Polyurethanes, their Formulations and Applications

Seminar Overview
The ‘Understanding Polyurethanes, Their Formulations and Applications’ training seminar provides a comprehensive overview of polyurethane formulations and processing technologies, applications and markets. In addition it provides a forum for interaction between material producers, systems producers and end-users.

Program Structure

The seminar program is modular and has been arranged to allow delegates to attend for one or two days. Session 1 (held on May 12) covers general PU chemistry and will provide a sound base for Sessions 2 and 3. (May 13). Session 2 is specific to the applications areas of Foams (rigid and flexible) and Session 3 covers Coatings, Adhesives, Sealants and Elastomers (CASE). Sessions 2 and 3 are each of one day's duration and run as parallel sessions.

Format of Presentation
The seminar will be conducted in a lecture style.

The presentation will be in power point and delegates will receive a hardcopy and CD-ROM of the presentation to take away.

Seminar Presenters

Dr. Jim O’Connor, SynUthane International Inc.
Prior to founding SynUthane, Jim has managed research and development in the polyurethane and chemical industry for nearly 30 years. His experience and research background covers all segments of the polyurethane industry from polyols to isocyanates; TPU’s to coatings as well as surfactants, polymers and other speciality chemicals. After gaining his Ph.D from Purdue University, Jim worked for Goodyear, NDM Corp, Olin Corporation, Olin Hunt (Electronics) and ARCO Chemical Company and authored over 50 US patents and publications.

Dave Russell, Akron BioMaterials Inc.

Dave is Managing Director of Akron BioMaterials Inc. and Director of Motion Preservation Engineering for Theken Spine. Dave has 40 years of experience in the polymer industry with extensive experience in synthesis, manufacturing, compounding, testing and analyzing a broad range of elastomeric polyurethanes including: castable and thermoplastic elastomers, polyurethane sponges and gels, and polyurethane and polyurea coatings.

Dave was previously Director of Polymer Services for Smithers Scientific Services Inc, Engineering Manager for Eaton Corporation's Engineered Polymer Products Division, and CEO of Akron Polymer Laboratory Inc. Dave received a BA in Natural Sciences from the University of Akron in 1972 and returned to the University of Akron from 1984-1988 for graduate studies in Polymer Science where he achieved the rank of Doctoral candidate. Dave has numerous patents and publications in the polyurethane field.

Seminar Program

Session One

Polyurethanes - Fundamental Chemistry and Additives, Testing and Processing Technology

This day should also be attended by those people attending either Session 2 or Session 3, who want to develop a full understanding of the chemistry and production of the major urethane materials polyols and isocyanates, a detailed description of all the other typical and not so typical ingredients used in the production of a polyurethane and recommendations on when to use and why.

A basic understanding of chemistry is desirable for a better appreciation of this section.

Polyurethane Market Overview and Introduction to the Chemistry

• Basic polyurethane chemistry - how do you make a polyurethane polymer?
• What are the major components?
  • Polyol
  • Isocyanate
• Major market segments: USA, Europe and Global
• Global market for polyurethane products
  • Flexible foam
  • Rigid foam
  • CASE
• Polyurethane nomenclature and calculations

This section and the session immediately after lunch will detail the major polyol and isocyanate types.

Polyol Details

• Structure, basic production technology, initiators, functionality, reactivity, unsaturation, reaction process and catalysis, OH#
  • Polyether (different types)
  • Polyester
  • Polymer polyols
    • POP
    • PIPA
    • Dendrimers
  • Acrylic
  • Mannich
  • Natural Oil and other Hydrophobic polyols

Isocyanate Details

• Structure, functionality, FNCO%, phosgene/nonphosgene process, adducts
  • TDI
  • MDI/Pure MDI/polymeric MDI / Liquid MDI Variants
  • Pre-polymers
  • Aliphatic light stable isocyanates
  • Aliphatic isocyanate adducts

This section will cover the many other components with which Polyurethanes can be formulated.

Key Chemistries for Polyurethane Formation

• Primary reactions: Isocyante/polyol; Isocyanate/water: Isocyanate/amine
• Secondary reactions: Biuret, Allophanate, Trimer
• Other less common reactions

Other key components in a polyurethane

• Polymer structure modifiers
  • Chain extenders
  • Cross-linkers
• Catalysts - the different types and mechanism of action
  • Blowing reaction
  • Gel reaction
  • Trimerization
  • Other
• Surfactants
  • Types
  • Activity
• Blowing Agents (A brief history and all the newest developments)
  • Chemical BA
  • Physical BA
• Other Additives
  • Antioxidants
  • UV Stabilizers
  • Flame Retardants
  • Fillers
• Environmental, Health and Safety (A brief discussion)
  • Handling Isocyanates
  • Handling Polyols, Catalysts, Surfactants etc.
  • Product stewardship

An overview of the different equipment available to process polyurethane.

• Polyurethane Manufacturing Equipment
  • Flexible Foam
  • Rigid foam
  • CASE
  
  Session Two

Rigid and Flexible Foams -

This session is intended as a follow-on for those attending Session One. Session Two will give an up to date overview of the flexible and rigid foam market and technology and general formulations for the different types of foams.

A basic understanding of chemistry would be helpful for a better appreciation of the content of this session.

Flexible Foam

• Market Overview
• Mechanism of Foam Formation
  • Balancing blowing verses gellation
  • Role of Catalysts
  • Role of Surfactants
• Flexible Foam Processing Equipment - this section describes the different processes and equipment utilized in the preparation of flexible foam.
  • Conventional
  • Flat top
  • CO2 Blowing
  • Variable Pressure Foaming
  • Molded Foam
• Test Methods - this section describes the key methods and equipment for flexible foams
  • Density
  • Surface Firmness
  • Deep Firmness
  • Support
  • Feel
  • Durability
• Types of Foam; Basic Formulations: Polyols, TDI versus MDI, Slab versus Moulded - this section describes the different types of foam, how they are formulated and why these different grades are chosen for specific applications)
  • Standard foams
  • High resilience (HR) foams
  • Combustion modified HR foams (CMHR)
  • High load bearing foams
  • Soft/supersoft foams
  • Viscoelastic (Dead) foam
  • Speciality foams i.e. packaging, flame laminatable etc.
• Flame Retardants
  • Common flame retardants
  • Small scale verses large scale testing
  • Testing by country

Rigid Foam

• Market Overview
• Mechanism of Foam Formation
  • Balancing blowing versus gellation
  • Role of catalysts
  • Role of surfactants
• Test Methods - description of the key methods and equipment for rigid foams
  • Density
  • Compressive strength
  • Open/closed cells
  • K-factor
  • Flame retardancy
    • Common flame retardants
    • Test methods
    • Testing by country
• Blowing Agents - Advantages and Disadvantages, Industry Trends
  • New HFC's
  • Pentanes
  • H2O
  • Other (methyl formate, methylal)
• Types of Foam - basic formulations/polyols/PIR versus PUR/processing equipment - this section describes the different types of foam, how they are formulated and why these different grades are chosen for specific applications.
  • Pour/injection of refrigeration appliances, water heaters
  • Pour/injection of discontinuous panels
  • Pour for continuous panels
  • Pour-in-place packaging, shock protection
  • Pour/injection of structural foam, wood imitation
  • Spray foam
  • Pour for bun and block foam

Session Three

Coatings; Adhesives, Sealants and Elastomers (CASE)

This session is intended as a follow-on for those attending Session One and covers the CASE urethane market overview, technologies and examples of formularies utilized for many of the different CASE applications.

The CASE area tends to have many more choices for the 'more exotic' raw materials. A 'basic understanding' of chemistry is desirable to get the most from this day.

Coatings, Adhesives, Sealants, and Elastomers (CASE)

• What is CASE (Coatings, Adhesives, Sealants and Elastomers):
• Examples of Types and Uses
• What are the Common Characteristics between the different applications

Polyurethane Market Overview and Major market segments: USA, Europe and Global Polyurethane structure/property relationships:

• Review of Relevant Functional Group Chemistry
• Basic polymer morphology fundamentals (soft and hard segments).
• Effect of polyol, Iso, Curative Type, Molecular Weight and/or Functionality
• Review of Common Elastomer Test Methods

Types of Urethane Elastomers, Formulary for Various Applications:

• Thermoplastic Polyurethanes
• Cast elastomers
• RIM
• Spray elastomers
• Microcellular elastomers

Types of Urethane Elastomers, Formulary for Various Applications: (cont)

Types of Polyurethane Sealants and Typical Formulary

• One and two component
• Moisture cure,
• Hybrids

Adhesive Types And Typical Formulary:

• Hot Melts
• Two Component
• Moisture Cure
• Hybrids

Urethane Binders: Types And Typical Formulary

• Metal Foundry,
• Carpeting,
• Wood Laminates,
• and Misc.

Polyurethane Coating Types and Typical Formulary:

• Solvent,
• Waterborne
• Moisture Cure,
• One and Two Component