PU Foam Composition for Shape Recovery After Extended Compression
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Solution Overview
Problem
Shaped PU foam articles, such as mattresses, are prone to material fatigue and fail to recover their original dimensions after compression due to the high forces required for storage and transport, leading to inefficient packaging and potential damage.
Innovation Solution
The production of PU foam articles involves the use of specific compounds of formulae (1a) and (1b) during the reaction of polyol and isocyanate components, enhancing the foam's ability to recover its original shape after extended compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If shaped PU foam articles are compressed for storage and transport, then space efficiency is improved, but the foam material suffers from material fatigue and fails to recover its original dimensions
Solution Approach 1:
The patent modifies the chemical composition parameters of the PU foam by incorporating specific compounds (formulae 1a and 1b) with reactive functionalities that interact with the polyurethane matrix. This changes the material's physical properties to enhance its ability to recover from compression while maintaining durability, directly addressing the contradiction between compression efficiency and recovery reliability
2Productivity
If high compression forces are applied to flatten mattresses for rolling, then packaging efficiency is improved, but the foam material experiences material fatigue and potential damage
Solution Approach 1:
The patent applies beforehand cushioning by incorporating compounds that preemptively strengthen the foam's cellular structure and matrix bonds before compression occurs. The reactive groups in formulae 1a and 1b create additional crosslinking that acts as a cushion against the damaging effects of high compression forces, allowing efficient packaging without compromising material strength
3Volume of stationary object
If extended compression is applied for vacuum packaging, then space utilization is improved, but the foam's ability to recover original shape deteriorates
Solution Approach 1:
The patent creates a composite material system by combining the base PU foam with compounds of formulae 1a and 1b that have complementary properties. The reactive functionalities in these compounds work synergistically with the PU matrix to create a composite structure that maintains shape recovery capability even after extended compression periods, resolving the contradiction between reduced packaged volume and shape recovery
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 foam articles can regain their original shape within 20 hours post-compression, with low amine emissions and compliance with environmental emission standards, ensuring effective storage and transport without material fatigue.
Implementation Method 1
the polyurethane foam has been obtained by reaction of at least one polyol component and at least one isocyanate component
Implementation Method 2
capable of recovering their original dimensions... well-suited to recover their original shape after compression over a period of at least 20 hours
Data Source
AI summary
Shaped PU foam articles, preferably mattresses and/or cushions, wherein the polyurethane foam has been obtained by reaction of 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.