Polyurethane Foam Composition for Low-Emission Aging-Resistant Mattresses
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Solution Overview
Problem
Mattresses and pillows containing polyurethane foam face challenges with material fatigue, leading to changes in hardness and the formation of lumps, which can cause back problems and sleep disorders, and also have high amine emissions, affecting their aging resistance and emission profile.
Innovation Solution
The use of a compound of formula (I) during the production of flexible polyurethane foam, which reacts with polyol and isocyanate components to reduce amine emissions and enhance aging resistance, improving heat resistance and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional amine catalysts are used to produce flexible polyurethane foam, then the foam can be manufactured effectively, but the aging resistance deteriorates and amine emissions increase
Solution Approach 1:
The patent changes the chemical structure parameters of the catalyst by using a specific amine compound with a cyclic carbamate group (formula I) instead of conventional amine catalysts. This structural modification allows the catalyst to maintain catalytic activity while reducing harmful effects on aging resistance and amine emissions, directly resolving the contradiction between ease of manufacture and reliability.
Solution Approach 2:
The patent introduces a specific amine compound (formula I) as an intermediary catalyst that mediates between the need for effective foam production and the requirement for good aging resistance. This intermediary catalyst performs the necessary catalytic function while having reduced negative impact on foam stability and emissions, thus resolving the contradiction.
2Ease of manufacture
If conventional amine catalysts are used to produce flexible polyurethane foam, then the foam can be manufactured effectively, but amine emissions increase
Solution Approach 1:
The patent modifies the chemical parameters of the catalyst by using a cyclic carbamate-containing amine (formula I) with specific structural characteristics. This parameter change reduces the volatility and emission potential of the catalyst while maintaining its catalytic efficiency, thereby resolving the contradiction between ease of manufacture and reduction of harmful emissions.
3Ease of operation
If polyurethane foam is compressed during use, then sleeping comfort is achieved, but material fatigue accelerates leading to hardness loss
Solution Approach 1:
The patent applies prior cushioning by using the specific amine catalyst (formula I) that preemptively protects the polyurethane foam structure from degradation. The catalyst structure is designed to minimize harmful side reactions and oxidative degradation that would otherwise occur during compression cycles, thereby extending the service life while maintaining comfort properties.
Solution Approach 2:
The patent changes the chemical composition parameters of the catalyst system to use compound (I), which has molecular structure characteristics that reduce degradation of the polyurethane chains during compression. This parameter change maintains the softness and comfort properties while improving durability and service life.
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 results in flexible polyurethane foams with significantly reduced amine emissions and improved aging resistance, maintaining compression hardness and porosity even after heat aging, addressing the issues of material fatigue and emissions in polyurethane foam-based mattresses and pillows.
Implementation Method 1
the flexible polyurethane foam being formed by reacting at least one polyol component and at least one isocyanate component in the presence of the compound of formula (I)
Data Source
AI summary
Aging-resistant and low-emission mattresses and/or pillows, comprising at least one section made of flexible polyurethane foam, the flexible polyurethane foam being obtained by reacting at least one polyol component and at least one isocyanate component in the presence of the compound of the formula (I) and at least one blowing agent are described .