Polyurethane foams filled with organophilic kaolin clay and method for making same

Claim 1

AN ESSENTIALLY OPEN-CELLED PLASTIC FOAM COMPOSITION COMPRISING THE FOAMED POLYMERIZATION PRODUCT OF WATER AND TERITARY AMINE CATALYST WITH A LIQUID POLYURETHANE PREPOLYMER CONTAINING FREE ISOCYANATO GROUPS, SAID POLYURETHANE PREPOLYMER BEING THE REACTION PRODUCT OF AN ARYLENE DIISOCYANATE AND AT LEAT ONE LONG CHAIN LINEAR POLYHYDROXYL COMPOUND SELECTED FROM THE GROUP CONSISTING OF A LINEAR POLYALKYLENE ETHER POLYOL HAVING AN EQUIVALENT WEIGHT OF AT LEAST 200, A LINEAR SATURATED POLYESTER HAVING TERMINAL HYDROXYL GROUPS WHICH IS THE ESTERIFICATION PRODUCT OF A DIABASIC ACID AND A DIHYDROC ALCOHOL, AND A FATTY ACID TRIGLYCERIDE HAVING A HYROXYL NUMBER OF AT LEAST 49, AND UNIFORMLY DISTRIBUTED THEREIN FROM ABOUT 5 PERCENT TO ABOUT 40 PERCENT, BASED ON THE WEIGHT OF SAID PREPOLYMER, OF KAOLIN CLAY SUBSTANTIALLY FREE FROM PARTICLES COARSER THAN 44 MICRONS AND HAVING AN AVERAGE EQUIVALENT SPHERICAL DIAMETER LESS THAN 0.80 MICRON, THE PARTICLES OF SAID KAOLIN CLAY BEING UNIFORMLY COATED WITH FROM 0.1 PERCENT TO 4 PERCENT, BASED ON THE WEIGHT OF SAID CLAY, OF AN ORGANIC CATIONIC MATERIAL SELECTED FROM THE GROUP CONSISTING OF AN ALKYL AMINE CONTAINING NITROGEN IN TRIVALENT STATE AND HAVING A TOTAL OF FROM 6 TO 22 CARBON ATOMS, MINERAL ACID SALTS THEREOF, AND ALKANOIC ACID SALTS THEREOF WHEREIN THE ALKYL GROU CONTAINS FROM 1 TO 17 CARBON ATOMS, SAID FOAM COMPOSITION BEING FURTHER CHARACTERIZED BY HAVING A VOLUME AT LEAST EQUAL TO THE FOAM VOLUME NORMALLY PRODUCED BY SAID PREPOLYMER IN THE ABSENCE OF SAID COATED KAOLIN CLAY PLUS THE FOAM VOLUME NORMALLY PROUDCED BY A VOLUME OF SAID PREPOLYMER EQUIVALENT TO THE VOLUME OF SAID COATED KAOLIN CLAY IN THE COMPOSITION.