Technical Papers

Below are abstracts of technical papers presented at the Polyurethane Foam Association Technical Sessions. Papers are prepared from materials submitted for the Technical Proceedings with the permission of the individual authors who are solely responsible for their content. The content has not been subjected to peer review. The PFA does not endorse or recommend the proprietary products or processes of any manufacturer. The PFA assumes no responsibility for the accuracy or use of the information presented.

Beginning in 2005, The Herman Stone Family Foundation endowed an award program for each Technical Proceeding Session where a minimum number of papers were presented, allowing the audience to vote on the best presentation. The winners of The Herman Stone Technical Excellence Award are identified in the abstracts below.

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    Abstracts 2010-Current                       Abstracts 2000-2009                  Abstracts 1991-1999

    Proceedings of the Polyurethane Foam Association Technical Program
    November 2023, Toronto, Ontario

    F23001 Improving the Sustainability of Polyurethanes in Automobiles. Damir Andrasek, EUROPUR.

    Polyurethane is the second most used plastic (by weight) in motor vehicles, and current projections point toward even wider use in automotive applications in the future. While polyurethane as a material is recyclable, one of the challenges associated with PU parts from vehicles is the fact that they are difficult to reuse or recycle with current design and waste treatment technologies.  European regulators have taken note of the relatively low rate of recycling of plastics in the automotive industry.  In July, the European Commission published on its proposal for the revision of the End-of-Life Vehicles Directive. The proposed legislation contemplates a vast transition of the automotive sector to a circular economy, considering all life-stages of vehicles, from design, production, distribution to EOL strategies.

    In a 2023 report, EURO-MOULDERS acknowledges such regulatory developments and assesses strategies to improve the sustainability of polyurethane in the auto sector. Based on primary and secondary research, three main opportunities have been identified. These are: (1) enhancing recycling of the material; (2) substituting some of the fossil-fuel-based precursors to polyurethane; and (3) incorporating environmental considerations in vehicle design.  Scaling these solutions will require a whole-of-value-chain approach and contribution from all the stakeholders along the polyurethane value chain.

    F23003 Sustainable PU Flexible Foams: Utilizing Renewable Materials from Biomass and Soy. Enoch Aquah, Kevin Dunne, Bher Anibal, Wanwarang Limsukon, Rafael Auras, and Mojgan Nejad, Michigan State University.

    This talk is focused on increasing the biobased carbon content of PU foams using a mixture of soy and lignin polyols without compromising performance. Lignin accounts for one-third of the dry mass of plants and is widely available through pulping and biorefinery processes. The flexible foam samples were prepared by replacing 10-50% fossil fuel-based polyols with different amounts of soy and lignin polyols. The developed biobased foams were analyzed by measuring their densities, tensile strengths, ultimate elongations, tear strengths, compression force deflections, support factors, biobased carbon content, and biodegradability. Our results showed the foams made by replacing up to 40% commercial polyol met all the requirements for automotive seating applications, and the biobased portion of foams was degraded in thermophilic composting conditions (58°C) in less than three months.

    F23005 Optimizing Slabstock Production And Quality, And Minimizing Waste Through A Modeling, Simulaton, Measurement, Reporting, And Tracking Platform. Angel Vinas, General Manager and Co-Owner, IPF, Bizkaia, Spain.

    Inefficiencies in the production, handling, transformation and management of end-of-life (EOL) of polyurethane foam can result in added costs and compromised sustainability.

    The Foamledge platform provides foam producers with tools to optimize efficiency throughout the process stretching from tank rooms, to foaming, block cutting, handling, transformation into products, and EOL fate. These features can be mixed and matched according to customer needs, or integrated into a comprehensive platform.

    • Manage your tank room, plan your foaming and forecast your use of raw materials. Link your foam results with the raw materials used.
    • Model and optimize your foaming process. Create and test formulas in a virtual environment.
    • Digitize your foam lab and connect it with your manufacturing process, to better understand and improve results.
    • Monitor the internal temperature of your foam blocks during curing. Includes alarm management and process analysis.
    • Measurement and weighing of foam blocks. Combines the most accurate block scanner (accuracy = 1 mm) and dynamic block weighing.
    • Create “foam passports,” which allow barcode tracking of foam throughout its lifecycle.

    Speaker Bio: Angel Vinas has served as General Manager of IPF since 2007. IPF has supplied handling and data management solutions for the FPF industry worldwide for more than 30 years. Angel holds a degree in mechanical engineering from the University of the Basque Country, Spain, and an MBA from the ESEUNE Business School. Before joining IPF, he worked in R&D for an engineering company serving the automotive industry.

    F23002 Chemical Upcycling of Commodity Thermoset Polyurethane Foams Toward High-Performance 3D Photo-Printing Resins. Tao Xie, State Key Laboratory of Chemical Engineering, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou, China

    Polyurethane thermosets are indispensable to modern life, but their widespread use has created end of life (EOL) environmental challenges. Here we report a highly efficient chemical strategy for upcycling thermoset polyurethane foams that yields products of higher economic values than the original material. Starting from a commodity foam, we show that the polyurethane network is chemically fragmented into a dissolvable mixture under mild conditions. We demonstrate that three-dimensional photo-printable resins with tunable material mechanical properties—which are superior to commercial high-performance counterparts—can be formulated with the addition of various network reforming additives. Our direct upcycling of commodity foams is economically attractive and can be implemented with ease, and the principle can be expanded to other commodity thermosets.

    F23004 Pathways to Circular Economy – A Co-created Vision By And For The Polyurethane Foam Industry. Mona Abadian (Ph.D Student at Virginia Tech) and Jennifer D. Russell, Ph.D. (Asst. Professor at Virginia Tech). Presenter: Jennifer D. Russell

    Diverse industries worldwide have begun to explore business models and value chain innovation opportunities tied to a circular economy (CE). However, CE engagement often requires the coordination of material and product flows across the value chain, which presents a significant challenge for individual companies to overcome independently. The polyurethane foam (PU foam) industry is no different: changing international regulations and consumer expectations are motivating PU foam value chain members to evaluate their strategic options.

    This presentation provides an update on a research project led by Dr. Russell and by Dr. Tim Long of Arizona State University, and involving a diverse group of stakeholders, including foam manufacturers, chemical suppliers, recyclers, academics and government. The project received funding from the National Science Foundation.

    To facilitate an organized and collaborative approach, this study utilized a workshop and semi-structured interviews focused on the potential for CE initiatives and priorities for the PU foam industry. Participant interactions and activities were structured according to the ABCD “backcasting” methodology:

    • Awareness and Defining Success (A);
    • Baselining the Current State (B);
    • Creative Solutions (C); and,
    • Decide on Priorities (D).

    First, (Steps A and B), individual participants attended a brief informational presentation on CE, and then used a digital collaboration tool to document personal responses to a series of questions regarding stakeholders, opportunities, and barriers related to CE for the PU foam value chain. In preassigned diverse groups, participants collaboratively developed visions and requirements of the future CE for each value chain stage, and related policy and research needs. Finally, (Step D), individuals and groups identified, ranked, and classified their preferred priorities into short- (up to 5-years), mid- (5 – 10 years), and long-term (>10 years) timelines. 

    Baseline activities surfaced common themes, most critically the interconnectedness, collaboration, and communication that CE requires of material value-chains. Participants were agreed on current-state constructive conditions, including consumer acceptance of recycled-content, proof-of-concept models (e.g., mechanical mattress recycling), and the feasibility of substituting biomaterials in place of primary feedstocks. Visioning activities revealed that CE transformation priorities (ranked as Top 3 by individuals and groups) were equally allocated across diverse value chain stakeholder groups. The majority of resulting co-created CE transition priorities were classified as short-term (within the next 5 years), including:

    • increased coordination between manufacturers, suppliers, and recyclers, to establish and communicate clear circular material specifications and requirements;
    • alternative applications for recycled-content feedstocks;
    • the use of product labelling requirements regarding end-of-life instructions (for consumers) and disassembly and recycling information (for recyclers); and,
    • collaborative research to understand the implications of chemical recycling for material properties, and the isolation and recovery of chemical recycling by-products.

    In the mid-term, the majority prioritized educating consumers about local circular economy options and offering incentives to encourage participation. The investment in, and development of markets for by-products of chemical recycling (e.g., urea, primary amines, isocyanates) was identified as a mid- to long-term priority. Co-created priorities, timelines, and coordination requirements are presented in the form of a strategic roadmap for the PU foam industry’s transition to CE. 

    Speaker Bio:  Dr. Russell works in the area of circular economy and sustainability, the flows of materials within economic consumption-production systems, and strategies for slowing and closing material loops.  As co-author of the UNEP International Resource Panel publication “Re-defining Value – The Manufacturing Revolution”, her background includes an emphasis on strategy for market transformation. Dr. Russell received her PhD degree from the Golisano Institute for Sustainability at the Rochester Institute of Technology. Prior to joining the department, the position she held was a lecturer in Sustainable Operations and Supply Chain, and Circular Value Chain, in the MBA in Sustainability program at Bard College. Prior to pursuing academia, Dr. Russell worked as an industry sustainability consultant for 10 years, for multi-national CPG clients based across North America and Europe.

    Dr. Russell’s research program is centered around the integration of, and opportunities for circular systems and practice for sustainable biomaterials. This work spans sustainable materials, applications in packaging and the built-environment, and circular practice including remanufacturing, refurbishment, repair, reuse, and recycling.

     

    F23006 Pump And Control Innovations To Optimize PU Foam Machines. Raphael Bretz, Hennecke Inc.

    The basic principles of flexible polyurethane foam production have changed little over the past decades. However, the wide variety of applications for foam demand high standards of quality and specific performance characteristics. There are substantial differences in the product required by the “comfort” segment for mattresses and furniture, on one hand, and the “technical foam” sourced for applications in the automotive industry. Sustainability goals like energy efficiency, raw material savings and more sustainable chemical precursors have also come into focus in recent years. Innovations in pump technology and control systems are two areas where suppliers to foam manufacturers are responding to these needs.

    In the last two years, Hennecke’s application experts have developed a new generation of pumps to be manufactured at the company’s site in Sankt Augustin, Germany. Hennecke’s HX series pump line is to be produced exclusively for polyurethane applications. Here, the focal point is on a precise, highly efficient, and future-fit metering line. 

    Hennecke’s FOAMWARE control system replaces the previous process data recording systems, NFLEX and PDE. Features include the high-performance hardware, diverse functions, intuitive user navigation, and a multitude of standard tools as well as useful plug-ins and additional options. The software offers a clear display of all relevant production data offering extensive calibration modules, and tank level monitoring. A noteworthy highlight is the ‘magic eye’ function, which recognizes and immediately presents metering deviations and irregularities during operation. Operators also benefit from a database module that stores information about the mixtures and chemicals and provides active support to adjust and create new formulations. A third-party interface is used to import and export the data and to connect to the customer’s own network or goods management system, or to communicate with SAP.

    Proceedings of the Polyurethane Foam Association Technical Program
    May 2023, St. Petersburg, FL

    S23001 Redeeming Carbon: CO2-Based Polyols for Polyurethane Applications, Liz Manning, Econic Technologies

    For heavy emission industries, like construction and chemicals, carbon capture and storage is a tool to offset emissions, but these technologies are typically expensive, do not generate value and cannot be implemented everywhere. Carbon capture and utilization, however, is significantly more attractive, especially when the transformation of CO2 adds value to existing industry. Econic’s proven technology enables polyol producers to do just this, today.

    Econic’s innovative catalyst technology allows captured waste CO2 to be used as a raw material for a range of polyols, replacing up to 50% of traditional oil-based feedstocks, in a low-energy, low-cost process. Here we present the particular properties of these CO2 containing polyols and their use in a range of polyurethane products, from slabstock and foam applications (such as mattresses, automotive seating and interior trims, furnishings, and insulation boards), and CASE applications (such as adhesives and coatings in the textiles arena).

    Econic’s technology offering three pillars of added value to the product and the industry:

    1. Economic: CO2 is an order of magnitude cheaper, and less volatile in price, than traditional oil-based feedstocks. Furthermore, Econic’s technology operates at low pressures and temperatures, so can be retrofitted onto existing manufacture assets, and means it has low-cost entry to market.
    2. Environmental: Our LCA concluded that for every ton of CO2 that is used as a raw material in polyol manufacture, a minimum of three additional tons of CO2 emissions are avoided.
    3. Performance: The CO2 content in the polyol can be selected to enhance the performance of polyurethane articles.

    In contrast to many ‘green’ chemical technologies, Econic’s offers a unique combination of economic, technical, and environmental performance benefits to industry and consumer.

    Speaker Biography:

    Liz Manning holds masters degree in both chemistry and business administration. She has worked in the chemical industry for 16 years, first with zirconium based chemistry for engineering materials and catalyst supports, then moving to a Unilever spin-out company; Catexel. Catexel’s technology was based on transition metal-based oxidation catalysts, aiming to replace harmful materials or allow existing processes to operate under more benign conditions. Liz joined the Econic team in 2022 to help accelerate the commercialization of their CO2 utilisation technology.

    S23003 Harmonizing Test Methods to Measure VOC Emissions from Polyurethane Foam used in Automotive Interiors, Furniture and Bedding, John Sebroski, Covestro

    This paper will discuss the status of harmonizing methods for measuring volatile organic compounds (VOC) emissions from polyurethane foams used in automotive interiors, furniture and bedding. Currently, there are several methods that describe how to measure emissions from materials including ASTM International, ISO, SAE International, automotive OEMs and certification programs such as CertiPUR-US®. However, these methods are often ambiguous and conflict with each other, which can cause confusion and increase the variability of the test results.

    The Molded Polyurethane Foam Industry Panel has been pursuing a “VOC Roadmap” to provide recommendations and define best practices for measuring VOC emissions from automotive interior flexible molded polyurethane seating foam. Several standards were collaboratively reviewed for consistency and sources of ambiguity that could bias the emission results. These data formed the foundation to begin developing a standard by the SAE VOC Committee, Work In Progress J3233, Harmonization of Test Methods to Measure VOCs from Polyurethane Foam used In Automotive Interior Cabins. The proposed industry standard will address the interests and requirements of OEMs and other stakeholders.

    CertiPUR-US® is a product certification program to demonstrate that flexible polyurethane foam meets standards for content, emissions, and durability. Its technical guidelines for emission testing reference several ISO standards including ISO 16000-6 Determination of organic compounds (VVOC, VOC, SVOC) in indoor and test chamber air by active sampling on sorbent tubes, thermal desorption and gas chromatography using MS or MS FID. This standard was revised in 2021 to allow the use of multi-sorbent tubes to improve the recovery of volatile organic compounds. The revised standard also provides several new options to calculate total volatile organic compounds (TVOC), which is a parameter required to pass the certification. The changes to the ISO standard will be discussed along with their potential impact to  the technical guidelines for measuring emissions for CertiPUR-US®.

    Speaker Biography:

    John Sebroski is Head of the Environmental Analytics group for Covestro LLC in Pittsburgh, Pennsylvania and has worked at Covestro for 35 years. John received a B.S. in Chemistry from West Liberty University and a M.S. in Environmental Science and Management from Duquesne University. John is the chair of the SAE International VOC Committee, and he serves on several technical committees including CertiPUR-US® Emissions Workgroup, ISO International, ASTM Committee D22 on Air Quality and the Molded Polyurethane Foam Industry Panel.

     

    S23005 Overview and Importance of Antioxidant Use in Slabstock Polyurethane Foam for use in Furniture and Bedding, John Hayes, Susan McVey, Nick Boes, Covestro

    This presentation will provide an overview of antioxidant use in slabstock polyurethane foams for the furniture and bedding industry. Antioxidants are important not only for the shelf-life stability of polyols used in the foam manufacturing process, but also for the resulting foam quality and for plant safety. The reaction of water and polyols with isocyanates in the foam making process is very exothermic, which can lead to discoloration, scorch, and potential fires. Slabstock foams typically reach internal temperatures in the range of 140°C to 170°C and can remain hot for 24 hours or longer due to the insulative properties of foams.

    Depending on the application, certain polyols may only contain a minimal amount of antioxidant to ensure product quality for storage, but not enough to protect the resulting foam from scorch or fire. The antioxidant formulations in the FPF market have changed over the years.

    Most recently, the supplier of a common antioxidant changed its GHS hazard classification from not classified (not hazardous) to a Category 2 reproductive toxin. Safety Data Sheets and labels for polyols exceeding 1000 ppm of this antioxidant were affected. Covestro is currently testing different antioxidants to target a non-hazardous classification for our polyols and to maintain the quality of both the polyols and the resulting foams.

    Speaker Biography
    Nick Boes is a Senior R&D Chemist at Covestro, working in the development of flexible polyurethane foam applications. He has been with Covestro since 2017. He holds a Bachelor of Science degree focused in Chemistry with a Biology Curricular Option from University of Pittsburgh. Prior to joining Covestro, he worked for Vascor, Inc., developing an implantable ventricular assist device using polyurethane elastomers and other components.
    S23002 Antifungal Test Methods, Jesse Turmenne, Microban International

    Degradation of materials by microorganisms is a major problem that can impact various aspects of materials including physical properties and aesthetics.  Antimicrobials are used to protect the materials, but evaluating the antimicrobial effectiveness is challenging. Currently, there are few test methodologies that are routinely used that accommodate a complex substrate such as polyurethane foam.

    This presentation will look into these test methodologies and their ability to assess these types of degradation focusing on their limitations, relevance, strengths, and overall assessment of antifungal properties in polyurethane foams.  Test methods will include AATCC 30, AATCC 100, ASTM G1, ASTM E1428, and ASTM E2180.

    Speaker Biography:

    As a Senior Microbiologist at Microban International, Jesse Turmenne conducts microbiological research and testing with a focus in supporting the innovations team to develop next generation products and services.  Jesse supports Microban and their customers by developing, modifying and testing various test methods for innovative products that routinely fall outside the scope of traditional test methodologies. Over the course of his 13-year tenure at Microban, Jesse has been a member of ASTM, AATCC and ISO committees developing and collaborating on test methods that shape the sanitization/disinfection, textile, polymer and antimicrobial industries. While supporting the innovations team at Microban, Jesse has worked alongside various high-level organizations, including the EPA, developing test methods and products that are registered worldwide.

    Prior to joining Microban, Jesse was a Quality Controller and Microbiologist at Whatman Filter Paper, a subsidiary of GE Healthcare and Life Sciences.

    Jesse holds a bachelor’s degree of science in Microbiology from The University of Maine.

    S23004 Sustainability Certification for FPF Supply Chains Using ISCC PLUS, Peter Hawighorst, International Sustainability and Carbon Certification (ISCC) Program

    The circular economy and the bioeconomy continue to grow, advancing the goals of reducing dependence on virgin fossil resources, and reducing GHG emissions. In Europe and North America, legal framework requirements like climate neutrality targets, recycling quotas, plastic taxes as well as consumer preferences, company commitments and stakeholder pressure are further driving the circular economy. CertiPUR-US®, which has historically certified FPF for chemical content and emissions, recently moved to certify bio-content.

    Along complex supply chains, chain of custody concepts like mass balancing ensure the credible connection of sustainability information to the materials and products in commerce, which is critical to the reputation of the companies involved. Companies, including FPF producers, are increasingly relying upon the International Sustainability and Carbon Certification (ISCC) scheme. ISCC is used by more than 7,000 companies worldwide, across entire supply chains from the point of origin of the initial petrochemical and chemical raw materials to converters, plastic producers and brand owners. ISCC provides credibility and acceptance for both B2B partners and consumers, and can potentially be used for reporting under regulatory frameworks or voluntary initiatives.

    ISCC operates different schemes, which now include ISCC PLUS, a voluntary certification program for the circular economy and the bioeconomy.  ISCC permits mass balancing. which allows companies to co-process sustainable and non-sustainable feedstocks. This presentation will provide an overview on ISCC and ISCC PLUS, its sustainability and traceability requirements, ways to get certified under ISCC and benefits for ISCC certified companies.

    Speaker Biography

    Peter Hawighorst is a project manager at the International Sustainability and Carbon Certification (ISCC) program. Before joining ISCC, he studied agricultural sciences at the University of Bonn and received a Ph.D. in forest sciences from the University of Goettingen. Afterwards he worked as a scientific coordinator at the Büsgen-Institut of the University of Goettingen. Dr. Hawighorst was part of the team that developed the ISCC PLUS approach and since then is supporting companies with the implementation of ISCC PLUS within supply chains in the chemical industry.

    Proceedings of the Polyurethane Foam Association Technical Program
    November 2022, San Antonio, TX

    F22001 Monitoring of Diisocyanate and Aromatic Amine Concentrations in Key Areas of Slabstock Production Facilities: Lessons Learned from 4 Plants in the Netherlands. Patrick de Kort, Europur.

    Monitoring of diisocyanates and aromatic amine levels in 4 plants was undertaken to provide input into occupational exposure limits (OEL’s) being considered at the EU level and in several Member States (NL, DE, FR, and BE).  Measurements were taken upon startup and during production at the mixing platform, paper windup, and sawing area. In addition, measurements were taken for tasks such as cleaning of mixing heads, curing operations, and specialized activities in particular plants.  Air concentrations around the mixing platform were notable low, and enclosures were deemed effective in controlling these levels.  Higher exposures were noted for employees in the tunnel during startup, for operators near the control panel during production, in connection with side paper placement and windup, and in operations involving the cutoff saw. These employees utilized respiratory protective equipment (RPE), and in the case of one plant a fresh-air fed booth near the cutoff saw.  Mixing head cleaning exhibited some elevated concentrations, requiring RPE, while wet lab operations entailed manageable concentrations.  Diisocyanate concentrations in operations involving cured foam were at non-detect or de minimis levels. The findings seem typical to the slabstock foam process and can be used by EHS managers to plan improvements.

    SPEAKER BIOGRAPHY

    Patrick de Kort serves as regulatory affairs manager for EUROPUR and EUROMOLDERS.

    Patrick received a degree in Biomedical Sciences from the University of Utrecht, interned for the European Parliament’s Research Service, and worked three years for the European Plastics Converters and its service company Polymer Comply Europe before joining EUROPUR. During this time there, he worked on various issues such as risk assessments of VOCs, chemicals legislation, and HSE related matters.

    F22003 An Evaluation of Stannous Octoate Replacements for Flexible Polyurethane Foam. David Pyles, Covestro.

    The polyurethane slabstock industry is currently reliant on the use of Tin(II) 2-ethylhexanoate (stannous octoate) as the standard metal gelation catalyst in most foam types. Recently, this material has come under scrutiny with the investigation into 2-ethylhexanoic acid (2-EHA) as a reproductive toxin. As a result, in the EU, 2-EHA and its tin salts have been reclassified as a 1B reproductive toxin. This will eventually restrict their use foams certified by leading polyurethane foam certification bodies.

    In this paper, we will share results from Covestro’s evaluation of commercially available tin-based metal catalysts that are potential replacements for stannous octoate. In-house flexible foam formulations and testing capabilities were used to prepare foam with alternative catalysts, using stannous octoate as a control. We evaluated at least two densities of conventional, high resiliency, and viscoelastic formulations in the study, with an emphasis on foam grades common in the industry. Foams were initially produced in our labs in a small scale box. Once the appropriate catalyst loading was identified, we scaled up to our box foam machine for a better comparison of the foam processing and properties. Performance testing was done by our on-site accredited physical testing lab to obtain common polyurethane foam properties using appropriate ASTM methods. While this work is ongoing, we will share some positive results to support the industry’s interest in moving beyond stannous octoate.

    Speaker Biography

    David Pyles started at Covestro in 2019 where he currently works as a Senior R&D Scientist in the raw materials division for slabstock flexible polyurethane foam. Prior to joining Covestro, David received a B.S. in Chemistry from Pennsylvania State University and a Ph.D. in Organic Chemistry from the Ohio State University, where he worked on covalent organic frameworks.

    F22005 Innovative Bio-based Polyether Polyols. Dr. Bin Yu, Wanhua Chemical (America)

    Achieving “green manufacturing” will be a key element of a global effort to realize “carbon neutrality.” The U.S. Department of Energy’s Roadmap for Biomass Technologies in the United States estimates that bio-based chemical compounds will replace 25% of petroleum-based organic compounds in this country by 2030.  Comparable publications in other parts of the world predict a 6%-12% replacement of chemical raw materials in the EU, and a 25% replacement in China by 2030.

    Wanhua has developed bio-based polyether polyols utilizing naturally-derived oils, which are then polymerized through the use of a special catalyst. Various bio-based polyether polyols with different bio content and different performance characteristics have already been commercialized.  This range of products is equipped to produce slab foam (viscoelastic and high resilience), molded foam (high rebound and slow rebound) and semi-rigid foam.

    This article provides an overview of Wanhua’s bio-based polyether polyol portfolio, discusses our evaluation of the resulting products, and offers application guidelines for the production of foam for key commercial applications, including furniture and automotive.  We found that by partially replacing petroleum-based polyether polyols with our bio-based polyols, foam products exhibited lower VOC and lower odor.  Further, the air permeability of foams can be effectively improved without impacting other physical and mechanical properties.

     

    F22002 A Life Cycle Analysis For Mattress Recycling In California, Michael Gallagher, Mattress Recycling Council

    The Mattress Recycling Council (MRC) undertook a life cycle analysis (LCA) to understand the major contributors to environmental impacts arising from its statewide California end-of-life mattress recycling program in 2021. In that calendar year, the program recycled over 1.6M discarded mattresses and transported over 15,000 loads of material. In the gate-to-gate evaluation we determined the impacts from receipt at MRC collection locations through transport to recycling facilities, mattress deconstruction and disposition of material into end markets. Overall, 2021 operations were found to have a very favorable environmental impact, displacing a net 26,000 metric tons carbon dioxide equivalents (-16.2 kg CO2e/unit recycled).

    The study also included a comparative environmental performance of several proposed or emerging recycling pathways against the current baseline. MRC will share these findings and discuss potential impacts on recycling asset allocation and investment, research strategy, policy development and industry engagement to improve product circularity.

    A final report, which follows ISO 14044 guidelines, will be released in Q3, 2022. It will cover greenhouse gas emissions and other environmental impacts in greater detail including particulate matter emissions, water resource depletion and primary energy demand. Scope 3 Consulting LLC, a California-based consulting firm, was selected to conduct the study.

    SPEAKER BIOGRAPHY

    Michael Gallagher is a research consultant for The Mattress Recycling Council,  a non-profit organization dedicated to the development and implementation of statewide mattress recycling programs for states that have enacted laws. The organization provides valuable information and resources for industry professionals. Prior to working with the Council, he was Head of Innovation and Business Growth Services For Covestro.

    F22004 Next Generation Stannous Octoate Catalysis Options in Flexible Slabstock Foam. Jane Kniss, Evonik.

    The flexible slabstock polyurethane foam industry is continually under pressure from a wide variety of global, state and federal entities, local agencies, certification protocols and customers to improve their health sensitivity, productivity, quality and cost of polyurethane articles. A recent market focus entails alternatives to chemicals now increasing their reproductive toxicity status from 2 to 1B.  Though part of a long-established material used in manufacture of flexible polyurethane foam for several decades, 2-ethyl hexanoic acid (2-EHA) and its salts are now involved in this activity. Residual amounts of 2-EHA exist in stannous octoate, an essential catalyst used in the manufacture of slabstock polyurethane foam combined with 2-EHA also being liberated via hydrolysis of stannous octoate during typical chemical reactions required to produce a high quality, flexible polyurethane foam product. Stannous Octoate is also critical for regulating foam airflow and enabling final foam cure, thereby compelling potential substitutes to be capable of doing the same during foam production without risk of 2-EHA emission. A family of new catalysts is offered for substitution of stannous octoate, thereby eliminating the risk of exposure to 2-EHA at its source, as well as providing suitable performance alternatives for the polyurethane manufacturer across a broad range of foam grades.

    This presentation describes work to provide raw material replacements that require minimal foam formulation adjustment while eliminating an exposure source of 2-EHA for workers and customers during manufacture, fabrication, shipment, and use of polyurethane flexible slabstock foam.

    Speaker Biography

    Jane Kniss is an ATDS Chemist with Evonik Corporation, located in Allentown, Pennsylvania. She received her B.S. degree in Polymer Science from Pennsylvania State University, University Park, PA in 1986. She is responsible for applications development and technical service for catalysts and surfactants in both the flexible polyurethane foam slab and flexible molded market segments. She has twice earned PFA’s Dr. Herman T. Stone Technical Excellence Award for her presentations at past meetings.

    F22006 Glass Transition Temperature of Viscoelastic Foam: Some Fundamental Studies. Vijay Nadgir and Mike Purvis, Monument Chemical.

    A commercially acceptable viscoelastic foam for bedding should feature an appropriate glass transition temperature (Tg).  If Tg is too high, for example 80 F, the foam will feel hard at room temperature.  If Tg is too low, such as 40 F, the foam may not behave as viscoelastic foam at room temperature or at the temperatures at which Americans sleep.

    Polyol, foam and mattress manufacturers measure the glass transition temperature of viscoelastic foams using various tools like DMA, DSC and sometimes by IFD instrument.  DMA provides alot of data but is difficult to interpret.  Companies have devised several ways to interpret such data to define comfort.  We have conducted some fundamental studies to correlate DMA data into useful data which can be understood easily.  We have also reviewed several analyses to define comfort and in this paper will propose new parameters for the comfort of foam in bedding applications.

    SPEAKER BIOGRAPHIES

    Dr. Vijay Nadgir received his Ph.D. in Chemical Engineering from Auburn University.  He joined Carpenter Company in 1994 and has since been associated with the polyurethane industry.  He also worked at INVISTA, Hickory Springs and Innocor.  He has worked in the areas of flexible foam, rigid foam, polyether polyols and polyester polyols.  He has been working with Monument since 2019.  His primary job includes developing applications and providing tech support for foam customers and working on fundamental R & D projects.

    Dr. Michael Purvis studied chemistry at Virginia Polytechnical Institute & State University with focus on Bio-organic Chemistry. In 1989 he joined the Pilkington Group working on polyurethane thermoplastics and coating for automotive applications. Additional polyurethane experience includes UV-curable optical fiber coatings formulations for the communications industry (Alcatel Communications) and PUD chemistry (Reichhold Chemical) for wood coatings.  He currently leads the R&D group at Monument Chemical developing polyether and specialty polyol materials for the Foams and CASE markets.

    Proceedings of the Polyurethane Foam Association Technical Program
    May 2022, St. Petersburg, FL

    S22001 Improved Passenger Experience in Automotive Interiors with Antimicrobial Foam Solutions., Mai Ha, Microban

    Automobiles are subjected to many contaminants on a daily basis. Children, pets, food deposits, cleaning lapses, and even simple temperature and humidity changes can all foster unwanted bacterial and fungal growth in HVAC and filter systems as well as on interior surfaces and supporting materials. 80% of consumers express concern about stains and persistent odors inside of their vehicle. Mold growth and microbial colonization are typically amplified in rideshare and public transportation settings because of the number of riders accommodated per day.  Automotive OEM’s should consider lasting treatments for vehicle interiors that elevate both passenger experience and OEM brand perceptions.

    SPEAKER BIOGRAPHY

    Dr. Ha is a Senior Product Development Engineer at Microban International. She has been a key engineer in customer focused projects and new product development. Her knowledge in incorporated polymeric products brings a unique skillset to Microban partners. She obtained her B.S. degree in Polymeric Material Engineering from Polytechnique University in Vietnam and has been working with polymers since 2002. In 2006, she received her M.Sc. degree from University of Oklahoma after working with emulsions and emulsion polymerization. Subsequently, she moved to the University of Houston and obtained her Ph.D. in nanocomposites and polymer blends. She has been with Microban since 2011.

    S22003 Hennecke AUTOFLAT Technology Delivers Block Geometry with More Efficient Startup and Reduced Manpower in the Foaming Tunnel. Raphael Bretz and Sven Burchardt, Hennecke

    The traditional Hennecke Flat Top System has helped slabstock operations reduce material waste by achieving block geometry. However, manual alignment of the system is sometimes error-prone and time-consuming upon startup, and entails the presence of operators in the foaming tunnel. AUTOFLAT software automatically controls the lowering of mats at the start of production and ensures precise positioning.  The mats are controlled by electric motors guided by a sophisticated sensor system and visualization on the computer screen. AUTOFLAT automatically adjusts the surface pressure in case of recipe changes, once defined and set the first time, the recipe will hold this information and replicate next time you pour the same recipe. The sensors provide feedback regarding not only the final height of the block, but also the block rise profile which further aids in understanding reactivity of the formulation.

    The following advantages can be realized:

    •  Lower material consumption due to direct block geometry
    • Higher reproducibility of production
    • Greater production reliability thanks to automation
    • Central adjustment of mat weight on PC or control box
    • Finer gradation of the mat weight in case of weight changes
    • Less manpower required for production starts, stops and changes, minimizing exposure to vapors in the foaming tunnel.
    S22005 The RENUVA™ Mattress Recycling Program: An Update, Ana Nunez, Dow
    The RENUVA™ Mattress Recycling Program is a circular economy program for converting end-of-life (EOL) polyurethane (PU) foam from mattresses back to one of their raw materials – polyol. Last Spring, Dow provided an overview of the project during its startup. Now that the program has been in operation, Dow will provide an update.

    The RENUVA™ Mattress Recycling Program is a circular economy program for converting end-of-life (EOL) polyurethane (PU) foam from mattresses back to one of their raw materials – polyol. This polyol can then be used in flexible or rigid foam production to go into applications such as building insulation and even back into new mattresses. The program aims to recycle up to 200,000 mattresses a year in France and help reduce incineration emissions and landfilling.

    The program is enabled by a collaboration among several companies. One entity is providing a turnkey installation for the first plant. Another company operates this initial production facility in France. A third party collects and dismantles mattresses and is supplying the EOL foam for recycling. A large pan-European company will produce flexible PU foams made with RENUVA™ polyols. Dow Chemical is leading the effort by providing technical and application development and serving the market for the recycled material.

    So far, RENUVA™ polyol performance has been verified with up to 50% recycled content in rigid foams and up to 30% recycled content in flexible foams. These polyols have also shown to have similar (compared to virgin polyols) volatile organic compound emission levels and were free from noticeable odor impacts.

    RENUVA is a Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow

    S22002 EHA-Free Tin Catalysts as an Alternative to Stannous Octoate in Flexible Polyurethane Foams: A Performance Comparison. Joerg Duebel, Gulbrandsen

    2-Ethylhexanoic acid (EHA) and its salts may soon be listed as Category 1B reproductive toxins under the EU REACH program. Stannous octoate, an important gelling catalyst for the production of slabstock foam, falls within the ambit of this classification. The anticipated classification may preclude flexible polyurethane foams made with stannous octoate from being certified by certain sustainability programs. Likewise, such foams may eventually face labeling requirements under California’s Prop 65 program, given the tendency of that program to “list” chemicals classified by EU health authorities. Stannous Neodecanoate (CAS no.: 49556-16-3) represents a 2-EHA free alternative to stannous octoate. The focus of this paper is a performance comparison of stannous octoate versus stannous neodecanoate in slabstock foam formulations.  Testing of foam samples is being conducted by Peterson Chemical Technology LLC.

    SPEAKER BIOGRAPHY
    Joerg Duebel is a Business Director responsible for tin catalysts at Gulbrandsen. He received his Master’s Degree in Chemical Engineering from the University of Karlsruhe, Germany and earned a Master’s Degree in Management from Purdue University.  Over his 30 years of chemical industry experience, he has held various engineering, product management and business management roles. He has been with Gulbrandsen since 2021.
    S22004 Digitization And Predictive Modeling Of Polyurethane Data Via Machine Learning And Artificial Intelligence. Keith Task (Presenter), Yinan Kang, Mark McBride, Amanda McCraw, Ted Smiecinski, Sebastian Wandernoth, Willie Wesley, Laura Chiandussi, BASF

    Data is often an abundant, and yet underutilized, resource in the chemical sector, including the polyurethane industry. There is a paradigm shift from planning pencil and paper experiments using intuition alone to learning from historic data and using it to guide experimentation. Data driven approaches can lead to a greater understanding of foams, better decision making, and accelerated development. Machine learning (ML) and artificial intelligence (AI) have been applied to flexible foam data, allowing us to develop predictive models which map foam formulation components and process conditions to foam properties.

    Preprocessing and cleaning of the data was first done, followed by data mining and exploratory data analysis to obtain a holistic view of the data. From here, a battery of ML models were trained, including linear (OLS), linear with dimension reduction (PLS, Elastic Net), semi-parametric non-linear (MARS), and non-parametric tree-based models. The inverse modeling approach, i.e. determining which inputs (formulation component levels) are needed to obtain targeted performance properties, was done via mathematical optimization. To obtain global solutions to this optimization problem, evolutionary algorithms were utilized, specifically differential evolution. This optimization framework can allow formulators to obtain recommendations of formulations which meet desired properties, thereby accelerating development.

     

    SPEAKER BIOGRAPHY

    Keith Task is a senior digitalization research scientist at BASF Corporation, and is based in Beachwood, OH. Keith obtained his B.S. and Ph.D. in Chemical Engineering from the
    University of Pittsburgh. Keith has been at BASF since 2015, and supports business and research units across the company through statistics and mathematical modeling. Keith’s
    primary interests include machine learning, experimental design, and linking data driven and mechanistic modeling.

    Proceedings of the Polyurethane Foam Association Technical Program
    November 2021, Charlotte, NC

    F21001 Managing Isocyanate Exposure in Foam Production Facilities: Best Practices in Production Equipment and Work Practices, Jim Shoup, Jim Shoup Equipment and Services, LLC

    Isocyanates are an indispensable foundation of polyurethane chemistry.  However, occupational isocyanate exposure has been linked to health effects, including respiratory sensitization from excessive exposures.  In flexible polyurethane foam operations, airborne isocyanate vapors are controlled through a combination of production equipment, engineering controls, work practices and PPE.  In 35 years with the industry, Jim has supervised the design and construction of slabstock and molded foam facilities, retrofitted pourlines to latest technologies and control systems, and trained operations and maintenance staff.  He will review technologies and work practices that can help manage exposure to isocyanates and other volatile compounds, including direct laydown, injector flushing, air flow monitoring, automated handling of startup and sample blocks, and automated tagging of foam buns.

    F21003 Realtime Compounding for Slabstock Foam Production, Achim Schmidt, Hansa Industrie-Mixer GmbH & Co. KG

    The PUR-MIX system from Hansa Mixer provides the user with the ability to precisely mix polyols with dry substances and powders such as melamine, graphite, flame retardants, and chalks. This real-time, continuous process significantly reduces many of the problems associated with batch mixing such as poor compound quality, inconsistent density, and heavy powder sedimentation. Precise control of each individual compound through user defined, pre-programmed recipes leads to reduced waste and greater process efficiency and sustainability.

    F21005 New Additives to Optimize the Compression Set Performance of Flexible Polyurethane Foam. Rob Borgogelli, Daniela Hermann, Jane Kniss, Annegret Terheiden, Evonik Industries

    Flexible  polyurethane  foam  is  a  versatile  polymer  that  has  become  a  key  material  of  construction  in  modern mattresses.  The main foam properties of density, hardness and resilience can be easily adjusted to achieve the support and comfort characteristics desired by bedding designers, giving consumers a wide range of options to fit their specific sleeping preferences.  In addition to the ‘feel” of the mattress, consumers are also searching for the best value, balancing cost with  durability  performance  and  shopping  convenience.    The  bedding  industry  has  responded  by  offering  high quality  mattress  products  that  can  be  purchased  online  and  can  be  compressed  and  shipped  directly  to  consumers  to minimize warehouse handling and transportation costs.

    These marketing trends have resulted in more stringent technical requirements on how well the mattress components recover after compression.  Polyurethane foam is being challenged to compete with other cushioning materials in the rate and extent of recovery after compression.  In 2019, Evonik initiated a global study to better understand factors that affect the compression set of flexible polyurethane foam.  The CPI presentation later that year reported on formulation and processing conditions that helped reduce foamheight loss as per Test D of ASTM D3574 (1)or EN ISO 1856 (2)a.  Some commercial additives that provided benefits in certain formulations were also presented.  In this paper, Evonik will present results of lab work on some new additives that have been developed to optimize compression set as per the ASTM test, but also another method that appears meaningful to evaluate foam performance in the lab that correlates to industrial conditions.

    F21002 Hybrid Mold Release Agents For Polyurethane Foam: Innovation, Application, and Environmental Impact, Javier Horas, Concentrol Performance Materials

    Hybrid release agents can offer a clear advantage with respect to the emissions of volatiles to the atmosphere and exposure risks for workers. This article describes innovations in hybrid mold release agents, which can replace up to 70% of solvent with water.  This ready-for-market technology combines the VOC-reduction and sustainability benefits of water-based release agents with the good performance and production efficiencies of solvent based release agents.

    F21004 Recent Advances In Flexible Foam. Mark McBride, Willie Wesley III, Theodore Smiecinski, and Lindsey Witte, BASF

    From mattress and bedding to automotive seating, foam formulations and, consequently, raw materials continue to diversify and define modern-day comfort. Since comfort is a critical driver in flexible foam innovation, application-based solutions vary for conventional, high resilience, viscoelastic and HyperSoft™ foam to meet customer needs.

    These innovations in foam formulations translate to manufacturing and process modifications, which introduce new challenges of their own. For example, as foam formulations continue to soften, slower cure time has become a consistent pain-point. These “stickier” formulations can slow production lines, increase operating expense and product loss resulting in a negative impact on the foam manufacturer’s bottom-line. This situation also applies to molded applications where de-molding time can be critical.

    Temperature points and heat build-up in mattresses continue to define ideal customer comfort. In response to this need, the polyurethane flexible foam industry developed specialized heat storage and transfer agents (HSTA). Although HSTAs meet a customer’s need for a cooler night’s sleep, earlier generation formulations introduced more variability to manufacturers. For example, some HSTAs cause challenges when utilizing with CO2 foam processing.

    To continue the pursuit of modern-day comfort with manufacturing and processing in mind, BASF continues to develop next generation materials for different grades of flexible polyurethane foams. This paper will discuss these innovative materials and their benefits to flexible polyurethane foam, specifically regarding their physical properties and processing improvements. Two innovations will be reviewed: foam formulations providing increased green strength and faster cure times as well as next generation Elastopan® polyurethane gel formulations for flexible foams.

    Proceedings of the Polyurethane Foam Association Technical Program
    May 2021, St. Petersburg, FL

    S21001 Silicone Surfactants For Reduced Emissions Of Aldehyde And Aromatic Emissions from PU Foam, Dr. Josep Nadal and Mr. Adria Lopez, Concentrol, Girona, Spain
    In recent years, automotive OEMs have prioritized the reduction of VOCs and odor from plastics in car interiors. This is a particular concern for some consumers in the fast-growing markets of Asia. Some requirements and test methods are generally recognized in some countries or economic areas, like the Verband der Automobilindustrie (VDA) in Europe, while other methods are specific to individual OEM’s. Difference between regions and automakers make it difficult to obtain standardized methods and comparable values.
     
    Progress is, however, being made on the technological front. New stabilizers have been designed and tested in commercial PU foams to lower emissions of aldehydes, aromatics and other volatiles. Some of the Concentrol’s new offerings feature excellent overall performance and very low emission profiles.

     

    S21003 Novel Silicone Surfactant With Improved Foam Properties For Conventional Foam, Melissa Kern, Momentive Performance Materials

    Polyurethane slabstock conventional foam is the core of the flexible foam production globally. Foam demand in the upholstery and especially for the mattress industry covers a wide range of foam densities and various property requirements especially targeting foam property distribution and compression sets. Improvement in foam quality is achieved through good foam stabilization combined with higher airflow. These are key features to achieve optimized foam property distribution through stabilization, as well as enabling improved compression sets through higher airflow. Silicone surfactants are known to have a large impact on foam stabilization, however a higher stability typically triggers a corresponding lower foam airflow. Momentive Performance Materials Inc. (Momentive) has dedicated significant efforts to further optimize these additives in recent years and has developed a new generation of silicone surfactants for conventional flexible slabstock foams. Niax* silicone L-894 is a novel silicone surfactant for polyether slabstock conventional foam, which provides optimum foam stabilization and cell structure control along with very good airflow for a broad range of foam densities.

    *Niax is a trademark of Momentive Performance Materials Inc.

    S21005 Non-FR Synergistic Additive can Reduce FR Loading and Improve FPF Physical Performance. Vasilios Dounis, Technical Sales Manager, Repi.

    Halogen flame retardants have come under increasing scrutiny and restriction by consumer and environmental regulators globally.  Just this February, Massachusetts banned 11 flame retardants in furniture, mattresses, carpeting and window treatments, at levels exceeding a de minimis threshold. Traditional FR additives can also adversely affect some desired performance characteristics of FPF. A halogen-free synergistic FR additive recently developed by Repi (AntiFIAMMA MD Repitan 00398) was evaluated in foam formulations containing various levels of FR additives. Foams were tested to two flammability test protocols: UL 94 (Horizontal Burning Foamed Material Test) and ASTM D 4986/ ISO 9772 (Standard Test Method for Horizontal Burning Characteristics of Cellular Polymeric Materials). Testing revealed that the additive works synergistically with the main FR compounds, allowing for an overall reduction (20-30%) in FR loading while maintaining flammability performance and improving physical property performance.

    S21002 The RENUVA™ Mattress Recycling Program, Hans Kramer, Paul Gillis, Nasim Hooshyar, Thomas Farmer and Marcel Moeller, Dow

     

    The RENUVA™ Mattress Recycling Program is a circular economy program for converting end-of-life (EOL) polyurethane (PU) foam from mattresses back to one of their raw materials – polyol. This polyol can then be used in flexible or rigid foam production to go into applications such as building insulation and even back into new mattresses. The program aims to recycle up to 200,000 mattresses a year in France and help reduce incineration emissions and landfilling.
    The program is enabled by a collaboration among several companies. One entity is providing a turnkey installation for the first plant. Another company operates this initial production facility in France. A third party collects and dismantles mattresses and is supplying the EOL foam for recycling. A large pan-European company will produce flexible PU foams made with RENUVA™ polyols. Dow Chemical is leading the effort by providing technical and application development and serving the market for the recycled material.

    This presentation will provide an update regarding the status of the RENUVA™ Mattress Recycling Program. So far, RENUVA™ polyol performance has been verified with up to 50% recycled content in rigid foams and up to 30% recycled content in flexible foams. These polyols have also shown to have similar (compared to virgin polyols) volatile organic compound emission levels and were free from noticeable odor impacts.

    RENUVA is a Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow

     

    S21004 High Aromaticity Polyether Polyol Additives can Reduce Halogen Loading in FPF FR Formulations, Steve Crain, PMP; Business Development Leader, Hexion Inc.

     

    Polyurethane flexible foams sometimes feature fire retardant (FR) chemistry to meet fire standards. Such standards can be embodied in law (e.g., the U.S. Department of Transportation FMVSS 302 requirements for foams used in automotive interiors) or specified by contract (e.g., for furniture used in public occupancies such as dormitories). However, a number of FR’s, particularly halogen-based compounds, have been adversely classified by health and environmental authorities, and have been prohibited by some U.S. states above certain thresholds in children’s products, furniture and mattresses. Hexion has developed a line of aromatic polyether polyols which, due to their high aromaticity, may be of use to the polyurethane foam formulator as an additive in either reducing or finding alternatives to halogenated flame retardants. Several polyols will be reviewed with a focus on the newest polyol, Resonance™ PL92-450. The aromatic polyether polyol will be described during this discussion as an additive to a flexible foam system.

    Proceedings of the Polyurethane Foam Association Technical Program
    November 2020 Online Meeting

    F20001 Novel Catalyst for Low Compression Set and Low Odor Foams for Bed-in-a-Box Mattresses. Yusuke Morioka (Presenter), Ryohei Takahashi, Hiroshi Fujiwara, Katsumi Tokumoto, Jeff Tucker, TOSOH Specialty Chemicals USA, Inc.

    In recent years, the growth of bed-in-a-box products has been a major feature of the mattress and foam markets. These products, typically sold online, are vacuum-compressed for shipping. Customers expect such mattresses to recover quickly to their functional shape upon unpacking, highlighting the compression set of polyurethane foam components. The choice of amine catalysts for FPF production is an important factor in compression set. Generally, reactive amine catalysts have difficulty achieving a low compression set due to the large catalyst dosage (insufficient gelling activity), which limits polymer growth of polyurethane foams by reacting with isocyanates.

    A separate issue, but one also tied to the use of amine catalysts, is the emission of Volatile Organic Compounds (VOCs) from FPF products such as mattresses. This phenomenon can compromise consumer acceptance and potentially raises issues of Indoor Air Quality. The use of reactive amine catalysts is one option to reduce VOCs and odor. Reactive amine catalysts are incorporated into the polyurethane structure, which prevents volatilization of amine compounds and enables lower VOCs and odor levels.

    For these reasons, amine catalysts that exhibit low compression set value and low odor levels simultaneously are in a growing demand from the industry. TOSOH has developed a novel reactive amine catalyst: RZETA®. RZETA® provides strong gelling ability and small catalyst dosage among reactive catalysts, yielding low compression set. In addition, RZETA® is completely incorporated into the structure and eliminate amine emissions, which reduces VOCs and odor levels.

     

    F20003 Improving Viscoelastic Foam Cure. Jane Kniss, Evonik

    The flexible slabstock polyurethane foam industry continuously strives to improve the productivity, quality and economics of polyurethane articles, and supplier innovations support this effort. One ongoing challenge involves progress toward lower and ultimately no emissions from the final polyurethane slabstock foam article. Cure profiles during the manufacturing process for most medium to low density foam grades are acceptable with state-of-the-art, non-emissive catalysis.  Unfortunately, higher density foams, especially visco-elastic foam, do not always have a suitable cure profile to avoid delay in foam handling and fabrication. This necessitates the supplemental use of emissive, tertiary amines.  In higher density foam, previous generations of non-emissive amines, when used alone, required high use levels due to the lack of water inhibiting development of rapid thermal kinetics, delaying effective cure and risking sub-standard final foam physical properties.

    This paper reports on recent work to offer the flexible slabstock market non-emissive amine catalysts that provide efficient gel catalysis, even in higher density, visco-elastic foam.

    F20005 Workplace Violence. Information Protection. Labor Disputes. Electronic Security Systems. These are just some of the Threats a Corporate Security Team can Support and Protect Against. Anthony Byrd, BASF

    Corporate Security teams manage a wide array of threats to personal safety, corporate assets, intellectual property, and customer data. Our goal is to ensure the proper functioning of the company and to mitigate risks. Through communication and collaboration with multiple functions of management, both individual sites and the global business can operate in a reduced risk environment.

    Anti-terrorism challenges were discussed by Doug Kelly (Covestro) at PFA’s November 2019 Technical Paper Session. Accordingly, my remarks today focus on the following topics:

    • Workplace violence includes any act or threat of physical violence, harassment, intimidation, or other threatening disruptive behavior that occurs at the work site. At its most extreme, it includes on-site physical assaults and even homicide. Training to respond to active shooter events should be provided to all employees and coordination done between company crisis management teams and local law enforcement.
    • Information Protection and Corporate Espionage. Intellectual property accounts for one-third of U.S. GDP, so these assets represent an attractive target for unscrupulous competitors. Companies should maintain robust training curriculum and on-site reminders about the types of information that require protection and access restrictions, and also provide guidelines for interacting with competitors.
    • Labor Disputes. Labor disputes can result in work stoppages, productivity shortfalls, destruction of property and unmet customer needs. During contract negotiations and other sensitive events, manpower and surveillance capabilities may need to be augmented to guard against impermissible conduct.
    • COVID Response. During the outbreak, Security supported site managers and Procurement in developing employee screening protocols and risk communications, and identifying equipment needs. We arranged for receipt of over 100,000 masks from FEMA for distribution to employees across the region.
    F20002 Methods Development for Assessing Pink Stain on Polyurethane Foam. Daniel L. Price Ph.D., Interface Inc.

    Staining of the built environment by microorganisms has been a nuisance for product aesthetics and overall quality for decades.   This is especially true in harsh marine environments where furnishings see periods of saturation followed by periods of dryness and harsh sun exposure.   Beyond the familiar black, brown and green stains often associated with mold colonization of plasticized vinyl is a microbially produced pink pigment called “Prodigiosin”.  Prodigiosin can be produced by bacteria and actinomycetes.

    Actinomycete production is often associated with pink staining of vinyl and other upholstery components including polyurethane foams.   Standard tests for assessing pink staining on flat vinyl upholstery (i.e. ASTM E 1428) have existed for decades.

    In recent years the need to assess polyurethane foam resistance to pink staining has created technical challenges that were overcome through collaborative methods development and modifications to address the open-cell non-uniform topography of many polyurethane foams.  Our work reviews the use of ASTM 1428 on vinyl and details protocol modifications designed to provide uniform contact of the pink stain inoculum with the foam surface.  An update on methods development and a recent interlaboratory study involving the foam pink stain method will also be presented.

     

    F20004 Thermolyzer Technology For Processing End-Of-Life Mixed Urethanes. Chuck Ludwig, CHZ Technologies.

    End-of-Life polyurethane foam is a difficult material to recycle.  Like most thermosets it can’t be melted or economically unzipped back into basic chemical building blocks.  The Thermolyzer technology can efficiently process EOL mixed urethane foam to a syngas, a Biochar and destroy the toxic chemistry.

    The Thermolyzer™ technology is a highly-modified pyrolysis system. This new approach converts all types of polyurethane foam wastes into a clean fuel gas and a clean “Biochar”. This novel technology overcomes the limitations of previous pyrolysis process. First, it is a continuous, self-sustaining, oxygen-free process meaning it operates 24/7. Secondly, all hazardous oils and tars are turned into fuel gas. The process is halogen-tolerant. Any halogens present are converted to simple salts to be safely removed in the waste water. Additionally, no toxic dioxins or furans are created as in all other open flame, co-gen or incineration processes with halogens present. This clean fuel gas created can be used directly in gas turbines for power or boilers for steam.  The solids remaining are considered a Biochar and used as a soil amendment adding carbon back in the ground.

    F20006 Modernizing Training of Foam Production Employees: Integrating Process Control Technology With Hands On Operator Skills And Experience. Jim Shoup, Jim Shoup Equipment & Services, LLC (Temporarily Unavailable)

    (Temporarily Unavailable)

    Proceedings of the Polyurethane Foam Association Technical Program
    November 2019, Louisville, KY

    F19001 Bismuth Catalysts As Alternatives To Tin In Flexible Foam Presenters: D. Patten, Everchem; N. Eckert, Shepherd Chemical Company

    Growing concerns about emissive amines, the health and environmental impacts of tin catalysts and accelerating adoption of hydrofluoroolefin (HFO) blowing agents are driving foam formulators to reinvent their chemistry, especially the catalyst packages.  Traditional catalyst strategies often do not meet the strict performance and EH&S requirements for current and developmental polyurethanes.  Innovations such as Shepherd Chemical’s patented BiCAT® 8840 and BiCAT® 8842, hydrolytically stable bismuth catalysts, can be viable alternatives to stannous octoate in rigid and flexible foam applications.  This presentation will provide information and data demonstrating BiCAT®’s comparable quality and efficiency to stannous octoate in an industrial slabstock foam matrix.

    F19003 Best Practices And Technology In Facility Security Doug Kelly, Covestro

    U.S. Federal Regulatory security requirements, such as the Department of Homeland Security Chemical Facility Anti-terrorism Standards (DHS CFATS) or the United States Coast Guard Maritime Transportation Security Act (USCG MTSA), provide a backbone for protection of assets.  Regulated, as well as Non-regulated facilities, often struggle with complexity of the regulations and implementing effective security concepts to their facilities.  Incorporating best practices and voluntary programs may provide a simplified and robust physical security posture for facilities.

     

    F19005 Comparing Direct Laydown and Trough Pouring Technology In Terms Of Processing Flexibility and Waste Minimization Raphael Bretz, Hennecke

    Process scrap foam results from changes in foam grade, color, pouring duration times, and from startups and shutdowns. Minimizing scrap foam reduces both environmental externalities and disposal fees associated with landfilling. This paper compares the quantity of scrap foam generated by the two most common production technologies: Direct Laydown and Trough Pouring.

    In Direct Laydown Technology, the chemicals are dispensed onto an adjustable pour plate that allows the mixture to spread out along the width of the block as the entrained air rises to the top. As the mixture starts to react it increases viscosity and begins falling down the incline of either the angled conveyor or fall plates. Trough Pouring Technology dispenses the reactive mixture of chemicals into a trough, where it rises and expands. The sides of the trough are angled to increase the volume capacity of the trough to allow for continued chemical reaction and expansion. The volume of the trough is designed to allow a specific dwell time to ensure that the reactive mixture is viscous enough to prevent it from running down the fall plate and under-cutting the rising foam. However, because the technology requires a size and volume-specific trough it also demonstrates limitations by causing additional startups, shutdowns and longer change-overs. In addition, more reactive foams such as Viscoelastic and MDI foams can cause a buildup in the trough causing a limitation in the pouring duration time. This further increases the number of shutdowns and startups thus, increased scrap foam.

    The authors review the historical trends in the utilization of these two technologies, present data on their relative efficiency in minimizing scrap foam generation, and discuss recent equipment refinements that improve the efficiency of Trough Pouring.

    F19002 Evaluation of Parameters that Impact Compression Set J.Kniss, R Borgogelli, K. White, A. Terheiden, R. Landers, D. Hermann, I Wessely, C Toyoshima (Herman Stone Technical Excellence Award Winner)

    Consumers are changing the way they shop. Shifts away from visits to “brick and mortar” stores toward internet purchase with direct shipment of a compressed mattress to the home is a significant trend. Upon arrival to the home, quick recovery to the original dimensions of the mattress is critical. Among other requirements, this trend re-focuses on performance of flexible foam physical properties, specifically compression set. Flexible slabstock foam manufacturers utilize ASTM D 3574 (1) or EN ISO 1856 (2) test methods to verify foam compression of less than 10% when subjected to certain conditions.

    Good compression set values of flexible slabstock foam are dependent of a variety of factors. Predictability of these factors and trends for acceptable compression set performance via additives, chemistries, foam cell size adjustments, processing conditions or foam curing regimens is a frequent topic of discussion. Of the long list of options, crosslinking chemistries provide straightforward options to support favorable compression set performance. A matrix of surfactants, catalysts, additives and crosslinking options suitable for use in various foam formulations will be discussed in this paper.

    F19004 Risk Assessment of Volatile Organic Compound Emissions from Flexible Polyurethane Foam Based in CertiPUR® Testing Patrick de Kort, EUROPUR

    The “Risk Assessment of Volatile Organic Compound Emissions from Flexible Polyurethane Foam Based in CertiPUR® Testing” report explains where specific VOC emissions are originating from and places them in context by comparing the worst-case emissions with toxicological benchmarks to determine if there is a risk for the consumer when using the foam. The report has been made available to EUROPUR members and can be used in the context of R&D efforts to limit specific emissions and in discussion with customers that question the safety of PU foam, as it has been demonstrated that end-consumers using flexible PU foam are not exposed to levels of individual VOCs to an extent that they would be at risk. In the presentation, the risk assessment methodology, the origin of specific individual emissions, and a summary of the results will be presented.

    Proceedings of the Polyurethane Foam Association Technical Program
    May 2019, St. Petersburg, FL

    S19001 The Molded Polyurethane Foam Industry Panel’s Approach to Developing a Roadmap for Measuring VOC Emissions John Sebroski, Covestro LLC (Presenter), Kelly Kiszka, The Dow Chemical Company, and Jennifer Holtz, BASF (Herman Stone Technical Excellence Award Winner)

    Currently there are over 150 standards to measure volatile organic compounds (VOCs) and aldehydes from molded polyurethane foams that are used in automotive seating. The standards from OEMs, ASTM International, SAE International, ISO and VDA can range from whole vehicle tests to micro-sized chambers or thermal desorption tubes to evaluate materials for their impact on vehicle interior air quality (VIAQ). Often these standard methods are ambiguous and conflict with each other which can cause confusion and increase the variability of the test results. To address these issues, the Molded Polyurethane Foam Industry Panel is developing a “VOC Roadmap” that will provide recommendations and define best practices for measuring VOC emissions from automotive interior flexible molded polyurethane seating foam. The proposed industry standard will address the interests and requirements of OEMs in the three major global automotive markets: North America, Europe, & Asia. The comprehensive standard will leverage existing consensus standards to draft four best practice documents: (1) Foam processing and handling, sample production, conditioning, packaging, storage, shipment, and specimen preparation, (2) Test methods to measure VOC emissions, e.g. chambers, air sampling and analytical methods, (3) Data analysis and expression of results, (4) Description and flowchart of combined documents – Unification document to form a comprehensive VOC Roadmap. This presentation will discuss the current status of the VOC roadmap and the industry panel’s approach to reach a consensus for the proposed standard to measure VOCs from automotive seating to evaluate the impact on VIAQ.

    S19003 Migration Testing of Melamine and TCPP Nick Ordsmith, Hall Analytical Laboratories

    This presentation will explain how we approach an analytical challenge, review in brief some of the key studies performed and focus specifically on recent studies looking at TCPP and Melamine migration in European foam products. TCPP and Melamine have become a hot topic in Europe in recent times due to concerns around carcinogenicity. Since they are both important FR additives Europur has been heavily involved and, to provide data for risk assessment, commissioned Hall Analytical to run two migration studies. Three foam producers provided samples with known loadings of TCPP and Melamine for this work. The methodology will be described and the results with conclusions presented.

    S19005 Migration of TDI and MDI From Flexible Foam Using EPA Indoor Exposure Guidance, Tim Feeley, III

    The International Isocyanates Institute (III) undertook this project to provide a practical objective benchmark test for member companies’ downstream customers to evaluate the potential for migration of TDI and MDI from finished products.  Earlier studies conducted by III investigated potential inhalation and dermal exposure to TDI from flexible polyurethane foam by emission and migration testing; a later project did similar work with MDI.  Following this, the US EPA published guidance for assessing indoor exposure from products that includes procedures for using migration testing to represent potential dermal exposure.  The objective of this III project was to: 1) develop and validate modifications of the earlier III TDI and MDI migration procedures to incorporate the EPA migration testing procedures; 2) conduct migration tests using the modified procedure on representative foams from various foam types provided by industry; and 3) publish the results of the study in a peer-reviewed journal.  Publication of a migration testing technique consistent with that suggested by the US EPA will provide a practical objective benchmark test for flexible polyurethane foam producers to evaluate the potential migration of MDI and/or TDI from their products.

    This presentation will describe the development of the migration testing method and report the results of testing of the representative foams using the method.

     

    S19002 Novel Flame Retardants Developments for the Flexible Foam Market, Munjal Patel, ICL-IP America

    Flame retardants play an important role in meeting public fire safety code requirements as well as product performance requirements in polyurethane (PU) foam applications. In automotive PU foams, the use of flame retardant has been effective in preventing ignition and reducing the number of vehicular fires. There is increasing interest in new solutions to replace traditionally used halogenated flame retardants due to stringent original equipment manufacturer (OEM) requirements for low/no emission or migration potential, improved hydrolysis and thermal resistance, low odor in automotive PU foams.

    ICL-IP America, Inc. (ICL-IP) has innovated and continues to develop new flame retardant products to meet the ongoing challenges of today’s market where superior fire test performance and product sustainability are required.

    In this presentation, laboratory bench scale work including flammability, physical, hydrolytic/thermal resistance and emission tests will be presented on new developmental FRs for flexible foam applications demonstrating its advantages over commercially available flame retardants.

    S19004 Next Generation Low Emission Surfactant for Increased Block Yield and Broad Processing Latitude Rob Borgogelli, Evonik

    FPF manufacturers are continuously challenged to find cost-effective solutions to produce slabstock foams that meet increasing regulatory and quality requirements.  Additives play a key role in optimizing formulations to help achieve these objectives.   Silicone surfactants are especially important as they can be designed to improve emulsification, support nucleation, provide bulk stability and broaden processing latitude.  Adjusting the structural parameters to find an optimal balance of these properties is key to the development of a surfactant that offers added value to the foam manufacturer.

    Evonik has recently developed a new low emission non-hydrolyzable silicone surfactant that provides improved performance regarding gas yield and block height while still maintaining fine cell structure and broad processing latitude.  For this next generation silicone surfactant, foam processing improvements and physical property benefits will be demonstrated in this paper through studies on various foam scales and several types of foam production equipment.

    Proceedings of the Polyurethane Foam Association Technical Program
    November 2018, St. Louis, MO

    F18001 Optimized Surfactants for MDI-based Viscoelastic and Supersoft Foams” Melissa Kern, Momentive Performance Materials (Herman Stone Technical Excellence Award Winner)

    Specialty foam grades, such as viscoelastic and supersoft foams, heavily rely on the use of specialized types of raw materials. Producing a variety of foam grades, each with a specialized formulation, requires a large number of raw materials. As a result, new product development encounters space and equipment constraints. One solution is to develop a silicone surfactant that can achieve the desired foam properties using common, readily available raw materials. 

    Silicone surfactants are essential not only for foam stabilization but also in the determination of final foam properties. These are achieved via the surfactant’s ability to control cell structure and foam openness. Momentive has dedicated significant effort to the development of distinct surfactants that allow production of specialty foam grades using readily available, standard raw materials. For example, Niax* Silicone L-417 and Niax Silicone L-422 can be used to produce multiple specialty foam grades (e.g., pneumatic viscoelastic and supersoft), using the same raw materials and nearly identical foam formulations. 

    *Niax is a trademark of Momentive Performance Materials Inc.

    F18003 Occupational Toluene Diisocyanate (TDI) Exposure and the Incidence of Occupational Asthma” Patrick Conner, ACC Diisocyanates Panel

    The American Chemistry Council’s Diisocyanates Panel and the National Institute for Occupational Safety and Health (NIOSH) engaged in a joint longitudinal study to inform the management of health risks in U.S. TDI manufacturing facilities. The objectives were to: 1) characterize workplace TDI concentrations; 2) monitor employee health through questionnaires and spirometry; 3) investigate potential cases of occupational asthma using a standardized medical evaluation process; 4) create a registry of occupational asthma cases, if any, occurring among workers with potential exposure to TDI; 5) evaluate the effectiveness of the program methods, including the standardized health and environmental monitoring procedures; and 6) communicate program findings. Ultimately, three plants, with an estimated eligible workforce of 300, participated between 2006 and 2012. Dr. Conner, retired from BASF, will discuss the study methods, including medical monitoring of workers; the exposure assessment to characterize jobs and specific tasks; and study results, including health outcomes from medical assessments and incidence of occupational asthma.

    F18005 Inter-Lab Testing Of Smolder Resistance of Upholstered Furniture Components” Lynn Knudtson, PFA

    PFA managed a multi-lab study to support ASTM’s translation of Calif. TB 117-2013 furniture regulation into an international standard test method. Participating labs included PFA Manufacturing and Associate/Supplier Members, government agencies and textile companies. This Round Robin evaluated the impact of two proposed changes to the TB-117-2013 test: (1) the use of a 3″ (vs. 2”) standard vertical foam substrate and; and (2) the use of weight loss (vs. vertical char length) as a pass/fail criteria. Data has been collected and is being processed by ASTM statisticians. Neither of the proposed changes appear to alter pass/fail results. Based on these results, the ASTM 05.15 sub-committee voted to continue using char length, along with either 2″ and 2″ or the 3″ and 3″ foam combinations (whichever has the best repeatability and reproducibility as determined by ASTM staff). This result should minimize disruption to the industry from large-scale retesting of components.

    F18002 “Volatile Emissions Research From Moulded Flexible Foams In Automotive Applications” Michel Baumgartner, EuroMolders

    EURO-MOULDERs, the European Association of Producers of Polyurethane Parts for the Automotive Industry, has carried out investigations on detection of emissions of aromatic amines from moulded flexible foams under the VDA 278 emissions test as amended in 2011. These investigations include assessing parameters that may lead to detection of such emissions, notably the influence of the temperature of the test method, evaluation of the evolution of such emissions over time and air monitoring in real life conditions in both foam plants and in a vehicle. Findings to be reported show that test conditions, water content and index as well as sampling are significant factors influencing the emissions considered.

    F18004 Improved Fire Safety Without Flame Retardants--An Industry Challenge Or Opportunity” Irena Amici-Kroutilova, Dow Chemical Co.

    In the UK, flammability standards (such as BS 5852, Crib 5) are the most stringent globally. They are mainly met through the use of halogenated flame retardants such as TCPP. In contrast, other European nations have no flammability regulations but mattresses and upholstery face limits on emissions of volatile compounds established by regulation, eco-labels and brand owner requirements. 

    The tension between flammability standards and VOC limits increases manufactuing costs and complexity and threatens the global availability of certain comfort innovations. And comfort is a key driver of bedding and furniture purchases. 

    The authors discuss the challenge of formulating polyurethane foam to meet all fire safety, emission standards, and customers expectations of comfort on a global basis.

    F18006 Non-Graphite, Halogen Free, Heat Resistant Flexible Foams for UL94 V0 Automotive Applications” Lawino Kagumba, FRX Polymers

    Automotive under-the-hood flexible molded foam parts such as engine covers, need to meet more stringent flame-retardant requirements and long-term heat resistance. To meet these standards, expandable graphite combined with filler-type additives are typically used. While graphite is an effective flame retardant, its processability, particularly in high-pressure systems remains a challenge. Nofia phosphonate oligomers are a new class of heat resistant flame retardants that are chemically bound into the polyurethane backbone during foaming. The resulting foams show significantly improved heat resistance and flame-retardant performance. An additional key benefit of the polymeric nature of Nofia phosphonates is a reduction in VOC and odor compared to small molecule flame retardant additives typically used in other automotive foam applications. This paper presents a heat resistant flexible foam solution based on Nofia phosphonate oligomers that meets the UL94 V0 requirement as an alternative to the graphite-based systems.

    Proceedings of the Polyurethane Foam Association Technical Program 
    November 2017, San Diego, CA

    F17001 Introducing SlabProcessing and SlabExpert Digital Tools” Stephen Hoskins, Covestro (Herman Stone Technical Excellence Award Winner)

    This paper introduces Covestro i4ptO™ 24/7 online digital services to support flexible polyurethane foam R&D and manufacturing initiatives. Under the i4ptO™ “umbrella,” SlabExpert software allows slabstock foamers to more efficiently and effectively formulate using Covestro raw materials, while SlabProcessing provides a custom-service that helps slab manufacturers more effectively collect, monitor and compare production data and processes. Covestro digital tools serve as self-technical service improvement opportunities that interpret thousands of data points to provide new, precise perspectives to the development and processing of slab foam. Through the creation of cloud-based, low-cost, flexible, and scalable products, we are excited to introduce these tools to support the slabstock foam industry.

    F17003 Vertifoam Variable Pressure Foaming, VPF-V: Full-scale Production Insights” Bill Blackwell, OPUS Technical, Ltd.

    The Vertifoam Variable Pressure Foaming Machine, VPF-V, is now in full commercial production. This paper gives insights into the operation of the VPF-V process and shows how the VPF-V equipment and process have been developed and refined to produce highly successful new foam that has opened up new profitable markets for the PU foam industry. The paper explains how a number of both formulation and equipment developments have given improved cell structure and bun yields. It explains how a unique high pressure technology has been applied to the process giving multiple advantages, and how a brand new technique was employed to allow extended runs (over 5 hours) of highly reactive formulations without the problems normally associated with build-up. Formulation savings will be explained, as well as the efficiency of peeling large diameter, near perfect round buns, to produce a new range of foams that can outperform polyester fiber in both cost and performance for bedding and furniture applications.

    F17005 Antimicrobial Treatment of Polyurethane Foams” Tom Robitaille, Lonza Microbial Control

    The use of antimicrobials in polyurethane foam applications continues to grow as the number of antimicrobial options continue to shrink. End-users and component manufacturers are specifying very rigorous performance characteristics. Identifying the right antimicrobial product can be a daunting task. There are many factors to consider when identifying the best antimicrobial product and loading. The EPA only allows certain registered products to be used in specific applications and substrates; these regulations should be understood. Characterization of possible reactivity changes must also be understood as well as the impact on air flow and cell size. Depending on the physical nature of the antimicrobial product to be used, solid dispersion or liquid, and viscosity, processes used to add and pump the antimicrobial into the foam should be reviewed. The intent of this paper will be to educate those that may be considering the addition of an antimicrobial for the first time or maybe considering switching to a different antimicrobial product. This paper can serve as a guide for consideration as you prepare to make the change to an antimicrobially treated polyurethane foam.

    F17002 Flammability Standards for Upholstered Furnishings and Vehicles: Past, Present, and Future” Vytenis Babrauskas, Fire Science and Technology, Inc.

    Since the 1970s, flammability standards for furnishings and vehicle interiors have led to use of flame retardants (FRs) in FPF. Research continues to demonstrate exposures and health risks from the use of FRs. Despite recent progress in California, voluntary standards organizations (VSOs) continue to work towards new flammability requirements for furniture; and federal motor vehicle flammability requirements remain and are outdated. Europe currently does not have a unified flammability requirement for residential upholstered furniture; however, a petition was filed in 2016 asking the E.U. government to consider a mandatory smolder standard for European furniture based on TB117-2013. This presentation will demonstrate that the most effective way to reduce harm from flame retardants is to improve flammability standards. To enhance fire safety, benign strategies should be considered that have a proven track record of success and do not lead to widespread exposures to hazardous chemicals. These include improvements in smoke alarm technology, wider introduction of automatic fire sprinklers, and enhanced public education efforts.

    F17004 Case Study in TDI Detection Using IMS Instruments in Foam Plants” Frank Thibodeau, Bruker Detection Corporation

    Ion Mobility Spectrometry (IMS) is a scientific technique of measuring ions across a uniform electric field. It is based on the principle that when different charged molecules (ions) are accelerated through an electric field (with a “drift flow” of gas slightly opposing them); they will travel at different speeds and reach a detector at different times. The advantages of IMS instruments are: designed in relatively small packages, fairly inexpensive, rugged, extremely fast and extremely sensitive. The effectiveness of the IMS technology has been assessed in numerous foam plants under field conditions. TDI was monitored in foam plants which produced automotive and slab products. A handheld IMS instrument surveyed in and around production lines, hot & cold foam, storage tanks, transfer lines, and transfer operations. The IMS instrument was programmed with a TDI library fixed to detect and alarm at or below 1 ppb. Spectra were also collected at various locations at all foam plants for more detailed post analysis. Findings, lessons learned and conclusions will be discussed in the technical paper and presentation.

    F17006 Why Is an Ultra-Open-Cell-Window Structure Important for Cooler Sleep in Memory Foam Mattresses?” Wenbo Xu, The Dow Chemical Company

    Viscoelastic memory foams are widely used as an important material for mattress constructions, due to their pressure relieving capability. A characteristic of memory foam mattresses early on has been that they can “sleep hot” as described by a mattress OEM in patent literature. A new ultra-high air flow memory foam technology was introduced in 2016. Simulation and materials testing capabilities at Dow Chemical were used to evaluate the various materials and their contribution to cooling effects: gas convection, gas/solid conduction, and gas diffusivity. The simulations are multiphysical in nature, taking into account thermal & mass transfer, and feedback loop from human body via the ASHRAE Human Comfort model. The same simulation capabilities are able to support the development of new generation of foam material that improve on thermal comfort.

    Proceedings of the Polyurethane Foam Association Technical Program
    May 2017, St. Petersburg, FL

    S17001 Gluing and Cutting of Synthetic Foams: Innovations in the PU Industry, Sevki Ergun, Baumer of America

    The production of mattresses and upholstered furniture in the high-end sector as well as the fabrication of household products is strongly influenced by combinations of different materials such as viscoelastic, cold foam or fleece. A wide array of materials may be combined in high-level mattresses and upholstery. In many cases, gluing or bonding of various components is required. Not all gluing processes are the same and there are different methods that may be applied, depending on the material, its end-use and intended performance characteristics. 

    This presentation will describe gluing techniques such as the application of cold or warm activated, water based adhesives using roll coater technology or the application of hot-melt adhesives through a beads based application system. In addition to the aforementioned standard practices, the presentation will show the newly designed technology to allow the full surface application of polyurethane hot melt. Finally, the automated combinations of these technologies engineered by Baumer of America, including integrated cutting capability, to add manufacturing efficiency and to enhance end-product value will be explained.

    S17003 Optimized Surfactant for Flame Laminated Polyether Foam, Gabriel Kiss, Momentive Performance Materials

    In the manufacturing of polyether flame lamination foams, additives are generally used to improve the peel strength between foam and the textile. Momentive Performance Materials Inc. (Momentive) has developed Niax*silicone L-645FL, a new silicone surfactant for polyether flame lamination foam, which can provide optimum foam stabilization and cell structure control, as well as improved flame lamination and flame retardant properties. The combination of Momentive’s new flame lamination silicone stabilizer with Momentive’s flame lamination additives can allow foam producers to manufacture polyether foam that has superior peel characteristics when compared to certain traditional additives. 

    *Niax is a trademark of Momentive Performance Materials Inc.

    S17005 Update: Community Awareness Program And Workbook, Wayne Bowman, Bowman Creative + Strategy

    In the 1990s, PFA created a Community Awareness Planner for member companies to help comply with EPA’s Risk Management Plan (RMP) communications requirements. The program provided a workbook for PFA members with additional guidance for managing possible crisis communications issues. The original workbook outlined best practices for informing stakeholders including media, local residents, community officials, and others about various key issues. Since that time, new media opportunities have significantly changed communications strategies and techniques. This presentation updates community communications strategies and will provide an overview of PFA’s new guidance tool.

    S17002 The Application of ViscoElastic HyperSoft Memory Foam Technology, T. Smiecinski, BASF

    The initial development of HyperSoft foaming was a breakaway idea many decades ago by several pioneering application scientists with minimal impact on the commercial polyurethane flexible foam industry. Taking two immiscible polyols and converting them into tangible comfort product wasn’t realized until more recent times. The main driver, a novel application of HyperSoft chemistry, coupled with unique processing techniques, resulted in polyurethane foam that provided a better night sleep. Whether MDI or TDI isocyanates, these new breathable viscoelastic memory foams provide another comfort type category beyond traditional conventional and high resilient products of the day. Standard pneumatic viscoelastic foam products are limited in scope. The new HyperSoft foam method provides an expansive degree of versatility in pursuit of a more comfortable life experience. This paper will discuss HyperSoft foaming, the introduction of MDI and TDI to the viscoelastic foundation, and information insight for an array of technically sound comfort applications.

    S17004 (Paper Not Available) New Soy-Based Polyols, Systems and Blends for Flexible Foam Applications, Rick Speas, BioBased Technologies

    Natural Oil Polyols (NOPs) are not new to sustainable flexible foam applications. However, an ongoing challenge remains achieving reasonable loadings without sacrificing key physical properties. BBT will outline our research, processes, challenges and successes surrounding our newest developments in plant-based polyols, systems and blends for the flexible foam market. With tremendous opportunities for eco-friendly polyurethane applications, BBT’s team of chemical experts is constantly developing new technologies and unique properties for foams with sustainability, cost savings and performance as the primary goals.

    Proceedings of the Polyurethane Foam Association Technical Program
    November 2016, San Antonio, TX

    F16001 2012 – 2015 Update: Survey of the Incidence of Occupational Asthma Among FPF Slabstock Plants” Jim McIntyre, McIntyre & Lemon, PLLC

    The combined results from foam production worker surveys covering 1988 – 2015 indicate that the incidence of self-reported occupational asthma is very low, representing less than 2% of the surveyed worker population from plant production areas. The incidence of medically confirmed cases of occupational asthma was even lower among the participating manufacturing sites representing more than 90% of U.S. FPF production volume. The very low number of self-reported or medically diagnosed cases of occupational asthma suggests that existing workplace technologies continue to provide effective ways to mitigate possible exposure to isocyanates in the workplace.

    F16003 New Flame Retardants Developments for the Flexible Foam Market” Munjal Patel, ICL-IP America, Inc.

    Flame retardants (FR’s) play an important role in public fire safety. In automotive polyurethane (PU) foams, the use of flame retardants has been effective in preventing ignition and reducing the number of vehicular fires. There are initiatives including Proposition 65 in California, GADSL (Global Automotive Declarable Substance List) and legislative bills that require the development of new products to replace the traditionally used tris(dichloropropyl) phosphate (TDCP). The interest in sustainable new product offerings has become a priority for consumers and producers of flame retardant products. ICL-IP America, Inc. (ICL-IP) has developed reactive and/or halogen-free flame retardant products to meet the ongoing challenges of today’s market where superior fire test performance and product sustainability are required. The focus of this paper will be on the introduction of a new reactive FR for use in flexible polyurethane foam. Flammability, scorch, fogging (FOG) and volatile organic compound (VOC) performance data are presented for the new product, illustrating its advantages over the commercially available product offering TDCP in automotive flexible foam applications. This paper documents a series of evaluations using laboratory bench scale tests to show improvements in the combustion and emission properties with this new product offering.

    F16005 Ester Flexible Foam Performance Comparisons Between EG Azelate (C9) and DEG Adipate (C6) Polyols” Michael Brooks, Emery Oleochemicals LLC

    EMEROX® Polyols are made from dibasic acids that are produced from Emery Oleochemicals’ proprietary ozonolysis technology. These polyester polyols possess a high level of renewable content while providing all the structural design freedom of petrochemical-based polyols. A broad range of functionalities and molecular weights are available including highly-branched to linear structures with high-to-moderate reactivity (primary and/or secondary hydroxyl groups). Emery Oleochemicals has developed EMEROX® 14060, an EG azelate C9 ester polyol for flexible foam and C.A.S.E. applications. This paper compares polyol structures and physical parameters as well as ester flexible foam performance properties for EMEROX® 14060 and a traditional DEG adipate C6 polyol in typical 2 pcf formulations. Overall, EMEROX® 14060 meets and exceeds (enhanced hydrophobicity, reduced hydrolytic degradation, and increased hydrocarbon resistance) the performance properties obtained from traditional DEG adipate polyester polyols for many applications and should be considered as a superior alternative.

    F16002 Variable Pressure Foaming Using the Vertifoam Process” Bill Blackwell, Opus Technical Ltd

    The purpose of this paper is to show how two well-proven foaming systems (VPF and Vertifoam) have been combined to make a brand new foaming process with advantages that are greater than the sum of its two halves. This paper explains the technical and commercial advantages of each process and shows how a range of new foam products with unique physical properties and price advantages can be produced which allow the foamer to expand into new markets with significant increases in profitability. It will show how the VPF-V process is affordable and compatible with all sizes of foaming companies and it will demonstrate how polyurethane foams can be engineered to meet new demands. applications.

    F16004 Detection of Isocyanates in the Workplace Using IMS Instruments” Frank Thibodeau, Bruker Detection

    The military in various countries around the world has used Ion Mobility Spectrometry (IMS) based detectors to protect personnel, platforms, facilities and even regions from the effects of chemical attacks for more than 40 years. IMS is a scientific technique of measuring ions across a uniform electric field. It is based on the principle that when different charged molecules (ions) are accelerated through an electric field (with a “drift flow” of gas slightly opposing them), they will travel at different speeds and reach a detector at different times. The advantages of IMS instruments are that they are designed in relatively small packages, fairly inexpensive, rugged, extremely fast and extremely sensitive. Disadvantages are that resolution and selectively is limited resulting in smaller libraries and potential for false positives. However, in the industrial setting where chemical environments are known, disadvantages are easily compensated for certain hazardous compounds. Bruker’s success in optimizing and developing best in class IMS can assist industry in protecting workers and communities while improving productivity and the bottom line.

    F16006 Recent JFLEX Technology Developments” Jim Shoup, Hennecke, Inc.

    This presentation details recent JFLEX technology developments that allow efficient smaller-scale production of a wider range of flexible polyurethane foams including high resilience, viscoelastic, high-load and low density foam varieties. Physical properties for a range of possible value-added products will be shared. The paper also explains and demonstrates new machine innovations to improve vertical cell orientation and to help produce consistent smaller-volume products with excellent cell structure.

    Proceedings of the Polyurethane Foam Association Technical Program
    Spring 2016, St. Petersburg, FL

    S16001 Responsible Management of Waste Foams Mixed with Flame Retardants” Sara Petty, Green Science Policy Institute

    Until recently, the foam in furniture contained flame retardants in order to meet a California flammability standard called Technical Bulletin 117 (TB117). This regulation was updated to a smolder standard called TB117-2013, which has made furniture without flame retardants increasingly available. But as consumers purchase new furniture, discarded furniture is typically either landfilled or given to a second-hand market, where the flame retardants continue to pose a risk to human health and the environment. Responsibly managing waste foams that contain flame retardants presents a complex challenge which could benefit from input from a broad base of experts. On April 12-13th, more than 40 experts from industry, academia, government, and nonprofits met in Berkeley, CA to investigate how to improve management of these wastes. Topics included the scope of the problem; lifecycle considerations; exposure to flame retardants based on waste management practices; and how to fund possible advancements. This presentation will highlight the topics covered in the workshop as well as outcomes and opportunities for potential partnerships between various stakeholders.

    S16003 Development of Flexible Polyurethane Foam with Improved Environmental Profile to Meet Stringent Flammability Tests” Kurt Reimann, Fogg, Reimann, Shen

    In recent years society has seen many changes regarding the acceptance of various fire retardants for flexible polyurethane foam (FPF). Fire retardant grades of FPF must comply with today’s environmental demands. While some application requirements have changed to the extent that fire retardant additives are no longer necessary, other applications with more stringent standards still require the use of fire retardant chemistries. The present work examines some of these requirements and has adapted specific chemistries to provide technically feasible solutions to meet future demands. Bench scale laboratory methods were combined with industry standard large scale tests to evaluate performance for furniture, mattress, and packaging foams. The resulting FPF have been shown to meet or exceed all test requirements. The laboratory methodology and results of appropriate large scale flammability test are presented.

    S16002 Update: Modification of the ASTM E-1428 Pink Stain Test Method” Tom Robitaille, Lonza

    Lonza previously presented a review of the rationale and manner for modifying the current ASTM E 1428 Pink Stain Test method. The current ASTM E 1428 test method may not be reliable and can be very frustrating for those that are required to pass the test routinely. The Committee Working Group is progressing to the final stages of its review. This presentation will provide the current status of this work with an update on the team’s effort to make the pink stain test more reliable and meaningful for both foam producers and end-users.

    S16004 Performance Comparisons of Renewable Resource Polyols for FPF” Michael Brooks, Emery Oleochemicals LLC

    Market demand and development for renewable resource polyols is increasing, but sustainability with performance can be challenging for flexible polyurethane foam systems. While the idea of making polyurethane foam from renewable resources is appealing, foam performance, quality and economics should not be negatively impacted. Natural (castor) oil or modified (soybean, cashew, canola, etc.) natural oil polyols (NOPs) can be more difficult to engineer for a specific application than their petrochemical equivalent. This paper explores conventional Toluene Diisocyanate (TDI) polyether flexible slabstock foam performance properties with partial substitution levels of renewable resourced polyols: EMEROX® 14050, Castor Oil, and two Soy-Based Polyols. Foam performance properties via ladder studies are compared.

    Proceedings of the Polyurethane Foam Association Technical Program
    November 2015, Niagara Falls, Ont.

    F15001 A New Method for Measurement of Propensity of Polyurethane Foam/Fabric Assemblies to Transition from Smoldering to Flaming Combustion” Stanislav Stoliarov, University of Maryland

    A transition from smoldering to flaming is a significant concern for regulatory agencies responsible for developing and enforcing fire safety standards for furniture. This phenomenon is poorly understood because of its sensitivity to a multitude of physical parameters and a lack of bench scale experiments where it can be observed under controlled and reproducible conditions. Here we report on development of a new apparatus which enables observation of this transition using a relatively small sample consisting of one 5x20x30 cm flexible foam block wrapped in a fabric of interest. In this apparatus, smoldering process is initiated using a local electric heating and gradually intensified due to self-heating and resupply of oxygen driven by natural convection. For a combination of a widely used flexible polyurethane foam and cotton fabric, this experiment yields a highly reproducible transition. It is also demonstrated that this experiment can be employed to discriminate between various foam/fabric compositions in terms of their propensity to transition to flaming.

    F15003 New Polymer Polyol for Slabstock Foam Applications, Scott Charlton, Covestro LLC

    Polymer polyols (PMPOs) are graft polyols, which contain finely dispersed particles, such as polystyrene and/or polyacrylonitrile in polyether polyols. These polyols are an integral component and are widely used in polyurethane production, typically in High Resilience (HR) and Conventional foam grades. Covestro LLC has developed and will soon bring Arcol® Polyol HS-200 into the flexible foam polyurethane industry. This new polyol will replace Covestro’s existing Arcol® polyol HS-100 and Arcol® polyol UHS-150. The information discussed in this paper will be the potential performance advantages of the new material with regards to better load building, lower TVOCs, lower viscosity, better CO2 foam processing, less material usage and better filtration properties.

    F15005 A Comprehensive Analysis of Carbon Black Colorant Technology: The Components, Their Function and Potential Effect on Urethane Flexible Foam, Lisa Collette, Chromaflo Technologies Corp.

    Carbon black colorants all appear similar and it is a common misconception that they all perform as such. However, carbon black colorants are a complex matrix consisting of multiple components, of which there are multiple grades and differing chemistries. This paper explores the potential components in a carbon black colorant and the impact they can have on the properties of the colorant as well as the effect on urethane production processes and the final urethane flexible foam. The goal is to educate decision makers to select the optimal carbon black colorant for their urethane flexible foam.

    F15002 Novel Technology to Influence Hardness of Flexible Polyurethane Foams” Roland Hubel, Evonik Industries AG

    There are several ways to influence hardness for the production of flexible polyurethane foam. Reduction of hardness usually has only limited impact on other foam physical properties. However, an increase in hardness is not always possible without undesirable changes to other foam physical properties. There are different ways to increase hardness. For example it is possible to strengthen the three dimensional network of the polyurethane foam. Usually better cross-linking leads to increased hardness. But, this approach can also create more closed cell structure. Porosity change can cause undesired loss of breathability and can affect long term performance. Evonik has put a lot of effort into understanding the hardening effect of foams. In order to create a foam hardener which does not affect other foam physical properties, Evonik has developed a tailor-made, highly sophisticated foam hardener additive, a synthesized new ORTEGOL product to combine low use level with a significant increase in hardness without impact on other foam physical properties.

    F15004 EMEROX® 14050 Renewable Polyol; Effect upon Substitution Rate on Flexible Foam Properties, Michael Brooks, Emery Oleochemicals LLC

    Emery Oleochemicals LLC, through its Eco-Friendly Polyols platform, offers EMEROX® renewable content polyols. Renewable (bio-based) polyols continue to be important to consumers and are increasingly specified by OEMs. Sustainability and performance can be challenging for flexible polyurethane foam systems based on modified natural oils (NOPs, or natural oil polyols). Typically NOPs can be more difficult to engineer to a specific application than their petrochemical equivalent. EMEROX® polyols are produced from renewable dibasic acids that are a product of Emery Oleochemicals’ proprietary ozonolysis technology. These polyols have all the design freedom of a petrochemical based polyol, but with high renewable content. This paper explores the performance properties of partial substitution of EMEROX® 14050 polyol into typical conventional TDI polyether and polyester foam formulations. Inclusion of a renewable content polyol can affect foam physical properties in unexpected ways. An interesting finding via ladder studies was that polyether foam compression sets and constant force deflections were only slightly affected while tensile strength, tear strength, and percent elongation increased by incorporating this renewable content polyol. Additionally, EMEROX® 14050 polyol also supports production of good quality polyester foams with the benefit of a more hydrophobic and flexible backbone. Minimal compromises in physical properties are apparent when substituting EMEROX® 14050 for traditional adipic acid/DEG based polyester polyols.

    Proceedings of the Polyurethane Foam Association Technical Program
    May 2015, St. Petersburg, FL

    S15001 Novel Catalyst for Low-Emission Viscoelastic (VE) Foams Ryohei Takahashi, TOSOH Corporation

    Viscoelastic (VE) foams are a type of flexible polyurethane foam which exhibit characteristics of both resiliency and viscosity. VE foams exhibit low resiliency, high viscosity, vibration damping, sound absorption and good texture. These characteristics have led to increased demand for VE foams in products such as high quality pillows, mattresses, care beds and seat pads for wheelchairs. For VE foam producers, Volatile Organic compounds (VOCs) emissions from polyurethane foams continue to be an important issue due to the growing interest in eliminating emission related problems, such as odor, blue haze and potential health risks. Using reactive amine catalysts is one option to reduce VOCs. Reactive amine catalysts are incorporated into the polyurethane structure by reacting with isocyanates, which enables lower VOCs levels. However, as VE foams exhibit narrow process latitude, existing reactive amine catalysts which have insufficient gelling abilities, fail to produce reliable and stable VE foams. Therefore non-reactive amine catalysts, such as Triethylenediamine, remain the catalyst of choice for VE foam production. TOSOH has developed a unique reactive amine catalyst: RZETA®. RZETA® provides strong gelling ability and higher catalytic activity among reactive catalysts. VE foams produced with RZETA® exhibit good formability and improved foam physical properties. In addition, amine emissions can be eliminated and total VOCs of VE foams can be reduced by using RZETA®.

    S15003 Improved Viscoelastic Foam Formulation Technology Bill Gower, Bayer Material Science LLC

    A continued trend in the manufacture of viscoelastic polyurethane flexible foams is to achieve higher quality and even lower density foams. Past formulation or machine processing limitations can be overcome by new formulation techniques which can reduce the need for multiple, unique polyols and/or isocyanates. This paper will introduce these simplified formulation options that may help foam producers to be able to offer foam grades from 1.5 pcf to 5 pcf density. It will also highlight the raw material versatility to achieve improved physical property and foam quality to introduce to the marketplace.

    S15005 Highly Sophisticated Cell Opener for Viscoelastic Foam Roland Hubel, Evonik

    TDI 80 viscoelastic formulations have a tendency toward closed cell structures, which often result in shrinkage. The role of the cell structure – cell fineness and porosity – turns out to be significant for viscoelastic foams relying on the pneumatic as well as the adhesion effect. Therefore, careful control of cell regulation and cell opening are the main challenges in production of viscoelastic foam. The foam structure is affected by the foam stabilizer and the processing conditions. Hence, the polyether siloxane foam stabilizer plays an essential role for both processing and the final foam properties. Evonik has put a lot of resources into the development of a tailor-made, highly sophisticated cell opener for TDI 80 viscoelastic foam. Therefore we have synthesized new polyether siloxane structures to combine smooth stabilization with controlled cell opening and present an optimized new product for TDI 80 viscoelastic foam cell opening. A smart combination of the chosen foam stabilizer and the new cell opening additive allow the tailoring of cell structure of TDI 80 viscoelastic foam.

    S15002 Renewable Carbohydrate Solution That Imparts Flame Retardant Properties in Polyurethane Foam David Patten, Everchem Specialty Chemicals

    This presentation discusses a new renewable carbohydrate solution based on sucrose that can be incorporated at low concentrations to improve foam combustion performance without the use of any traditional flame retardant chemicals. The discussion will introduce the molecule and to the patented technology that is used to reduce the water level of the sucrose so that it can be incorporated into flexible foam formulations. The Safety Data Sheet information will be reviewed and the physical properties of the carbohydrate solution presented. The presentation will provide foam properties based on physical testing using a typical starting formulation.

    S15004 Aliphatic Polyester Polyols with Recycled Content for Flexible Polyurethane Foam Rick Beatty, INVISTA

    Polyurethane formulators continue to develop new applications using INVISTA’s TERRIN™ polyols, which are 100% aliphatic polyester polyols with unique structures that contain a minimum of 50% recycled content; some also have renewable content. These polyols offer formulators alternatives that can help achieve the often contradictory objectives of meeting performance requirements, while also minimizing cost. This paper describes TERRIN™ polyols, and reviews the properties of viscoelastic (VE) and high-resilience (HR) foams made using model foam formulations. The results suggest that TERRIN™ polyols can be considered as partial drop-in replacements for polyols commonly used in these types of foams. Little or no adjustment is needed to the formulations and, depending on the formulation, some improved properties may be obtained. Key benefits seen with both VE and HR foams include increased strength, increased compression force deflection (CFD) for improved load-bearing capability, and possibly lower burn rate. The strength and CFD improvements suggest that TERRIN™ polyols have potential to replace graft polyols in HR foam when seeking improved load bearing properties.

    Proceedings of the Polyurethane Foam Association Technical Program
    November 2014, Chattanooga, TN

    F14001 Art and Science of Microencapsulated Phase Change Materials in Flexible Polyurethane Foam, Jei McKinney, Encapsys® (Herman Stone Technical Excellence Award Winner)

    This presentation provides an introduction and overview of the microencapsulation technology and will discuss the application of Encapsys® Phase Change Materials (PCM) in flexible polyurethane foam production. This technology is based on the performance of extremely small capsules (typically 5 to 40 microns for use in foam production) that permanently contain PCMs and allow the PCM to absorb thermal energy when exposed to heat. Test results demonstrate the ability of Encapsys® microencapsulated PCM to provide significant cooling benefits in flexible polyurethane foam in mattresses and pillows. The presentation will provide information on capsule size and performance consistency, energy absorption control, and compatibility with flexible polyurethane foam continuous pouring production.

    F14003 Understanding Pink Stain Testing Scott Brown, Lonza

    This paper addresses significant industry concerns regarding recent polyurethane foam failures in the standard ASTM E-1428 pink stain test protocol. Understanding what actually causes pink stain, how and why it occurs, and what it takes to pass the current ASTM 1428 test standard is critical to identifying why these failures are occurring at foaming plants around the world. Prodiginine pigments are the typical components that are responsible for the pink staining of both polyurethane foams and vinyl substrates. These are pigments are the metabolic excretions of various bacteria called Streptomyces; Streptoverticulum reticulum being the specific Streptomyces used in the ASTM E-1428 test. The marine environment is especially prone to pink staining, however, bedding, flooring and other construction components are also susceptible to pink stain problems. This paper highlights the details of the staining process and provides a review of the current ASTM E-1428 test as it specifically relates to polyurethane foams. Modifications to this test are likely the key to success for the polyurethane foam industry. The current work underway and the positive results to date will also be discussed.

    F14005 Conversion of FPF Residues into Polyol on an Industrial Scale Lyudmila Skokova, H&S Anlagentechnik GmbH

    This paper describes commercially-viable H&S Technology for conversion of flexible PU foam residues into polyol based on an optimized acydolysis method. FPF residues are dissolved in a mixture of polyether polyol, carboxylic acids and catalyst. The recovered polyols, having the appropriate hydroxyl number, very low acid groups which is important for good polyol reactivity, and minimal concentrations of primary aromatic amines, can replace up to 20% – 25% of the original basic polyol. Currently, various grades of conventional foams and HR foams produced with SAN polyols can be recycled using H&S technology. Recycling technology for viscoelastic foams is under development.

    F14002 Controlled Pore Size in FPF Manufacturing Tom Cushman, Cushman Engineering

    Flexible polyurethane foams for technical applications with tight performance specifications manufactured for further processing (e.g.: chemical or thermal reticulation) require uniformly controlled pore size. Basic elements of pore size control are addressed. These elements are largely the relationship of processing parameters such as pressure, temperature, dissolved gas and mixing shear to resultant pore size. The effect of adjusting each of these control parameters is examined. An emphasis is placed on controlling dissolved gas level in the isocyanate stream and polyol stream. Examples of equipment configurations required to obtain good pore size control are discussed and illustrated with piping schematics and equipment diagrams.

    F14004 Final Report: Emissions Testing of Cured FPF for TDI / MDI Nick Ordsmith, Hall Analytical

    This comprises the final report on emissions testing of high-density specimens of conventional, high resilience, super-soft and viscoelastic foams for the presence of TDI or MDI. Small chamber testing was conducted using the International Isocyanates Institute protocol for the collection and analysis of emanations of flexible polyurethane foam. TDI/MDI emissions testing was performed on 24 freshly-cured foams samples representing 6 specimens in each of 4 foam categories using a validated emissions testing and analysis method. There were no detectible TDI/MDI emissions.

    F14006 How Maxfoam Machine Design Affects Pour Yield, Waste Reduction and Gross Margin Per Henning Vaagen, Laader Berg®

    This paper provides a brief history of foaming system developments and examines the effect of the Maxfoam mechanical pour system on foam yield, waste generation and gross margin. Data are provided to demonstrate how machine design impacts bun shape, density distribution and raw material consumption.

     

    Proceedings of the Polyurethane Foam Association Technical Program
    May 2014, St. Petersburg, FL

    S14001 JFLEX Technology Production Results Jim Shoup, Hennecke

    Hennecke JFLEX foaming technology was presented at the 2013 Fall PFA meeting. Since this meeting, the first production JFLEX plant has been installed and is operational. The results of the foam production and status of the plant will be presented in this paper. Observations and data demonstrate that resulting foam production have been very good. The novel JFLEX technology laydown method produces pin hole free foam as entrained air is able to escape prior to the foam starting to react. The technology also performs well with higher viscosity chemicals. Data and production samples demonstrate processability of Visco polyols, Graft polyols and MDI. The color distribution is excellent and uniform and color changes are very short as compared to a traditional trough machine. The cell size will be shown to be very fine and controllable.

    S14002 Flexible Polyurethane Flammability Performance and Sustainability Technologies Mike Goode, ICL-IP America

    Recently, flame retardants have been much maligned and the subject of what seems endless public debate. “Flexible Polyurethane Flammability Performance and Sustainability” provides a look at the recent development and evolution of flame retardants for flexible polyurethane from longstanding commodity products to newer products with improved sustainability profiles. This paper will introduce these new more sustainable flame retardants by benchmarking their flame retardant efficacy versus the antiquated commodity products and highlight their more sustainable characteristics and attributes.

    Proceedings of the Polyurethane Foam Association Technical Program
    November 2013, New Orleans, LA

    F13001 New JFLEX Continuous Process Slabstock Machine for Lower Volume Production Needs Jim Shoup, Hennecke (Herman Stone Technical Excellence Award Winner)

    Traditional slabstock equipment used in the US today typically provides high-volume output of about 650 pounds per minute. This output rate may not be practical for smaller-volume pour runs. This paper presents the new Hennecke JFLEX pour technology, new continuous processing equipment capable of pouring conventional foam products are a rate of as slow as 3 feet minute, or about 25% of typical pour speed, for better management of small-volume pour runs. JFLEX equipment requires a much smaller “footprint,” having a machine length of about 30 feet. This paper will discuss new foaming principles supported by the JFLEX machine, equipment design and operation, and how a JFLEX machine can provide a better way to serve smaller-volume custom formulation needs.

    F13003 Low Volatile Organic Compound Aromatic Polyester Polyol for Flexible Slabstock Foams Khalil Khameneh, Stepan Company

    Recent activity within the flexible foam industry has focused on reducing the presence of Volatile Organic Compounds (VOCs) introduced into the foam from the raw materials.The presence of VOCs is of particular concern in both CertiPUR-US® rated foams and flame laminated foams used in automotive applications. Aromatic polyester polyols are known to improve foam bond strength to fabric, boost mechanical properties, increase foam hardness and may reduce the required flame retardant usage in flexible slabstock foams. However, standard grades also contribute to fogging and VOC emissions. Stepan has developed STEPANPOL PF-185, a novel aromatic polyester polyol that when used in polyether slabstock foam formulations provides the traditional benefits associated with aromatic polyester polyols while meeting new industry requirements for fogging and VOC emissions.

    F13005 New Tin Catalyst for Use in Flexible Foam Applications, 2-Ethylhexanoic Acid Free Alternative to Stannous Octoate Greg Pickrell, Momentive

    Momentive Performance Materials Inc. introduces Niax® catalyst D-25, a new tin catalyst manufactured to be free of 2-Ethylhexanoic acid (2-EHA). This new product is in response to the industry need for an alternative gel catalyst to Stannous Octoate, without 2-EHA. Niax catalyst D-25 may be considered for use in the production of flexible slabstock foam, including conventional, high resilience and viscoelastic applications. It typically yields high catalytic efficiency in the polyurethane foam gelling reaction comparable to Stannous Octoate, tin catalyst currently used for these applications. This new tin catalyst can provide equivalent foam performance to Stannous Octoate without the inclusion of 2-EHA in the finished foam product. Depending on the foam formulation, optimization of the tin and amine catalysts use levels may be required to achieve desired reactivity profiles and foam properties. This paper addresses the use of Niax Catalyst D-25 in flexible foam applications, including catalytic activity, foam performance and elimination of 2-EHA, compared to the current industry standard Stannous Octoate tin catalyst.

    F13007 Testing Emanations of Flexible Polyurethane Foam for the Presence of Free TDI or MDI Nick Ordsmith, Hall Analytical

    This paper provides a preliminary report on emissions testing of high-density specimens of conventional, high resilience, super-soft and viscoelastic foams for the presence of TDI or MDI. Small chamber testing was conducted using the International Isocyanates Institute protocol for the collection and analysis of emanations of flexible polyurethane foam. This protocol was published based on TDI only and an initial method implementation and validation study was performed to demonstrate linearity over a range of concentrations. At this stage, the addition of MDI as an analyte was also validated. This also served to develop a cost effective on-going analytical strategy for regular monitoring of foam samples. During the routine testing of foam samples, as part of the CertiPUR-US® program, additional TDI/MDI testing has been performed on suitable candidate foams using the expanded, validated method. This has yielded some preliminary data as part of a planned experiment to cover multiple samples from each foam family. The results to date will be shown.

     

    F13002 Advancements in PET-based Flexible Polyurethane Foams Michael Dubois, Soft Spuma

    Current raw material economics invite investigation of formulation technologies to reduce dependence on petroleum based components while maintaining or improving foam product physical properties. This paper discusses advancements in commercialized flexible polyurethane foam with significant PET resin content of up to 40% for some applications. Possible PET-based formulation applications include foams for furniture, bedding and automotive, including viscoelastic foam products. New achievements in PET formulation and processing technologies will be discussed with resulting foam physical and performance properties.

    F13004 Reactivity Rates and Physical Properties for Zinc Pyrithione Formulated Low-density Conventional Polyether/TDI-based Slabstock FPF Tom Robitaille, Lonza

    Zinc pyrithione is well known for providing strong antimicrobial effects to polyurethane foams as well as many other materials. The antimicrobial performance of zinc pyrithione provides both hygienic surface effects (ex-US) and true preservative effects to treated articles such as bedding, pillows and other shock absorbing foams. The fact that zinc pyrithione provides strong performance in both types of antimicrobial “effects” distinguishes it from other antimicrobials on the market today. Despite the exceptional antimicrobial performance characteristics of zinc pyrithione in polyurethane foams, it can have a negative impact on the foaming process and the resulting physical properties of finished foams. This report characterizes the impact of zinc pyrithione on these parameters in a light-density slab-stock foam with special focus on the impact of Lonza’s in-house proprietary stabilization of zinc pyrithione. This work demonstrates a positive impact of the stabilization of zinc pyrithione on reducing the catalytic effects typically seen with standard zinc pyrithione. This positive effect is seen primarily in the reactivity rate (~30% improvement), air flow (~4X improvement), and rebound resilience (25.7% improvement) over un-stabilized zinc pyrithione.

    F13006 New Polymer Polyol for Combustion Modified High Resiliency Foams Chris Thiede, Dow Chemical

    Dow recently developed a new polymer polyol with intrinsic flammability performance for high resilience and combustion modified high resilience flexible polyurethane foams. The polyol can be used to produce a wide range of foam densities with hardness up to 400 N in both standard and flame retardant grades for BS 5852 (Crib 5). Foams can be produced with a broad processing latitude, resulting in excellent foam physical properties such as high resilience, low compression sets and dynamic fatigue hardness loss. Foams required to meet British Standard Furniture and Furnishings Fire Safety Standard BS 5852 can easily be produced using melamine, TCPP or a synergistic combination of both with significantly reduced levels of flame retardants in comparison to foams prepared using styrene acrylonitrile (SAN) copolymer polyol (CPP) technology. The performance and versatility of this new technology means that a single polymer polyol can be used to produce the entire product range without the addition of other flame retardant polyols or high solids SAN CPP. This paper demonstrates the versatility of this polyol via an overview of foam grades, physical properties and flammability performance.

     

    Proceedings of the Polyurethane Foam Association Technical Program
    May 2013, St. Petersburg, FL

    S13001 Past, Present And Future Trend Of PentaBDE In Foam Products In The Use And Waste Phases From 1980-2020 Miriam Diamond, University Of Toronto, Great Lakes Coalition

    This is a preliminary report on the temporal trends in the mass of pentaBDE in polyurethane foam products from 1980 to 2004, and the mass in products that move from the use to waste phase with comparisons to those of octa- and decaBDE mixtures that have been used in electronic products and the transportation sector. Use of pentaBDE in furniture polyurethane foam was higher than in the transportation and electronic sectors. Research is on-going to quantify the use of decaBDE to flame retard textiles. Results suggest that despite the rapid decrease in the mass usage of pentaBDE after 2004, this substance will remain in products in the use phase until 2020. The accumulation of pentaBDE containing products in the waste phase will continue to contribute to the environmental burden of this mixture unless appropriate waste management practices are implemented.

    S13003 Methods For Identification Of Flame Retardants In Polyurethane Foams Graham Peaslee, Hope College (Herman Stone Technical Excellence Award Winner)

    Changing flammability standards and increasing public awareness of the eco-toxicity of halogenated flame retardants may have significant implications for polyurethane foam manufacturers and their customers. There will be increasing interest in end-of-life alternatives for existing products with halogenated foam. Similarly, increasing costs of petrochemical feedstock will continue to drive interest in polyurethane foam recycling. In both cases, identifying whether a sample of soft polyurethane foam has flame-retardant chemicals added to it will play a key role. The traditional methods for determining the presence of flame retardant chemicals in foam and identifying them are both time-consuming and costly, or else they are limited in the type of halogen they detect (only Br). This presentation describes a novel method for the rapid detection and identification of all chemical flame retardants in foams, plastics and fabrics and provides preliminary results of ion beam analysis of several hundred foams samples compared to traditional methods with an estimate of relative analysis costs. The impact of this technology (and future technologies) in this area is discussed.

    S13005 Application Of WALKI Technologies In Continuous Flexible Foam Production Ari Pietila, Walki Group

    WALKI “Peelable Products” are specifically designed to improve the efficiency of flexible polyurethane foam production through foam waste reduction. All PeelFoam and CoverFoam products contain strong craft paper. Re-use or sale of scrap paper for other usage provide attractive options for the foam manufacturer. Coated film is attached to foam block. PeelFoam products are specifically made to provide adjustability and low adhesion. This assures that the peelable film is well attached to the foam bun and that the paper can be rolled off efficiently. The peelable film therefore protects the foam and creates the desired insulating layer. CoverFoam products require extremely high adhesion and must be kept attached to the bun as part of the lamination process at all times.

    S13002 Low VOC Cal TB117 Using Bio Renewable Technologies Jeff Rowlands, Green Urethanes Limited

    The well-respected Cal TB117 flammability standard is on the block because of its environmental impact through the historic use of flame retardants which have now been found to leave the foam and impact people. The paper discloses an alternative route to passing this internationally accepted flammability standard which ensures that the flame retardant remains within the foam. The route involves heavy use of recently developed novel “Green Chemistry” , and this ensures that the two original objectives of Cal TB117; enhanced resistance to ignition leading to a fire and, enhanced escape time from a fire, are still preserved.

    S13004 Novel Reactive Gelling Catalyst For Extremely Low-Emission Flexible Polyurethane Foam Takao Suzuki, TOSOH Corporation

    TOSOH Corporation has developed a novel reactive amine catalyst (Reactive-TEDA) that demonstrates strong gelling ability in the polyurethane (PU) reaction and exhibits extremely low emissions while promoting improved foam durability and properties. Within certain applications, reducing the Volatile Organic Compound (VOC) content in PU systems continues to be an important issue as a means to improve product performance and user safety. The choice of PU catalysts plays a role in the VOC issue. A variety of reactive amine catalysts, which have a hydroxyl or an amino group as a reaction site with isocyanates, have been proposed to reduce VOC issues. Many of these reactive catalysts provide inferior durability performance. Fundamentally, reactive amine catalysts can be incorporated into the polymer network and lose their catalytic activity during the latter stages of the foaming process. Typical reactive amine catalysts can also work as chain terminators, thus hindering the growth of the polymer structure; this can result in inferior foam properties. Since most reactive catalysts available today demonstrate blowing or balanced catalytic activity, the need for a strong gelling reactive catalyst remains present in the marketplace. This technical paper describes the performance of TOSOH’s newly developed reactive gelling catalyst evaluated in both flexible slabstock and HR-molded foam formulations. A new catalyst package is also proposed for the reduction of VOC using non-fugitive catalysts.

    S13006 The Cusum Chart: An Additional Tool For Quality Control Stuart Watson

    Statistical Process Control (SPC) has long been a staple of quality control methodology, but in some applications it has not been sufficiently sensitive to detect small changes in product quality. An alternate method termed a Cusum Chart is reviewed and shown in application to polyurethane foam manufacturing. Cusum Charts are demonstrated to be highly sensitive to process change and give rapid signally of small changes.

     

    Proceedings of the Polyurethane Foam Association Technical Program
    November 2012, Hilton Head, SC

    F12001 Summary of Recent Studies Presented at the Isocyanates & Health Conference Mark Spence, III; Barbara Cummings, Dii Panel

    This presentation summarizes six papers submitted by the International Isocyanates Institute (III) for presentation at the “Isocyanates and Health” conference covering III research on worker and consumer exposure, toxicology testing, human cancer risk, environmental exposure and monitoring, and occupational health management of interest to the flexible polyurethane foam industry.

    F12003 Comparison of NIST SRM 1196 and Various Commercial FSC Cigarettes for Smolder Testing Bob Luedeka, PFA

    This presentation summarizes the results of a nine-month investigation by the Polyurethane Foam Association of the smolder testing performance of a number of cigarettes including various FSC brands and the NIST SRM 1196. Initial smolder testing of more than 1,100 commercially-purchased FSC cigarettes showed that some brands of FSC cigarettes had a very high probability of burning full length without relights when tested using the TB 117 protocol with a cover sheet. This led to more smolder evaluations and interlaboratory validation of the findings. Interlaboratory trials confirmed that as foam density goes down, smolder-caused substrate weight loss decreases and that as firmness increases smolder weight loss drops. There was no statistically significant difference in weight loss effects from smolder testing between one brand of FSC and the NIST SRM 1196 cigarette, or in the variations of physical properties including cigarette length, diameter and weight. Results of more than 4,000 total trials support the recommendation that smolder test standards specify cigarette physical characteristics within a tolerated variance instead of naming a specific smolder ignition material.

    F12005 Viscoelastic Foam with Temperature Independent Comfort Charles Ritchie, PCC Rokita

    This presentation describes PCC Rokita Rokopol vTec polyols that can provide a broad range of glass transition and optimum low resiliency performance over a wide ambient temperature range. These characteristics help to improve comfort qualities in bedding and also improve handling of viscoelastic foam products during conversion processing. Typical viscoelastic foams are difficult to handle and move when they are warm and are difficult to cut when cold, so they need to be stored and conditioned at a convenient temperature in advance. Rokopol vTec based foams avoid this need.

    F12007 Ultra-green Non-hazardous Cured Polyurethane Cleaner Andrew Hiron, Bio8 Ltd

    Bio8 Ltd Envii700 series products are non-hazardous, environmentally-compatible cleaning solutions for use with cured polyurethane foam. The series includes products for specific applications such as EN705, a liquid cured polyurethane cleaning product for use in dip tanks, and EN706, a gel for use on larger items and production equipment. The presentation describes other new products including EN720, an ester-based flushing compound that can be used in place of Methylene Chloride for in-line flushing of pour lines and heads. This product can be filtered and reused numerous times.

    F12002 Precision and Bias of the CertiPUR-US® Test Method for Volatile Organic Compounds Stu Watson, AFPF; Doug Sullivan, AFPF

    A 24 designed experiment with replication was conducted with flexible polyurethane foams having higher or lower levels of emitted volatile organic compounds (VOC). The testing revealed that the data were normally distributed and that no statistically significant difference between testing chambers or operators existed, and the test could reproducibly distinguish between the High and Low emission samples. The population standard deviations for Aromatic Hydrocarbons and Siloxanes yielded strong guidance for attainment of passing values while the results for TVOC (Base Rate) suggested opportunities for continuous improvement in sampling and testing. The values were used to give probabilities of success in future confirmation tests.

    F12004 Survey of the Incidence of Occupational Asthma among FPF Slabstock Plants Lynn Knudtson, PFA

    The combined results from foam production worker surveys covering 1988 – 2011 indicate that the incidence of self-reported occupational asthma was low, representing less than 2% of the surveyed worker population. The incidence of medically confirmed cases of occupational asthma was even lower (six cases) among the participating manufacturing sites representing more than 90% of U.S. FPF production volume. The very low number of self-reported or medically diagnosed cases of occupational asthma suggests that workplace controls were adequate and/or effective in the surveyed plants.

    F12006 Novel CO2-based Polyols as Flexible Foam Strength Enhancers Jason Anderson, Novomer, Inc.

    Novomer has developed a unique route to high performance sustainable polyols using a proprietary catalyst system to combine waste carbon dioxide (CO2) with standard epoxides. This original technology delivers renewable polycarbonate polyols that are up to 50% CO2 by weight, have a 3-9x carbon footprint advantage vs. existing petroleum-based materials, and can be cost competitive with existing polyether and polyester polyols at commercial scale. In recent flexible foam testing studies, use of Novomer polypropylene carbonate (PPC) polyols as a minority component of the polyol formulation resulted in foams with significantly increased compression force deflection, tear strength, and tensile strength. These novel polyols show promise as strength enhancing components of viscoelastic foam formulations.

     

    Proceedings of the Polyurethane Foam Association Technical Program
    May 2012, Baltimore, MD

    S12001 California TB 117: Does The Regulation Add Value? Matthew Blais, Southwest Research Institute

    California TB 117 (CA TB 117) was created to protect life and property from fires initiated by small sources such as matches, cigarettes and lighters. The standard was not intended to prevent ignition of a furnishing in a large fire where it would contribute to the fuel load of a room. To evaluate the effectiveness of the standard, used furniture items and new comparison cushions having various filling components were tested. Both CA TB 117-compliant and non-compliant pieces and equivalent composite mock-ups were evaluated using a small flame ignition source. The paper concludes that the use of CA TB 117 foam increases the safety of home furnishings by delaying the onset of free burning conditions and reducing the total energy released by the event.

    S12003 New Additives for Polyester and Flame Lamination Foam Greg Pickrell, Momentive Performance Materials

    Momentive has developed a new surfactant for use in flexible polyester slabstock foam applications. Niax L-537XF surfactant is specifically designed to provide finer cells and increased airflow across a wide range of densities. Performance improvements in low-density foams with more stable buns and finer cells are also expected. This new product can be used for conventional polyester foam, semi-rigid and foams with die-cuttable properties. Additionally Momentive is launching a new additive for flame lamination for polyether and polyester applications. Niax CS-26LF is specifically designed to increase the flame bonding properties. The typical range of peeling strength increase in polyether foam is between 20% and 30% when compared to previous generation additives like Niax CS-22LF. This new product also provides mild antioxidant properties and low emission properties. In applications like polyester foam this new product may help increase the initial peeling strength by 40% to 50% when compared to a reference ester foam.

    S12002 PTZ: A Troublesome Ingredient; Promising Solutions John DeMassa, R.T. Vanderbilt

    Phenothiazine (PTZ) continues to be an effective scorch inhibitor used by a number of slab-stock foam manufacturers. It has a long successful history as an additive, which is often used in combination with other antioxidants. However, this industrial workhorse comes with an unwanted side effect. Polyurethane foams containing trace quantities of PTZ or its post-reaction derivatives have been observed to occasionally “pink” during warehouse storage. The present paper will examine relevant reaction chemistry; underlying reasons for PTZ induced discoloration and offer some promising new solutions that eliminate “pinking” while providing scorch reduction benefits.

    S12004 New Developments in Flame Retardant Additives For Use In Flexible Polyurethane Foam Products Mike Nagridge, ICL - IP America

    The addition of flame retardants plays a critical role in allowing FPF products to meet flammability performance requirements. Flame retardants must not only perform well in mitigating ignition and combustion, they also must be compatible with FPF production formulation and processing. ICL-IP has developed new flame retardant products to meet the ongoing challenges of today’s market where superior performance in fire tests, foam properties, and scorch is required. Product sustainability continues to be a major criterion for product development. Large scale production evaluations show improvements in flame retardant related properties at low, medium, and high densities. The results of production trial evaluations will be discussed.

    Proceedings of the Polyurethane Foam Association Technical Program
    November 2011, Phoenix, AZ

    F11001 Low Density HR MDI Based Foams Venkat Minnikanti, Dow Chemical Company

    Obtaining low density (less than 30Kg/m3) foams in all water blown MDI based foams without compromising mechanical performance (Tensile strength and Tear Strength) and compression sets has been a significant challenge for polyurethane foamers. While it is straight forward to make such foams with TDI, with MDI it becomes very difficult. This paper presents low density MDI based foams with Dow’s proprietary technology.

    F11003 Enabling Surfactant Technology for Flexible Slabstock Flame Retardant Polyurethane Foam Jane Kniss, Air Products & Chemicals

    As regulations on polyurethane foam manufacture continue to tighten, and the economy continues to be fraught with recovery delays, the flexible polyurethane foam (FPF) industry must find new methods of producing quality foams across a matrix of densities and hardness levels that also provide the specified combustion standards. These additional economic hurdles have accelerated the search for additives that allow the manufacturer to continue to produce high quality polyurethane flexible slabstock foam with the various mechanical processes employed today, while scrutinizing the level and type of flame retardant (FR) necessary to maintain product certification under current flammability statutes.

    This paper reports on a surfactant which enables reduced FR use-levels at equal or lower burn length with halogenated or non-halogenated FR additives. The surfactant processes well across the wide range of foam densities and firmnesses, provides good nucleation, a high degree of emulsification, excellent froth stability, and good bulk stability. Several evaluations on commercial equipment have been conducted and foam properties were compared among current commercially available surfactants. The resulting foam’s physical properties include fine, regular cell structure, substantial reduction of cell structure striations, and a smooth, velvety hand. FR performance, in addition to all of these desired properties, will be discussed in detail, along with several other benefits.

    F11005 Evaluation of New Additives to Maximize the Use and Processing Performance of NOPs in Conventional Slabstock Foam Roland Hubel, Evonik Goldschmidt

    Over the past decade, there has been increased interest within the polyurethane industry to use natural oil based polyols, either as a stand alone product or in conjunction with petroleum-based polyols. Compared to conventional polyether polyols, most natural oil based polyols (NOPs) have different solubility characteristics due to the presence of long hydrocarbon chains. As a result of this chemical structure, these polyols are much more non-polar, hydrophobic and oleophilic. Furthermore they show a different reactivity regarding the gelling reaction which is mainly related to the steric hindrance of the hydroxyl groups. Due to the different chemical nature of NOPs, their use in conventional slabstock formulations is often accompanied by undesired changes to the processing and physical properties of the final foam.

    This paper provides an evaluation of how different types of additives can support the increased use of NOPs in conventional slabstock applications. In contrast to previous studies which focused more on emulsification aspects, this paper mainly investigates the impact on reaction conditions and kinetics when NOPs are added to a formulation. Different approaches are discussed to counteract the negative effect on foam physical properties when the use level of NOP is increased.

    F11002 New Chemical Technology for the Production of Super High Air Flow Flexible Foams Adona Marcum, Bayer MaterialScience (Herman Stone Technical Excellence Award Winner)

    New polyether polyol and formulating technology is being developed which enables the direct production of very high air flow foams comparable to those achieved in a reticulation process. This technology also helps to significantly enhance the air flow of low porosity foam types such as viscoelastic and even semi-rigid. In addition, the surface characteristics of the foams can be controlled through formulation or through coating processes; thus facilitating use in a wide range of prospective end-use applications including bedding, seating and other cushioning applications where air circulation and the transfer of moisture away from the body are desirable performance traits.

    F11004 Modifications in CertiPUR-US® VOC Test Methods Doug Sullivan, Alliance for Flexible Polyurethane Foam, Inc.

    In response to a proposal to change the CertiPUR-US TVOC testing protocol from ASTM-5116 to the more specific ISO-16000-Parts 6, 9 & 11, as specified for CertiPUR in Europe, comparative testing was conducted. As part of the test method conversion process, the effect of increasing the chamber conditioning time for VOC analyses will be reported.

    F11006 Global Regulatory Changes and Antimicrobial Replacement Alternatives Tom Robitaille, Lonza

    Regulatory changes are driving change around the world and altering the choices of antimicrobials allowed for use in polyurethanes. The most recent examples are the allowed use of OBPA (10,10′- oxybisphenoxarsine), tributyl tin compounds and triclosan, as antimicrobial agents in many polyurethane formulations.

    In light of the recent lack of support for OBPA in the European Biocidal Product Directive process (BPD) users will need to find alternative means of protecting their finished goods from the growth of fungi and bacteria. This paper will characterize the antimicrobial performance and formulation compatibility of n-octyl-isothiazolinone (OIT) and 4,5-dichloro-2-n-octyl-4-isothiazoline-3-one (DCOIT), silyl quats, n-butyl 1,2 benzisothiazolin-3-one (BBIT), zinc pyrithione (ZPT) and combinations in polymer formulations as preferred alternatives.

     

    Proceedings of the Polyurethane Foam Association Technical Program
    May 2011, Baltimore, MD

    S11001 Flame Retardant Developments for the FPF Market Mike Nagridge, ICL Industrial Products

    Flame retardants play an important role in meeting code requirements as well as product performance requirements in flexible polyurethane foam (FPF) applications. ICL-IP has developed phosphorus based flame retardant products to meet the ongoing challenges of today’s market where superior performance in fire tests, foam properties, and scorch is required. Product sustainability continues to be a major criterion for product development. A series of evaluations was conducted using lab bench scale as well as some large scale testing to show improvements in flame retardant related properties at low, medium, and high densities. Reactive, polymeric, and non-reactive products were also evaluated to show benefits of each. The results of evaluations of these development products will be presented.

    S11003 Risk Assessment Tool to Evaluate TDI Emission and Migration Data in Flexible Polyurethane Foam Jim Chapman, Bayer MaterialScience

    As reported at the May, 2010 PFA conference, recent studies conducted by the International Isocyanate Institute demonstrated problems determining “free” TDI from flexible PU foam (FPF) using solvent extraction techniques. Measuring the emission of TDI from FPF to air and migration of TDI from FPF to surfaces was proposed as better representing the residual TDI that could be “bioavailable” from FPF. That work described the techniques used to measure emission and migration and showed that no detectable emitted or migrated TDI could be found from a model FPF with detectable levels of extractable TDI. This presentation describes the risk assessment approach used to evaluate the results from emission and migration testing.

    S11002 Flame Retardation of FPF: Recent Developments and Research in EMPA – Swiss Federal Laboratories” Sabyasachi Gaan, EMPA

    Flexible polyurethane foams (FPF) find application in home, transportation and public / business infrastructures. FPF owing to their chemistry and open cell structure pose fire hazards. They have high heat of combustion and heat release rate capacity and also release toxic gasses during thermal decomposition and flaming. This presentation covers recent developments in flame retardants for flexible polyurethane foams and presents work on development of new flame retardant chemistries for FPF. The presentation focuses on effect of addition of these new flame retardants on mechanical, flame retardant and thermal properties of FPF.

    S11004 Technology to Separate Fabrics from FPF for Reapplication in Flame Lamination Operations Tony Gutierrez, Publibordados

    This presentation describes the process used to separate rolls of flame laminated vinyl-foam, leather-foam and cloth-foam so that the recovered face material can be reapplied to a different foam substrate.

    Proceedings of the Polyurethane Foam Association Technical Program
    November 2010, Atlanta, GA

    F10001 Non-Contact In-Process Foam Dimension Measurement Daryl Rutt, RangeMetrics

    Current practice for determining processed foam dimensions typically relies on QA lab measurements of sample pieces. Modern requirements for lower missed defect rate along with the increasing implementation of MRP/ERP systems in foam plants makes 100% in-process measurement a desirable and cost-beneficial addition to foam manufacturing. A measurement method based on a laser line / rangecamera technique previously developed by RangeMetrics has been successfully implemented in a number of foam plants to capture closely-spaced dimensions of the top and side surfaces of hot or cold slabstock buns. The technique is non-contacting and measurements are collected in real time as a bun passes past the laser / rangecamera, for example on a pouring line or on a transfer conveyor in the cold shop. However, measurements of different dimensional variables at different points in the foam fabricating process lead to a variety of different requirements and a variety of technical challenges which are discussed in the paper.

    F10003 Versatile High Renewable Content Based Polyol for the Production of Multiple Flexible Slabstock Foam Technologies William Gower, Cargill Biobased Polyurethanes

    This paper will describe the development and evaluation of a new BiOH Polyol designed for the production of multiple TDI based flexible slabstock foam technologies such as: low density CO2 foaming; solids free load building capability; high resiliency, viscoelastic, and traditional trough foams.

    F10002 Combustible Dust Regulatory Update Brian Edwards, Conversion Technology, Inc.

    Combustible dust presents a significant hazard to industrial facilities, and it is at the forefront of regulators’ agendas, especially the U.S. Occupational Safety and Health Administration (OSHA). OSHA enacted a National Emphasis Program (NEP) in 2008, and the agency is conducting inspections under this program. OSHA has issued an Advanced Notice of Proposed Rulemaking (ANPR), and is working to develop a specific combustible dust rule. This paper will discuss the characteristics of combustible dust, current regulations and standards, anticipated regulatory initiatives, and how facilities should address combustible dust safety.

    F10004 PLX 982: A New Liquid Scorch Inhibitor John DeMassa, R.T. Vanderbilt Company

    The present paper explores a new scorch inhibitor blend that reduces scorch significantly when compared with state-of-the-art products and adds minimally to foam discoloration when exposed to selected stresses such as light or NOx fumes. A short discussion will also be offered on the mechanism of thermo-oxidative degradation and inhibitor stabilization of PUR foam.

     

    Proceedings of the Polyurethane Foam Association Technical Program
    May 2010, Baltimore, MD

    S10001 Seal Less High Pressure Metering Pump for Toluene-diisocyanate Thomas P. Cushman, Cushman Engineering, Inc.

    The integration of state of the art canned motor technology and the bent axis hydraulic pump inside a hermetic case is demonstrated to be an effective seal-less and leak free method of delivering a metered throughput of toluene di-isocyanate (TDI) to the modern foam machine mixing chamber. This technology eliminates the dynamic shaft seal as a source of fugitive emissions of isocyanates. All connections to the assembly are sealed with static seals. This technology is a viable method of protecting employees, the factory and the surrounding community by preventing nuisance leaks and subsequent fugitive emissions at the pump. An opening and brief overview of NIOSH regulations and hazards regarding TDI is included.

    S10003 High Efficiency Silicone Surfactant for Flexible Slabstock Foam Applications Gregory A. Pickrell, Momentive Performance Materials

    In difficult economic times, when raw materials prices rise and demand is weak, foam manufacturers search for effective ways to improve foam production yield. Polyurethane additive suppliers can play a pivotal role in helping foam manufacturers achieve this initiative. This paper describes Momentive’s new high efficiency Niax* silicone L-595, a surfactant to consider for providing higher yield foam as well as fine cell structure and wide processing latitude. The typical benefits of Niax silicone L-595, compared to generally used surfactants, have been exhibited in many batch and continuous machine line trials over a wide range of conventional flexible slabstock foam formulations in use throughout the world. This new surfactant can help optimize foam stabilization and enhance cell-opening characteristics, yielding higher foam buns with minimal density gradients, leaner top and bottom skins, integrated cells and excellent product quality consistency. In addition, this silicone stabilizer can be considered for use in manufacturing processes that use liquid CO2 as auxiliary blowing agent.
    *Niax is a trademark of Momentive Performance Materials Inc.

    S10002 'Free' TDI in PU Flexible Foam: Update on Recent Studies Mark W. Spence, International Isocyanate Institute, Inc.

    Some researchers have reported presence of isocyanate in PU by non-quantitative colorimetric methods, as well as quantifiable residual toluene diisocyanate (TDI) monomer using analytical measurements involving solvent extraction and derivatization of fully cured PU products. In this study a rigorous methodology was developed to extract and quantify TDI from flexible PU foam. Furthermore influence of methodological variables was assessed and consideration was given whether extractable TDI represented free (unreacted) TDI in the polymer matrix, or if TDI was being regenerated by the analytical procedure. More exposure-relevant techniques for providing such data were developed; specifically, emission to air and migration to a surface in contact with the PU foam. 

    Results showed that TDI can be extracted from a cured PU foam sample using a range of organic solvents and derivatizing methods. There is evidence that the detected TDI is, at least in part, an artifact of the solvent extraction methods. In both emission and migration tests no TDI was detected as being released from the foam sample. Consideration of the use of data for risk assessment of possible monomer in a PU product was made, with the conclusion that emission and/or migration study data are more relevant for development of risk assessments.

    S10004 Additive Flame Retardants Identified in Consumer Products and Furniture Containing Polyurethane Foam Heather H. Stapleton, Nicholas School of the Environment, Duke University

    A majority of furniture and consumer products which contain polyurethane foam, manufactured both in the United States (U.S.) and abroad, are treated with additive flame retardants to meet flammability standards. The flammability standard which primarily drives this use is California Department of Consumer Affairs Bureau of Electronic and Appliance Repair, Home Furnishings and Thermal Insulation (BEARHFTI) Technical Bulletin 117 (TB 117). In order to identify the primary chemicals and/or mixtures of chemicals being used to meet TB 117 in foam for upholstered furniture, we analyzed foam collected from various furniture items including: sofas, chairs and futons, and we also examined non-furniture items such as pillows, mattress pads, baby strollers, baby car seats, and nursing pillows. Foam was collected from products purchased primarily between the years 2003- 2010. The foam was extracted and analyzed using gas chromatography mass spectrometry (GC/MS) at Duke University. Analysis of indoor dust samples collected from the east coast of the U.S. revealed elevated levels of FR components similar to those found through extraction of finished goods. Preliminary studies conducted by Dr. Stapleton’s laboratory to date suggest that certain FR additives found in analyzed products may be as potent a neurotoxicant as organophosphate pesticides. These data and implications will be discussed during the presentation.

     

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