Foamable Polyurethane Composition Using Fatty Amide
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Solution Overview
Problem
The increase in water usage as a blowing agent in polyurethane foam production leads to reduced shape stability and durability of the foam, along with increased material costs due to the need for more polyisocyanate to generate carbon dioxide.
Innovation Solution
A foamable polyurethane composition comprising at least one polymeric polyol, one polyisocyanate, one fatty amide with at least two carbon atoms, and a basic catalyst, which allows the composition to foam under room temperature without relying on water as a blowing agent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If water is used as a blowing agent to replace CFC-11, then environmental protection is improved, but shape stability and durability of the foam deteriorate
Solution Approach 1:
The patent changes the chemical composition parameters by introducing a fatty amide compound with specific carbon chain length (C12-C22) and controlled water content (0.1-5 wt%), replacing the conventional high water content formulation. This parameter optimization allows the foam to achieve both environmental compliance and shape stability by controlling the blowing agent composition and reaction kinetics.
Solution Approach 2:
The patent uses a composite blowing agent system combining water and fatty amide compound together with polyisocyanate. This composite approach leverages the environmental benefits of water while the fatty amide and polyisocyanate combination provides controlled gas generation and foam structure stability, resolving the contradiction between environmental protection and foam quality.
2Productivity
If water content is increased to achieve blowing effect, then blowing performance is improved, but material cost increases due to higher polyisocyanate requirement
Solution Approach 1:
The patent optimizes the water content parameter to a controlled range (0.1-5 wt%) rather than using high water content formulations. This parameter control reduces the amount of polyisocyanate needed for CO2 generation while maintaining adequate blowing performance through the synergistic action of water and fatty amide compound, thereby reducing material costs.
Solution Approach 2:
The fatty amide compound acts as an intermediary that enhances the blowing efficiency of water. By introducing this intermediate substance, the system achieves effective foam expansion with reduced water and polyisocyanate content, lowering material costs while maintaining productivity.
3Productivity
If conventional water-blown formulation is used, then blowing effect is achieved, but durability of the foam deteriorates
Solution Approach 1:
The patent employs a composite formulation containing water, fatty amide compound, and polyisocyanate in optimized proportions. This composite system provides controlled and sustained gas generation, creating a more uniform and stable foam structure that maintains durability while achieving the required blowing effect.
Solution Approach 2:
The patent modifies the chemical composition parameters by introducing fatty amide compound with specific chain length and controlling water content. These parameter changes result in improved crosslinking density and foam structure stability, enhancing durability without sacrificing blowing performance.
Data Source
AI summary
The present invention relates to a foamable polyurethane composition comprising a fatty amide having at least two carbon atoms, in particular a foamable polyurethane composition comprising a fatty amide having at least two carbon atoms, which is able to foam under room temperature, to a foam obtained by curing the foamable polyurethane composition, and to a method of bonding substrates by using the foamable polyurethane composition.