Allied Develops Extra-Soft Foams - C&EN Global Enterprise (ACS

Nov 6, 2010 - Allied Develops Extra-Soft Foams. Urethane foam formulated with new Allied polyether holds physical properties and hydrolytic stability...
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Allied Develops Extra-Soft Foams Urethane foam formulated with new Allied polyether holds physical properties and hydrolytic stability Latest .development in flexible ure­ thane foams is a new extra-soft grade developed by Allied Chemical's Na­ tional Aniline Division (C&EN, May 28, page 4 7 ) . The foam is softer than conventional foams of the same den­ sity: Only about one third the force is needed to produce a 25% deflection. Yet it retains good physical properties and hydrolytic stability, the firm says. It falls under the "extra-super-soft" des­ ignation of the Society of the Plastics Industry. It's based on a low molecu­ lar weight, high hydroxyl number poly­ ether. Allied feels that the new foam is ideal for such products as bed and throw pillows, blankets, comforts, backs for automotive seats, textile laminates, and chair arms and backs. The firm figures that the new foam is a good bet to quickly capture 10% of the total flexible foam market. And it looks for the share to climb eventu­ ally to about 2 5 % . Standard flexible foams will hit about 125 million lb. this

year and should increase about 20 mil­ lion lb. a year for the next several years, climbing to about 220 million lb. yearly by 1966, according to Na­ tional Aniline's market research de­ partment. In addition to this, t h e division sees a market opportunity for the new extra-super-soft foam of 60 million lb. a year by 1966. Key to the foam is a new Allied polyether called Actol 32-160 triol-a polyoxypropylene triol having a mo­ lecular weight of about 1000 and a hydroxyl number of about 160 mg. KOH per gram. Conventional foams —such as Allied's Actol 31-56 triol, for example, are based on polyethers with a molecular weight of about 3000 and a hydroxyl number of 40 to 70. According to Allied, the main vari­ ables controlling physical properties of a foam are cross-link density, ratio of urea to urethane groups, and toluene diisocyanate index ( ratio of isocyanate groups to active hydrogens). Cross­ link density in turn is determined

mainly by equivalent weight and functionality of the polyether. A secondary factor is number of branching reactions forming such groups as biurets, allophanates, and isocyanate trimers. To produce a soft foam, these factors should be kept as low as possible while still keeping a stable foam. It's possible to formulate somewhat softer foams using conventional polyethers with hydroxyl numbers in the 40 to 70 range by lowering the TDI index, dropping the urea/urethane ratio, or adding a fluorocarbon blowing agent. But these methods are of limited value, Allied says. When the TDI index drops much below 1, foam quality falls rapidly. For hydrolytically stable foams, the minimum urea/ urethane ratio is 3. And blowing agents lower density and degrade some physical properties. But Allied has found that with a polyether having low molecular weight and high hydroxyl number, the urea/ urethane ratio can be dropped to 1.2 to 1.6 and the T D I index to about 0.7. This removes much of the foam's stiffness while retaining good physical properties. For example, the indentation load on a 4-in.-thick piece of extra-supersoft foam having a density of 1.6 lb. per cu. ft. is 11 lb. for 2 5 % deflection. This is a standard ASTM test. The load for a conventional foam of the same density is about 35 lb. Adding 20 parts of a fluorocarbon. like Genetron 11 per 100 parts of Actol 32-160 triol drops* the density of the extrasuper-soft foam to 1 lb. per cu. ft. and the 2 5 % indentation load to 5 lb., Allied says. On the surface, going to a low molecular weight polyether seems to be a move in the wrong direction, since it increases the number of cross-linking sites and thus raises the potential cross-link density, Allied says. But the low TDI index offsets this effect, the firm adds. Lowering the relative amount of TDI leaves some OH groups unreacted and dangling. This limits secondary branching reactions and cross-link density. Exactly why the system works the way it does isn't completely clear. Allied has a theory that does give a satisfactory picture, however. Trouble is, it's impossible to prove how much TDI reacts with the water to form urea linkages and how much reacts with polyether to form urethane linkages. At any rate, in conventional foam systems, there are barely enough cross-

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linkages to make a reasonable foam, Allied says. Subjecting such a foam to hydrolytic aging breaks a few crosslinks. But since there are barely enough, foam properties change substantially. Thus, the ratio of urea groups, which are more hydrolytically stable than urethane groups, must be kept high. In the new system, though, there are more urethane cross-links. Even when a few are broken, there are still enough others to maintain foam properties. So a high urea content and TDI index aren't required. To get foams with properties between conventional and the new soft grade, blends of polyols of hydroxyl numbers 56 and 160 can be made. TDI index and urea/urethane ratio would have to be suitably adjusted at the same time. Actol 32-160 triol costs about 2 cents a lb. more than Actol 31-56 triol. But since less TDI is needed, the over-all foam cost is about the same, Allied explains. The firm also makes Nacconate diisocyanates and Genetron fluorocarbon blowing agents for use in urethane foams. But Allied's National Aniline Division stresses that it's not in the foam business. It does conduct applications research on foams at its applications research laboratory, Buffalo, N.Y. The division has applied for a patent on the use of its new polyether in making the new foam.

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Polypropylene molding compound with built-in antistatic properties is com­ mercially available from Union Car­ bide Plastics Co., New York, N.Y. Ac­ cording to the company, the antistatic properties are a characteristic of the bulk material, protection is permanent and does not diminish with time as is the case with surface treatments. Called Bakélite JMD-4501, the new material was developed especially for appliance housings and housewares where the normal tendency of conventional polypropylene to retain static charges can produce unsightly results, Union Carbide adds. C 1

Insecticide formulation that combines the antiresistance of Antiresistant/ D D T with the rapid paralytic action of synergized pyrethrins has been developed by S. B. Penick & Co., New York, N.Y. Called Pramex, it has been granted label clearance by US DA for killing DDT-resistant houseflies and roaches that have developed resistance to chlorinated hydrocarbon insecticides. It also kills bedbugs, ants, and silverfish, the company says. C2

Depolymerized rubber is available from DPR, Inc., subsidiary of H. V. Hardman Co., Belleville, N.J. Called DPR, it is pure natural rubber reduced to a flowable form, available in low and high viscosity grades. Intermediate grades of fluidity can be obtained by blending. DPR and its compounds are used in three basic forms—uncured, soft rubber, and hard rubber. C3

New thermosetting resin is being introduced by Freeman Chemical Corp., Port Washington, Wis. Called Nypol, the resins are extremely resistant to heat, solvents, and chemicals, the company says. They are compatible and copolymerize readily with a wide range of unsaturated materials. Freeman recommends them for prepreg, pre-mix, and filament winding and molding applications. C4

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