Method of forming high resilience slabstock polyurethane foam displaying latex-like characteristics

摘要

The subject invention provides a method of forming high resilience slabstock polyurethane foam having random cell structures and displaying latex-like feel and characteristics with superior physical performance to latex foam, including complying with California Technical Bulletin 117 and British Standard 5852:Crib 5 flame tests. The method includes the first step of providing an isocyanate-reactive component and an isocyanate component substantially free of toluene diisocyanate comprising diphenylmethane-2,4′-diisocyanate present in an amount of from 15 parts by weight to 55 parts by weight based on 100 parts by weight of the isocyanate component and diphenylmethane-4,4′-diisocyanate present in an amount from 45 parts by weight to 85 parts by weight based on 100 parts by weight of the isocyanate component to react with the isocyanate-reactive component. A first nucleation gas is provided under low pressure and is added into at least one of the isocyanate-reactive component and the isocyanate component to produce a first cell structure in the polyurethane foam. A second nucleation gas different than the first nucleation gas is provided under low pressure and is added into at least one of the isocyanate-reactive component and the isocyanate component to produce a second cell structure in the polyurethane foam different than the first cell structure.