Polyurethane Foam Flame Lamination Adhesion Balance
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Solution Overview
Problem
Polyurethane foams used in flame lamination methods face issues with adhesiveness to fabrics and leathers, compression residual strain, and volatile organic compound (VOC) emissions, leading to insufficient performance in interior materials for vehicles and furniture.
Innovation Solution
A polyurethane foam produced using a foam raw material comprising a polyol, polyisocyanate, foaming agent, foam control agent, amine-based catalyst, and a urea compound, with specific weight ratios and types of urea compounds, such as urea and azodicarbonamide, to enhance adhesiveness and reduce VOC emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an organic phosphorus compound is used as a plasticizer in the foam raw material, then the foam flexibility is improved, but the compression residual strain increases and adhesiveness deteriorates
Solution Approach 1:
The patent removes the organic phosphorus compound from the foam raw material composition. By extracting this problematic plasticizer, the invention eliminates the cause of deterioration in compression residual strain and adhesiveness while maintaining foam flexibility through alternative formulation approaches.
Solution Approach 2:
The patent changes the chemical composition parameters of the foam raw material by eliminating the organic phosphorus compound and adjusting the ratios of other components. This parameter change resolves the contradiction by improving compression residual strain and adhesiveness while maintaining necessary foam properties through reformulated composition.
2Strength
If the catalyst content in the foam raw material is increased to improve physical characteristics, then the foam density and hardness are improved, but VOC emissions increase causing bad odor and health concerns
Solution Approach 1:
The patent extracts and removes excessive catalyst components from the foam raw material formulation. By reducing catalyst content to optimized levels, the invention achieves the necessary physical characteristics while eliminating the source of harmful VOC emissions and bad odor.
Solution Approach 2:
The patent optimizes the catalyst content parameter within a specific range rather than using excessive amounts. This parameter change allows the foam to achieve adequate density and hardness while minimizing VOC emissions and eliminating health concerns associated with high catalyst levels.
3Adaptability or versatility
If a polyetherester polyol is used in the foam raw material, then the foam softness is improved, but the wet-heat resistance deteriorates
Solution Approach 1:
The patent changes the polyol composition parameters by selecting specific types of polyether polyols with controlled molecular weights and hydroxyl values. This parameter change enables the foam to achieve softness through molecular structure selection rather than relying on polyetherester polyols, thereby maintaining wet-heat resistance.
Solution Approach 2:
The patent uses a composite approach by combining specific polyether polyols with other foam raw materials in optimized ratios. This composite formulation achieves the desired softness through synergistic effects while maintaining excellent wet-heat resistance that would be lost using polyetherester polyols alone.
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 achieves excellent balance between adhesiveness, compression residual strain, and wet-heat resistance, reducing VOC emissions and improving durability and stability in laminated bodies for vehicle interior components.
Implementation Method 1
a polyurethane foam produced using a foam raw material comprising a polyol, a polyisocyanate, a foaming agent, a foam control agent, an amine-based catalyst and a urea compound
Implementation Method 2
a foaming agent
Implementation Method 3
an amine-based catalyst
Data Source
AI summary
The object of the present invention is to provide a polyurethane foam for flame lamination which has an excellent balance between adhesiveness to a fabric comprising synthetic fibers or natural fibers, a leather or the like and residual compression strain and has an excellent wet-heat resistance, and a laminated body including a foamed material layer consisting of the polyurethane foam. The polyurethane foam for flame lamination is characterized by being produced using a foam raw material containing a polyol such as a polyether polyol, a polyisocyanate, a foaming agent, a foam control agent, an amine-based catalyst and a urea compound such as urea and azodicarbonamide.