Boat Seats Armrests
Foam Cutting Sample Photoes
polyurethane foam machine foam continuous cut line onto the sofa, mattress, uphostry
What is polyurethane foam (PU FOAM)?
(Soft polyurethane foam or semi-rigid)
(1) Polyurethane
Commonly abbreviated PU is any polymer consisting of a chain of organic units joined by urethane links. Polyurethane polymers are formed by the reaction of a monomer containing at least isocyanate functional groups with another monomer containing at least two alcohol groups in the presence of a catalyst. Polyurethane formulations cover an extremely range large stiffness, hardness and density. These materials include low density flexible foam used in upholstery and bedding, low density rigid foam used for thermal insulation, soft solid elastomers used for gel pads and printing rolls and rigid plastic solid used as instrument panels electronic and structural parts. Polyurethanes are widely used in the seat foam high resilience flexible panels of rigid foam insulation, seals and gaskets microcellular foam, durable elastomeric wheels and tires, electrical potting compounds, high performance adhesives and sealants, Spandex fibers, seals, gaskets, carpet underlay, and pieces of hard plastic. Polyurethane products are often called "urethanes". They do not to be confused with the specific substance urethane, also known as ethyl carbamate. Polyurethanes are not produced from ethyl carbamate, nor contain it.
Upholstery is the work of providing furniture, especially seats with padding, springs, webbing, fabric or leather and copper. The word "Upholstery" comes from the Middle English words up and holden, meaning support. The term is applied to domestic furniture and also for applications in cars and boats. A person who works with upholstery is called an upholsterer, an apprentice upholsterer is sometimes called an outsider or trimmer.
The Polyurethane products have many uses. More than three quarters of global consumption of polyurethane products is in the form of foams, with flexible and rigid types being roughly equal in market size. In both cases, the foam is usually behind other materials: flexible foams are behind upholstery in commercial and domestic furniture; rigid foams are inside the metal and plastic walls of most refrigerators and freezers, or behind paper, metals and other surface materials in case of thermal insulation panels in the construction sector. Its use in garments is growing: for example, in lining the cups of brassieres. Polyurethane is used mold which include door frames, columns, balusters, window headers, pediments, medallions and rosettes.
The precursors of the foam expansion Polyurethane is available in many forms, for use in thermal insulation, acoustic insulation, flotation, industrial coatings, packaging material, and even cast on site upholstery padding. Since they adhere to surfaces and automatically fill in the blanks, they became very popular in these applications.
Chemistry
Polyurethanes are the class of compounds called polymers of reaction, including epoxy resin, unsaturated polyester and compounds phenolics. The urethane linkage is produced by reacting an isocyanate group-N = C = O with a group (alcohol) hydroxyl, OH. Polyurethanes are produced by polyaddition reaction of polyisocyanate with a polyalcohol (polyol) in the presence of a catalyst and other additives. In this case, a polyisocyanate is a molecule with two or more isocyanate functional groups,-R (N = C = O) n ≥ 2 and a polyol is a molecule with two or more functional hydroxyl groups, R'-N (OH) ≥ 2. The reaction product is a polymer containing the urethane linkage, RNHCOOR-'-. Isocyanates react with any molecule that contains an active hydrogen. Importantly, isocyanates react with water to form a bond of urea and carbon dioxide, but also react to form polyureas polyetheramines. Commercially, polyurethanes are produced by reacting an isocyanate liquid with a liquid mixture of polyols, catalysts and other additives. These two components are referred to as a polyurethane system, or simply a system. The isocyanate is commonly referred to in North America as the "A side 'or just' iso 'on. The mixture of polyols and other additives is commonly referred to as the 'B side' or 'polis'. This mixture can also be called the "resin" or "resin mixture. In Europe, the meanings of" side A and side B are reversed. resin mixture of additives include chain extenders, cross linkers, surfactants, flame retardants, blowing agents, pigments and fillers.
The first essential component of a polymer polyurethane is isocyanate. Molecules containing two isocyanate groups are called diisocyanates. These molecules are also referred to as units or monomers monomer, since they themselves are used to produce polymeric isocyanates that contain three or more isocyanate functional groups. Isocyanates can be classed as aromatic, such as diphenylmethane diisocyanate (MDI) or toluene diisocyanate (TDI), or aliphatic such as hexamethylene diisocyanate (HDI) and isophorone diisocyanate (IPDI). An example of a polymeric isocyanate is polymeric diphenylmethane diisocyanate, which is a mixture of molecules with two, three and four or more isocyanate groups with an average functionality of 2.7. The isocyanates can be modified later by the party to react with a polyol to form a prepolymer. A quasi-prepolymer is formed when the stoichiometric ratio of isocyanate to hydroxyl groups is greater than 2:1. The prepolymer is actually formed when the stoichiometric ratio is equal to 2:1. The important characteristics of isocyanates are their molecular backbone,% NCO content, functionality, and viscosity.
The second component essentials of a polyurethane polymer is the polyol. Molecules that contain two hydroxyl groups are called diols, those with three hydroxyl groups are Triols called, et cetera. In practice, they are distinguished from short chain polyols or low molecular weight glycol chain extenders and cross linkers such as ethylene glycol (EG), 1,4-butanediol (BDO), diethylene glycol (DEG), glycerine, and trimethylol propane (TMP). Polyols are polymers in their own right. They are formed by addition free radical of propylene oxide (PO), ethylene oxide (EO) in a hydroxyl or amine containing initiator or polyesterification a di-acid, as acid adipic acid, with glycols such as ethylene glycol or dipropylene (DPG). Polyols extended with PO or equal opportunities are polyether polyols. Polyols formed by polyesterification polyols are polyester. The choice of initiator, extender, and molecular weight of polyol greatly affect its physical state and properties Physical polymer polyurethane. Important characteristics of polyols are their molecular backbone, initiator, molecular weight,% primary hydroxyl groups, functionality and viscosity.
PU reaction mechanism catalyzed by a tertiary amine gas carbon dioxide and water formed by reacting isocyanate
The polymerization reaction is catalyzed by tertiary amines as dimethylcyclohexylamine organometallic salts such as dibutyltindilaurate. Moreover, catalysts can be chosen based on whether they favor the urethane (gel) reaction, as diazobicyclooctane, or urea (blow) reaction, such as bis dimethylaminoethylether, or specifically the trimerization reaction of isocyanate unit, such as potassium octoate.
One of the most desirable polyurethanes is its ability to be transformed into foam. blowing agents such as water, hydrocarbons, HFC-245fa as certain (1,1,1,3,3 Pentafluoropropane) and HFC-134a (1,1,1,2-tetrafluoroethane), and hydrocarbons such as n-pentane, can be incorporated on the poly or added as an auxiliary flux. The water reacts with the isocyanate to create carbon dioxide, which expands and fills cells created during the mixing process. The reaction is a three-step process. A water molecule reacts with an isocyanate group to form a carbamic acid. Carbamic acids are unstable and decompose to form carbon dioxide and an amine. The amine reacts with the isocyanate to give a more substituted urea. Water has a very low molecular weight, so even if the weight percent of the water may be small, the proportion molar water can be high and considerable amounts of urea produced. Urea is very soluble in the reaction mixture tends to separate and form "hard segment of "phase consisting mainly of polyurea. The concentration and organization of these phases polyurea may have a significant impact on the properties polyurethane foam [11]. Halocarbons and hydrocarbons are chosen such that they have boiling points at or near room temperature. Since the reaction polymerization is exothermic, these blowing agents volatilize into a gas during the reaction process. They fill and expand the polymer matrix cell, creating a foam. It is important to know that blowing gas does not create the cells of a foam. Instead, they are formed during the mixing process of nucleation sites the blowing gas fills and expands. Indeed, microcellular foams of high density can be formed without the addition of foam blowing agents or nucleating the mechanical polyester before use.
(2) Use of Polyurethane
1. Furniture
2. car seats
3. Varnish
4. computer mouse pads
5. Cola
6. Wheels
7. Homes, sculptures and decorations
8. Vessel
9. Construction sealants and fire stop
10. Tennis Grips
11. Electronic components
12. Binding industry
13. Watch band involvement
1.Furniture
Polyurethane is also used in furniture manufacture for casting soft edges around table tops and panel that are stylish, very durable and prevent injury. These tables are used in schools, hospitals, banks and mobile as well as shop counters and displays.
Much of the foam used in chairs, sofas and mattresses Comfy Sacks is polyurethane foam. This type of foam is made by mixing polyols, diisocyanates, catalysts, blowing agents and other additives and allowing due to increased foam freely. This can be done in a batch process where relatively small blocks of foam are made in a mold open at the top, or continuously, where the components are dumped into an inclined moving belt. The foam is then cut into desired shape and size for use in furniture making.
Safety concerns about the flammability of polyurethane foam, particularly in upholstered furniture, sometimes requires the addition of flame retardants flame to this foam.
Polyurethane is in other countries like the Netherlands used as a ground solution for homes, offices, museums.
2. car seats
flexible polyurethane foams and semi-flexible are used extensively for interior components of automobiles, in seats, backs head, arms, roof liners and instrument panels
polyurethane foam at the bottom of the mold it was made. When mounted on a seat Car, this foam makes the back seat. The part facing the front of the seat back is the surface of the foam face down in the pan. The two holes in the foam at the top of the picture are for the headrest posts.
Foam after removal of the mold.
Polyurethanes are used to make car seats in a remarkable way. The seat manufacturer has a mold for each seat model. The mold is a "clamshell" closeable type of structure that will allow the conversion Quick seat, called flexible molded foam, upholstered after removal of the mold.
You can combine these two steps, called "In situ" foam in fabric or direct molding. In this case, the inner surfaces of the cast have hundreds of small holes that communicate with a vacuum pump. This creates a constant flow of air from the core mold for the collector. The operator places a first complete assembly, seat cover fully assembled in the mold and adjusts that the vacuum in the collector pulls the seat cover firmly against the mold surface. In some operations, this effect is enhanced by the addition of a film thin soft plastic as support for the screen to help the vacuum work more effectively. When the seat cover is in place, the operator places the structure metal seat in the mold and the mold closes. At this point the mold contains what could be viewed as a "hollow seat, a seat fabric firmly in place by the vacuum manifold containing a cavity with a metal frame in place.
The next step is to inject the chemical mixture of polyurethane into the mold cavity. This is a mixture of two parts that is accurately measured through a mixing head. Then the mold is maintained at a reaction temperature predetermined by the chemical mixture has foamed, filled the mold and formed a stable foam soft. The time required is about 2:58 minutes, depending on size Seat, formulation and operating conditions. Then the mold is usually opened slightly for a minute or two for an additional cure time before of the fully upholstered seat is removed. The operator then cuts off any excess skin and the bank puts the bank ended in a carrier.
3 Varnish
Polyurethane materials are commonly formulated as paints and varnishes for finishing coats to protect or seal wood. This results in a hard use, abrasion resistant and durable finish that is popular for wooden floors, but considered by some to be difficult or unsuitable for finishing furniture and other detailed parts. Compared to oil or shellac varnishes, polyurethane varnish forms a film that is most likely to de-laminate when subjected to heat or shock, fracturing the movie and leave white spots. This tendency increases when it is applied over softer woods like pine. This is also partly due to lower penetration polyurethane for wood. Several techniques are employed conditioning to overcome this problem, including the use of certain oil varnishes, specified "dewaxed" shellac, epoxy clear and penetrating, or "oil-modified" polyurethane designed for this purpose. Polyurethane varnish may also lack the "hand-rubbed" brightness of drying oils such as linseed or tung oil, in contrast, however, is capable of much faster and higher "build" of film, performing in two layers that may require several applications of oil. Polyurethane can also be applied over an oil finish straight, but because of the relatively slow healing oils, the presence of volatile byproducts of curing, and the need for prolonged exposure of the oil with oxygen, care must be taken to that the oils are sufficiently cured to accept the polyurethane.
Unlike oil and alkyd drying, curing, after evaporation the solvent, the reaction with oxygen in the air, polyurethane coatings cure after evaporation of the solvent by a variety of chemical reactions inside the original mix, or by reacting with moisture in the air. Certain products are "hybrids" and combine different aspects of components from their parents. "Oil modified "polyurethanes, either by water or solvent, are currently finishing wood floors over used.
Foreign use of varnish Polyurethane can be problematic due to their susceptibility to the deteriorating ultra-violet light exposure. It should be noted, however, that all varnishes clear or translucent, and in fact all the coats of polymer film (iepaint, stain, epoxy, synthetic plastic, etc.) are susceptible to this damage in varying degrees. Pigments, paints and stains protect against UV damage, while UV-absorbers are added to polyurethane and other varnishes (in "spar" particular varnish) to work against UV rays. Polyurethanes are typically the most resistant to water, high humidity, extreme temperatures and mold or mildew, which also adversely affect the performance of the varnish and paint.
mouse pads 4.Computer
Polyurethane is used on the bottom of some mouse pads.
5.Glue
The Polyurethane is used as an adhesive, especially as a wood glue. Its main advantage over more traditional wood glues is its water resistance. Was introduced in the U.S. market in general in the 1990s as Gorilla Glue and Excel, but has been used for much longer in Europe.
6.Wheels
Polyurethane is also used to make solid tires. Modern skates and skateboarding became economical only with the introduction of tough, polyurethane parts resistant to abrasion. Other products were developed for tires and made microcellular foam variants are widely used in tires for wheelchairs, bicycles and other such uses. These types of foams also are widely encountered in car steering wheels and other interior and exterior automotive parts, including bumpers and fenders.
7.Houses, sculptures and decorations
The walls and ceiling (not just insulation) of the futuristic Xanadu House was constructed from polyurethane foam. vaulted ceilings and other strange shapes are easier to make the foam timber. Foam was used to construct buildings in a strangely, statues and decorations section Seuss Landing Islands of Adventure theme park. Sell rigid foam manufactures specialty foam to replace the wooden sign carved in 3D topography and industries.
8.Watercraft
Some surfboards are made with a solid core polyurethane. The rigid foam blank is shaped in the form of specification, then covered with fiberglass cloth and polyester resin.
The hull of the Boston Whaler motorboat is polyurethane foam sandwiched in a fiberglass skin. The foam provides strength, buoyancy and insulation.
9.Construction sealants and fire stop
Head-to-wall Firestop common: the presence of penetrating demonstrates the need to have both fire and operational compatibility between the sealant-tested, mechanical / electrical through-penetrations. In other words, it is easier to insist on the use firestops of common, which can also be used for penetration seals, otherwise piercing can be managed by mechanical and electrical subtrades unintentionally invalidate the classification of fire resistance of wall, which jeopardizes the entire fire safety plan in place for a building.
Head-to-wall penetrated by two Firestop common electrical and mechanical services, demonstrating the need for operational consistency and fire-tested firestop joint system between the and penetrating, whether electrical, mechanical or structural.
Polyurethane sealants are available in 1, 2 and 3 systems up part or in cartridges, bucket or drum format. polyurethane sealants are also sold for firestopping applications. Obviously, the sealant does not provide for any serious obstacle fire, as their hydrocarbon bonds readily support combustion. However, when accompanied by inorganic insulation such as rock wool or fiber ceramics, which can act as an effective seal to prevent passage of smoke and hose stream, particularly in the joints inorganic. It is, however, advisable to avoid direct contact with sharp metal and by the penetration of cable, as the heat carried by the piercing may compromise the sealant. This, however, requires great vigilance. In concrete to concrete, concrete or masonry joints, however, that are free from sharp mechanical or electrical, that works well and safely. Like all products of passive fire protection systems and the key to compliance with the code is demonstrable bounding.
10.Tennis Grips
Polyurethane has been used to make various overgrips Tennis Supergrap as Yonex, Wilson Pro overgrip and many other grips. These claws are highly elastic to ensure adherence wraps neatly around the racket handle.
11.Electronic Components
Often electronic components are protected against environmental influences and mechanical shock by placing them in polyurethane. Typically polyurethanes are selected for resistance to abrasion, good properties electrical, excellent adhesion, impact resistance and low-temperature flexibility. The disadvantage of polyurethanes is the limited upper service temperature (usually 250 ° F (121 ° C)). In the production of electronic manufacture would purchase a two-part urethane (resin and catalyst) would be mixed and poured over the assembly circuit (see casting resin). In most cases, mounting the circuit board would be irreparable after the final cured urethane. Because of its physical properties and low-cost, encapsulation of polyurethane (pot) is a popular option in the automotive industry for automotive circuits and sensors.
12.Bookbinding Industry
On the way to a new and better glue for bookbinders, a new adhesive system was first introduced in 1985. The basis for this system is polyether or polyester, while polyurethane (PUR) is used as prepolymer. Its special feature is the coagulation at room temperature and react to moisture.
1st Generation (1988 drupa) – Low starting solidity – high viscosity – Drying time of more than 3 days
2nd generation (1996 drupa) – Low starting solidity – high viscosity – Drying time of less than 3 days
3rd Generation (at drupa 2000) – Good starting solidity – Low viscosity – The drying time between 6 and 16 hours
Fourth generation (present) – Good starting solidity – Very low viscosity – Drying time is reached within a few seconds due to the Dual-Core-Systems
Advantages of polyurethane glue in the bookbinding industry: PUR is real wonder compared to hotmelt and cold glue. Due to a lack of moisture in the glue, papers with the wrong grain direction can be processed without problems. Even supercalandered paper printed and can be connected seamlessly. It the most economical glue with an application of theoretical thickness 0.01 mm. But in reality, you can not apply to less than 0.03 mm. PUR glue is very weather-proof and stable at temperatures of -40 ° C to 100 ° C.
13.Watch Band Involvement
Polyurethane is used as a black casing for watchbands on the main material, which is usually stainless steel. It is used for comfort, style and durability.
About the Author 34 Sea Ray sundancer 2004 Castaway Yachts sales 419-834-0788
