Shaped flexible PU foam articles
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Solution Overview
Problem
Shaped flexible polyurethane foam articles, such as mattresses, face challenges in recovering their original dimensions after compression due to material fatigue caused by the high forces required for storage and transport, leading to prolonged compression periods.
Innovation Solution
Incorporating organic esters into the production of flexible polyurethane foams, which catalyze isocyanate-polyol reactions and improve dimension recovery, while also reducing volatile organic compound emissions, allowing the foams to regain their shape over extended periods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If shaped flexible PU foam articles are compressed for storage and transport, then space is saved, but material fatigue occurs and dimension recovery capability deteriorates
Solution Approach 1:
The patent modifies the chemical composition parameters of the PU foam by incorporating specific organic esters (isopropyl myristate, isopropyl palmitate, isopropyl stearate) as additives in controlled amounts (0.1-10 wt%). This changes the material's viscoelastic properties, enabling it to withstand compression forces (40,000-250,000 N) during storage and transport while maintaining the ability to recover its original dimensions after compression, thus resolving the contradiction between volume reduction and reliability preservation
2Productivity
If compression forces are applied to flatten mattresses for rolling, then transport efficiency is improved, but the force required (4-25 tons) causes material fatigue
Solution Approach 1:
The patent creates a composite material system by combining traditional PU foam components (polyol, isocyanate, blowing agent, catalyst) with specific organic ester additives. This composite formulation enhances the material's structural strength and fatigue resistance, allowing it to withstand the high compression forces (4-25 tons) required for efficient rolling and transport while maintaining integrity and recovery capability
3Loss of time
If extended compression periods are used for vacuum packaging, then shipping costs are reduced, but shape recovery time increases to at least 20 hours
Solution Approach 1:
The organic ester additives perform a preliminary action during the foam formation process by modifying the polymer matrix structure and cell morphology. This preliminary modification enables the foam to maintain its compressed form stably during extended shipping periods while pre-configuring the material's recovery mechanism, allowing it to rapidly regain its original shape (within 20 hours or less) once unpacked, thus resolving the contradiction between shipping time optimization and recovery time minimization
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 use of organic esters in polyurethane foam production enhances the ability of shaped flexible foam articles to recover their original dimensions after compression, meeting low emission standards and ensuring effective shape recovery over 20 hours or more, particularly after vacuum packaging.
Implementation Method 1
the flexible PU 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 blowing agent and one or more catalysts that catalyse the isocyanate-polyol and/or isocyanate-water reactions and/or isocyanate trimerization and further additives, wherein the additives comprise organic esters
Implementation Method 2
reaction of at least one polyol component and at least one isocyanate component
Implementation Method 3
reaction of at least one polyol component and at least one isocyanate component in the presence of at least one blowing agent
Data Source
AI summary
What are described are shaped flexible PU foam articles, preferably mattresses and/or cushions, wherein the flexible 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 blowing agent and one or more catalysts that catalyse the isocyanate-polyol and/or isocyanate-water reactions and/or isocyanate trimerization and further additives, characterized in that the additives comprise organic esters.