Highly Filled Polyurethane Foam with Amine Polyols
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Solution Overview
Problem
Polyurethane foams face challenges such as brittleness, poor adhesion to substrates, dimensional instability, and poor demolding due to high urea concentration and exothermic reactions, limiting their application.
Innovation Solution
Development of highly filled polyurethane or polyisocyanurate foam stocks with a filler content of 50-90% by weight, formed by reacting isocyanates with polyols in the presence of a catalyst, allowing the mixture to rise freely in a mold, resulting in foams with enhanced mechanical properties and improved handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high urea concentration is used in polyurethane foam, then adhesion to substrates is improved, but brittleness increases and dimensional stability deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters by replacing a portion of the urea-forming polyol with a polyol containing amine groups. This substitution modifies the reaction products to reduce urea concentration while maintaining adhesion properties, thereby improving dimensional stability without sacrificing bond strength.
Solution Approach 2:
The patent creates a composite foam structure by combining polyurethane matrix with alternative polyol components that contain amine groups. This composite approach allows the material to exhibit both the adhesion benefits of urea-based chemistry and the stability advantages of reduced urea concentration through the synergistic interaction of different polyol types.
2Productivity
If water-blown reaction is used, then foam formation is achieved, but exothermic nature causes poor demolding and dimensional instability
Solution Approach 1:
The patent modifies the reaction parameters by introducing polyols with amine groups that form different reaction products compared to conventional water-blown systems. This changes the thermal profile of the reaction, reducing exothermic intensity and allowing for easier demolding while maintaining effective foam formation.
Solution Approach 2:
The patent converts the potential harm of strong exothermic reactions into a benefit by using the heat generated during the reaction to control foam cell structure and improve final product properties. The modified polyol system allows the exothermic nature to be harnessed for favorable foam formation while minimizing negative effects on demolding.
3Strength
If filler content is increased to 50-90% by weight, then mechanical properties and structural stability are improved, but processing complexity increases
Solution Approach 1:
The patent adjusts the formulation parameters by selecting specific polyols with amine groups that are compatible with high filler loadings. This parameter optimization allows the system to accommodate 50-90% filler content while maintaining processability, as the amine-containing polyols provide better dispersion and bonding with filler materials.
Solution Approach 2:
The patent uses polyols containing amine groups as intermediary agents that facilitate the integration of high filler content into the foam matrix. These polyols act as mediators between the filler particles and the polyurethane matrix, improving compatibility and reducing processing difficulties associated with high filler loadings.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves foams with increased flexural strength, improved adhesion, and reduced brittleness, enabling their use in various applications as structural materials or composite boards.
Implementation Method 1
a polyurethane or polyisocyanurate formed by the reaction of (i) one or more isocyanates selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof, and (ii) one or more polyols
Implementation Method 2
the reaction mixture of the one or more isocyanates and one or more polyols is allowed to rise freely
Data Source
AI summary
Polyurethane or polyisocyanurate foam stock and methods of manufacturing are described herein. The foam stock can include (a) a polyurethane or polyisocyanurate formed by the reaction of (i) one or more isocyanates selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof, and (ii) one or more polyols; and (b) a filler present in an amount from greater than 50% to 90% by weight, based on the total weight of the foam stock. The density of the foam stock can be from 10 lb/ft3 to 35 lb/ft3. The flexural strength of the foam stock can be at least 100 psi. The resulting foam stock can be used to produce polyurethane or polyisocyanurate foam to be used in composite panels.