Polyurethane and other Polymeric Foams

Foam is a polymeric material where gas-filled cells that are either open to or are isolated from each other fill the bulk of the matrix. 

In building applications rigid polyurethane foam is used laminated to board stock (or to other substrates such as foil or paper), discontinuous or continuous sandwich panels, slabstock, spray, and as pipe insulation material. Some of these sandwich structures are used in building (and transportation) applications that do not exploit their insulation characteristics. The largest volume building application is in roofing insulation [where both PUR and polyisocyanurate (PIR) foams are used]. 

Data was reported in Appliance Engineer (June 2000, p. 68). The survey was sponsored by the Alliance for Polyurethane Industry. 

Integral skin PUR foams are made by injecting the reactants into a closed (vented) or open mold. Reaction under fliese conditions produces a foam with a high-density outside skin layer and a soft foam interior. Common products such as steering wheels, footwear components, and computer housings generally employ integral skin PUR foams. 

Chemistry Polyurethane is produced by the reaction of a polyol with an diisocyanate (or in some instances a polyisocyanate) in the presence of catalysts. The polyols of choice are poly(propylene glycol), block copolymers of ethylene oxide (10-15%) with propylene oxide, or the newer polymer polyols (based on polymers such as polystyrene or styrene-acrylonitrile copolymer). Polyester diols such as polycaprolactone diol can be used in place of the polyether polyol in this reaction. The isocyanate of choice is a mixture of the 2,4 and 2,6 isomers of tolylene di-isocyanate in the ratio of 80 20, generally referred to as 80 20TDI. Other isocyanates such as diphenylmethane di-isocyanate (MDI), hexamethylene di-isocyanate (HMDI), and isophorone di-isocyanate (IPDI) are also used. A tin-based or amine catalyst is used to promote the reaction. Given the wide choice of reactants available, the reaction can yield foams with a range of different mechanical and thermal characteristics. 

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