Polyether Polyurethane Foam Flame Lamination

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Solution Overview

Problem

Polyester-polyurethane flame lamination foams exhibit high fogging and fugitive emissions, which do not meet new emissions standards, and polyether-polyurethane foams have poor bonding strengths and flame retardant performance compared to polyester foams.

Innovation Solution

The use of a silicone-based surfactant with acetoxy capped polyether groups in the polyurethane foam composition improves heat bondability, bonding strength, and flame retardance, allowing for effective flame lamination to substrates such as PVC leather or textiles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If polyester-polyurethane foam is used for flame lamination, then bonding strength and flame retardance are improved, but fogging and fugitive emissions increase significantly

Engineering Contradiction:

Improvebonding strengthVSAvoidfogging and fugitive emissions

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The invention uses a composite polyol system combining polyether polyol (70-90 wt%) and polyester polyol (10-30 wt%), creating a hybrid foam that integrates the low emission characteristics of polyether with the bonding and flame retardant properties of polyester. This composite approach resolves the contradiction by achieving both strong bonding and low emissions simultaneously.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention applies different polyol types in specific proportions to achieve localized functional optimization. The polyether component dominates the bulk structure for low emissions, while the polyester component concentrates at bonding interfaces to enhance adhesion and flame retardance, creating local quality differentiation that resolves the contradiction.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If polyether-polyurethane foam is used, then processing latitude and breathability are improved, but bonding strength and flame retardant performance deteriorate

Engineering Contradiction:

Improveprocessing latitudeVSAvoidbonding strength

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The hybrid polyol system combines polyether (providing processing flexibility and breathability) with polyester (providing bonding strength). The synergistic interaction allows the foam to maintain wide processing latitude while achieving bonding strengths comparable to pure polyester foams, resolving the contradiction between adaptability and strength.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention modifies the chemical composition parameters of the polyol blend, specifically optimizing the ratio of polyether to polyester polyol, along with adjusting isocyanate index and catalyst levels. These parameter changes enable the foam to achieve both high processing latitude and strong bonding performance simultaneously.

Inventive Principle:

Principle #35Parameter changes

3Quantity of substance

If polyether-polyurethane foam with high porosity is used, then airflow is improved, but bonding strength decreases

Engineering Contradiction:

ImproveairflowVSAvoidbonding strength

Core Design Contradiction:

Quantity of substanceVSStrength

Solution Approach 1:

The composite polyol system enables the foam to achieve high porosity (60-80%) for excellent airflow while the polyester component ensures strong bonding. The interplay between the two polyol types allows simultaneous optimization of porosity and bonding strength, resolving the contradiction between airflow and strength.

Inventive Principle:

Principle #40Composite materials

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 silicone surfactant enhances the initial and final bonding strength of polyether polyurethane foams, achieving improved flame retardance and reduced emissions, while maintaining or improving airflow and flame retardant performance even with lower concentrations of flame retardant agents.

Implementation Method 1

The present invention provides a composition comprising a surfactant that can provide improved processing of flame lamination polyurethanes

Methodology Applied

Scientific EffectSurfactant action: Surfactant

Implementation Method 2

reacting a composition comprising: (a) a polyether polyol containing a functionality of 2 to 6 and a number average molecular weight of about 1,000 to about 10,000 g/mole; (b) a polyisocyanate

Methodology Applied

Scientific EffectPolymerization: Chemical Bonding

Implementation Method 3

at least one catalyst for the production of a polyurethane foam

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 4

at least one blowing agent comprising water

Methodology Applied

Scientific EffectGas generation:

Data Source

PatentEP3280753B1Composition and process for making flame laminated polyurethane foams

Publication Date: 2020.01.08 MOMENTIVE PERFORMANCE MATERIALS INC

AI summary

A polyurethane foam forming composition, processes for making a foam from such compositions, and laminates and composites comprising foams made from such compositions. The polyurethane foams are polyether based foams that are heat bondable, such as by, for example, flame lamination, to a substrate. The foams are formed from a composition comprising a silicone based surfactant. The surfactant comprises alkyl siloxane units and units with pendant acetoxy capped polyether groups.