Patent EP-1571168-A1 (EP)
Title: Flexible moulded  parts from foamed polyurethane and their use
Inventor: GRIMM WOLFGANG
IPC: C08G18/48
Filed: 2005-02-19
Abstract: Flexible polyurethane foam moldings of density under 350 kg/m 3> and, on one side, a 0.5-3 mm thick compressed denser edge zone with enclosed hollow microspheres, with molding shrinkage less than 1.5%, are obtained from organic di-, tri- or tetra-isocyanate(s), polyol component(s) comprising polyether-ester-polyols plus polyether-polyol(s) and/or polyester-polyol(s), crosslinker/chain extender, blowing agent mixture and optional components. Flexible polyurethane foam moldings with average density under 350 (preferably under 300) kg/m 3> and, on one side, a 0.5-3 (0.7-2.5) mm thick compressed edge zone of average density of over 650 kg/m 3>, with enclosed hollow microspheres, and molding shrinkage less than 1.5% (to DIN ISO 02769) are obtained from (a) organic isocyanate(s) with 2-4 isocyanate (NCO) groups per molecule and 6-49 (wt.)% NCO, (b) polyols comprising (b1) plus (b2), (b3) or (b4); (c) 5-25% crosslinker/chain extender, (d) blowing agent mixture of (d1) nitrogen, air and/or carbon dioxide, (d2) chemical blowing agent(s) and/or physical blowing agent(s) with boiling point in the -30 to 75[deg]C range and (d3) physically expanding hollow microspheres, and optionally (e) emulsifiers, (f) additives and ancillaries and/or (g) catalysts, such that NCO index is 95-115. The polyol components are: (b1) polyether-ester-polyols [number average molecular weight (Mn) 800-6000 (1200-4000) g/mole, average functionality (aF) 1.7-4 (1.8-2.7), ether/ester group weight ratio 5:95 to 48:52 (8:92 to 30:70)] obtained by polycondensation of (b1.1) dicarboxylic acid(s) with = 12 carbon atoms and/or their derivatives, (b1.2) polyether-polyol component(s), comprising polyether-polyols [Mn 1000-8000 (1500-6000) g/mole, 10-40 (15-35, especially 18-32)% ethylene oxide (EO)] and an ether-based polymer polyol [hydroxyl number (OH no.) 10-149, aF 1.7-4 (1.8-3.5)] with 1-50 (1-45)% filler, (b.1.3) polyol(s) [Mn 62-750 (62-400, especially 62-200) g/mole, aF 2-8] with not less than 2 terminal OH groups per molecule, (b1.4) optionally ester-based polymeric polyols [OH no. 10-149, aF 1.7-4 (1.9-3.5)] and 1-50 (1-45)% filler; (b2) a mixture of (b2.1) polyester-polyol component(s) comprising polyester-polyols (I) [Mn 1000-4000 g/mole, aF 1.7-4] and ester-based polymeric polyols (II) [OH no. 10-149, aF 1.7-4 (1.8-3.5)] with 1-50 (1-45)% filler and (b2.2) 5-48 (8-30)% polyether-polyol component(s) with EO groups [Mn 900-18000 (2000-8000) g/mole, aF 1.7-4 (1.8-2.7), 10-40 (15-35, especially 18-32)% EO] and ether-based polymer polyols [OH no. 10-149, aF 1.7-4 (1.8-3.5)] with 1-50 (1-45)% filler; (b3) polyol component(s) with average OH functionality 2.02-2.95, comprising (b3.1) polyether-diol(s) [OH no. 10-115] prepared by propoxylation of a difunctional starter, then ethoxylation to give propylene oxide (PO) to EO weight ratio of 60:40 to 85:15, and (b3.2) polyether-triol(s) [OH no. 12-56] prepared by propoxylation of a trifunctional starter, then ethoxylation to give PO:EO weight ratio of 60:40 to 85:15, with 0-20% filler based on styrene-acrylonitrile copolymer, polyurea or polyhydrazocarbonamide; (b4) polyester-polyol component(s) selected from (I) and (II), optionally with 1-50 (1-45)% filler(s). An independent claim is also included for production of the moldings.