Polyurethane foam formulation, products and methods
First Claim
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1. A method of making an open cell, molded polyurethane foam object, comprising:
- reacting a reaction mixture in a mold to produce a reaction product, wherein the reaction mixture comprises;
a base polyol having a molecular weight of from 5000 to 10000 and a monol content of less than 10% by weight;
an isocyanate;
a surfactant; and
water;
curing the reaction product in the mold;
removing the reaction product from the mold; and
crushing the reaction product by performing a crushing step, wherein the crushing step comprises first compressing the reaction product to about 50% of its original height, then compressing the reaction product to about 90% of its original height, and then again compressing the reaction product to about 90% of its original height to generate an open cell, polyurethane foam material having a comfort value of less than 13.0, and the comfort value is the natural frequency multipled by the peak measured transmissivity.
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Abstract
A foam article for use in a seat cushion includes an open cell, polyurethane foam material that includes a base polyol; a crosslinker; an isocyanate; a surfactant; and water, that are reacted together to produce a seat cushion having dynamic and static performance specifications that are better than the performance characteristics for a traditional, high resilient material seat cushion, as well as other seating materials.
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Citations
16 Claims
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1. A method of making an open cell, molded polyurethane foam object, comprising:
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reacting a reaction mixture in a mold to produce a reaction product, wherein the reaction mixture comprises; a base polyol having a molecular weight of from 5000 to 10000 and a monol content of less than 10% by weight; an isocyanate; a surfactant; and water; curing the reaction product in the mold; removing the reaction product from the mold; and crushing the reaction product by performing a crushing step, wherein the crushing step comprises first compressing the reaction product to about 50% of its original height, then compressing the reaction product to about 90% of its original height, and then again compressing the reaction product to about 90% of its original height to generate an open cell, polyurethane foam material having a comfort value of less than 13.0, and the comfort value is the natural frequency multipled by the peak measured transmissivity. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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Specification