Nitrile Polyurethane Foam Composition for Water-Free Room-Temperature Foaming
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Solution Overview
Problem
The increased use of water as a blowing agent in polyurethane foam production due to the ban on CFC-11 leads to shape stability and durability issues, along with higher material costs, necessitating a non-water-based foaming solution that maintains similar properties under room temperature.
Innovation Solution
A foamable polyurethane composition comprising polymeric polyol, polyisocyanate, aliphatic or alicyclic nitrile, and catalyst, which foams at room temperature without water, using ammonia generated from nitrile-polyol reactions to achieve stable foam formation.
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 compliance is improved, but shape stability and durability of the foam deteriorate
Solution Approach 1:
The invention extracts water from the blowing agent system entirely, replacing it with organic nitrile compounds (acetonitrile, propionitrile, butyronitrile, or isobutyronitrile). This removes the harmful effect of water-induced CO2 generation that compromises foam reliability, while maintaining environmental compliance by eliminating CFC-11.
Solution Approach 2:
The invention changes the chemical parameter of the blowing agent from water (inorganic, produces CO2) to organic nitrile compounds (organic, produces ammonia). This parameter change fundamentally alters the foam formation mechanism and gas generation chemistry, improving both environmental compliance and foam durability through the use of ammonia instead of CO2.
2Productivity
If water amount is increased to achieve blowing effect, then blowing performance is improved, but material cost increases due to higher polyisocyanate requirement
Solution Approach 1:
The invention uses small amounts of inexpensive organic nitrile compounds (acetonitrile, propionitrile, butyronitrile, or isobutyronitrile) as blowing agents instead of large amounts of water. These nitrile compounds are volatile and decompose completely to provide blowing action, requiring minimal quantities and reducing overall material costs while maintaining effective blowing performance.
Solution Approach 2:
The invention changes the blowing agent from water requiring stoichiometric polyisocyanate reaction to organic nitriles that provide blowing effect with minimal polyisocyanate consumption. This parameter change in the blowing mechanism reduces the quantity of expensive polyisocyanate needed, thereby lowering material costs while preserving blowing performance.
3Object-affected harmful factors
If water is used as blowing agent, then blowing effect is achieved, but the system requires higher temperature or longer time to achieve stable foam formation
Solution Approach 1:
The invention changes the blowing agent from water (requiring thermal decomposition to release CO2) to organic nitrile compounds that decompose at lower temperatures and faster rates to release ammonia. This parameter change in the chemical composition and decomposition characteristics of the blowing agent accelerates the foam formation process and reduces the time required to achieve stable foam structure.
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 composition provides stable foam formation at room temperature, maintaining shape stability and durability while reducing material costs by eliminating the need for water as a blowing agent.
Implementation Method 1
at least one nitrile selected from an aliphatic nitrile having 2 to 20 carbon atoms, an alicyclic nitrile having 6 to 20 carbon atoms, and combination thereof
Implementation Method 2
The composition provides stable foam formation at room temperature, maintaining shape stability and durability
Implementation Method 3
at least one catalyst
Data Source
AI summary
The present invention relates to a foamable polyurethane composition comprising a nitrile, in particular a foamable polyurethane composition comprising an aliphatic nitrile having 2 to 20 carbon atoms and/or an alicyclic nitrile having 6 to 20 carbon atoms, which is able to foam under room temperature, to a foam obtained by curing and foaming the foamable polyurethane composition, and to a method of bonding substrates by using the foamable polyurethane composition.