Viscoelastic polyurethane foam with coating

Abstract

A coated viscoelastic polyurethane foam includes a viscoelastic polyurethane foam having the coating thereon, the viscoelastic polyurethane foam having a resiliency of less than or equal to 20% as measured according to ASTM D3574, and a coating material on and embedded within the viscoelastic polyurethane foam, the coating material including an aqueous polymer emulsion and an encapsulated phase change material.

1 . A coated viscoelastic polyurethane foam, comprising:
 a viscoelastic polyurethane foam having the coating thereon, the viscoelastic polyurethane foam having a resiliency of less than or equal to 20% as measured according to ASTM D3574, the viscoelastic polyurethane foam being the product of a reaction system having an isocyanate component that includes at least one isocyanate and an isocyanate-reactive component that includes a polyol component, and an isocyanate index of the reaction system being from 50 to 150; and   a coating material on and embedded within the viscoelastic polyurethane foam, the coating material including an aqueous polymer emulsion and an encapsulated phase change material.   
     
     
         2 . The coated viscoelastic polyurethane foam, wherein the reaction system further includes an additive component that includes at least one catalyst and at least one selected from the group of:
 (i) 0.1 wt % to 6.0 wt % of a preformed aqueous polymer dispersion, based on the total weight of the mixture, the preformed aqueous polymer dispersion having a solids content from 10 wt % to 80 wt %, based on the total weight of the preformed aqueous polymer dispersion, and being one of an aqueous acid polymer dispersion or an aqueous acid-modified polyolefin polymer dispersion in which the polyolefin is derived from at least one C 2  to C 20  alpha-olefin, and   (ii) from 0.1 wt % to 6.0 wt % of a preformed aqueous polymer dispersant having a pH from 6.0 to 12.0, based on the total weight of the mixture, the aqueous polymer dispersant including from 5 wt % to 60 wt % of a polymeric component and from 40 wt % to 95 wt % of a fluid medium that includes at least water, the polymeric component including at least one base polymer derived from 20 wt % to 100 wt % of at least one hydrophilic acid monomer having at least one carbonyl group, phosphate group, phosphonate group, or sulfonyl group, and optionally derived from at least one hydrophobic terminally unsaturated hydrocarbon monomer.   
     
     
         3 . The coated viscoelastic polyurethane foam as claimed in  claim 2 , wherein the preformed aqueous polymer dispersion is a continuous liquid phase component at ambient conditions of room temperature and atmospheric pressure and is derived from a liquid phase and a solid phase, the liquid phase being water and the solid phase being an acid or an acid-modified polyolefin in which the polyolefin is derived from at least one C 2  to C 20  alpha-olefin. 
     
     
         4 . The coated viscoelastic polyurethane foam as claimed in  claim 2 , wherein the preformed aqueous polymer dispersion is a continuous liquid phase component at ambient conditions of room temperature and atmospheric pressure and is derived from a liquid phase and a solid phase, the liquid phase being water and the solid phase including an ethylene-acrylic acid copolymer. 
     
     
         5 . The coated viscoelastic polyurethane foam as claimed in  claim 1 , wherein the polyol component includes at least one polyoxyethylene-polyoxypropylene polyether polyol that has an ethylene oxide content of at least 50 wt %, has a nominal hydroxyl functionality from 2 to 4, and accounts for 25 wt % to 90 wt % of the isocyanate-reactive component. 
     
     
         6 . The coated viscoelastic polyurethane foam as claimed in  claim 1 , wherein the polyol component includes a blend of at least three polyols, the blend including:
 (i) a polyoxyethylene-polyoxypropylene polyether polyol that has an ethylene oxide content of at least 50 wt %, has a nominal hydroxyl functionality from 2 to 4, has a molecular weight from 700 g/mol to 1500 g/mol, and accounts for 25 wt % to 90 wt % of the isocyanate-reactive component,   (ii) a polyoxypropylene-polyoxyethylene polyether polyol that has an ethylene oxide content of less than 20 wt %, has a nominal hydroxyl functionality from 2 to 4, has a molecular weight greater than 1500 g/mol and less than 6000 g/mol, and accounts for 5 wt % to 50 wt % of the isocyanate-reactive component, and   (iii) a polyoxypropylene polyether polyol that has a nominal hydroxyl functionality from 2 to 4, has a molecular weight from 700 g/mol to 1500 g/mol, and accounts for 5 wt % to 50 wt % of the isocyanate-reactive component.   
     
     
         7 . The coated viscoelastic polyurethane foam as claimed in  claim 1 , wherein the polyol component includes a blend of at least four polyols, the blend including:
 (i) a first polyoxyethylene-polyoxypropylene polyether polyol that has an ethylene oxide content of at least 50 wt %, has a nominal hydroxyl functionality from 2 to 4, has a molecular weight from 700 g/mol to 1500 g/mol, and accounts for 25 wt % to 85 wt % of the isocyanate-reactive component,   (ii) a second polyoxyethylene-polyoxypropylene polyether polyol that has an ethylene oxide content of at least 50 wt %, has a nominal hydroxyl functionality from 4 to 8, has a molecular weight from 8,500 g/mol to 14,500 g/mol, and accounts for 5 wt % to 50 wt % of the isocyanate-reactive component,   (iii) a polyoxypropylene-polyoxyethylene polyether polyol that has an ethylene oxide content of less than 20 wt %, has a nominal hydroxyl functionality from 2 to 4, has a molecular weight from 3000 g/mol to 6000 g/mol, and accounts for 5 wt % to 50 wt % of the isocyanate-reactive component, and   (iv) a polyoxypropylene polyether polyol that has a nominal hydroxyl functionality from 2 to 4, has a molecular weight from 700 g/mol to 1500 g/mol, and accounts for 5 wt % to 50 wt % of the isocyanate-reactive component.   
     
     
         8 . The coated viscoelastic polyurethane foam as claimed in  claim 1 , wherein the coating material includes from 5 wt % to 95 wt % of one or more encapsulated phase change materials and from 5 wt % to 95 wt % of one or more aqueous polymer emulsions. 
     
     
         9 . The coated viscoelastic polyurethane foam as claimed in  claim 1 , wherein the coating material further includes at least one selected from the group of a silicone surfactant and a silica. 
     
     
         10 . The coated viscoelastic polyurethane foam as claimed in  claim 1 , wherein the coating material further includes water.