Note: Descriptions are shown in the official language in which they were submitted.
~W094/~937 21 S 8 6 ~ 4 PCT/GB94/00776
PREPARATION OF POUR-IN-PLACE ARTICLES
EMPLOYING ELASTOMER COATING
.. .
Field of the Invention
This invention relates to the preparation of
pour-in-place articles. More particularly, this
invention relates to the employment of coatings in the
preparation of pour-in-place, material covered
articles.
Backqround of the Invention
Pour-in-place articles are generally prepared by
placing a material covering, such as a piece of vinyl
or fabric, into a mold and then pouring a liquid foam
forming reaction mixture, such as a polyurethane
composition, into the mold. A vacuum is often used to
insure that the material covering snugly fits the
contour of the mold. For example, U.S. Patent No.
4,806,088 discloses an apparatus for preparing textile
covered cushions in which a fabric cover is adapted to
the contour of a mold cavity by the application of a
vacuum and then a foam forming reaction mixture is
introduced into the mold. U.S. Patent Nos. 4,046,611
and 4,637,789 also disclose the preparation of
cushions by vacuum molding.
After the foam forming reaction mixture is poured
into the mold and the foam cures, the foam and the
material covering are firmly adhered to one another
thereby producing a material covered molded article.
However, one problem encountered with this procedure
is that the liquid foamable composition has a tendency
to seep through the interstices of the material
covering to the outer surface of the material causing
disruptio~ and discoloration of the material's
exterior surface. This phenomenon is known as
W094l~937 PCT/GB94100776
21S~F~S4 ~
"strike-through." The problem of strike-through is
made much worse by the application of a vacuum.
To prevent strike-through, a variety of methods
have been employed. For example, in U.S. Patent No.
3,932,252, a strippable coating is sprayed onto one
side of a fabric, the fabric is placed in a mold
cavity so that the coating will be between the fabric
and the mold, a vacuum is applied to the fabric, a
foamable compound is placed into the mold, the
compound is foamed, and then the strippable coating is
removed from the molded article.
The most common method, however, of preventing
strike-through is to adhere a film or sheet to the
back side of the covering. For example, U.S. Patent
No. 4,610,923 discloses a process for preparing
laminated fabric structures in which a flexible
elastomeric skin containing microspheres is adhered to
a stretchable fabric, the laminate is placed into a
vacuum mold, and a liquid foamable composition is
added to the mold and foamed.
While solving the problem of strike-through, the
use of such films and sheets generates other problems.
one problem is that the film must be adhered to the
material covering in order for there to be sufficient
adhesion between the covering, the film and the foam
substrate of the upholstered article. The film or
sheet is usually adhered to the covering by using an
adhesive or by flame bonding. Attaining the
appropriate adhesion adds a step to the preparation of
material covered articles thereby increasing the cost
and time of production. Another problem is that many
of the thermoplastic films employed and/or the methods
used to adhere the film to the covering give the
_W094/~937 PCT/GB94/00776
~ 21S8~S,~
-- 3
covering a boardy and uncomfortable feel, i.e. a "poor
hand".
Another way to avoid strike-through is to first
prepare a foam body and then adhere the material
covering to the foam body. For example, U.S. Patent
No. 4,975,135 discloses a process for preparing a
vehicle seat in which a composite insert is prepared
by laminating a porous fabric to a polymeric foam
sheet, placing the composite into a vacuum mold, and
adhering a foam bun to the composite insert. This
method, however, is not as convenient as preparing the
foamed body in the mold by the pour-in-place method
and adds an additional step to the preparation of
material covered articles, namely the step of adhering
the material to an already formed foam body.
In U.S. Patent No. 4,740,417, a process is
disclosed for preparing an article wherein a flexible
polyurethane foam is laminated to the backside of a
fabric, the laminated fabric is placed in a vacuum
mold, and a thermoplastic substrate is heated until it
sags and flows into the mold.
Accordingly, there is a need for a process for
preparing an article covered by a material which
avoids the step of adhering an already formed film or
sheet to a material covering and the step of adhering
a material covering to an already formed foam body.
There is a further need for an efficient and
economical process for preparing material covered
foamed articles. There is also a need for a process
for producing pour-in-place molded articles which
eliminates strike-through while providing a material
cover with a good hand.
W094/~937 ~ S 4 PCTIGB94/0077~
It is therefore an object of this invention to
provide an efficient and economical method of
preparing material covered articles.
It is another object to provide a means of
preparing vacuum molded articles that have a material
covering which is not stiff or boardy.
It is yet another object to provide a process for
preparing material covered molded articles that
eliminates strike-through.
It is a further object to provide material
covered articles that have excellent properties.
These and other objects are obtained by the
process of this invention.
summarY of Invention
The invention is a process for preparing material
covered, pour-in-place articles comprising the steps
of:
(a) applying a polymeric coating, which is
prepared by reacting a polyisocyanate and an
isocyanate reactive material at an isocyanate index in
the range of 30 to 1500, to one side of a material
covering before or after placing the material covering
in a mold;
(b) pouring a liquid foamable composition onto
the coated side of the material;
(c) foaming the liquid foamable composition; and
(d) removing the resulting foamed, laminated,
material covered article from the mold.
In a preferred embodiment, a textile fabric is
used as the material covering and the process
comprises the steps of:
(a) applying a polymeric coating, which is
prepared by reacting a polyisocyanate and an
~0 94nu937 ~SO~s~ PCT/GB94/00776
isocyanate reactive material at an isocyanate index in
the range of 30 to 100, to one side of a textile
fabric covering before or after placing the covering
in a vacuum mold;
(b) pouring a liquid foamable composition onto
the coated side of the textile fabric covering in the
mold;
(c) foaming the liquid foamable composition; and
(d) removing the resulting foamed, laminated,
fabric article from the mold.
The present invention further comprises a
process for preparing an upholstered, vacuum molded
pour-in-place article, comprising the steps of:
(a) applying a polymeric coating, which is
prepared by reacting a polyisocyanate and a polyol at
an isocyanate index in the range of 30 to 1500, to one
side of a textile fabric covering before or after
placing the covering in a mold;
(b) vacuum forming the textile fabric covering in
the mold;
(c) pouring a liquid foamable composition onto
the coated side of the textile fabric covering in the
mold;
(d) foaming the liquid foamable composition; and
(e) removing the resulting foamed, laminated,
fabric article from the mold.
The material covered, pour-in-place, article
~ produced by the present process is comprised of:
(a) a material covering;
(b) a polymeric coating, prepared by reacting a
polyisocyanate and an isocyanate reactive material at
an isocyanate index in the range of 30 to 1500,
affixed to one side of the material covering; and
(c) a foam body adhered to the coating.
W094/~937 ~ ~S~l6S PCT/GB94/0077~
The process can be used to make a wide variety of
upholstered articles. It is particularly useful for
making upholstered seats for vehicles.
Detailed Descri~tion of the Invention
The articles prepared according to the process of
this invention are foamed articles having a material
covering. The material covering can be any material
to which the polyurethane coating firmly adheres.
Suitable materials include vinyl, leather, and textile
fabric coverings. The preferred covering is a textile
fabric covering. As used herein, the term "textile
fabric covering" includes any porous fabric or cloth
that can be employed as a covering. The textile
fabric covering can be made from synthetic or natural
fibers or a blend of synthetic and natural fibers.
The size and shape of the material covering of
course depends upon the type of foamed article being
prepared. The material covering is usually comprised
of a single piece of material which has been cut to
fit the contour of a mold. However, the material
covering can be prepared from several pieces of
material which are attached to each other, e.g. by
sewing.
After the material covering is prepared so that
it has the desired shape, the material covering is
coated on one side with a polymeric coating. The
- coating can be applied either before or after the
material covering is placed into a mold. If the
coating is applied before the material covering is
placed into the mold, the covering is placed into the
mold so that the uncoated side is against the interior
surface of the mold. Preferably, the material
covering is vacuum formed after being placed into the
~ 094/~937PCT/GB94/00776
~1S~65~
mold so that the material snugly fits the contour of
the mold. If the material coating is placed into a
vacuum mold before being coated, it is preferred to
coat one side of the material covering before the
5covering is vacuum formed.
The polymeric coating applied to the material
covering is preferably a polyurethane and/or polyurea
coating (i.e. a polyurethane coating, a polyurea
coating, or a coating having both polyurethane and
10polyurea linkages). More preferably, the coating is
a polyurethane coating. The coating can be prepared
at an isocyanate index in the range of 30 to 1500.
However, an isocyanate index above 200 will generally
only be used when a coating having isocyanurate
15linkages is used or when a moisture-cure system is
used to prepare the coating. As used herein,
"isocyanate index" is the ratio of isocyanate (-NCO)
equivalents to the total number of equivalents of
isocyanate-reactive groups expressed as a percentage.
20Preferably after curing, the polyurethane and/or
polyurea coating is soft and flexible so that the
material covering is not boardy or stiff, and the
coating is strong enough so that if it is stretched by
a vacuum, it remains intact. In order to achieve
25these properties, the polyurethane and/or polyurea
coating is preferably prepared at an isocyanate index
in the range of 30 to 100, more preferably in the
range of 40 to 80, still more preferably in the range
of 45 to 60, and most preferably in the range of 45 to
3055. Although it is possible to use an isocyanate
index below 30, the resulting coating will be tacky
and will not completely cure. As a result, the coa.ted
material covering will be difficult to handle and to
process. On the other hand, if the isocyanate index
W094/~937 PCT/GB94/0077~_
2158S~ ~
exceeds about lOO, the covering may be stiff and
boardy once the coating cures.
The organic polyisocyanates which may be used in
the preparation of the polyurethane coating include
any of the aliphatic, cycloaliphatic,. araliphatic or
aromatic polyisocyanates known in polyurethane or
polyurea chemistry, especially those that are liquid
at room temperature. Examples of suitable
polyisocyanates include ethylene diisocyanate, 1,6-
hexamethylene diisocyanate, isophorone diisocyanate,
cyclohexane 1,4-diisocyanate, 4,4'-dicyclohexylmethane
diisocyanate, 1,4-xylylene diisocyanate, 1,4-phenylene
diisocyanate, 2,4-toluene diisocyanate, 2,6-toluene
diisocyanate, 4,4'-diphenylmethane diisocyanate (4,4'-
MDI), 2,4'-diphenylmethane diisocyanate (2,4'-MDI),
polymethylene polyphenylene polyisocyanates (crude
MDI) and 1,5-naphthylene diisocyanate. Mixtures of
polyisocyanates can be used and also polyisocyanates
which have been modified by the introduction of
urethane, allophanate, urea, biuret, carbodiimide,
uretonimine or isocyanurate residues.
In general, the aromatic polyisocyanates are
preferred. The most preferred aromatic
polyisocyanates are 4,4'-diphenylmethane diisocyanate,
2,4'-diphenylmethane diisocyanate, polymeric MDI, MDI
variants, and mixtures thereof. Suitable MDI variants
include compounds in which the MDI has been modified
by the introduction of urethane, allophanate, urea,
biuret, amide, carbodiimide, uretonimine or
isocyanurate residues.
Isocyanate-terminated prepolymers may also be
employed and are prepared by reacting an excess of
polyisocyanate with polyols, including aminated
polyols, imine or enamine polymers, or polyamines. A
~W094/~937 ~S~ PCTIGB94/00776
particularly preferred isocyanate terminated
prepolymer is the reaction product of a polymeric MDI
and a polyether polyol. Pseudo-prepolymers may also
be employed. A pseudo-prepolymer is a mixture of a
prepolymer and one or more monomeric di- or poly-
isocyanates. Examples of suitable materials include
Rubiflex 26A available from ICI Americas.
The isocyanate reactive resins that are useful in
the preparation of the polyurethane and/or polyurea
coatings include polymeric polyols, amines, imino-
functional and enamino-functional compounds having
molecular weights in the range of 1500 to 12,000.
Preferably, the isocyanate reactive material is a
polyol.
Suitable polyols that may be used to prepare
polyurethane coatings include those selected from the
group consisting of polythioether, polyester,
polyester amide, polycarbonate, polyacetal,
polyolefin, polysiloxane and polyether polyols.
Polyether polyols are preferred.
Suitable polyether polyols include products
obtained by the polymerization of a cyclic oxide, for
example ethylene oxide, propylene oxide or
tetrahydrofuran in the presence, where necessary, of
polyfunctional initiators. Suitable initiator
compounds contain a plurality of active hydrogen atoms
and include water, polyols, for example ethylene
glycol, propylene glycol, diethylene glycol,
resorcinol, bisphenolA, glycerol, trimethylolpropane,
1,2,6-hexanetriol, triethanolamine, pentaerythritol,
sorbitol or sucrose, ammonia, primary monoamines, for
example aniline or benzylamine, polyamines, for
example ethylene diamine, hexamethylene diamine,
toluene diamines, diaminodiphenylmethanes and
W094/~937 PCTIGB94/0077~
2ol~8 6 5 4
1 0 --
polymethylene polyphenylene polyamines obtained by the
condensation of aniline and formaldehyde, and amino
alcohols, for example ethanolamine and diethanolamine.
Mixtures of initiators and/or cyclic oxides may be
used.
Especially useful polyether polyols include
polyoxypropylene, polyoxyethylene, and
poly(oxyethylene-oxypropylene) diolsand triols, which
are obtained by the simultaneous or sequential
addition of ethylene and propylene oxides to
appropriate di- or tri-functional initiators as fully
described in the prior art. Mixtures of the diols and
triols are also useful. -The most preferred polyether
polyols are polyoxyethylene capped polyoxypropylene
diols and triols.
Polyester polyols which may be used include
hydroxyl terminated reaction products of polyhydric
alcohols such as ethylene glycol, propylene glycol,
diethylene glycol, 1,4-butanediol, bis(hydroxyethyl)
terephthalate, glycerol, trimethylolpropane or
pentaerythritol or mixtures thereof with
polycarboxylic acids, especially dicarboxylic acids or
their ester-forming derivatives, for example,
succinic, glutaric and adipic acids or their dimethyl
esters, sebacic acid, phthalic anhydride,
tetrachloroph~halic anhydride or dimethyl
terephthalate. Polyesters obtained by the
polymerization of lactones, for example caprolactone,
in conjunction with a polyol, may also be used.
Polyesteramides may be obtained by the inclusion of
aminoalcohols such as ethanolamine in
polyesterification mixtures.
Polythioether polyols which may be used include
products obtained by condensing thiodiglycol either
094/1937 ~ S8 ~CTIGB94/00776
alone or with other glycols, dicarboxylic acids,
formaldehyde, aminoalcohols or aminocarboxylic acids.
Polycarbonate polyols which may be used include
products obtained by reacting diols such as 1,3-
propanediol, 1,4-butanediol, 1,6-hexanediol,
diethylene glycol or tetraethylene glycol with diaryl
carbonates, for example diphenyl carbonate or with
phosgene.
Polyacetal polyols which may be used include
those prepared by reacting glycols such as diethylene
glycol, triethylene glycol or hexanediol with
formaldehyde. Suitable polyacetals may also be
prepared by polymerizing cyclic acetals.
Suitable polyolefin polyols include hydroxy-
terminated butadiene homo- and copolymers, and
suitable polysiloxane polyols include
polydimethylsiloxane diols and triols.
Examples of suitable polyols for use in the
present invention include FFS-2805 available from ICI
Americas.
The types of amino functional compounds suitable
for the preparation of a polyurea coating are well
known to those skilled in the art. Suitable imino-
functional and enamino-functional compounds for
preparing polyurea coatings are disclosed in U.S.
Patent Nos. 4,749,129, 4,866,103, and 4,910,279, which
are incorporated herein by reference. Preferably, the
amino-, imino- and enamino-functional compounds are
compounds in which all or part of the OH groups on a
polyol have been replaced by the respective functional
groups.
In preparing the polyurethane and/or polyurea
coatings, one or more polyisocyanates are reacted with
one or more isocyanate reactive materials at an
W094/~937 ~ ~ PCT/GB94/0077
- 12 -
isocyanate index in the ranges given above under
substantially anhydrous conditions at a temperature in
the range of room temperature to 180C. Chain
extenders and cross-linkers, such as amines, glycols,
imines and enamines, may be included in the reaction
mixture. Generally, the chain extenders and cross-
linkers will have molecular weights below about 1500.
In addition, the polyisocyanates and isocyanate
reactive materials can optionally be reacted in the
presence of catalysts known in the art, such as
dibutyltin dilaurate and tertiary amines such as
triethylene diamine. Suitable catalysts are disclosed
in U.S. Patent No. 4,7g4,129, which was previously
incorporated by reference. Optionally, a molecular
sieve can be included in the reaction mixture to serve
as a water scavenger so that any water that is present
will not blow and cause the coating to foam. Suitable
catalysts and molecular sieves for use in a specific
formulation will be evident to one skilled in the art
from the present disclosure.
The polyisocyanate and the isocyanate reactive
material (as well as any catalysts, chain extenders,
and other ingredients) are usually mixed just prior to
applying the coating to one side of the material
covering. The isocyanate reactive material and the
polyisocyanate can be mixed and applied to the
material covering by any suitable means. For example,
they can be mixed with a drill mixer and applied by
hand, such as with a spatula or knife. However, it is
preferred that the isocyanate reactive material and
the polyisocyanate be applied by spraying. Most
preferably, the isocyanate reactive material and the
polyisocyanate are impingement mixed in a spraying
apparatus, and the coating is sprayed onto the fabric.
~CV. ~'OI~i: EP~A-,MUENCHEN 2 . 14-_ ~-95 : _16: 14 +32 2 758990~-- +49 8'd 23994465; # 4
21S86S
~ny ~on~entional sprayQr for spr~yln~ polyurethane and
.pGlyure~ material~ known to thas~ skilled in th~ art
may ~e ~ployed.
Pr~ferably, the spraying de~ice has a compart~ent
in which the poly~ socyanate can be ~tor~ and a
~o~p~rtmcnt in which the iso~yanate reactiv~ ~ateria}
f~s well ~5 chain ext~ndQrs ~nd othor lngredients) c~n
b~ s~ored. Such ~ sprayer should hav~ a moans to pump
the p~lyLs~yanats and the isocyanats reac~c
lo m~te~ial from the comp~rtments into a sprayhead.
0 ~en~rally, the polyisocyanate and the i~ccyan~te
r~actiYe csmpounds ~re imp~nge~snt mixed in the n~ls
o~ the spr~yer. A sulta~l~ sp~ayln~ apparat~ i8 a
Graco.Hydra C~t sprayor and pump unl~, which i~
t S aYaila~le ~rom Graco, equipped with a Gusm~r GX7
sprayhead, which is ~Yail~ble fro~ G~ r. Pric~ to
be~ ixed, the po~yisocyanate ant the isocyanate
reactive ~at~rial are maintalned in their re~pective
co~partments ~t a tQmperaturc in the range of 18 3C to
about SOqC. The polyisocyanate and th~ isocyanate
rQactive matexial ~r~ usually ~etered tog~ther at a
pressure in ~he rang~ o ~600 to 2000 ps$~ and t~e
pressure ~n eac~ co~p~nent is usually th~ sa~e.
C I~ is, o~ co~rse t pOSS lble to rsaCt the
~5 isccy~nate and the i30cyAn~te re~ctiv~ m~te~al b~or~
applyin~ ~hQ coAt~n~ ~ long ~s the r~su~ting
prep~lymer c~n be rQ~d$1y ~ppli~d to ~h~ mat~rlal
covering
~he coat~ng i5 us~ally appli~d ~t ~ ~hicknoss of
abou~ 0.05 milliweter~ up to abcut ~iv~ mlll~eters to
one s~de of the material co~-~in~. ~he coating i~
allow~d to cur~ ~c~ s~eral s~nds to se~eral ~nutes
lgeneral~y n~t ~ore th~n ab~t two ~nut~s) beforo th~
coated covering is placed into a moLd. The length a~
r Y~ ~0 ~a ~
o~o S~
-
W094/~937 ~ 65 PCT/GB94/0077
cure time varies with the type of formulation used to
prepare the coating.
Either before or after being coated, the covering
is placed into a mold. The shape of the mold will of
course depend upon the type of article that is
desired. After the covering is placed into the mold,
it is preferred to pull a vacuum so that the material
covering snugly fits the contour of the mold.
The types of vacuum molds suitable for use are
well known to those skilled in the art. Suitable
vacuum molds are described in U.S. Patent Nos.
4,046,611, 4,637,789, 4,740,260, 4,860,415 and
4,975,135, all of which are incorporated herein by
reference.
After the coated material covering is in the
mold, a liquid foamable composition is poured onto the
coated side of the covering and foamed. The type of
liquid foamable composition is not critical, and
virtually any type of composition which can be poured
into a mold and foamed and which will adhere to the
polyurethane and/or polyurea coating can be employed.
Neither is the type of foam produced from the liquid
foamable composition critical. Both flexible and
rigid foams may be used, depending upon the end use of
the product which is produced. The type of product
being prepared will determine the type of liquid
foamable composition that is needed as well as the
nature of the resulting foam (i.e. flexible or rigid)
that is needed. The preferred liquid foamable
compositions are polyurethane, polyurea and/or
polyisocyanurate liquid foamable compositions.
The preparation of polyurethane, polyurea and/or
polyisocyanurate foams is well known. When the foam
body is a polyurethane foam, the liquid foamable
:C~. VON EPA-MI '~ENCHEN 2 ~ ~ _ 14- 3-95 : _16: 14 +.3~ 2 7589904-- +49 89 23g~34465: # 5
` ' S86,S~
- teaction sys~em from which the polyur~than~ foam is
prepared ls comprised of one or ~ore polyisocyanates,
on~ or more polyols, and a blowing agent. When the
li~uid ~oa~able composition i8 ~ poly~r~a liquid
S foa~able composition, it will ~e ca~prised of one or
~or~ polyisocya~ates, on~ or m~r~ amino, lmin~ or
en~m$no f~ncti~nal compounds, ~nd a blowing agcnt.
W~en the compo~ on $s a polyisocyanu~ate, lt will be
prepa~ed ~t an i~ocyar.at~ index excas~ln~ a~out 200
an~ with d catalys~ suita~e for thQ i6ccyanurats
O react~on. Such c~talysts and the preparation of
~- pclyi~ocy~nurata foams a~e well known ~n t~e art.
Suitabl~ co~ponents us~ful to ~orm specific fo~ms
ln a par~u1ar appl~cation will be evident to those
1~ ~ki~d in the 2~t fro~ ~he present sp~ific~t~on. A
pr~s~ntly preferred ~oam is tha~ formed ~y ~e
r~action ~f Rubi~l~x 25A i~ocyan~te prepolymer and
PF5-30~8 p~lyol, ~oth availa~le ~ron ~CI A~ericas.
The polyisocyanat~s lis~et ~bo~ whlch are
suit~ble ~Qr preparing tha polymeric coating nay be
used to prepare the 1~ d ~o~mabl~ c~mpo~t~on. All
th~ isocyanate reactive resi~s li~t~d aho~e a8 ~einq
R~itabl~ ~or pr~p~ri~g th~ coa~ing may be us~d to
pr~p~re a l~quid foa~lQ co~pos~t~on. ~it~hle
~lo~ing ag~nts ine~ude ~ater, di~solved or disper~ad
~a~3, such ~s air, car~on diox~de, n~tr~g~n cxides
and n~trogen, ~n~ low bo~l~ng ha~og~n~t~d
hy~oc~rbons, such as meth~lon~ chlor~de and
trichloromono~l~cro~thane. ~h~ amo~nt o~ b~awlng
ag~nt us~d is preferab~y less than abo~t ~our perccn~
by w~ght o f th~ ~otal ~eactants.
Wh~n a li~uid ~oa~ble compos~tlon $~ used, any
of the convantiona~ ch~i~ ex~enders and ~dtitlve~,
such a3 sur~ac~ants, ~oa~n stabiliz~rs, fire retard~nts
~ S~
W094/~937 21 S 8 6 S 4 PCTIGB94/007 ~
- 16 -
and fillers, known in the art may also be employed.
Suitable examples of such chain extenders and
additives are described in U.S. Patent No. 4,935,460,
which is incorporated herein by reference.
Since the coating on the material covering is
preferably prepared at an isocyanate index in the
range of 30 to 100, there may be unreacted sites in
the coating which can react with the liquid foamable
composition. As a result, the coating and the foam
body produced from the liquid foamable composition
will, in most cases, be strongly bonded to one
another.
The process of this invention can be used to
prepare a wide variety of upholstered articles. The
process finds particular application in the automotive
industry where it can be used to prepare interior trim
parts of vehicles, such as door panels and package
trays, head rests and seats. The most preferred
application of the process is to prepare pour-in-place
upholstered vehicle seats. The vacuum molds disclosed
in U.S. Patent Nos. 4,740,260, 4,860,415, and
4,975,135 can be used to prepare such seats. The
articles prepared by the process of this invention can
have material coverings which are soft and flexible,
have a good hand, and are not marred by strike-
through.
The invention is illustrated with reference to
~ the following non-limiting examples.
cr~ IVG~ ACI~ ~ ~ 1~ ; t~5~U~-- ~`
~ 21S86S
17
FxAMPL ES
In e~ch o~ the ~ollow-nq examples, all parts are
by weight unles3 speci~ied.
~xa~e 1
A ~8 c~nti~eter by 38 centimate~ pl~ca of
automotlve ~abric was placed flat on a table. The
palyurethane coa~'ns was prepar~d by ~ixing 5.4 par~-s
o~ ~u~lflcx 26A, wh~ch i~ availabl~ from ~CI America~
Inc. and w~ich is an M~I prepolymer havin~ ~ free
I O isocyanate contsnt of 2 S . 3 to 2 6 . ~ p~rcent and
C pr~pared by reacting a ~nixture of ~, 4 t -M~I and 4, 4 ~-
! ~D~ with a po~yoxypropylene polyol ~nd then with a
poly(oxyethy~ne-oxypropyl~n-~ tricl, 100 parts af
F~S-280S, whi~h is an ethylene ox~de diol ~nd wh~ch ~s
i5 avalla~ ro~ ICI A~erica~ Inc., 2 part~ of Uni~ e
~a~te, wh~ch ~ ~ so~id molecul~r ie~e aYail~ble fro~
U~P c~ Pl~nQs, Illin~l~, and 1 part o~ ~a~co
33LV, ~ ~riet~yLene ~ia~in~ in glycoli catalyst
~alla~le from A~r Product~, Inc. Th8 Unis ~e Pa~ta
served as a w~ter scaveng~r and preves~ted th~ coating
frorn foa~ing. The i~ocyanate indQx o~ th~ coatin~ was
SO .
C Th~ ingred~ ents were ~lxe~l ln a ~esse~ w~th a
dri~l s~lxer at ~ ~00 RPM for ~ scond~. The reaction
~lxt~re ~as t~en p~ured frc~ the v~s~l direct~y onto
~hs expo3ed slde ~ th~ ~a~ric and ~pre~d eYcnly w~th
a ~p~tula to for~n ~ co~ting ha~ ~ng a th~clcnc~s of 2 to
5 ~ ~eter~. A~t~r th~ coating c~r~d, tl~e coat~
~abric wa~ placed ~ nto a vacuu~n ~no~d ~o tt~at th~
uncoated side was ln c~ntact w~th the $nterio~ sur~ace
of th~ ~old. A vacu7~m was ~p~ d to draw the fabric
to th~ shape of the mc~
O S~
~ o6~sl
A polyu~ethane liquid foa~able compo~ition was
~ then prepar~d by m~xing Ru~i~lex 26A (the ~A
.co~ponent~ nd FFS-30~6B ~th~ "~ co~ponent~l~, both
avai~abl~ fro~ ICI Ameri~as Inc., in a r~t~o of 0.589
(~ubiflex 2~A to FFS-3066~. The co~ponents wer~
~ix~ in a high ~pingement pouring ~achin~. The
co~posit~on wa~ then pour~ on~o the coatin~ on th~
fabr~c, ~oam~d ~nd allowed to cure. ~h~ fabrLc on the
res~ltant article had a soft ~eel and thQre w~s no
str~ke-through of the ~oam.
~xam~l~ 2
Exampls 1 W~5 repeated except that the
ingr~dients for thQ ~oat~ng were placed into a high
p~ess~rs sprayRr dnd were impin~e~ent m~xed as they
1~ w~r~ fed into the ~pray nozzle a~d the po}yur~than~
coatin~ wa~ sprayed onto the ~a~ric at ~.thlcknes~ o~
ab~ut 2 to 3 ~llll~eter~. Th2 ~brlc o~ th~
resul~ing a~ticl~ had a soft ~eel, ~nd t~er2 was no
strike-~hrough o~ the ~Qam.
2 0 C~xam~ 1~ 3
Exa~ple 1 wa~ repeat~d ex~ept that the amo~nts of
C~ ~ubi~l~x 2~A ~nd FFs-~aQ5 were ad~u~te~ ~o th~t the
yanate ind~x o~ the coating was 25. Although t~e
resultln~ art~ had a fabric co~ring wlth a ~cod
~g h~nd, the polyu~ethan~ coatlng wa~ qu~tQ t~c~y th~r~y
ma~in~ it di~f~c~l~ t~ handle ~h~ f~bric ~en ~he
~abric was placed into the ~acuum m~ld.
~xam~l- 4
. Example 1 wa~ repeated except that thc amount~ o~
Rukifl~x 26~ an~ FF5-28QS wer~ ad~ustsd so that the
isocyana~ index ~ th~ coatin~ was lOS. Th~
,~S~
- 19 -
result~n~ a~ticl~ had a fabri~ covering whlch was
stiff and boardy.
Th~ exa~ples ~llustrate th~t upholstered f~bric
cove~ed zrtlcle8 witho~t strike-through and w~th
~ood hand can ~e prepared ~y th~ p~ur-in-plac~ method.
~h~ exa~ple~ further illus~rate that va~u~m ~ormed
articles wlth g~od exterior propertie~ can be prepared
without the ~tap of adher~ng a pr~formed fllm or sheet
to th~ ~aterl~l co~erin~ to ~ravent ~tri~e-thraugh.
lt can also be sa~n from the exsmples that wh~n the
c i~ocyanate index is too low, thB polyurethane coatin~
~s too taG~ to be easily handled, and that when th~
~._
~ocyanat~ ind~x is too h~h, the materi~l covering
~ay be Sti~f and bcardy.
l~ ~x~m~le
Exa~pl~ 1 wa~ rep~at~d, ~x~ept that the ~ollo~in~
fo~m2bl~ composition wa~ used. Thc foam ~o~ui~tlon
compris~d 100 parts o~ F280S; 80.5 p~rts o~ Rubi~lex
26A; 1.~ part of X-8~62; 1.0 part o~ SPF, 2.0 pa~s of
2û Unilin~4200; and ~. ~ parts o~ water. F2so5 is a
poly~l a~railable ~rom ICI Amerlcas; X-8~S~ is an a~inQ
catalyst ~vall~ ro~ ~ir Prcducts ~nc.; SPF is an
c amine catalyst avallable from Toyo Soda; and Unilink
42~a i~ a chain ext-nde~ av~ilable fro~ UOP.
The foam for~ulaticn w~ mixed using a dr~11
pre~6 and a mixln~ blade. The fa~r~c ~s th~n coated
with the fo~mulation and th~ fab~ic Wa~ then ~laced
into a YaCUUm mold 5~ that th~ uncoat~d ~ide of the
fa~ric was in contact with the interior ~urface of thQ
mold. A Yacuu~ was appli~d to draw the fabrLc to thQ
shap~ c~ th~ ~ld. ~Q ~oam fo~mulation was then
pour~d dir-ctly onto the fabric and was a~Lowed to
cure.
. _
p,~E~E~ SHEE~
W094/23937 ~5 ~ PCTIGB94/0077
- 20 -
The foamed article had a soft feel and there was
no strike-through of the foam.
The present invention may be embodied in other
specific forms without departing from the spirit or
essential attributes thereof and, accordingly,
reference should be made to the appended claims rather
than to the foregoing specification as indicating the
scope of the invention.
