Abstract: A stack emission control system utilized to remove organic contaminants as water-soluble solids from air collected from the vicinity of a polyurethane foam line assembly prior to the exhaust of the air into the surrounding atmosphere is described. A conventional packed tower scrubber is utilized containing an inert material as packing and pH-adjusted water as the wash fluid. The pH-adjusted water serves to remove essentially all of the organic contaminants as water-soluble solids from the air prior to exhaust of the air. The contaminant water-soluble solids are then readily separable from the pH-adjusted water by post-treatment to allow for the separate disposal of the essentially contaminant-free water and the contaminant solids.

Abstract: Flexible polyurethane foams based on a blend of polyether and polyester polyols are described. The polyurethane foams of the invention have at least one of (a) enhanced pourability of a predominantly polyether foam; (b) flame laminability to a predominantly polyether foam without having as an essential ingredient an additive; (c) improved flame retardancy of a predominantly polyether or polyester foam; (d) improved hydrolytic stability to a predominantly polyester foam, or (e) increased softness to a predominantly polyether or polyester foam.

Abstract: An antistatic polyester polyurethane foam containing substantially uniformly incorporated therein as an antistatic material a combination of a particulate, electrically conductive material, such as carbon black, and a haloacetic acid, such as dichloroacetic acid. The combination of conductive material and haloacetic acid which is incorporated into the polyurethane foam during its in situ preparation is believed to be tied into the foam through reaction of the haloacetic acid and at least the diisocyanate used in the foam formulation. The polyurethane foams of this invention have excellent antistatic properties while retaining the desirable features of a good polyurethane foam including uniformity of cell size, no pinholing, and good structural stability.

Abstract: Flame retardant, char-forming, flexible polyurethane foams are described which include, in addition to suitable diisocyanates and other basic foam-forming components, a flame retardant material and a polyol which has substantially non-reactive hydroxyl groups with respect to the diisocyanate component under the conditions of the foam-forming reaction. Accordingly, the polyol remains in the finished polyurethane foam substantially unreacted. When the finished foam product is subjected to combustion conditions the flame retardant material and unreacted polyol combine to retard flame formation and to provide a dripless char. In addition to the flame retardant and char-forming characteristics, the flexible polyurethane foam is firm, permitting the manufacture of clickable foams.

Abstract: Polyurethane foam products comprising a foam filled with a foam and a large amount of solid material inert to the foam products are described. The foams are prepared by foaming a polyurethane foam-forming diisocyanate and polyol around pre-formed polyurethane foam chips having incorporated therein or therewith solid materials inert to the foam. The inert material can be a fire- or combustion-retardant material; a material such as graphite or the like to render the foam conductive; or a filler material to impart various other characteristics. The polyurethane foam-filled foams can be tailored to have excellent physical characteristics and are particularly suitable for furniture upholstery, cushioning applications including in mattresses, and where special properties are required.

Abstract: Polyurethane foam products comprising a foam filled with a foam and a large amount of combustion retardant materials are described. The foams are prepared by foaming a polyurethane foam-forming diisocyanate and polyol around pre-formed polyurethane foam chips having incorporated therein solid combustion retardant materials. The polyurethane foam-filled foams have excellent physical characteristics and, because of their combustion properties, are particularly suitable for furniture upholstery and cushioning applications including in mattresses.

Abstract: Rebonded polyurethane foams having incorporated into the foam urea and/or melamine are described. The rebonded foams have excellent resistance to smoldering combustion and flaming combustion. The rebonded foam is highly suitable, inter alia, for cushioning and seating structures.

Abstract: Flexible polyurethane foams having low resistance to air flow and, in addition, having good load bearing characteristics and high strength comprising the reaction product of polyisocyanate, a polyol blend including about 40-60 percent by weight of a polyether triol having an average molecular weight of about 4500-6500 and about 60-40 percent by weight of a reinforced polymer polyol having an average molecular weight of about 4500-5500 for the base polyol, and a low molecular weight cross-linking agent, such as 1,4-cyclohexanedimethanol or 4,4' methylene-bis (2-chloroaniline). Preferably the air flow characteristics are improved by crushing the reaction product before it is fully cured.