Flexible Polyurethane Foam Formulation With Delayed-Action Amine Catalysts
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Solution Overview
Problem
Existing polyurethane foam production methods using chlorofluorocarbons as blowing agents deplete ozone, while water-based systems face issues with CO2 bubbling and tertiary amine catalysts pose safety and toxicity concerns, leading to undesirable product properties and high costs.
Innovation Solution
A process involving a halogen-containing composition with tertiary amine catalysts blocked by acids to create delay-action catalysts, combined with polyol, surfactants, and crosslinking agents, to produce polyurethane foam with improved humid-aged properties and reduced emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If water is used as a blowing agent instead of CFC, then environmental harm is reduced, but CO2 bubbles out causing cell structure collapse
Solution Approach 1:
A tertiary amine catalyst is introduced as an intermediary substance to mediate between water (blowing agent) and polyisocyanate. The catalyst accelerates the reaction between water and isocyanate to generate CO2 in a controlled manner, ensuring proper foaming before the CO2 can bubble out and collapse the cell structure. This resolves the contradiction by enabling water to function as an effective blowing agent without compromising cell integrity.
2Productivity
If tertiary amine catalysts are used to accelerate blowing, then foaming speed increases, but product safety and toxicity concerns arise
Solution Approach 1:
The patent employs a tertiary amine catalyst that is fully consumed during the reaction process, converting into non-toxic urea linkage within the polymer structure. This disposable catalyst approach allows high foaming speed to be achieved temporarily during the reaction, but the catalyst does not persist in the final product, thereby eliminating ongoing toxicity and safety hazards.
3Object-affected harmful factors
If isocyanate-reactive groups are added to immobilize amine catalysts, then emissions are reduced, but humid aged properties degrade
Solution Approach 1:
The patent changes the chemical parameter of the catalyst system by selecting a tertiary amine catalyst with specific molecular weight and volatility characteristics. The catalyst is designed to have sufficient reactivity to be immobilized through isocyanate reaction (reducing emissions) while maintaining appropriate reaction kinetics to preserve foam structure and properties under humid aging conditions. This parameter optimization resolves the contradiction between emission reduction and property preservation.
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 process enables the production of polyurethane foam with enhanced properties under ambient and humid conditions, minimizing emissions and handling risks, without requiring significant facility modifications.
Implementation Method 1
A process involving a halogen-containing composition with tertiary amine catalysts blocked by acids to create delay-action catalysts
Implementation Method 2
Use of water as a blowing agent involves generation of CO2 from the reaction of the water and the polyisocyanate
Implementation Method 3
CFC is used as a blowing agent which vaporizes as a result of a reaction exotherm causing a polymerizing mass to form into foam
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 halogen containing composition with a polyurethane foam product pre-mix. The polyurethane foam product pre-mix includes the halogen containing composition. The polyurethane foam product formulation includes a polyol component, an isocyanate component, and a halogen containing compound component. The polyurethane foam product is formed by the pre-mix having the halogen containing composition.