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[54] WATER BASED MOLD RELEASE 4,491,607 l/ 1985 Wesala .............................. .. 427/135
COMPOSITIONS FOR MAKING MOLDED 4,532,096 7/1985 Bogner et a1. . . . . . . . . . .. 264/109
THANE 4,534,928 8/1985 Martin . ...... ..... . . . . .. 264/334
POLYURE FOAM 4,609,511 9/ 1986 Fischer et a1. .. ..... .. 264/51
[75] Inventors: Mark E. Harakal, Coopersburg; 4,770,827 9/ 1988 Fischer . . . . . . . . . . . . . . . . . .. 264/51
George J, wgs?czyk, Allentown; 4,783,296 11/1988 Fischer et a1. .................... .. 264/338
Gary D. Andrew, Walnutport, all of
Pa;- zdizslaw Makus Bad wiesse, FOREIGN PATENT DOCUMENTS
Fed. Rep. of Germany; Michael 223233 5/1987 European Pat. Off. .
Scarpati woodhaven Mich. Rep. of Germany .
. 2702930 7/ 1978 Fed. Rep. of Germany .... .. 264/338
[73] Assrgnee: Air Products and Chemicals, 1116., 2637919 8/1978 Fed. Rep. of Germany .
Allentown, Pa. 592606 2/1978 U.S.S.R. ............................ .. 264/338
1043572 9/1966 United Kingdom .
[21] APPl- N-= 142,970 1193882 2/1969 United Kingdom .
[223 Filed Jm- 12 1988 OTHER PUBLICATIONS
Int. Cl.5 .............................................. .. Bareco Operating Group of Petrolite Corp. External
[52] US. Cl. ........................... .. 264/51; 264/338 .,
58 F, m f S h 264/338 51 DIG 65_ Mold Release Formulations .
[ 1 e o 106/38 2 3g 22 3'8 25 Hoechst-Wachse, Raw Materials for the Manufacture
' ' ' of Mould Release Agents. .
above
perature
theofmelt
the point
vesselof
contents
the hotstayed
organic
at materials
least 5-10mix-
C. 10 ,Efglflbmm
Diethanolamine l.5
ture. While under high agitation, the temperature of the WM" C 4
.contents was reduced to 5-10 C. above the melting 22x19 T425 0907
point of the hot organic materials mixture and water at m BL 015
ambient temperature was rapidly charged to drive the 15 Dabco 334A, @ 0:5
temperature of the contents through the melt point Dabco BL-l7 0.1
range to yield an emulsion of solids in water. When the T131 30 102 Index
composition was cooled to about 35 C., the poly(silox "Trlfunctional polyether polyol (48(1) mol. wt.) from Dow Chemical
ane-glycol) surfactant was added. olyether polyol from Mobay Chemical
Dabco catalysts from Air Products and Chemicals, inc.
Typically in the art, commercial molds are pretreated
with solvent-based or paste wax prior to application of Table I sets forth the various poly(siloxane-glycol)
the mold release composition. surfactants that were tested and the resulting release
EXAMPLE 1 performance and product surface (includes subsurface)
evaluation. The surfactants were added at levels of 3, 5
In this example various poly(siloxane-glycol) surfac 25 and 7 wt%.
tants which are used commercially as cell stabilizers in A foam with a good/good release/surface rating is
polyurethane foam compositions were added to the considered as a commercially acceptable foam. A
following water-based mold release composition: fgood release is identi?ed by an operator being able to
remove the foam part from the open mold with a mini
Nmional wax 160/65 33 30 malveffort. A good surface is one described as having
Alkoxylated triglyceride wax 2.: minimal blistering, skinning and voiding.
TABLE I
PERFORMANCE
SURFAC- CLOUD RELEASE/SURFACE
RUN TANT PT. xzy 3% 5% 7%
1 DC 5039 35 5:1 Very Good/ Very Good/ Very Good/
Very Good Very Good Very Good
2 L-540 30.5 14:1 Good/Good Very Good/ Good/Good
Good
3 l..-560 30.5 14:1 Poor/Poor Good/Good Poor/Poor
4 DC-l90 36.5 12:1 Good/Good Good/Good Good/Good
5 DC-l98 35 10:1 Good/Poor Good/Good Poor/Good
6 DC-5043 NS 15:1 Poor/ Poor/ Poor/
Very Poor Very Poor Very Poor
7 DC-l97 53 2:1 Good/ Very Poor/ Very Poor/
, Very Poor Very Poor Very Poor
8 DC-l93 79 3:1 Poor/ Poor/ Poor/
Very Poor Very Poor Very Poor
9 L-6202 33.5 Very Poor/ Very Good/ Good/
Poor Good Very Good
Not soluble - essentially equivalent to a cloud point at 21' C.
DC surfactants are marketed by Dow Corning Corp.
L surfactants are marketed by Union Carbide Corp.
zyhc 501w, M It can be seen from the data in Table I that those
Fatty alcohol polyglycol ether (10 E0) 2.7 55 poly(siloxaneglycol) surfactants having a cloud point
olctadecyhmme 1-; outside the 25_-50 C. range did not provide for com
o '"c "d .
Spec. Naphthollte
0'
2.2
mercially acceptable, release performance and foam
Wm, 37 product surface quallty.
~ 100
poly(siloxaneglycol) See Table 1 EXAMPLE 2
In this Example various waxes having different melt
Each mold release composition was evaluated in the ing points were incorporated into the following water
production of a polyurethane foam article in a mold based mold release composition to which was added
under the following mold operating temperatures: 4% L540 poly(siloxane-glycol):
65
application of release composition 150-155 F. (es-es- c.) pbw " %
foam composition pour 130-135 F. (54-57 C.) wax (see Table II) 48 6
oven 175-180 F. (79-s2' c.) oleic acid 2 0.25
5,028,366
9 10
continued TABLE IV-continued
pbw wt % PHYSICAL STATE PERFORMANCE
octadecylamine 10 L25 RUN POUR/DEMOLD RELEASE/SURFACE
fatty alcohol polyglycol ether (10 E0) 12 1.5 5 20 liquid/liquid very good/poor
naphthol spirits 32 4 21 solid/liquid excellent/very good
water 700 87 22 solid/solid poor/poor
Each mold release composition was evaluated as The data shows that all the mold release compositions
v described in Example 1 for the production of a polyure- which contained a release effective system that was
thane foam article. liquid at demold and gave good release performance.
Table 11 presents the information regarding the vari- However, only those compositions with a release effec
ous waxes that were used and the performance regard- tive system that was also solid at pour gave good sur
ing release efficiency and product surface quality. face/subsurface results.
TABLE II '
PHYSICAL STATE PERFORMANCE
RUN wAx (mp 'c.) POUR/DEMOLD RELEASE/SURFACE
l0 LOOBWAX 0605 (72')1 solid/liquid excellent/good
11 National wax 160/65 (71-74')b solid/liquid good/good
12 National wax 160/65 (162') solid/liquid good/good
Zylac 30l (74-77')"; lzl wt ratio
l3 National wax 160/65 (162) solid/liquid good/good
x-zms (71-74311; 1:1 wt ratio
14 VYBAR 260 (46-49') liquid/liquid good/poor
l5 Zylac 30l (74-77) solid/solid very poor/good
l6 WSZIS (49y liquid/liquid excellent/
very poor
Microcrystalline wax from Dura Chem
bparaf?n wax from National Wax
Ethylene/propylene copolymer wax from Petrolite
Ethylene/propylene eopolymer wax from Petrolite
Ethylene/propylene copolymer wax from Petrolite
lAlltoxylated triglyceride (10,01) mol wt) from Dun Chem