Appeal 2007-3396
Application 1 11008,592
zeolites in water-based processes reacting polyols with polyisocyanates
improves the flame-resistance of such foams. The prior art also teaches
using polyols with mean hydroxyl (OH) ful~ctioi~ality of at least 2.2 and a
mean hydroxyl number of at least 300.16
Horn specifically teaches a process of reacting in a closed mold with
compaction: l 7
a) an organic andlor modified organic poly~socyanate
with
b) at least one relatively high-molecular-weight
compound containing at least two reactive hydrogen
atoms,
c) optionally, a low-molecular-weight chain extender
andlor crosslinking agent, in the presence of
d) a blowing agent,
e) a catalyst,
f) additives, wherein one of the additives is an
amorphous, microporous silica gel, and,
g) optionally, assistants.
The high-molecular weight compound b) has a functionality of from 2
to 8. The precise functionality relates to the resulting foam rigidity: a higher
functionality results in a more rigid foam. Polyols are recommended as
being particularly successful. l 8 In each of Horn's examples, a "urethane-
containing quasi-prepolyrner" called Component B is prepared by reacting a
polyisocyanate with a polyol or polyol mixture having a hydroxyl number of
250.'~
l6 Horn 2:8-28.
17 Horn 2:56-3:12 & claim 1.
Horn 4:5 1-5:5.
19 Horn 15:30-38, 16:28-38 & 17: 18-32.
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