Polyurethane foam moulded body
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Solution Overview
Problem
PU foam moldings, such as mattresses, face challenges in regaining their original shape after prolonged compression due to material fatigue caused by high forces required for compression and storage, leading to issues with dimensional recovery.
Innovation Solution
The use of polyurethane foam produced by reacting a polyol component and an isocyanate component in the presence of specific compounds of formulas (1a) and (1b), which enhance the foam's ability to regain its original dimensions after compression over a period of at least 20 hours, while also reducing amine emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If PU foam moldings are compressed and vacuumed for storage and transport, then space efficiency is improved, but material fatigue occurs and dimensional recovery deteriorates
Solution Approach 1:
The patent modifies the chemical composition parameters of the polyurethane foam by incorporating specific compounds (formula 1a and 1b) with reactive functionalities. This changes the material's physical properties to enhance its ability to recover from compression while maintaining compressibility for storage, directly resolving the contradiction between space efficiency and dimensional recovery.
2Productivity
If high compression forces are applied to flatten PU foam for rolling, then transport efficiency is improved, but material fatigue increases
Solution Approach 1:
The patent creates a composite polyurethane foam structure by combining multiple chemical components (polyol, isocyanate, blowing agent, and compounds of formula 1a and 1b). This composite material structure provides both the compressibility needed for efficient transport and the structural integrity to resist material fatigue from repeated compression cycles.
3Quantity of substance
If PU foam is kept in compressed form for prolonged periods, then storage efficiency is improved, but shape recovery capability deteriorates
Solution Approach 1:
The patent incorporates compounds with specific reactive functionalities (isocyanate-reactive groups) during the foam manufacturing process. These compounds perform a preliminary chemical action that creates a molecular structure pre-configured to facilitate rapid shape recovery when compression is released, even after prolonged compression periods, thus maintaining both storage efficiency and shape recovery capability.
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 allows for improved dimensional recovery of PU foam moldings after compression, maintaining their original shape and reducing emissions, meeting specifications like CertiPur and VDA 278, and enabling efficient storage and transport without material fatigue.
Implementation Method 1
the polyurethane foam is produced by reacting at least one polyol component and at least one isocyanate component in the presence of at least one compound of the formula (1a) and at least one compound of Formula (1b)
Implementation Method 2
reacting at least one polyol component and at least one isocyanate component in the presence of at least one blowing agent
Data Source
AI summary
PU foam molded bodies, preferably mattresses and/or pillows, wherein the polyurethane foam was obtained by reacting at least one polyol component and at least one isocyanate component in the presence of at least one compound of formula (1a) and at least one compound of formula (1b) and at least one blowing agent, are described.