Properties and applications of flexible foams

In addition to freedom from bottoming out , most people prefer a seat which effectively provides a soft surface with a firm interior. One measure of the relationship between such surface softness and inner support is the sag factor or support factor. In one commonly used test this is obtained by dividing the force required to compress a foam by 65% of its height by the force needed to obtain 25% sample compression. This generally increases with density but is typically 2.5 for a conventional slabstock foam but 2.5 for a high-resilience foam. 

Today polyether foam with a density of less than half that of rubber latex foam is widely used as a cushioning material. Polyester foams, although tending to be more expensive, continue to have a number of outlets, particularly where a high initial modulus is desirable. In addition to miscellaneous upholstery applications 

Polyurethane foams do, however, suffer from one serious disadvantage. Unless modified they bum with copious evolution of smoke and toxic by-products, which has led to a number of fatal fires, particularly in domestic accommodation. To some extent the problem may be reduced by suitable upholstery covering, but as mentioned on p. 775 a number of countries have now made mandatory the use of fire retardent additives. At the time of writing there is considerable activity in the development of new safer systems, particularly in the use of amino materials such as melamine as additives. Further developments may also be expected in the near future. 

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In the manufacture of highly resilient flexible foams and thermoset RIM elastomers, graft or polymer polyols are used. Graft polyols are dispersions of free-radical-polymerized mixtures of acrylonitrile and styrene partially grafted to a polyol. Polymer polyols are available from BASF, Dow, and Union Carbide. In situ polyaddition reaction of isocyanates with amines in a polyol substrate produces PHD (polyhamstoff dispersion) polyols, which are marketed by Bayer (21). In addition, blending of polyether polyols with diethanolamine, followed by reaction with TDI, also affords a urethane/urea dispersion. The polymer or PHD-type polyols increase the load bearing properties and stiffness of flexible foams. Interreactive dispersion polyols are also used in RIM applications where elastomers of high modulus, low thermal coefficient of expansion, and improved paintability are needed. 

Hie most representative member of this class of polyesters is the low-molar-mass (M 1000-3000) hydroxy-terminated aliphatic poly(2,2/-oxydiethylene adipate) obtained by esterification between adipic acid and diethylene glycol. This oligomer is used as a macromonomer in the synthesis of polyurethane elastomers and flexible foams by reaction with diisocyanates (see Chapter 5). Hydroxy-terminated poly(f -caprolactonc) and copolyesters of various diols or polyols and diacids, such as o-phthalic acid or hydroxy acids, broaden the range of properties and applications of polyester polyols. 

Classification. Flexibie urethane foams have the largest market of all polyurethane products. The production properties and applications of various flexible urethane foams are described in the following sections. Flexible urethane foams are defined as open-cell urethane foams having the property of complete recovery immediately after compression. They can be classified into two kinds, i.e., polyether foams and polyester foams. Polyether foams are further classified as follows conventional flexible foams, high-resilience flexible foams (HR foams), cold-molded foams, super-soft foams, and viscoelastic foams. 

Flexible Cellular Polymers. The application of flexible foams has been predominantly in comfort cushioning, packaging, and wearing apparel (142,170, 171), resulting in emphasis on a different set of mechanical properties than for rigid foams. The compressive nature of flexible foams (both static and dynamic) is their most significant mechanical property for most uses (Table 3). Other... 

The mechanical properties of rigid foams vary considerably from those of flexible foams. The tests used to characterize these two classes of foams are, therefore, quite different, and the properties of interest from an application standpoint are also quite different. In this discussion the ASTM definition of rigid and flexible foams given earlier is used. 

This book series presents in-depth reports on the most important new developments in urethane technology. Volumes 2-5 contain papers written only by Japanese specialists. A number of these papers concern rigid and flexible foams. Polyurethanes and polyisocyanurates are widely used in Japan. The papers cover recent developments in chemistry, processing, properties and applications. 

The water absorption of flexible foams is much more difficult to measure than that of rigid foams, and when this property is requested it is usually in relation to a specific application need. There is no standard test method. 

Compressive Behavior. The most informative data in characterizing the compressive behavior of a flexible foam are derived from the entire load-deflection curve of 0-75% deflection and its return to 0% deflection at the speed experienced in the anticipated application. Various methods have been reported (3,142,172-175) for relating the properties of flexible foams to desired behavior in comfort cushioning. Other methods to characterize package cushioning have been reported. The most important variables affecting compressive behavior are polymer composition, density, and cell structure and size. 

Polyester polyols account for only ca. 10% of the total polyol market, which is dominated by polyether polyols such as hydroxy-terminated polyoxyethylene or polyoxypropylene. Polyester polyols are preferred for applications where better mechanical properties, wear resistance, and UV stability are required. The largest application of polyester polyols is flexible specialty polyurethane foam in the furniture, packaging, and automotive industries. Polyester polyols are also used for nonfoam applications such as coatings, paints, sealants, and adhesives 47... 

Polymerization of the oxiranes is typically propagated from a starter molecule that is chosen to define the functionality if) of the final polyol. The functionality and the molecular weight of polyols are the main design features that define the polyurethane properties in the end-use applications. Additionally, the balance of EO and PO in the polyether polyols, mainly for flexible foam polyols, is tailored to enhance the compatibility of formulations and the processability of the foam products. The exact composition of the polyols defines the crucial performance features of the final polyurethane product. Even seemingly small differences in polyol composition can result in changes to polyol processabihty and polyurethane performance. This becomes a crucial issue when replacing conventional petrochemical polyols with polyols from different feedstocks. To demonstrate the sensitivity of commercial formulations to changes in feedstocks, a simple example is offered below. 

Rigid foams are used for structural and insulation uses while the flexible materials are used for a vast variety of applications as seen in Figure 2.20. The versatility of polyurethane positions the product as unique in fire polymer world because of the breadth of applications. As we will show, small changes in chemistry can achieve a broad range of physical properties. This statement emphasizes the physical properties and serves as a testament, however, to the lack of chemical interest. It is supported by a description of the independent variables of density and stiffness and the range of products based on the primary attributes of polyurethanes. See Figure 2.21. 

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