Polyurethane Gel Particles, Methods and Use in Flexible Foams

Abstract

Combinations of open cell flexible foams with polyurethane gel particles, and methods of making the combinations are described using a variety of procedures. The open cell flexible foam may partially or wholly comprise polyurethane foam and latex foam.

What is claimed is: 
     
         1 . A composition comprising:
 a polyurethane foam;   a gel particle embedded in the foam, the gel particle comprising a product of a reaction between a polyisocyanate and a polyether polyol or a product of a reaction between a polyisocyanate and a polyester polyol; and   a plurality of phase change materials coupled to the gel particle, the phase change materials having a solid/liquid phase transition temperature range of from about −10° F. to about 220° F. (about −23° C. to about 104° C.).   
     
     
         2 . The composition of  claim 1 , wherein the phase change materials homogeneously dispersed within the gel particle. 
     
     
         3 . The composition of  claim 1 , wherein, the phase change materials heterogeneously dispersed within the gel particle. 
     
     
         4 . The composition of  claim 1 , wherein the phase change material is attached, grafted, or bound to at least part of an outer surface of the gel particle. 
     
     
         5 . The composition of  claim 1 , wherein the phase change material is encapsulated within the gel particle. 
     
     
         6 . The composition of  claim 1 , wherein, the phase change material has an average particle size of between about 1 and 1000 microns. 
     
     
         7 . The composition of  claim 1 , wherein the gel particle comprises the product of the reaction between the polyisocyanate and the polyether polyol, wherein the polyether polyol comprises linear or branched polyethers including at least two hydroxyl groups. 
     
     
         8 . The composition of  claim 1 , wherein the gel particle comprises the product of the reaction between the polyisocyanate and the polyether polyol, wherein the polyether polyol is selected from the group consisting of polyoxyethylene polyether polyols, polyoxypropylene polyether polyols, and mixed poly (oxyethylene/oxypropylene) polyether polyols. 
     
     
         9 . The composition of  claim 1 , wherein the polyether polyol and the polyester polyol have a functionality of 2.0 to 8.0 using a single or mixed initiator. 
     
     
         10 . The composition of  claim 1 , wherein the initiator is selected from a group consisting of glycerin, glycerol, trimethylolpropane, propylene glycol, dipropylene glycol, ethylene glycol, diethylene glycol, methylpropanediol, water, sucrose, D-sorbitol, glucoside, starch glycosides, aliphatic amines, polyfunctional alcohols, aminoalcohols, alcoholamines, aromatic amines, and mixtures thereof. 
     
     
         11 . The composition of  claim 1 , wherein the isocyanate has an isocyanate index of between 0.62 and 0.90. 
     
     
         12 . The composition of  claim 1 , wherein the isocyanate is selected from a group consisting of 2,4-toluene diisocyanate (2,4-TDI), 2,6-toluene diisocyanate (2,6-TDI), hexamethylenediisocyanate (HDI), isophorone-diisocyanate 4,4′-Diphenylmethane diisocyanate (4,4′-MDI), 2,4′-Diphenylmethane diisocyanate (2,4′-MDI), Polymeric MDI (PMDI), 4,4′-Dicyclohexylrnethane diisocyanate (HMDI), uretidinedione, and uretonimine-linked isocyanates, and mixtures thereof. 
     
     
         13 . The composition of  claim 1  further comprising an additive comprising between 2 and 6, inclusively, active hydrogen groups. 
     
     
         14 . The composition of  claim 13 , wherein the additive selected from a group consisting of diethanolamine (DEOA), ethylene glycol (EG), diethylene glycol (DEG), propylene glycol (PG), dipropylene glycol (DPG), 1,4-butanediol (BDO), methyl-propane diol, glycerin, difunctional and polyfunctional polyether, difunctional or polyfunctional polyester polyols, and mixtures thereof. 
     
     
         15 . The composition of  claim 13 , wherein the additive is a plasticizer. 
     
     
         16 . The composition of  claim 15 , wherein the plasticizer is selected from a group consisting of paraffinic oil, naphthenic petroleum oil, aromatic-free paraffinic food and technical grade white petroleum mineral oil, naphthenic food and technical grade white petroleum mineral oil, synthetic oil, natural oil, polyols made from natural oils, natural polyols, and mixtures thereof. 
     
     
         17 . The composition of  claim 1 , wherein the reaction between the polyisocyanate and the polyether polyol further includes water and the reaction between the polyisocyanate and the polyester polyol further includes water. 
     
     
         18 . The composition of  claim 1  further comprising a thermally conductive material having a thermal conductivity value in a range of 0.1 W/(m-K) to 2000 W/(m-K). 
     
     
         19 . The composition of  claim 18 , wherein the thermally conductive material is selected from a group consisting of talc, melamine, carbon black, graphite, aluminum oxide, aluminum nitride, zinc oxide, ferric oxide, diamond, titanium dioxide, magnesium oxide, silicon carbide, boron nitride, sodium carbonate, sodium bicarbonate, calcium carbonate, barium sulfate, metal flakes, fumed silica, clay, and mixtures thereof. 
     
     
         20 . The composition of  claim 1 , wherein the polyurethane foam is a flexible polyurethane foam.