Consumers, brands and manufacturers are seeking to adopt sustainable materials and practices. Within polyurethane, we have seen three types of sustainable polyol emerge; chemically recycled, bio-based and polyols produced with captured CO2. Econic Technologies’ catalyst and energy-efficient process transforms waste CO2 into a key raw material that partially replaces oil-based epoxides in polyether polyols. The Econic catalyst allows for the amount of CO2 to be tuned, whilst retaining control over the molecular weight and functionality of the polyol.

Polyols manufactured from CO2 via Econic’s unique process can be used in a variety of polyurethane applications, with control over the polyol physical properties crucial to their wide-ranging use. In flexible foam, Econic has investigated the utility of these polyols in conventional and viscoelastic foams – in a previous presentation we have demonstrated the ability to prepare slabstock flexible foam from its polycarbonate ether (PCE) polyols. Today, we build on this by showing the utility of PCE polyols in viscoelastic and conventional foams across a range of densities and isocyanate types, using industry standard additives and hitting performance targets.

There will also be a focus on the impact moving to a more sustainable solution has on the environmental impact of the product. Econic has prepared a Life Cycle Assessment (LCA) on its PCE polyols and is using it to predict the reduction in climate impact of a PU foam product. Finally, the current outlook on commercial production and the future impact of CO2 polyols will be shared.

At PFA’s 2024 conference in New Orleans, we were privileged to present on the sustainability benefits provided by mattress and foam compression and rolling technologies. We focused that talk on the volume reduction benefits of compression, which improve transport efficiency and warehouse space requirements and thereby lower fuel and power use.

This presentation will broaden the discussion to include the sustainability benefits of:

• Advanced packaging materials, including low-density polyethylene (LDPE) film with reduced thickness, as well as film and paper employing recycled content; and,
• Reduced energy consumption for the automated packaging process thanks to breakthrough innovations in the compression and sealing areas of the facility.

We will present data on the emission reductions and carbon footprint reduction associated with volume reduction, advanced packaging and packaging process innovations.

Our message is that implementing such improvements in the polyurethane foam industry is consistent with both sustainability and economic goals.

In the evolving landscape of polyurethane flexible foam additives, Everaox 501 and Eversorb 673N represent a significant breakthrough in phenol-free multifunctional stabilization technologies. These products provide comprehensive protection for polyurethane foam, addressing critical performance challenges in material durability.

Both Everaox 501, an antioxidant, and Eversorb 673N, a light stabilizer, share common capabilities:

• Exceptional core burning resistance
• Advanced NOx yellowing prevention
• Phenol-free formulation

Everaox 501 excels in antioxidant performance, offering robust thermal stability and protection against material degradation. Its targeted approach ensures long-term material integrity in polyurethane foam applications.

Complementing this, Eversorb 673N extends protection with superior light stability characteristics. This additive not only prevents core burning and NOx-induced yellowing but also provides resistance to photodegradation, making it ideal for applications exposed to varied environmental conditions.

The strategic development of these multifunctional additives represents a significant innovation in material science. By integrating multiple protective mechanisms into single-solution products, manufacturers can:

• Reduce overall additive usage
• Simplify formulation complexity
• Enhance operational efficiency
• Facilitate easier new product development

The evolution from traditional single-function additives to these comprehensive stabilization solutions offers polyurethane foam producers new opportunities for performance optimization.

One of the key opportunities in the bedding industry is the development of standardized methodologies to measure performance attributes of mattresses and other comfort products. This has the potential to positively impact the entire value chain. For consumers, it can improve the quality of information available when making a product selection. For OEMs, it can facilitate advances in the design and quality of their products. For raw material suppliers, it can direct the focus of their innovation efforts.

Dow and GoodBed have been collaborating to address this opportunity by developing new testing methods and techniques to measure and enhance comfort. We categorize comfort into ergonomics, microclimate, and sensation, allowing us to delve into the fundamental material properties that influence performance.

This study focuses on the microclimate performance of a series of mattresses. We employ a comprehensive approach to examine how mattresses behave under wet and dry conditions, aiming to quantify how various mattress characteristics affect the microclimate and overall sleeping experience.

Speaker Biography

Ana Nunez works at the Dow Chemical Company as part of Core R&D – Analytical Sciences, which she joined in 2015. She earned a Bachelor’s degree in Chemistry from the University of Texas at El Paso, and a Ph.D. in Inorganic Chemistry from the University of Texas at Austin.

In marine applications, ensuring the cleanliness and durability of materials like polyurethane foam is critical due to the harsh environmental conditions and the potential for microbial contamination. Microbial growth, particularly from Streptomyces sp., can lead to staining, deterioration, and odors, compromising material integrity. The ASTM E1428 pink stain method, a widely used test method for polymeric solids, is designed to detect microbial contamination by visually identifying, pink-colored staining. However, when applied to polyurethane foam, this method presents significant limitations. The porous structure of the polyurethane foam can cause the liquid inoculum to be absorbed unevenly, as well as preventing it from making proper contact with the agar plate. This leads to inconsistent results and makes it difficult to interpret microbial staining. Moreover, the subjective nature of visual inspection increases the risk of false positives or negatives.

The new ASTM E3364-22 pink stain test method is better suited for the porous nature of polyurethane foams, providing more dependable, and consistent results. This method was developed and approved by a work group consisting of many companies and scientists including Daniel L. Price of Interface Incorporated. Several years ago, Dr. Price presented recent interlaboratory studies that led to this new pink stain method. The new method addresses these challenges by changing the inoculation procedure to ensure consistent contact with the inoculum, and eliminating the visual inconsistencies by rating all staining, not just pink. Additionally, the adoption of the modified method ensures higher confidence in microbial monitoring for polyurethane foam used in marine applications, ultimately enhancing product quality. This emphasizes the importance of choosing the right pink stain test method to obtain accurate and reliable results when assessing staining caused by microbial contamination in polyurethane foams.

This presentation will explore technical advancements in packaging solutions for the polyurethane foam industry, with a specific focus on volume reduction of shipments. Innovative packaging machines can significantly reduce logistical complexities and operational costs, while also meeting the industry’s growing demand for sustainability.

A primary logistic challenge for the PU foam and mattess producers lies in managing the large volumes of shipped and stored material. Advanced compression technology enables manufacturers to reduce the volume of PU foam by up to 80%. This degree of compression leads to a considerable increase in transport efficiency and a marked decrease in warehouse space requirements. These gains reduce direct operational costs and also help lower carbon footprint, by reducing the number of trucks on the road and associated CO2 emissions. Packaging systems are designed to accommodate a range of applications, including both polyurethane buns and mattresses

This presentation will demonstrate how companies in this industry can deploy compression technologies to optimize logistics strategies. Data will be presented to quantify how packaging technologies can support the FPF industry’s growth and realization of economic and environmental goals.

SPEAKER BIOGRAPHY: Mark DeCoteau is the Director of Operations for Dolphin Pack USA.  Mark has a bachelor’s degree in mechanical engineering from Wentworth Institute of Technology an MBA from Kansas Wesleyan University and an Executive Certificate in Management and Leadership from MIT.  Prior to joining Dolphin Pack 5 years ago Mark was the Regional Operations Director for Innocor based out the West Chicago location.

This presentation follows up on one given at the November 2022 PFA Technical Paper program. As noted then, glass transition temperature (Tg) is a very important property for visco-elastic or memory foam.  There are many formulation variables that affect the Tg and foam customers typically specify Tg in a specific range.  One factor that is frequently overlooked is ambient humidity during the measurement of Tg.  We found that Tg can vary if the humidity is changed.  Normally, Tg measurements are taken under dry conditions. However, the humidity in American homes varies based on season and location.  So, we undertook a study of variation in Tg measurement under a range of humidities.

Flexible polyurethane foams (PUF) are used in many consumer products. PUF may contain trace levels of aromatic diamine impurities that could represent a potential health risk. The risk associated with sleeping on a PUF mattress was evaluated. Toxicity benchmarks for sensitization and non-cancer endpoints were derived from the respective points-of-departure using standard assessment factors. For the cancer endpoints, toxicity benchmarks were derived from the 25th-percentile values of animal studies. Recently published emission and migration data allowed to link exposure with the CertiPUR^TM voluntary quality limits of ≤5 mg.kg^-1 for 2,4-toluene diamine and 4,4′-methylene dianiline in PUF. Using conservative exposure scenarios, lifetime-average daily internal doses from the combined inhalation and dermal exposures were calculated. Margins of safety for non-cancer and sensitization endpoints were >10⁴. The theoretical excess cancer risk was ≤1.5 × 10^-7. It is concluded that sleeping on a mattress that satisfies the CertiPUR limit value does not pose undue risk to consumers.

Polyurethane flexible foam demand in the upholstery and mattress industry covers a wide range of foam densities and various property requirements, particularly targeting physical property distribution. Optimal foam quality is achieved through good foam stabilization. While choosing the correct surfactant provides bulk stabilization, insufficient dimensional stabilization may impact physical property gradients such as density and hardness. GeoliteTM Modifier additives by Momentive Performance Materials (Momentive) have provided improved dimensional stabilization for soft, low index foams for over 30 years. Continuous development of GeoliteTM Modifier additives has led Momentive to introduce an enhanced generation focused on improved property gradients in flexible slabstock foam.

Consumers, brands and manufacturers are seeking to adopt sustainable materials and practices. Within polyurethane, we have seen three types of sustainable polyol emerge; chemically recycled, bio-based and polyols from captured CO₂. Econic Technology’s catalyst and energy-efficient process transform waste CO₂ into a key ingredient that replaces oil-based epoxides in polyether polyols. The Econic catalyst allows for the amount of CO₂ to be tuned, along with the molecular weight and functionality of the polyols.

In 2023 Econic presented an overview of the properties seen in comfort foams prepared with these polyols. Since then, Econic has expanded the application data to viscoelastic and combustion modified foams. This data will be shared along with an overview of how molecular weight and CO­₂ content in the polyol, impacts on foam properties. Finally, an update on the commercial production of these polyols by our USA licensee, Monument Chemical, will be shared and key learnings on scaling of a sustainable technology for polyurethane applications.

Development of viscoelastic foam technology is a focal point within the Flexible Slabstock foam market, particularly for its prevalence in the construction of bedding products. Viscoelastic foam is known for its characteristic delayed response, low resiliency, and superior weight distribution properties, all of which contribute to the development of more comfortable sleep products.

There is a diverse array of formulation strategies for this technology, with the selection of an appropriate formulation largely contingent upon desired performance criteria, as well as preferences and availability of raw materials. While the impact of individual raw material variables on viscoelastic foam properties is generally well-established, understanding the relationships among interdependent variables across various formulation methods can be challenging.

The study and deconvolution of these relationships requires a methodical approach to examine the different variables influencing foam properties and their interrelations. A model has been developed that aims at elucidating the impact that formulation components have on the physical attributes of the foam. A selection of polyether polyols encompassing a range of compositions was chosen to introduce variability in raw materials across potential formulations based on both MDI and TDI.

The findings of this research can enhance comprehension of raw material selection based on desired foam performance. Furthermore, the developed model and experimental framework can serve as a foundation for future modeling endeavors aimed at enhancing formulation adaptability and solution delivery through machine learning and digitalization.

Sustainability has become a major economic driver, fuelled by regulation, consumer demand and necessity. If corporate annual reports in the 1990s featured safety, and in the 2000s cost, that emphasis in now about carbon footprint. Most market leading companies by now have developed corporate sustainability strategies, public commitments to reduce carbon emissions, and investments in sustainable growth and full circularity. 

In this presentation, we will discuss sustainable innovations and our belief that only a systematic and ambitious approach built on partnerships will allow the flexible PU industry to achieve net zero and ultimately drive the circular economy. It is vital that we as an industry take a science-based approach to not only setting our emission reduction targets, but also in measuring the impacts of the choices we make.

Life Cycle Analysis is the only normalised and scientific method to (1) validate how sustainable your product or process is; and (2) reflect its full environmental impact. We will discuss our LCA model, and how it may serve as a roadmap for the flexible PU foam industry on its path to CO2 reduction.

Biography

Mike Murray is the Chief Innovation Officer for The Vita Group, having joined in April 2020 after spending 25 years at Morgan Advanced Materials plc. He has a passion for sustainable innovation and bringing them to market and understands the vital role the academic, supply chain, industrial collaboration plays on increasing the chance of technical and commercial success.

He holds a Bachelor’s and Ph.D. in Materials Science from the University of Birmingham. He has played a leading role in Government/Industrial Advisory Board’s and plays an active role within Europur and is Vice Chair of the Sustainability committee.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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®.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.