Flexible Polyurethane Foam Composition for Low Odor and Fast Curing
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Solution Overview
Problem
Conventional flexible polyurethane foams used in automotive seat pads face issues with odor emission and inadequate curability, leading to decreased productivity due to longer reaction times and residual deformation under load.
Innovation Solution
A composition comprising polyether polyol, reactive and non-reactive amine catalysts, and silicone foam stabilizers, with specific mass ratios and surface tensions, is used to produce flexible polyurethane foam with reduced odor and enhanced curability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If conventional odor-suppressing technology is used to reduce VOC emissions, then odor is reduced, but curability becomes inadequate and residual deformation occurs
Solution Approach 1:
The invention changes the chemical parameters of the catalyst system by introducing a reactive amine catalyst with specific functional groups (amino and hydroxyl) that participates in the polymerization reaction. This catalyst achieves both odor reduction through suppressed VOC generation and improved curability by enhancing the chemical reaction efficiency, resolving the contradiction between odor control and curing performance
Solution Approach 2:
The invention uses a composite catalyst system combining reactive amine catalyst with specific polyol components. This composite approach allows the catalyst to simultaneously achieve odor suppression and adequate curability by working synergistically with the polyol to control both VOC emissions and polymerization reaction completeness
2Reliability
If longer reaction times are used to improve curability, then curability is improved, but productivity decreases
Solution Approach 1:
The reactive amine catalyst changes the kinetic parameters of the polymerization reaction by providing active amino and hydroxyl groups that accelerate the chemical reaction. This allows the foam to achieve adequate curability faster, reducing the required reaction time from conventional extended periods to a shorter, productivity-friendly duration while maintaining complete curing
3Productivity
If conventional catalysts are used to reduce reaction time, then productivity is improved, but odor increases due to VOC generation
Solution Approach 1:
The invention changes the chemical composition parameters of the catalyst from conventional VOC-generating types to a reactive amine catalyst that suppresses amine and styrene generation. This catalyst maintains high reaction efficiency for productivity while eliminating odor-causing VOC emissions through its unique chemical structure and reaction mechanism
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 composition enables the production of flexible polyurethane foam with reduced odor and improved curability, ensuring uniform reaction and defect-free formation, even in complex molds, while maintaining comfort and durability.
Implementation Method 1
a reactive amine catalyst (B) that is a compound having one or more amino groups and one or more hydroxyl groups
Implementation Method 2
the silicone foam stabilizer (D) comprises a silicone (D1) with a surface tension of 22 mN/m or more, and a silicone (D2) with a surface tension of less than 22 mN/m
Data Source
AI summary
A composition for a flexible polyurethane foam that enables manufacturing of a flexible polyurethane foam with reduced odor and excellent curability is provided. The composition for a flexible polyurethane foam contains a polyether polyol (A), a reactive amine catalyst (B) with one or more amino groups and one or more hydroxyl groups, a non-reactive amine catalyst (C) with one or more amino groups and no hydroxyl group, and a silicone foam stabilizer (D), wherein, when the total amount of polyol components without amino groups is considered to be 100 parts by mass, the content of the reactive amine catalyst (B) is 0.01 to 1.3 parts by mass, the non-reactive amine catalyst (C) is 0.01 to 0.20 parts by mass, the silicone foam stabilizer (D) is 0.2 to 1.5 parts by mass, and the silicone foam stabilizer (D) contains two types of silicones (D1 and D2) with different surface tensions.