Mold Release Mixture with Curing Catalyst for Polyurethane Foam

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Solution Overview

Problem

Conventional mold release compositions for polyurethane foams often result in skin delamination and increased de-molding times due to incomplete curing, leading to production inefficiencies and odor issues from solvent-based compositions.

Innovation Solution

A mold release mixture combining a barrier release coating and a curing catalyst, optionally with surfactants, is applied to the mold surface to prevent adherence of polyurethane reactants and enhance curing, allowing for faster de-molding and improved skin quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional mold release compositions are used, then mold release function is provided, but skin delamination occurs and de-molding time increases

Engineering Contradiction:

Improveskin integrityVSAvoidde-molding time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The mold release composition is applied to the mold surface before foam injection, creating a pre-cured skin layer that prevents delamination. The barrier coating and curing catalyst are applied in advance to ensure the skin is properly formed before the main foam body is molded.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention changes the chemical composition parameters of the mold release system by combining a barrier release coating with a curing catalyst. This parameter change enables the skin to cure properly at lower temperatures and shorter times, preventing delamination while reducing de-molding time.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If solvent-based mold release compositions are used, then mold release function is achieved, but odor issues arise

Engineering Contradiction:

Improvemold release effectivenessVSAvoidsolvent odor

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The invention converts the harmful solvent odor issue into a benefit by using a water-based or solvent-free mold release composition. The barrier coating and curing catalyst system works effectively without requiring volatile organic solvents, eliminating odors while maintaining mold release effectiveness.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If extended curing time and temperature are applied, then skin quality improves, but production output decreases

Engineering Contradiction:

Improveskin qualityVSAvoidproduction output

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The invention changes the curing parameters by using a curing catalyst in the mold release composition. This catalyst enables the skin to cure at lower temperatures and shorter times while maintaining high quality, thus improving production output without sacrificing skin integrity.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention replaces the mechanical/thermal curing process (relying on extended heat and time) with a chemical curing mechanism using the curing catalyst. This substitution allows rapid curing at lower temperatures, increasing production speed while maintaining skin quality.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 effectively reduces skin delamination and de-molding time, improving production rates while eliminating solvent odors and enhancing surface cure and porosity of polyurethane foams.

Implementation Method 1

a curing catalyst to catalyze the reaction between polyisocyanate and polyol

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

a barrier release coating to prevent adherence of polyurethane reactants to a mold surface

Methodology Applied

Scientific EffectPhysical barrier:

Implementation Method 3

with the possible optional addition of a surfactant or combination of surfactants

Methodology Applied

Scientific EffectSurfactant action: Surfactant

Data Source

PatentUS10486341B2Low delamination mold release

Publication Date: 2019.11.26 L & P PROPERTY MANAGEMENT CO

AI summary

Methods and combinations of a curing catalyst with a mold release mixture, which is then subsequently applied to the surface of a mold prior to the application of polyurethane reactants to said mold, where the curing catalyst component has the effect of catalyzing the reaction at the surface of the molded part. This catalysis results in greater reactivity at the surface between reacting portions and lower delamination of the surface of the foam, thereby leading to more attractive skins with a more consistent cell structure, and lower de-mold times due to skins whose nature makes them less likely to adhere to the surface of the mold. These foams will be less likely to tear upon opening of the mold, and production quality and output will be improved.