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What is polyurethane foam (PU FOAM)?
(Soft polyurethane foam or semi-rigid)

(1) polyurethane
Short commonly PU is any polymer consisting of a chain of organic units joined by urethane links. Polyurethane polymers are formed by the reaction of a monomer containing at least two isocyanate functional groups with another monomer containing at least two alcohol groups in the presence of a catalyst. Polyurethane formulations cover a wide range of stiffness, hardness and density. These materials are low density foam hose used in upholstery and bedding of low density rigid foam used for insulation heat, soft solid elastomers used for gel pads and rollers, hard plastic cups and rigid structural elements constituting and electronic instruments. Polyurethanes are widely used in the foam seat high strength, flexible panels, rigid insulation foam, microcellular foam seals and gaskets, durable elastomeric wheels and tires, electrical potting compounds, adhesives and sealants for high performance, spandex fibers, seals, reinforcing carpets and pieces of hard plastic. Polyurethane products are often called "urethanes". Not to be confused with the specific substance urethane, also known as ethyl carbamate. Polyurethanes are not produced from ethyl carbamate, nor do they contain.

Upholstery is the work of providing furniture, especially seats with padding, springs, webbing, and fabric or leather. The word "upholstery" comes from words and East Holden, ie to remember. The term applies to furniture household and also for applications in automobiles and boats. A person who works with upholstery is called an upholsterer, upholsterer Learning is sometimes called foreign or the mower.

Polyurethane products have many uses. More than three-quarters of global products is cell polyurethane flexible and rigid types are more or less equal to the size of the market. In both cases, the foam is usually behind other materials: flexible foams are behind upholstery fabrics commercial and domestic furniture, rigid foams are inside the metal and plastic walls of most refrigerators and freezers, or behind paper, metals and other surface materials in the case of thermal insulation panels in the construction sector. Its use in garments is growing: for example, in the vessel walls bras. Polyurethane is also used for moldings which include door frames, columns, balustrades, window lintels, pediments, medallions and rosettes.

The precursors of expanding polyurethane foam are available in many forms, for use in insulation, sound insulation, flotation, coating industrial packaging materials, and even distribution of filler there. From that adhere to most surfaces and automatically fill in the gaps, they have become very popular in these applications.

Chemistry
Polyurethanes are the reaction class of compounds called polymers, which include epoxies, unsaturated polyester and phenolic compounds. A urethane linkage is produced by the reaction of an isocyanate group,-N = C = O with a hydroxyl (alcohol) group,-OH. Polyurethanes are produced by the polyaddition reaction of polyisocyanate with a polyalcohol (polyol) in the presence of a catalyst and other additives. In this case, a polyisocyanate is a molecule with two or more functional isocyanates R-(N = C = O) n ≥ 2 and a polyol is a molecule with two or more hydroxyl, R '(OH) n ≥ 2. The reaction product is a polymer containing urethane ratio, RNHCOOR. " Isocyanates react with a molecule containing an active hydrogen. It is important, isocyanates react with water to form a bond of urea and carbon dioxide gas also reacts with polyester to form polyureas. Commercially, polyurethanes are produced by reaction a liquid isocyanate with a liquid mixture of polyol, catalysts and other additives. These two elements are considered a polyurethane system, or simply a system. Isocyanate commonly known in North America as a "side" or simply "iso." The mixture of polyols and other additives commonly called the "side B "or" poly ". This mixture can also be called a" resin "or" resin mixture. In Europe, the meaning of "side by side B are reversed. Mixture of resin additives may include chain extenders, crosslinkers, surfactants, flame retardants, foaming agents, pigments and fillers.

The first essential component of a polyurethane polymer is the isocyanate. Molecules containing two isocyanate groups are called diisocyanates. These molecules are called monomers or monomer units, and used to produce polymeric isocyanates that contain three or more isocyanate functions. aromatic isocyanates can be classified as diisocyanate diphenylmethane (MDI) or toluene diisocyanate (TDI) or hexamethylene diisocyanate aliphatic (HDI) or isophorone diisocyanate (IPDI). An example of a polymeric isocyanate polymeric diphenylmethane diisocyanate is, a mixture of molecules with two, three, four or more isocyanate groups, with an average functionality of 2.7. Isocyanates yet can be changed in part the reaction of a polyol to form a prepolymer. A quasi-prepolymer is formed when the stoichiometric isocyanate to hydroxyl groups is greater than 2:1. A true prepolymer is formed when the stoichiometric ratio is 2:1. Isocyanates are the key features of its molecular skeleton,% NCO content, functionality, and viscosity.

The second essential element of a polyurethane polymer is the polyol. Molecules containing two hydroxyl groups are called diols the three hydroxyl groups are called triols, and so on. In practice, polyols are distinguished from short chain and low molecular weight glycol chain extender and crosslinking, such as ethylene glycol (EG), 1.4-butanediol (BDO), diethylene glycol (DEG), glycerine and trimethylolpropane (TMP). Polyols are polymers your account. They are formed by free radical addition of propylene oxide (PO), ethylene oxide (EO), a hydroxyl or amine containing initiator, or by esterification a di-acid and adipic acid with glycols such as ethylene glycol or dipropylene glycol (DPG). Polyols extended with PO and EO are polyether polyols. The polyols are polyols polyester formed by esterification. The choice of initiator, the length and molecular weight polyol greatly affect its physical condition and properties polyurethane polymer physical. Important characteristics of polyols are their molecular backbone, initiator, primary hydroxyl groups% molecular weight, functionality and viscosity.
reaction mechanism catalyzed by an amine of higher carbon dioxide gas formed by central water and isocyanate answer
The reaction polymerization is catalyzed by tertiary amines such as dimethyl cyclohexylamine, and organometallic salts as dilaurate. In addition, catalysts can be selected according whether they favor the urethane (gel) reaction, as diazobicyclooctane, or urea (blow) reaction, such as bis-dimethylaminoethylether, or more precisely the isocyanate trimerization reaction unit, such as potassium octoate.

One of the most desirable attributes of polyurethanes is their ability to transform into foam. Agents expansion like water, some halocarbons such as HFC-245 bis (1,1,1,3,3-Pentafluoropropane) and HFC-134a (1,1,1,2 tetrafluoroethane) and hydrocarbons such as n-pentane, can incorporated into poly side or added as auxiliary power. Water reacts with isocyanate to create carbon dioxide, which fills and expands cells created during the mixing process. The reaction is a three-step process. A water molecule reacts with an isocyanate group to form a carbamic acid. carbamic acids are unstable and decompose to form carbon dioxide and an amine. The amine reacts with more isocyanate to give a substituted urea. Water has a very low molecular weight, so even though the percentage by weight of water may be low, the molar ratio of water can be high and produces large quantities of urea. Urea is not very soluble in the reaction mixture and tends to be different "hard segment phase mainly consisting of polyurea. The concentration and organization, these polyurea phases can have a significant impact on properties of polyurethane foam. [11] Halocarbons and hydrocarbons are chosen as their boiling points at or near room temperature. Since the reaction polymerization is exothermic, these blowing agents volatilize into a gas during the reaction process. Fill and expand the extracellular polymeric matrix, creating of foam. Importantly, no cell gas explosion creates a foam. Rather, it formed during the mixing process of nucleation sites that blowing gas filled and expands. Indeed, microcellular foams, high density can be formed without the addition of blowing agents or by mechanical means polyester foam nucleation before use.

(2) The use of polyurethane

1. Furniture
2. car seats
3. Varnish
4. Rugs
5. Glue
6. Wheels
7. Casas, sculptures and decorations
8. Jetski
9. construction sealants and firewall
10. Tennis handles
11. Electronic Components
12. Industry binding
13. See packing tape

1.Furniture

Polyurethane is also used in the manufacture of furniture casting soft edges around the tables and the panel are elegant, very durable and prevent injury. They are used in school tables, hospital furniture and windows of banks and a shop and displays.

Much of the foam used in chairs, sofas, mattresses and sacks of Commodus is polyurethane foam. This type of foam is formed by the mixture of polyols, diisocyanates, catalysts, foaming agents and other additives and allow the resulting foam to rise freely. This can be done in a discontinuous process relatively small blocks of foam are made in a top open mold, or continuously, where the components are paid on a treadmill incline. The foam is then cut to the desired shape and size for use in the manufacture of furniture.

Safety concerns flammability of polyurethane foam, especially upholstered furniture, sometimes requires the addition of flame retardants in the foam.

Polyurethane is in other countries like the Netherlands use as a soil solution for homes, offices, museums.

2. Automotive seats
flexible polyurethane flexible foams and semi-are widely used for automotive interior components, seats, headrests, arms, headliners and dashboards

Polyurethane foam in the bottom half of the mold in which it was made. Once mounted on a seat car, the foam makes the back seat. The match in front of the seat is back on the surface of the foam in the mold upside down. The two holes in the foam at the top of the image are the messages of support for the head.

The foam after removing the mold.

Polyurethanes are used for car seats significantly. The seat manufacturer has a mold for each seat model. Mold is a resealable clamshell-type structure that will allow rapid conversion of the pad, flexible molded foam call, which is then filled following the withdrawal of the mold.

You can combine these two steps, called tissue foam in-situ directly or molding. In this case, the inner surfaces of the hundreds of small holes molds that are connected to a vacuum manifold. This creates a constant air flow mold base in the collector. The operator places all first complete, fully assembled seat cover mold and adjust the manifold vacuum pulls the seat cover firmly against the mold surface. In some operations, this effect is greater by the addition of a thin plastic film and flexible as a fabric to help keep the vacuum to work more efficiently. When the cover is in place, the operator is placed Seat the metal structure in the mold and the mold is closed. At this point the mold contains what could be perceived as an "empty chair", a fabric Seat maintained in proper position on the manifold vacuum space that contains a hollow steel structure in place.

The next step is to inject the mixture polyurethane chemicals in the mold cavity. It is a mixture of two parts that is exactly measured by a mixing head. Then the mold is maintained at a temperature preset reaction until the chemical mixture has foam fills the mold to form stable foam soft. The time required is two to three minutes, depending on the size the seat and the precise formulation and operating conditions. Then the mold is usually opened slightly for a minute or two for additional curing time before that is fully upholstered seat has been removed. The operator then releases any excess fabric seat cover and laid siege ended in a conveyor belt.

3 Varnish

Polyurethane materials are commonly formulated as paints and varnishes for finishing layers of protection or stamp of wood. This results in use in a hard and tough abrasion resistant coating and is popular for hardwood floors, but considered by some to be difficult or unsuitable for finishing furniture or other detailed elements. Compared with oil varnish or shellac, polyurethane varnish forms a film that is difficult to laminate if subjected to heat or shock, rupture of the film and leave white spots. This tendency is increased when applied to soft woods like pine. This is also partly due to a penetration rate polyurethane low in the forest. Various techniques are used to start to overcome this problem, including the use of certain oil varnishes, specified "dewaxed" epoxy shellac, clear penetrating, or "oil-modified" polyurethane designed for this purpose. Polyurethane varnish may also lack the "hand-rubbed" drying oil sheen as linseed oil or tung, on the other hand, however, is capable of much faster and "construction" of the film, completion of two layers This may require several applications of oil. Polyurethane can also be applied to a straight oil finish, but because relatively slow curing time oils, the presence of volatile byproducts of curing, and the need for oil prolonged exposure to oxygen, care must be taken that the oils are what healed sufficiently to accept the polyurethane.

Unlike drying oils and alkyd harden after evaporation of the solvent, the reaction with oxygen in the air, polyurethane coatings cure after evaporation of the solvent by a variety of chemical reactions in the original mixture, or by reacting with moisture in the air. Some products are "hybrids" and combine the different aspects of the components of their parents. Oil modified "polyurethanes if the source of water or solvent based finishes are currently the most commonly used wood flooring.

external use of polyurethane varnish may be problematic due to susceptibility to degradation by ultraviolet light exposure. It should be noted, however, that all clear or translucent coating layers of film polymer (iepaint, stain, epoxy, synthetic plastic, etc) are susceptible to this damage in varying degrees. Pigments in paints and stains to protect against UV rays, while UV absorbers are added to polyurethane and other varnishes (in particular, Spar varnish) to combat the damage of UV rays. Polyurethanes are generally more resistant to exposure to water, high humidity, extreme temperatures, and fungi or molds, which also adversely affect varnish and paint performance.

t 4.Computer
Polyurethane is used in the bottom of mouse pads.

5.Glue
Polyurethane is used as an adhesive, especially as a wood glue. Its main advantage over more traditional wood glues is its water resistance. It was introduced in the General Market in North America Gorilla Glue and Excel 1990, but used much longer in Europe.

6.Wheels
The Polyurethane is also used in tire manufacturing solid. skate skating has become modern and accessible introduction to the highest standards, abrasion resistant polyurethane parts. Other constructions have been developed for tires, and microcellular foam variants are widely used in tires on wheelchairs, bicycles and other applications. These latter types of foam also are commonly found on the steering wheel and other interior and exterior car parts, including bumpers and fenders.

7.Houses, sculptures and decorations
The walls and ceiling (not just the insulation) to the futuristic Xanadu House were built in polyurethane foam. Vaulted ceilings and other odd shapes are easier to do with the foam timber. Foam was used to construct buildings so strange statues and decorations Seuss Landing section of theme park islands adventure. Specialty rigid foam that makes the sale replace wooden sign engraved on 3D topography and industries.

8.Watercraft
Some tables surf are made with a solid polyurethane core. A rigid foam blank is shaped, tailored to the specifications, then covered with fiberglass cloth and polyester resin.

Boston Whaler hull is made of polyurethane foam sandwich boat in a fiberglass skin. The foam provides strength, buoyancy and sound insulation.

Sealants and fire 9.Construction

Chef-du-Mur Firewalls common: the pervasive presence demonstrates the need for compatibility operational and testing of fire between the sealant and mechanical / electrical penetrations. In other words, it is easier to insist on the use of fire also Commons can be used for penetration seals, if it penetrates the body can be handled by mechanical and electrical trades without wanting the annulment of the resistance fire wall, endangering the fire plan in place to ensure a building.

Chief Fire the common wall so permeated by electric utilities and mechanical, which demonstrates the need for interoperability and testing of fire between fire and penetrating joint system, whether electrical, mechanical or structural.

Polyurethane sealants are available in 1, 2 or even 3 part systems, or cartridge, a bucket or drum format. polyurethane sealants are also sold for firewall applications. Obviously, the sealant by itself provides no serious hindrance to fire their links easily keep burning oil. However, when the support of an inorganic insulation such as rock wool or ceramic fiber, can act as an effective seal to counteract the flue and upstream passage, especially in the joints inorganic. It is advisable to avoid direct contact with sharp and penetrating metal-wire, the heat carried by the penetration to prevent its closure. This, however, requires great vigilance. On the boards of concrete masonry or concrete, however, they are free of mechanical or penetrating power, which works well and reliably. Like all products of passive fire protection, the key to compliance with the code selection is demonstrable.

10.Tennis Grips
Polyurethane is used to make several Tennis Overgrips as Supergrap Yonex, Wilson Pro Overgrip and deals with many others. These drivers are very scalable to ensure adherence wraps snugly around the racket handle.

11.Electronic Components
Often electronic components are protected of environmental influences and impact by enclosing them in polyurethane. Typically polyurethanes are selected for resistance to abrasion, good electrical properties, excellent adhesion, impact resistance and low temperature flexibility. The disadvantage of polyurethanes is limited upper service temperature (usually 250 ° F (121 ° C)). In the production of electronics manufacturing is the purchase of a two-component polyurethane (resin and catalyst) is mixed and poured the entire circuit (See resin molding). In most cases, the entire circuit board would be irreparable after final cured urethane. Due to their physical properties and low cost polyurethane encapsulation (potting soil) is a popular choice in the construction sector racetracks and sensors.

Industry 12.Bookbinding
On the way to a new and better glue for bookbinders, a new adhesive system was first introduced in 1985. The basis of this system is polyether or polyester, while that of polyurethane (PUR) is used as prepolymer. Its uniqueness is the coagulation temperature and reaction to moisture.

1 st generation (1988 the drupa) – Lower starting strength – high viscosity – Drying time over 3 days

2 nd generation (1996 to the drupa) – Low starting solidity – high viscosity – Drying time of less than 3 days

3 rd Generation (2000 at the drupa) – Good Output – low viscosity – Drying time between 6 and 16 hours

4 th generation (current) – good, solid start – Very low viscosity – Drying time is reached in a few seconds because of dual core systems

Advantages of polyurethane glue in the bindery: PUR is the real demand of the merger and cold glue. Due to lack of moisture in the glue, paper in the wrong direction of grain can be treated without problems. Even the printed supercalandered can be linked without problems. It is the cheapest with cement application the theory of thickness of 0.01 mm. But in reality it is not possible to apply less than 0.03 mm. Polyurethane glue is very resistant and stable at temperatures of -40 ° C to 100 ° C.

13.Watch packing tape
Polyurethane is used as a black container to watch in the main material, usually stainless steel. It is used for convenience style and durability.

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