Claims
- 1. A method of manufacturing a microcellular polyurethane foam, comprising:
selecting a methylene diphenyl diisocyanate (MDI)-ester isocyanate-terminated prepolymer containing less than 12% functionality; preparing a curative component by mixing a polyol, water, a foam surfactant, and a catalyst component comprising a standard solid cast polyurethane catalyst and a delayed-action metal catalyst wherein said water comprises between 1% and 5% by weight of said curative component; and mixing said curative component with said MDI-ester isocyanate-terminated prepolymer at a mole ratio of about 1:1, provided that if said MDI-ester isocyanate-terminated prepolymer or said curative component is present in excess of one over the other, the maximum percentage of said excess over the other is 2%.
- 2. The method of claim 1, further comprising dispensing the reactive mixture into a mold to cure.
- 3. The method of claim 2, further comprising maintaining a mold temperature of about 160° F. to about 200° F.
- 4. The method of claim 2, wherein the mold is configured to form a solid circular tire for attachment to a hub of a bowling ball lift wheel.
- 5. The method of claim 2, wherein the mold is configured to form a solid circular tire for attachment to a molded solid cast elastomer, which is attached to a steel roller for use as a zero crush roll in the manufacturing process for producing corrugated board-stock.
- 6. The method of claim 1, further comprising preheating the prepolymer prior to the introduction of the curative component.
- 7. The method of claim 1, further comprising injecting a gas into the mixture of the curative component of the prepolymer.
- 8. The method of claim 1, wherein the isocyanate-terminated prepolymer has an isocyanate concentration of less than about 10%.
- 9. The method of claim 1, wherein the water concentration is between about 1.5 to about 3% by weight of the curative component.
- 10. The method of claim 1, wherein the foam surfactant concentration is above about 1% of the curative component.
- 11. The method of claim 1, wherein the catalyst component concentration is between about 0.5 to about 0.6% of the curative component.
- 12. The method of claim 1, wherein the NCO to OH ratio is between about 0.96 and 1.02.
- 13. The product manufactured according to the method of claim 1.
- 14. A method of making a solid circular tire for attachment to a hub of a bowling ball lift wheel, comprising:
configuring a mold to a shape defining a solid circular tire for attachment to a hub of a bowling ball wheel lift; selecting a methylene diphenyl diisocyanate (MDI)-ester isocyanate-terminated prepolymer containing less than 12% functionality; preparing a curative component by mixing a polyol, water, a foam surfactant, and a catalyst component comprising a standard solid cast polyurethane catalyst and a delayed-action metal catalyst wherein said water comprises between 1% and 5% by weight of said curative component; mixing said curative component with said MDI-ester isocyanate-terminated prepolymer at a mole ratio of about 1:1, provided that if said MDI-ester isocyanate-terminated prepolymer or said curative component is present in excess of one over the other, the maximum percentage of said excess over the other is 2%; and molding the mixture thus produced in said mold.
- 15. The product manufactured according to the method of claim 14.
- 16. A method of making and using a solid circular tire, comprising:
configuring a mold to a shape defining a solid circular tire; selecting a methylene diphenyl diisocyanate (MDI)-ester isocyanate-terminated prepolymer containing less than 12% functionality; preparing a curative component by mixing a polyol, water, a foam surfactant, and a catalyst component comprising a standard solid cast polyurethane catalyst and a delayed-action metal catalyst wherein said water comprises between 1% and 5% by weight of said curative component; mixing said curative component with said MDI-ester isocyanate-terminated prepolymer at a mole ratio of about 1:1, provided that if said MDI-ester isocyanate-terminated prepolymer or said curative component is present in excess of one over the other, the maximum percentage of said excess over the other is 2%; molding the mixture thus produced in said mold; attaching the solid circular tire thus formed to a molded solid cast elastomer; and attaching said molded solid cast elastomer to a steel roller for use as a zero crush roll in the manufacturing process for producing corrugated board-stock.
- 17. The product manufactured according to the method of claim 16.
- 18. The method of claim 1, further comprising applying pressure to one or both of the components during processing.
Parent Case Info
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 09/714,424, filed Nov. 16, 2000, which is based on priority Provisional Application No. 60/165,857, filed Nov. 16, 1999, which is incorporated herein by reference.
Provisional Applications (1)
|
Number |
Date |
Country |
|
60165857 |
Nov 1999 |
US |
Continuation in Parts (1)
|
Number |
Date |
Country |
Parent |
09714424 |
Nov 2000 |
US |
Child |
10802535 |
Mar 2004 |
US |