Polyurethane Foam Composition for Thermal Compression Molding
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Solution Overview
Problem
Conventional polyurethane foams lack favorable strain characteristics during thermal compression molding, and existing thermoplastic and thermosetting resins have their own limitations in shaping and post-processing.
Innovation Solution
A polyurethane foam produced using a mechanical froth method with a polyurethane reaction composition containing a polymer polyol and acid-modified polyolefin powder, allowing for thermal compression molding with improved strain characteristics, achieved by preheating and compression pressing with an ambient-temperature die to form surface irregularities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional polyurethane foam is subjected to thermal compression molding at high temperature, then shaping is achieved, but strain characteristics deteriorate
Solution Approach 1:
The invention changes the chemical composition parameters of the polyurethane foam by incorporating specific amounts of polymer polyol (5-30 wt%) and acid-modified polyolefin powder (5-30 wt%) into the polyurethane reaction composition. This compositional parameter change enables the foam to achieve both good strain characteristics (residual compression strain of 10% or less) and favorable shaping capability through thermal compression molding, resolving the contradiction between maintaining shape and achieving good strain characteristics.
2Ease of manufacture
If thermoplastic resins are used for shaping, then ease of shaping is improved, but strain characteristics worsen due to large strain
Solution Approach 1:
The invention creates a composite material system where polyurethane foam incorporates both polymer polyol and acid-modified polyolefin powder as reinforcing components. This composite structure combines the shaping ease of thermoplastic materials with the strain resistance of crosslinked polyurethane networks, achieving residual compression strain of 10% or less while maintaining thermal compression molding capability.
3Reliability
If thermosetting resins are used for shaping, then strain characteristics are improved, but post-processing capability deteriorates
Solution Approach 1:
The invention modifies the crosslinking density and chemical composition parameters of the polyurethane system by controlling the content of polymer polyol and acid-modified polyolefin powder. This parameter optimization achieves favorable strain characteristics (residual compression strain of 10% or less) while retaining sufficient thermal plasticity for post-processing operations such as thermal compression molding, unlike conventional thermosetting resins.
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 method enables the production of a molded body with favorable strain characteristics, maintaining surface irregularities and preventing plastic deformation over time, while avoiding surface burning or roughness.
Implementation Method 1
a polyurethane reaction composition containing a polyol component, a foam stabilizer, a catalyst and an isocyanate component
Implementation Method 2
obtained from an inert gas and a polyurethane reaction composition... by a mechanical froth method
Implementation Method 3
preheating a sheet comprising the polyurethane foam described in any one of (1) to (4) above at from 160 to 210° C.
Implementation Method 4
subjecting the sheet after the preheating to thermal compression molding by compression pressing using an ambient-temperature die provided with irregularities at a mold face
Data Source
AI summary
A polyurethane foam which is obtained from an inert gas and a polyurethane reaction composition containing a polyol component, a foam stabilizer, a catalyst and an isocyanate component, by a mechanical froth method, wherein: the polyol component contains a polymer polyol having a solid content of from 20% by weight to 43% by weight; and the polyurethane reaction composition contains an acid-modified polyolefin powder.