Flexible slabstock

Monofunctional, cyclohexylamine is used as a polyamide polymerization chain terminator to control polymer molecular weight. 3,3,5-Trimethylcyclohexylamines ate usehil fuel additives, corrosion inhibitors, and biocides (50). Dicyclohexylamine has direct uses as a solvent for cephalosporin antibiotic production, as a corrosion inhibitor, and as a fuel oil additive, in addition to serving as an organic intermediate. Cycloahphatic tertiary amines are used as urethane catalysts (72). Dimethylcyclohexylarnine (DMCHA) is marketed by Air Products as POLYCAT 8 for pour-in-place rigid insulating foam. Methyldicyclohexylamine is POLYCAT 12 used for flexible slabstock and molded foam. DM CHA is also sold as a fuel oil additive, which acts as an antioxidant. StericaHy hindered secondary cycloahphatic amines, specifically dicyclohexylamine, effectively catalyze polycarbonate polymerization (73). 

The resulting slate of polyols has been demonstrated in conventional flexible slabstock foam [143], viscoelastic foam [144], and high resiliency slabstock and molded foams [145],... 

This type of alkoxylation chemistry cannot be performed with conventional alkali metal hydroxide catalysts because the hydroxide will saponify the triglyceride ester groups under typical alkoxylation reaction conditions. Similar competitive hydrolysis occurs with alternative catalysts such as triflic acid or other Brpnsted acid/base catalysis. Efficient alkoxylation in the absence of significant side reactions requires a coordination catalyst such as the DMC catalyst zinc hexacyano-cobaltate. DMC catalysts have been under development for years [147-150], but have recently begun to gain more commercial implementation. The use of the DMC catalyst in combination with castor oil as an initiator has led to at least two lines of commercial products for the flexible foam market. Lupranol Balance 50 (BASF) and Multranol R-3524 and R-3525 (Bayer) are used for flexible slabstock foams and are produced by the direct alkoxylation of castor oil. 

Authors carefully investigated the potential causes of an increase in compressive modulus, which had been previously reported for flexible slabstock foams prepared from the polyols of the study [166]. Flexible foams prepared from a standard formulation containing two different levels of the epoxidized/hydroxylated soybean... 

Flame retardants are incorporated into the formulations in amounts necessary to satisfy existing requirements. There are four main types of flexible slabstock foam conventional, high resiliency, filled, and high load-bearing foam. 

In 1991 Vandichel and Appleyard (15) described a new promising approach for the production of "soft" flexible slabstock urethane foam blown exclusively by COj generated by the water-isocyanate reaction. These workers found that by the addition to the formulation of certain hydrophilic materials a substantial hardness reduction is obtainable, thereby permitting a considerable reduction, or even total elimination, of CFC-11 from some "conventional" foam formulations. The hydrophilic additive is called CARAPOR 2001. An example is a foam produced with an ILD value of 80N at a density of 21.5 kg/m" (1.34 Ib/ft ) (15). 

The main field of polyurethane application is the furniture industry, around 30% of the total polyurethanes produced worldwide is used for the production of mattresses from flexible slabstock foams. Automotive manufacture is the second important application for flexible and semiflexible polyurethanes (seat cushioning, bumpers, sound insulation, and so forth). Rigid polyurethane foams are used in thermal insulation of buildings and refrigerators, cold stores, pipe insulation, refrigerated transport, thermal insulation in chemical and food industries. The polyurethane elastomers are used for shoe soles,... 

It can be seen that moulded flexible PU foams using EO capped polyether polyols (block copolymers PO-EO with terminal poly[EO] block) represent only 22% of total worldwide consumption and that the majority of foams are flexible slabstock PU foams which use random copolyethers of PO-EO. It can therefore be concluded that the most important polyols for flexible PU foams production are in fact the random copolyethers PO-EO. 

In this section the most important random copolyether PO-EO structures were presented. Considering the highest production volume, the random copolyethers PO-EO with a MW of 3000-3600 daltons are the most important polyether type produced worldwide, used in continuous flexible slabstock foams, with the highest volume of consumption (of around 78% from the total flexible foams). 

The polyether polyols for flexible PU foams frequently have a distinct, unpleasant smell. In case of flexible slabstock foams where, in the centre of the PU bun, there are high temperatures (150-170 °C), an unpleasant odour appears during the foaming process which remains for a long time in the resulting PU foams. 

Foam-blowing flexible slabstock polyurethane CFC-ll Methylene chloride 100 2.2 50... 

AI3-26794 Araldite accelerator 062 BDMA Benz-enemethanamine, N,N-dimethyl- Benzyl-N,N-dimethyl-amine Benzylamine, N,N-dimethyl- Benzyldimethyl-amine N-Benzyldimethylamine N-Benzyl-N,N-dimethyl-amine CCRIS 6693 Dabco B-16 Dimethyl-benzylamine N,N-Dimethylbenzylamine N,N-Dimethyl-N-benzylamine N,N-Dimethylbenzenemethanamine EINECS 203-149-1 NSC 5342 Pentamin BDMA N-(Phenylmethyl)dimethylamine Sumine 2016 UN2619. Amine-based catalyst for flexible slabstock PU foam. Used as a polyurethane catalyst and an epoxy curing agent. Liquid mp = -75° bp = 181° d° = 0.915 7.m = 252, 268, 265 nm (cyclohexane) slightly soluble in H2O, freely soluble in EtOH, Et20 LD50 (rat orl) = 265 mg/kg. Air Products Chemicals Inc. Pentagon Chems. Ltd. -... 

Beilstein Handbook Reference) AI3-24288 BRN 0102969 CCRIS 4818 EINECS 202-885-0 N-Ethylmorfolin Ethylmorpholine 4-Ethylmorpholine N-Ethylmorpholine HSDB 1644 Morpholine, 4-ethyl- NEM NSC 6110 Texacat NEM Toyoca -NEM. Catalyst for PU molded flexible, semirigid, and rigid applications. Amine-based catalyst for flexible slabstock PU foam. Liquid mp = -63° bp = 138.5° d = 0.9050 freely soluble in H2O, EtOH, Et20, soluble in Me2CO, CeHe LDso (rat orl) = 1780 mg/kg. Texaco Tosoh. 

The largest-volume use of flexible foam is furniture and bedding, which account for nearly 47% of the flexible polyurethane foam market. Almost all furniture cushioning is polyurethane. Automobile seating is either made from flexible slabstock or poured directly into frames, so-called deep seating, using HR chemical formulations. Semiflexible polyurethane foams find use in crash pads, arm and head rests, and door panels. 

Chem. Descrip. Dibutyltin dilaurate CAS T7-5 -7] EINECS/ELINCS 201-039-8 Uses Gelation catalyst for PU flexible molded foam, semiflexible, flexible slabstock, rigid, elastomer, shoe sole, and coatings Properties Liq. above 65 F insol. in water sp.gr. 1.05 vise. 43 cps vapor pressure 0.15 mm Hg (160 C) f.p. 18 C flash pt. (COC) 235 C... 

Chem. Desap. Polycat DBU with an acid blocker CAS 6674-22-2 EINECS/ELINCS 229-713-7 Uses Catalyst for PU flexible slabstock, coatings, rigid, elastomeric, shoe sole applies. 

Methyl isocyanate Toluene-2,4-diisocyanate PU foam, flexible slabstock Dimethicone copolyol PU foundry resin additive 3-Glycidyloxypropyltriethoxysilane PU mfg. 

Data presented herein was derived from a combination of handmix and high pressure impingement-mixing machine produced foam. Foams were prepared using several general types of formulations for toluene diisocyanate (TDI) and two general types of formulations for methylenediphenyl diisocyanate (MDI) which are representative of currently utilised formulations in the automotive interior component industry. In addition, an all water blown formulation was used to represent the flexible slabstock industry. 

Dabco NE500 Newly developed non-fugitive gelling catalyst for flexible slabstock foam from APCI. APCI... 

Handmix rate of rise comparison tests were performed using the same equipment and process as described for TDI and MDI hand mix foam. The formulations used are listed in Table 1.42 and the rate of rise data reported in Table 1.43. Dabco BLV with Dabco T-9 was used as the industry standard catalyst control for the water blown flexible slabstock foam formulations. The silicone surfactant used in the reported flexible slabstock formulations was DC5160. All water blown formulations were made at densities of 23 kg/m. ... 

Table 1.43 Hand mix free rise reactivity comparison using flexible slabstock formulations ...

Dabco NE600 in combination with Dabco NE500 or Dabco NE600 as a sole amine catalyst used with increased levels of T-9 provides for equal or improved performance compared to Dabco BLV in all water-blown flexible slabstock foam. In all cases, these catalyst combinations can completely replace Dabco BLV and eliminate amine emissions from the flexible slabstock foam. 

Table 1.44 Physical properties for flexible slabstock foam ...

The chemical flexible slabstock foam model provides a detailed look at the performance of the industry standard catalyst Dabco BLV compared to the non-fugitive catalysts Dabco NE500 and the Dabco NE500/Dabco NE600 package, keeping the Dabco T-9 level constant. Selectivity and conversion can be calculated as described previously. Note that... 

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