Claims
- 1. A process for preparing a polyurethane foam pad for use as either an attached carpet cushion or a detached carpet underlay, said process comprising admixing a polyurethane formulation under reaction conditions such that said polyurethane formulation is both frothed and chemically blown, said polyurethane formulation comprising:a) at least one isocyanate-reactive material having an average equivalent weight of about 1,000 to about 5,000; b) from about 0.5 to about 3 parts water per hundred parts of said at least one isocyanate-reactive material; c) from about 0.01 to about 3.5 parts urethane catalyst per hundred parts of said at least one isocyanate-reactive material; d) from about 1 to about 2 parts surfactant per hundred parts of said at least one isocyanate-reactive material; and e) an isocyanate-based prepolymer prepared by reaction of an isocyanate with a polyol having a molecular weight of up to about 800.
- 2. The process of claim 1 wherein the formulation includes from about 0.01 to about 3.0 parts catalyst.
- 3. The process of claim 1 wherein the formulation includes from about 0.02 to about 2.5 parts catalyst.
- 4. The process of claim 1 wherein the formulation includes from about 0.02 to about 2 parts catalyst.
- 5. The process of claim 1 wherein the formulation includes from about 0.02 to about 1.8 parts catalyst.
- 6. The process of claim 1 wherein the formulation includes from about 0.02 to about 1.6 parts catalyst.
- 7. The process of claim 1 wherein the formulation includes from about 0.02 to about 1.4 parts catalyst.
- 8. The process of claim 1 wherein the formulation includes from about 0.02 to about 1.2 parts catalyst.
- 9. The process of claim 1 wherein the formulation includes from about 0.02 to about 1 part catalyst.
- 10. The process of claim 1 wherein the formulation includes from about 0.02 to about 0.5 part catalyst.
- 11. The process of claim 1 wherein the formulation includes from about 0.02 to about 0.05 part catalyst.
- 12. The process of claim 1 wherein the formulation includes from about 0.02 to about 0.03 part catalyst.
- 13. A polyurethane foam prepared by the process of claim 1.
- 14. The foam of claim 13 wherein the foam has a density of from about 3 to about 30 pounds per cubic foot.
- 15. The foam of claim 13 wherein the foam has a density of from about 8 to about 18 pounds per cubic foot.
- 16. The foam of claim 13 wherein the foam has a density of from about 8 to about 14 pounds per cubic foot.
- 17. The foam of claim 13 wherein the foam has a density of from about 8 to about 10 pounds per cubic foot.
- 18. The foam of claim 13 wherein the foam has a density of less than about 10 pounds per cubic foot.
- 19. The foam of claim 13 wherein the foam is useful as an attached foam cushion.
- 20. The foam of claim 13 wherein the foam is useful as a detached foam underlay.
- 21. The process of claim 1, wherein said polyurethane formulation further comprises an organic polyisocyanate, a modified polyisocyanate, or a combination of an organic polyisocyanate and a modified polyisocyanate.
- 22. The process of claim 1, wherein said isocyanate-based prepolymer is an MDI prepolymer.
- 23. The process of claim 1, wherein said isocyanate-based prepolymer is prepared by reaction of an isocyanate with at least one of dipropylene glycol and tripropylene glycol.
CROSS-REFERENCE STATEMENT
This application is a continuation of U.S. patent application Ser. No. 09/305,569, filed May 5, 1999, which is a continuation in part of U.S. patent application Ser. No. 08/785,077 filed Jan. 17, 1997, now abandoned, which claims the benefit of U.S. Provisional Application No. 60/010,247, filed Jan. 19, 1996.
US Referenced Citations (1)
Number |
Name |
Date |
Kind |
5104693 |
Jenkines |
Apr 1992 |
A |
Provisional Applications (1)
|
Number |
Date |
Country |
|
60/010247 |
Jan 1996 |
US |
Continuations (1)
|
Number |
Date |
Country |
Parent |
09/305569 |
May 1999 |
US |
Child |
09/730153 |
|
US |
Continuation in Parts (1)
|
Number |
Date |
Country |
Parent |
08/785077 |
Jan 1997 |
US |
Child |
09/305569 |
|
US |