Patent ID: 8178591

Claim:
A process for the production of a microcellular polyurethane comprising reacting a diisocyanate and/or polyisocyanate in the presence of carbon dioxide with an isocyanate-reactive component comprising: a) a polyol having a hydroxyl group functionality of at least 1.7 and a molecular weight of from about 1,000 to about 12,000 Da, b) a catalyst, c) a surfactant, d) optionally, a crosslinking agent, e) optionally, water, and f) dissolved carbon dioxide in an amount ranging from 0.2g/L to 4g/L in which (1) the dissolved carbon dioxide is present in an amount sufficient to produce an isocyanate-reactive component froth density of from about 0.1 to about 0.8 g/cc and (2) total amount of the dissolved carbon dioxide plus any carbon dioxide generated during reaction of the water with the isocyanate will produce a polyurethane-forming reaction mixture having a free rise density of from about 0.03 to 0.3 g/cc.