Cure rebond binder
First Claim
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1. A process for producing a cured polyurethane foam article that comprises particles of one or more polyurethane foams bonded together with a binder, which process consisting of:
- a) forming a mixture consisting of;
i) a plurality of particles of polyurethane foam;
ii) a prepolymer made from an organic isocyanate and a polyol;
iii) a catalyst of 2,2′
- dimorpholinodiethylether; and
iv) optionally a surfactant, an organic or silicon based extender oil, an ester, a solvent or a blowing agent; and
b) curing said mixture by contacting it with steam.
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Abstract
The present invention provides processes for producing re-bonded polyurethane foam constructs that are useful in applications such as carpet underlayments. According to the invention, a tertiary amine is employed as a catalyst either alone, or preferably in combination with other catalysts in a binder which comprises an organic isocyanate and a polyol. Inclusion of a tertiary amine as a catalyst dramatically increases production throughput.
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Citations
17 Claims
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1. A process for producing a cured polyurethane foam article that comprises particles of one or more polyurethane foams bonded together with a binder, which process consisting of:
- a) forming a mixture consisting of;
i) a plurality of particles of polyurethane foam;
ii) a prepolymer made from an organic isocyanate and a polyol;
iii) a catalyst of 2,2′
- dimorpholinodiethylether; and
iv) optionally a surfactant, an organic or silicon based extender oil, an ester, a solvent or a blowing agent; and
b) curing said mixture by contacting it with steam. - View Dependent Claims (2, 3, 4, 5, 6, 7)
- a) forming a mixture consisting of;
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8. A method consisting of:
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coating a plurality of polyurethane foam particles with a binder system, said binder system consisting of an organic isocyanate, a polyol, a catalyst of 2,2′
- dimorpholinodiethylether and optionally a surfactant, an organic or silicon based extender oil, an ester, a solvent or a blowing agent;compressing the coated polyurethane particles; and curing the coated polyurethane particles with steam. - View Dependent Claims (9, 10, 11, 12, 13)
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14. A process for producing a cured polyurethane foam article comprising:
- a) forming a mixture consisting of;
i) a plurality of particles of polyurethane foam;
ii) a prepolymer made from an organic isocyanate and a polyol;
iii) a catalyst of 2,2′
- dimorpholinodiethylether; and
iv) optionally a surfactant, an organic or silicon based extender oil, an ester, a solvent or a blowing agent; and
b) curing said mixture by contacting it with steam; and
wherein the cured polyurethane foam article consists of the cured mixture. - View Dependent Claims (15, 16, 17)
- a) forming a mixture consisting of;
Specification