Manufacturing process of polyurethane foam

 

Three main raw materials are used in the production of polyurethane foam . There raw materials are polyol , water and TDI . The use of water allows foam to expand and rise . The three raw materials are accurately conditioned and are carried to the best processing temperature , that is between 20 degree Celsius to 25 degree Celsius . The reaction takes place in one to three minutes . This is the time in which the foam block reaches fixed dimensions . 

The harmful gases for environment such as CFC and methylene chloride are not used in the process now . After coming out of the processing , the foam is cut into blocks for maturation system . After 72 hours of production process , the reaction of the polyurethane ends . At the end of the process the blocks are stored in the warehouses .

The explanation of raw materials used in the production of foam -

Polyol -this is high viscosity oil , which is orderless and colourless . The amount of polyol decides the chemical formulations . This does not pose any danger to the eye etc , but safety glasses are used during its handling .

TOLUENE DI-ISOCYANATE (TDI) is commonly used for flexible foam slab stocks . The raw material is odourless , clear with low viscosity liquid and has pungent smell . However , it is toxic substance and its can be dangerous to health . The reaction of TDI with polyol gives rubber like mixture . The adding of water then gives foaming reaction . The amount of water Foam Machine Manufacturer in India and TDI are used according to the formulations of the manufacturing company .

Blowing agents – the main blowing agent which causes the foam to expand is carbon dioxide . The carbon dioxide is released during the reaction of water with isocymate .

Catalysts used in the foam production is amine . The amine can be toxic to the human beings and can cause skin irritations . The amine has unpleasant smell. Its ingestion is avoided as it may lead to health problems . Tin and stannous are also used as catalysts .

Then foam stabilizers are also in the production . The silicon stabilizer is used for two functions , first, Batch Foaming Machine Manufacturer in India to help the components to form homogeneous liquid , and second , to prevent the collapse before liquid polymerizes phase by stabilizing the bubbles in the forming process .Finally water is added and mixing is done .