Production of porous polyurethane layers
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Solution Overview
Problem
The production of high-quality porous polyurethane layers is challenging due to the need for balancing material flow and cell stabilization, while also reducing volatile organic compound emissions, which existing methods fail to achieve effectively.
Innovation Solution
The use of silicon-containing compounds with a specific formula, which simultaneously stabilize cells and improve the flow of the reaction mixture, enabling the production of uniformly structured and fine-cell porous polyurethane layers with low emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional siloxanes are used as stabilizers in foamed layers, then cell coalescence is prevented, but material flow and leveling properties are not improved
Solution Approach 1:
The silicon-containing compound of formula (1) performs multiple functions simultaneously: it stabilizes foam cells during the foaming process while also improving the leveling properties and flow behavior of the reaction mixture. This multi-functionality eliminates the need for separate stabilizer and flow improver additives, resolving the contradiction between cell stabilization and material flow.
Solution Approach 2:
The patent changes the molecular structure parameters of the siloxane by introducing specific polyether side chains with controlled molecular weights (1000-5000 g/mol) and composition (at least 60% oxyethylene units). These parameter changes enable the compound to exhibit both stabilizing and flow-improving properties, unlike conventional siloxanes that only stabilize cells.
2Object-generated harmful factors
If high-solid processes are used, then VOC emissions are reduced, but material flow and cell stabilization become more difficult to balance
Solution Approach 1:
The silicon-containing compound acts as an intermediary substance that mediates between the conflicting requirements of high-solid processes. It enables the reaction mixture to maintain both low viscosity for good flow and sufficient stability for uniform cell formation, even at high solids contents where these properties are normally difficult to balance.
Solution Approach 2:
The invention uses a composite silicon-containing compound combining siloxane backbone with polyether side chains. This composite structure provides both the stabilizing function of siloxanes and the flow-improving properties of polyethers, enabling successful high-solid foaming processes with uniform cell structures.
3Stability of the object's composition
If conventional stabilizers are used to prevent cell coalescence, then foam stability is improved, but uniformly structured fine-cell porous layers are not achieved
Solution Approach 1:
The silicon-containing compound provides different functional properties at different molecular levels: the siloxane backbone provides bulk foam stability while the polyether side chains provide local flow improvement and cell size control. This local quality differentiation enables both foam stability and uniform fine-cell structure to be achieved simultaneously.
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
This approach allows for the production of high-quality, uniformly structured, and low-emission porous polyurethane layers, addressing the challenges of material flow and cell stabilization, and meeting stringent emission standards.
Implementation Method 1
the use of silicon-containing compounds of the formula (1) in the production of porous polyurethane layers enables the aforementioned problem to be solved... the stabilization of the cells so that uniformly structured and in particular fine-cell porous layers are produced
Implementation Method 2
the use of silicon-containing compounds of the formula (1) in the production of porous polyurethane layers enables the aforementioned problem to be solved... good flow of the reaction mixture... can be guaranteed during the production of the layers in question
Data Source
AI summary
It is the use of certain silicon-containing compounds in the production of porous polyurethane layers to improve the leveling properties of the reaction mass reacting to the polyurethane layer and/or to optimize the cells of the resulting polyurethane layer, preferably to homogenize the cell structure over the entire resulting polyurethane layer, in particular in the context of artificial leather or foam film production described. The silicon-containing compounds satisfy the following formula: