0.5 measured at a temperature of from 40°

C. to 60°

C. as determined according to ASTM D 4065, and wherein the appliance is further defined as a dishwasher.

19. A method as set forth in claim 1 wherein the resin composition comprises a diol and a triol, each having a number average molecular weight of less than 1,000 g/mol, and wherein the isocyanate composition comprises an isocyanate prepolymer.

20. A method as set forth in claim 19 wherein the polyurethane foam has a glass transition temperature of from 30°

C. to 60°

C. determined according to ASTM D 4065, wherein the density is further defined as from 25 to 35 pounds per cubic foot as determined according to ASTM D 1622, wherein the damping factor is further defined as greater than 0.5 measured at a temperature of from 40°

C. to 60°

C. as determined according to ASTM D 4065, and wherein the appliance is further defined as a dishwasher.

21. A method as set forth in claim 20 further comprising the step of applying an outermost layer on at least a portion of the polyurethane foam sandwiching the polyurethane foam between the outermost layer and the outermost surface of the housing, wherein the outermost layer has a density that is greater than a density of the polyurethane foam.

22. A method as set forth in claim 21 wherein the outermost layer comprises a polyurethane-polyurea hybrid elastomer.

23. A method as set forth in claim 1 wherein the polyurethane foam has a glass transition temperature of from 30°

C. to 60°

C. determined according to ASTM D 4065.

24. A method as set forth in claim 1 wherein the density is further defined as from 25 to 35 pounds per cubic foot as determined according to ASTM D 1622.

25. A method as set forth in claim 1 wherein the damping factor is further defined as greater than 0.5 measured at a temperature of from 40°

C. to 60°

C. as determined according to ASTM D 4065.

26. A method as set forth in claim 1 wherein the appliance is further defined as a dishwasher.

27. A method as set forth in claim 1 wherein the polyurethane foam has a glass transition temperature of from 30°

C. to 60°

C. determined according to ASTM D 4065, wherein the density is further defined as from 25 to 35 pounds per cubic foot as determined according to ASTM D 1622, wherein the damping factor is further defined as greater than 0.5 measured at a temperature of from 40°

C. to 60°

C. as determined according to ASTM D 4065, and wherein the appliance is further defined as a dishwasher.

28. A method of forming a dishwasher comprising a housing having a top panel and a bottom panel that are disposed opposite each other and also having a plurality of walls connected to the top and bottom panels, wherein the top and bottom panels and the plurality of walls define a cavity and wherein the housing has an outermost surface, said method comprising the step of applying a polyurethane foam about at least a portion of the outermost surface, wherein the polyurethane foam comprises the reaction product of an isocyanate composition and a resin composition comprising at least one polyol, and has (1) a density of from 20 to 50 pounds per cubic foot as determined according to ASTM D 1622, (2) a damping factor of at least 0.2 measured at a temperature of from 40°

C. to 60°

C. as determined according to ASTM D 4065, (3) a K-factor of less than 2.0 btu-in/hr-ft²-°

F. as determined according to ASTM C 518, and (4) a glass transition temperature of from 30°

C. to 60°

C. determined according to ASTM D 4065.