FORM 2
THE PATENT ACT 1970
&
The Patents Rules, 2003
PROVISIONAL SPECIFICATION
(See section 10 and rule 13)
1. TITLE OF THE INVENTION:
"Foam for Automotive Seating System"
2. APPLICANT:
(a) NAME: Tata Johnson Controls Automotive Ltd, Pune
(b) NATIONALITY: Indian Company registered under the
provisions of the Companies Act-1956.
(c) ADDRESS: Tata Johnson Controls Automotive Ltd
Hinjewadi, Pune -411 057 Maharashtra State, INDIA
3. PREAMBLE TO THE DESCRIPTION:
PROVISIONAL COMPLETE
The following specification deserirbes the The following specification
invention. particularly describes the invention and
the manner in which it is to be
performed.

Foam for Automotive Seating System
Field of invention
The present invention relates to foam for automotive seating system, and more particularly, it relates to natural oil polyol (NOP) based flexible foam for automotive seating system.
Background of the invention
Conventionally, foam pads used in automotive seats are made from 100% petroleum based polyurethane foam. However, the petroleum based polyurethane foam has following disadvantages
• More carbon dioxide gas emission increasing green house effect, and
• Fully dependent on petroleum base chemicals.
Accordingly, there exist needs for foam which emits less carbon dioxide and is environment friendly.
Objects of the invention
An object of the present invention is to provide foam for automotive seating system, which is made from natural oil polyol (NOP).
Another object of the present invention is to provide foam for automotive seating system, which emits less C02 during manufacturing process.
Yet another object of the present invention is to provide foam for automotive seating system, which is not fully dependent on petroleum base chemicals.

Summary of the invention
The present invention provides a 1. A process for preparation of polyurethane foam for automotive seating system, the process comprising reacting castor oil polyol in the range of 5-10 % with toluene di-isocyanate index 70 to 105% along with catalysts, polymeric polyol 35%, distilled water 3.5% , cross linker 1.4 -1.6%, and silicone surfactant 0.9-1.1% to obtain a rigid foam structure.
Typically, wherein the catalyst comprises amine catalyst-1 0.2-0.4%, gel catalyst-2 0.2-0.45%. delayed action catalyst-3 0.2-0.4%.
Typically, the amine catalyst is (A400) (Amine Catalyst)
Typically, the gel catalyst is 33 LV. ( Mixture of Dipropylene glycol and triethylenediamine, TEDA)
Typically, the delayed action catalyst is C225. (Bis (2-dimethyIamino ethyl) ether, BDMAEE)
Typically, wherein the cross linker is DEOALF. (Diethanolamine)
Typically, wherein the water in the mixture reacts with toluene diisocyanate to liberate carbon dioxide which provides cellular structure to the foam.
Detailed description of present invention
The foregoing objects of the present invention are accomplished and the problems and shortcomings associated with the prior art, techniques and approaches are overcome by the present invention as described below in the preferred embodiment.

The present, invention provides a process for preparation of polyurethane foam for automotive seating system. The process includes reacting castor oil polyol in the range of 5-10 % with toluene diisocyante index 70 to 105% along with catalysts, polymeric polyol 35%, HOH 3.5%. cross linker 1.4%, silicone surfactant 0.9% and water to obtain a rigid foam structure.
Specifically, when tri-functional castor oil polyol is reacted with tojuene di-isocyanate, a rigid structure is formed. Thus, with increasing castor polyol in the formulations, there is increase in rigidity of the foam produced.
The catalyst used for the process includes an amine catalyst- 0.2-0.4%, gel catalyst- 0.2-0.45%, and delayed action catalyst- 0.2-0.4%). Specifically, the amine catalyst ( Grade Name A400) is the gel catalyst is (Mixture of Dipropylene glycol and triethylenediamine, TEDA) and, the delayed action catalyst is (Bis (2-dimethylamino ethyl) ether, BDMAEE).Further, the cross linker is (Diethanolamine)
The castor oil polyol used in the reaction is obtained from seeds of a plant Ricinus Communis, family Euphorbiaceae. The castor oil contains mainly esters of 12-hydroxy-9-octadecanoic acid. Thus, the presence of hydroxyl groups makes the oil suitable for use in urethane type reactions. Also, the hydrogen bonding of hydroxy! group confers a high viscosity on the oil although the oil is not edible.
The reaction of the process proceeds in three directions, leading to a large molecule of toluene diisocyanate rigidly held into a 3-dimensional structure of the castor oil polyol.
Further, the water in the reaction mixture reacts with toluene diisocyanate to liberate carbon dioxide which provides cellular structure to the foam.

In an embodiment, any natural oil having properties similar to that of castor oil may be used for preparing foam in accordance with the present invention.
The properties of the castor oil polyol used are shown in Table 1. These properties do not deviate greatly. Also, the various polyurethane formulations and their respective properties are shown in Table 2. Formulation J constitutes a conventional polyurethane composition and it contains 100% polyol. The product prepared by the process of the present invention has a good texture and it is taken as the control formulation 2. Formulation 2 contains 5% castor polyol as a substitute for poiyol as shown in Table 2.
Table I - Properties of Castor Polvol

Parameter Values Specification
Appearance Clear pale yellow viscous liquid Clear pale viscous liquid yellow
Acid Value 0.46 0.8
Moisture 0.12% 0.25%
Colour Gardner < 1 IG
Hydroxy] Value 161.24 Minimum 150
Iodine Value 87.4 82 to 90
Peroxide Value 1.32 Maximum 5.0
Refractive Index at 20°C 1.479 1.477 to 1.481
Relative Density at 30°C 0.959 0.957-0.961
Saponification Value 179.29 176 to 187
Mechanical properties of the foam obtained by the process of the present invention
Polyurethane foam obtained by the process of the present invention were tested for tensile strength (ISO 1798), tear strength (JISK6301), elongation-at-break

Table-2 - Physical Properties for conventional formulation and NOP formulation

Sr.
No. Foam Properties Specifications Equivalent Std. Conventional properties NOP
Formulation
1 Flammability Burn rate < 1 OOmm/min FMVSS 302:
2008
IS 15061:
2002 51 mm /min .51 mm /min
2 Hardness I90±20N ISO 2439 192 N 197N
3 Tensile strength 1.03
kg/Sq.cm. (Min.) ISO 1798 1.643 kg/Sq.cm. 1.813
kg/Sq.cm.
4 Tear strength 0.5 kg/cm. (Min.) JISK630I 0.762 kg/cm. 0.733 kg/cm.
5 Break
Elongation 100% (Min.) ISO 1798 118.6% 116.0%
6 Resilience 50 % (Min.) ISO 8307 54% 53%
7 Compression set 10% (Max.) ISO 1856 4.80% 5.20%
8 Ingress/Egress No weld breakage. No fracture and all mechanisms working after 30,000 cycles (S96AB
A60004 AA
OI EA) -
Height
reduction
allowed up to
10 MM after
test. 3.4 MM 4.90 MM


Effect of material variation on foam properties
The result (Table 2) shows that with NOP in foam formulation, the tensile strength is better than conventional foam formulation. With the introduction of NOP in formulation of the present invention, compression set was slightly increased as compared to conventional foam formulation. This could probably be due to the cleavage of rigid cross finks formed between castor pofyol and toluene di-isocyanate which prevents substantial elastic recovery. It then implies that foam formulations containing castor polyol (NOP) more than 10 % are not suitable for cushioning purposes since recovery from elastic deformation will generally be poor. It is perhaps the properties of 5 % NOP formulation that is reasonably close to the conventional formulation. Also, the results show a gradual decrease of the elongation-at-break with NOP base formulation. This result is likewise due to the rigid cross links produced between toluene di-isocyanate and castor Polyol.
Chemicals used for preparing foam

Chemicals Conventional formulation NOP formulation of the present invention
Polyether polyol 65.0 60.0
Polymeric Polyol 35.0 35.0
NOP ( Castor Polyol) 0.0 5.0
HOH 3.5 3.5

Cross linker 1.4 1.4
Amine Catalyst-1 0.2 0.2
Gel Catalyst-2 0.2 0.2
Delayed action Catalyst-3 0.2 0.2
Silicone Surfactant 0.9 0.9
Isocyante Index 70 to 105 70 to 105

Polyether polyo! Hydroxyl Valve 34
Molecular Weight 5000
Polymeric Polyol Hydroxyl Valve 20
Molecular Weight 7900
isocyante Blend of MDI and TDI ie
TM8020
NOP (Castor Oil) Hydroxyl Valve 160
Advantages of the present invention and impact on environment
The present invention enables in reducing the environmental foot prints like:
• Reduce the overall production of carbon dioxide, the most notable greenhouse gas
• NOP based manufacturing process produce,

- 36% less global warming emissions (carbon dioxide),
- 61 % reduction in non-renewable energy use (burning fossil fuels), and
- 23% reduction in the total energy demand, (all relative to polyol produced from petrochemicals)
• Abundant availability of natural resources near-by. E.g. green foam NOP
is easily and available in India in-excess.
It is to be understood that the present invention is not limited in its application to the details of the construction and to the arrangement of the components as mentioned in the above description or illustrated in the drawings. However, it is

to be taken as the preferred example of the invention and that various changes in the shape, size and arrangement of parts considering the space constraint may be resorted to without departing from the spirit of the invention. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, the terminologies used herein are for the purpose of description and should not be regarded as limiting.

We Claim
1. A process for preparation of polyurethane foam for automotive seating system, the process comprising reacting castor oil polyol in the range of 5-10 % with toluene di-isocyanate index 70 to 105% along with catalysts, polymeric polyol 35%, distilled water 3.5% , cross linker 1.4 -1.6%, and silicone surfactant 0.9-1.1% to obtain a rigid foam structure.
2. The process of claim 1, wherein the catalyst, comprises amine catalyst-1 0.2-0.4%, gel catalyst-2 0.2-0.45%, delayed action catalyst-3 0.2-0.4%.
3. The process of claim 1, the amine catalyst is of grade A400.
4. The process of claim I, the gel catalyst is mixture of dipropylene glycol and triethylenediamine
5. The process of claim 1, the delayed action catalyst is bis (2-dimethylamino ethyl) ether.
6. The process of claim 1, wherein the cross linker is diethanolamine.
7. The process of claim 1, wherein the water in the mixture reacts with toluene diisocyanate to liberate carbon dioxide which provides cellular structure to the foam.