Enhanced homogeneous polyurethane foam comfort cushioning and process for making same

摘要

Preparing a flexible, polyurethane foam: (a) placing a polyol polyurethane foam-forming reaction mixture in a reaction zone and allowing the mixture to rise, thereby forming a partially cured cellular material, (b) applying a compressive force to the partially cured cellular material after the elapsing of a period of time after completion of the rise to thereby reduce the volume of the partially cured cellular material, and (c) removing the compressive force and completing the cure of the compressed cellular material. The cellular material has enhanced cushioning properties including a unique and superior feeling of comfort resulting from a soft touch yet with a deep firm support with an appropriate springiness to the foam. The polyol in the polyurethane foam-forming reaction mixture contains a mixture of (d) from 90-10 parts by weight of a polymer-polyol composition containing about 10-40% polymer solids, and (e) from 10-90 parts by weight of a base polyol having a molecular weight of at least 4500 up to 7000. The cellular material has a final volume which is reduced by about 10-60% of the original volume of the partially cured cellular material after the compressive force is removed based on the weight of the polyol components cellular material has a Support Factor of from about 2-5.