PU Hot-Curing Flexible Foam Composition for Compression Set Recovery
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Solution Overview
Problem
PU hot-curing flexible foam moldings, such as mattresses, experience material fatigue and fail to regain their original dimensions after prolonged compression due to the high forces required for storage and transport, leading to bulkiness and space inefficiency.
Innovation Solution
The production of PU hot-curing flexible foam involves reacting a polyol component and an isocyanate component in the presence of specific compounds of formulas (1a) and (1b), along with a blowing agent and catalyst, to enhance dimensional recovery and reduce material fatigue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If PU hot-curing flexible foam moldings are compressed for storage and transport to save space, then volume is reduced, but material fatigue occurs and the foam fails to regain its original dimensions
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition parameters of the foam - specifically using polyether siloxane compounds with controlled molecular weights and structures (formulas 1a and 1b) to change the viscoelastic properties of the foam, enabling it to withstand compression and recover its dimensions after prolonged compression periods
Solution Approach 2:
The patent uses composite materials by incorporating polyether siloxane compounds (formulas 1a and 1b) into the polyurethane foam matrix. These siloxane compounds act as modifiers that enhance the foam's ability to resist compression set and maintain dimensional recovery, creating a composite foam system with superior mechanical properties
2Ease of manufacture
If high compression forces (40,000 to 250,000 Newtons) are applied to flatten the mattress for rolling, then compressibility is improved, but material fatigue increases
Solution Approach 1:
The patent applies beforehand cushioning by incorporating polyether siloxane compounds into the foam structure prior to compression. These compounds provide internal cushioning and energy dissipation mechanisms that protect the foam matrix from damage during high-force compression, allowing the foam to be compressed for shipping while maintaining its strength and fatigue resistance
3Stability of the object's composition
If conventional foam stabilizers are used, then foam stability is achieved, but emissions of low-molecular-weight linear and cyclic siloxanes increase
Solution Approach 1:
The patent applies local quality by carefully selecting siloxane compounds with specific molecular weight ranges and structures (formulas 1a and 1b) that provide foam stability locally within the polymer matrix without generating harmful emissions. The controlled structure of these siloxanes ensures they remain bound in the foam network rather than volatilizing, achieving both stability and low emissions
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 regains its original shape effectively after compression, maintaining structural integrity and reducing emissions of low-molecular-weight siloxanes, meeting low-emission standards like CertiPur, and ensuring rapid expansion from compressed states.
Implementation Method 1
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 and at least one catalyst
Implementation Method 2
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
Implementation Method 3
the PU hot-curing flexible foam molded body, preferably a mattress and/or pillow, wherein the PU hot-curing flexible foam was obtained by reacting... which are well suited to regaining their original shape after compression over a period of at least 20 hours
Data Source
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AI summary
PU hot-dip ductile foam molded bodies, preferably mattresses and/or pillows, wherein the polyurethane hot-dip ductile 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 and at least one catalyst, are described.