Polyurethane Foam Production Using Blocked Catalysts
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Solution Overview
Problem
Existing polyurethane foam production methods face challenges with ozone-depleting chlorofluorocarbons and volatile tertiary amine catalysts, which lead to environmental concerns and undesirable product properties, particularly under humid aged conditions, and are costly and inefficient.
Innovation Solution
Incorporating a halohydrin component with a tertiary amine catalyst blocked by different acids to create a delay action catalyst, allowing for improved mold-filling and physical properties in polyurethane foam products without emitting volatile substances, using a pre-mix formulation including polyol, isocyanate, and silicone surfactants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If water is used as a blowing agent to replace CFC, then environmental harm is reduced, but CO2 generation from water-polyisocyanate reaction creates additional challenges
Solution Approach 1:
A halohydrin component is introduced as an intermediary substance that reacts with polyisocyanate to generate blowing gas. The halohydrin serves as a mediator between the blowing agent function and the polyisocyanate, controlling the reaction to produce foam while managing CO2 generation through its specific chemical properties
Solution Approach 2:
The invention changes the chemical parameters of the blowing system by using halohydrin instead of pure water. This parameter change modifies the reaction characteristics, allowing control over CO2 generation rate and amount, thereby reducing the harmful effects while maintaining the environmental benefits of water-based blowing
2Productivity
If tertiary amine catalysts are used to accelerate blowing with water, then blowing speed is improved, but CO2 bubbles out and foam structure collapses
Solution Approach 1:
The invention changes the catalyst system parameters by using blocked tertiary amine catalysts instead of conventional tertiary amines. This parameter change allows controlled acceleration of the blowing reaction while preventing excessive CO2 generation that would collapse the foam structure, thus maintaining both productivity and manufacturing precision
Solution Approach 2:
The blocked catalyst is prepared in advance with a blocking group that temporarily deactivates it. During the foaming process, the blocking group is removed or the catalyst becomes active at the appropriate time, allowing controlled acceleration of blowing without causing structure collapse. This preliminary preparation enables precise timing of the catalytic action
3Object-generated harmful factors
If isocyanate-reactive groups are added to immobilize amine catalysts, then emission is reduced, but product degrades under accelerated ageing with hot humidity
Solution Approach 1:
A blocking group serves as an intermediary between the tertiary amine catalyst and the isocyanate-reactive groups. The blocking group temporarily prevents the catalyst from reacting with isocyanate, maintaining catalyst activity while preventing emission. After foaming, the blocking group is removed or becomes inactive, allowing the catalyst to be immobilized without degrading the product's humid aged properties
4Object-generated harmful factors
If low vapor-pressure, high-molecular weight amine catalysts are used to reduce emission, then emission is minimized, but high amounts of catalyst are required making it cost prohibitive
Solution Approach 1:
The invention changes the molecular weight and vapor pressure parameters of the catalyst system by using blocked tertiary amine catalysts. This allows the use of lower molecular weight, more cost-effective catalysts while maintaining low emission characteristics through the blocking mechanism, thereby reducing manufacturing costs while minimizing catalyst emission
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 enhances the production of polyurethane foams with improved ambient and humid aged physical properties, such as tensile strength, elongation, and compression set, while minimizing emissions and costs, and maintaining mechanical integrity and performance.
Implementation Method 1
contacting a halohydrin component with a polyurethane foam product pre-mix
Implementation Method 2
CFC is used as a blowing agent which vaporizes as a result of a reaction exotherm causing a polymerizing mass to form into foam
Implementation Method 3
Tertiary amine catalysts are known to be used to accelerate blowing when the blowing agent is water
Implementation Method 4
use of a tertiary amine catalyst blocked by different acids to create a delay action catalyst
Implementation Method 5
generation of CO2 from the reaction of the water and the polyisocyanate
Data Source
AI summary
Disclosed are a process of producing a polyurethane foam product, a polyurethane foam product pre-mix, polyurethane foam product formulation, and a polyurethane foam product. The process of producing the polyurethane foam product includes contacting a halohydrin component with a polyurethane foam product pre-mix. The polyurethane foam product pre-mix includes the halohydrin component. The polyurethane foam product formulation includes a polyol component, an isocyanate component, and a halohydrin component. The polyurethane foam product is formed by the pre-mix having the halohydrin component.