Polyurethane foaming

Nacconate 100 A lachrymatory liquid b.p. 25l°C. Manufactured from phosgene and 2,4-diaminotoJuene. Used for preparing polyurethane foams and other elastomers by reaction with polyhydroxy compounds. Produces skin irritation and causes allergic eczema and bronchial asthma. 

Sorbitol is manufactured by the reduction of glucose in aqueous solution using hydrogen with a nickel catalyst. It is used in the manufacture of ascorbic acid (vitamin C), various surface active agents, foodstuffs, pharmaceuticals, cosmetics, dentifrices, adhesives, polyurethane foams, etc. 

Foams. Polyurethane foams are prepared by the polymerization of polyols with isocyanates. 

The structure of elastomeric fibers is similar to that illustrated for polyurethane foams. 

Siace the pores ia an aerogel are comparable to, or smaller than, the mean free path of molecules at ambient conditions (about 70 nm), gaseous conduction of heat within them is iaefficient. Coupled with the fact that sohd conduction is suppressed due to the low density, a siUca aerogel has a typical thermal conductivity of 0.015 W/(m-K) without evacuation. This value is at least an order of magnitude lower than that of ordinary glass and considerably lower than that of CFC (chloro uorocarbon)-blown polyurethane foams (54). 

Superabsorbents. Water-sweUable polymers are used extensively in consumer articles and for industrial appUcations. Most of these polymers are cross-linked acryUc copolymers of metal salts of acryUc acid and acrylamide or other monomers such as 2-acrylamido-2-methylpropanesulfonic acid. These hydrogel forming systems can have high gel strength as measured by the shear modulus (134). Sometimes inorganic water-insoluble powder is blended with the polymer to increase gel strength (135). Patents describe processes for making cross-linked polyurethane foams which contain superabsorbent polymers (136,137). 

Pentabromodiphenyl Oxide. Pentabromodiphenyl oxide [32534-81-9] (PBDPO) is prepared from diphenyl oxide by bromiaation (36). It is primarily used as a flame retardant for flexible polyurethane foams. For this appHcation PBDPO is sold as a blend with a triaryl phosphate. Its primary benefit ia flexible polyurethanes is superior thermal stabiUty, ie, scorch resistance, compared to chloroalkyl phosphates (see Phosphate esters). 

Diester/Ether Diol of Tetrabromophthalic Anhydride. This material [77098-07-8] is prepared from TBPA in a two-step reaction. First TBPA reacts with diethylene glycol to produce an acid ester. The acid ester and propylene oxide then react to give a diester. The final product, a triol having two primary and one secondary hydroxyl group, is used exclusively as a flame retardant for rigid polyurethane foam (53,54). 

Laboratory experiments using rodents, or the use of gas analysis, tend to be confused by the dominant variable of fuel—air ratio as well as important effects of burning configuration, heat input, equipment design, and toxicity criteria used, ie, death vs incapacitation, time to death, lethal concentration, etc (154,155). Some comparisons of polyurethane foam combustion toxicity with and without phosphoms flame retardants show no consistent positive or negative effect. Moreover, data from small-scale tests have doubtful relevance to real fine ha2ards. 

The urethane forming ingredients in a polyurethane foam formulation are the isocyanate (1) and the polyol (2) as shown in equation 3. 

Several manufacturiag processes can be used to produce phenohc foams (59,79) continuous production of free-rising foam for slabs and slab stock similar to that for polyurethane foam (61,80) foam-ia-place batch process (61,81) sandwich paneling (63,82,83) and sprayiag (70,84). 

Fig. 2ab. Photomicrographs of foam cell stmcture (a) extmded polystyrene foam, reflected light, 26 x (b) polyurethane foam, transmitted light, 26 x (c) polyurethane foam, reflected light, 12 x (d) high density plastic foam, transmitted light, 50x (22).

Strengths and moduli of most polymers increase as the temperature decreases (155). This behavior of the polymer phase carried over into the properties of polymer foams and similar dependence of the compressive modulus of polyurethane foams on temperature has been shown (151). 

Compression Set. The compression set is an important property ki cushioning appHcations. It has been studied for polyurethane foams (185,186), and has been discussed ki reviews (32,60,156). Compression set has been described as flex fatigue and creep as weU. 

The thermal conductivity of a cellular polymer can change upon aging under ambient conditions if the gas composition is influenced by such aging. Such a case is evidenced when oxygen or nitrogen diffuses into polyurethane foams that initially have only a fluorocarbon blowing agent in the cells (32,130,143,190,191,198-201). 

Electrical Properties. CeUular polymers have two important electrical appHcations (22). One takes advantage of the combination of inherent toughness and moisture resistance of polymers along with the decreased dielectric constant and dissipation factor of the foamed state to use ceUular polymers as electrical-wire insulation (97). The other combines the low dissipation factor and the rigidity of plastic foams in the constmction of radar domes. Polyurethane foams have been used as high voltage electrical insulation (213). 

Foams prepared from phenol—formaldehyde and urea—formaldehyde resins are the only commercial foams that are significantly affected by water (22). Polyurethane foams exhibit a deterioration of properties when subjected to a combination of light, moisture, and heat aging polyester-based foam shows much less hydrolytic stabUity than polyether-based foam (50,199). 

Commercial Construction. The same attributes desirable on residential constmction appHcations hold for commercial constmction as weU but insulation quaHty, permanence, moisture insensitivity, and resistance to free2e—thaw cycling in the presence of water are of greater significance. For this reason ceUular plastics have greater appHcation here. Both polystyrene and polyurethane foams are highly desirable roof insulations in commercial as in residential constmction. 

The insulating value and mechanical properties of rigid plastic foams have led to the development of several novel methods of buUding constmction. Polyurethane foam panels may be used as unit stmctural components (220) and expanded polystyrene is employed as a concrete base in thin-sheU constmction (221). 

Another type of polyol often used in the manufacture of flexible polyurethane foams contains a dispersed soHd phase of organic chemical particles (234—236). The continuous phase is one of the polyols described above for either slab or molded foam as required. The dispersed phase reacts in the polyol using an addition reaction with styrene and acrylonitrile monomers in one type or a coupling reaction with an amine such as hydrazine and isocyanate in another. The soHds content ranges from about 21% with either system to nearly 40% in the styrene—acrylonitrile system. The dispersed soHds confer increased load bearing and in the case of flexible molded foams also act as a ceU opener. 

Catalysis of the flexible polyurethane foaming operation is accompHshed through the use of tertiary amine compounds, often using two different amines to balance the blowing and gelling reactions. OrganometalHc compounds, usually staimous salts, are also used to faciHtate gelling and promote final cure. 

Applications. Carpet undedayment as just descdbed is a substantial market. Most furniture cushioning is made from blocks of slab-produced polyurethane foam in the density range of 16 to 29 kg/m (1.0—1.8 lbs /fT). A minor portion of the market, 9—14 thousands of metric tons (20—30 million pounds) uses 40 kg/m (2.5 lbs/fT) high resident (HR) foam for higher pnced furniture cushions. The furniture market for polyurethane foams grew strongly until saturation occurred around 1979. Market use now tends to reflect the current economic trends. 

For passenger car seating about 90% is made by the molded foam process. The transportation market has expedenced a decline since 1979 due to decreased automotive production and also because U.S. cars have been downsized, resulting in the use of less polyurethane foam per car. 

Consumption of polyurethane foam in bedding reached a maximum in 1978 and has since declined. The innerspring mattress has remained the standard in the United States whereas aH-foam mattresses have gained a dominant market share in Europe. 

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