GB2256871A - Weldable polyurethane foam - Google Patents
Weldable polyurethane foam Download PDFInfo
- Publication number
- GB2256871A GB2256871A GB9213191A GB9213191A GB2256871A GB 2256871 A GB2256871 A GB 2256871A GB 9213191 A GB9213191 A GB 9213191A GB 9213191 A GB9213191 A GB 9213191A GB 2256871 A GB2256871 A GB 2256871A
- Authority
- GB
- United Kingdom
- Prior art keywords
- foam
- polyurethane foam
- range
- polyol
- weldable
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/0061—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof characterized by the use of several polymeric components
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
- C08G18/65—Low-molecular-weight compounds having active hydrogen with high-molecular-weight compounds having active hydrogen
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/12—Bonding of a preformed macromolecular material to the same or other solid material such as metal, glass, leather, e.g. using adhesives
- C08J5/121—Bonding of a preformed macromolecular material to the same or other solid material such as metal, glass, leather, e.g. using adhesives by heating
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/0008—Organic ingredients according to more than one of the "one dot" groups of C08K5/01 - C08K5/59
- C08K5/0016—Plasticisers
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G2110/00—Foam properties
- C08G2110/0041—Foam properties having specified density
- C08G2110/005—< 50kg/m3
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G2110/00—Foam properties
- C08G2110/0041—Foam properties having specified density
- C08G2110/0058—≥50 and <150kg/m3
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2375/00—Characterised by the use of polyureas or polyurethanes; Derivatives of such polymers
- C08J2375/04—Polyurethanes
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2427/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers
Landscapes
- Chemical & Material Sciences (AREA)
- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
- Compositions Of Macromolecular Compounds (AREA)
Abstract
A weldable high density polyol based polyurethane foam is produced from a foam formulation having a hydroxyl value in the range from 60 to 300 The polyol may have a molecular weight of substantially 3000 or below and a hydroxyl value in the range from 56 to 160. Alternatively a polyol having a molecular weight in the range from 300 DEG to 650 DEG is used in combination with a cross linking additive. The foam provides both good bar and tear/seal welding. The foam may comprise a plasticizer e.g. dialkyl phthalate, phosphate, sebacate, epoxidised oil, chlorinated paraffin or fatty acid ester, tricresyl phosphate, or oxalate and/or a thermoplastic filler, e.g. melamine, urea, polyvinyl chloride or polyvinylidene chloride. The foam can be welded by high frequency, e.g. radio frequency, welding, and may have a foam density of 15 to 100 Kg/m<3>.
Description
WELDABLE POLYURETHANE FOAM
This invention relates to plastics material foam
which is capable of being welded and more particularly
weldable polyurethane foam.
It is known that polyvinyl chloride foam can be
welded both to itself and to other materials.
Polyvinyl chloride is considerably more expensive than
some other plastics materials, notably polyurethane
and, therefore, economic benefits can be achieved if
those other plastics materials can be made weldable.
It has been suggested that polyurethane foam be
used as a weldable foam.
The major types of welds used for foams are called tear seal welds and bar welds. The known polyurethane weldable foam provides a good bar weld, but a poor tear/seal weld.
The present invention has been made from a
consideration of this problem.
According to the present invention there is
provided a weldable polyurethane foam, wherein the
polyurethane foam formulation has a hydroxyl value in the range from 60 to 300.
This may be achieved either by using a polyol based foam having a molecular weight of substantially 3000 or below and having a high hydroxyl value in the range from 56 to 160 or using a polyol having a higher molecular weight in the range from 3000 to 6500 in combination with a cross linking agent.
In a preferred embodiment of the invention the hydroxyl value is in the range from 100 to 200.
The foams of the present invention require a lower level of power to be used than known foams in order to obtain both good tear/seal welds and bar welds. The provision of a good tear/seal weld is important where products encapsulating weldable polyurethane foam (or
PVC foam) are produced. Here the ability to weld and cut through a composite of materials including weldable foam is of paramount importance. Good tear/seal and bar welds may be achieved with the foams of the present invention at similar (low) power and dwell settings to PVC foam. The foams of the present invention therefore may be used as weldable foams in place of PVC foams.
The cross linking agent preferably has a low molecular weight such as 1000 or below and may be in the form of a liquid or powder. Preferably the cross linking agent will react with isocyanate. The cross linking may be achieved by the use of reactive hydrogen compounds such as those on nitrogen containing compounds including amines. Preferred examples include any of the following either alone or in combination: polyols, polyamines, amino hydroxy compounds or reactive hologenated flame retardants. Other cross linking agents known in the art to produce foams with high cross-link densities should also be suitable.
The use of a polyol is particulary preferred. The polyol may be of low molecular weight in the range from 1000 to 3000 with a high hydroxol value in the range from 56 to 160, but more preferably has a higher molecular weight in the range from 3000-6500 and is used in combination with a cross linking additive as described above.
When a low molecular weight polyol type foam is made the polyol may be used in an amount up to 100%.
When the high molecular weight type foam is used the amount of cross linking agent used may be in the range from 1 to 35 parts per hundred parts of polyol (php) but is more preferably in the range from 10 to 25 php.
Since the relatively high cross-link density obtained tends to increase the rigidity of the foam obtained, as with PVC foam, it is possible to include a plasticiser which will give the foam obtained a flexible character.
Dependant on the final application of polyurethane weldable foams a plasticiser may or may not be used.
If such a plasticiser, as defined previously, is used then the end use for the weldable polyurethane foam will determine the plasticiser choice. That is to say for automobile applications, a usual area for plasticiser PVC foam, a low volatile plasticiser is chosen and the occurrence of fogging problems is greatly reduced.
The plasticiser may comprise at least one of the following either alone or in combination: dialkyl phthalate, phosphate, sebacate, polymeric, epoxidised oil, chlorinated paraffin, fatty acid ester or oxalate plasticier. The plasticiser may be present in the range from 0 to 200 parts per hundred of polyol (php) but more preferably from 50 to 150 php.
The above combination of highly cross-linked and plasticised polyurethane foam imparts good welding characteristics compared to that of foams known in the art. However further improvements may be made by the introduction of a thermoplastic filler.
The thermoplastic filler preferably comprises resin which may be added to the formulation in powder form and which may comprise for example any of the following either alone or in combination: melamine, urea, polyvinyl chloride, polyvinylidene chloride or the like. The thermoplastic filler material, in addition to rendering the polyurethane foam weldable may also impart flame retardant properties.
The thermoplastic filler is preferably added to the foam formulation in the range from 0 to 120 parts per hundred parts of poly (php) but more preferably is in the range from 30 to 120 php and still more preferably from 40 to 100 php. The particle size of the filler material is chosen so as to suit the foam to be produced from the formulation.
With certain applications it is necessary to alter the core to surface effectiveness of the weldable polyurethane foam and hence it may be necessary to post treat the weldable polyurethane foam by impregnation or spraying. Post treatment on the surface of the invention allows a high level of surface bonding whilst allowing a permanent weld through the foam. This post treatment may be by way of a thermoplastic resin such as melamine, urea, PVC or the like.
The final foam density of the polyurethane foam product is generally in the range from 15 to 100kg/m3 and more preferably in the range from 25 to 65kg/m3.
The low density foams are of particular interest.
For many applications weldable plastics foam is required in thin sheets. These are produced by splitting or peeling large blocks so as to form continuous sheets which are suitable for continuous process operations in which welding forms a part. The low density polyurethane foam product of the present invention enables much larger blocks to be produced so that, as a consequence, very long continuous sheets of weldable foam can be formed therefrom. This in turn reduces the down time between changes of lengths of sheet material in the continuous processes in which the sheets are used.
As stated above the polyurethane foam of the invention can be welded in the same way as polyvinyl chloride foam, for example by high frequency welding using for example radio frequency welding at current welding frequencies of 27 MHz, and will produce welds of equivalent strength. The invention can be applied to all types of polyurethane foam, that is to say high resilience polyether polyurethane foam, conventional or standard polyether polyurethane foam and polyester polyurethane foam. The foam may include other additives, for example additional flame retardant.
The following example further illustrates the invention:
EXAMPLE
The following formulation was made in accordance with the invention:
% by finished foam weight
Polyurethane foam 54.2%
Rigid polyol (OH = 580) 5.1%
Plasticiser (Tricresyl phosphate) 30.5%
Resin (Polyvinyl chloride) 15.3%
Final Foam density 4Okg/m3 A sample of PVC foam and the weldable polyurethane foam defined above were welded using a combined tear/seal and bar weld tool (smaller in scale but typical of the type used in industrial applications) using a Stanelco 4kWatt Radio Frequency welding machine set at 27.12 MHz (Model FP40). A section from each of these foams was cut such that the bond strength could be measured across both the bar weld and the tear/seal weld and the following results were obtained:
DRIP MAT WITH DRIP MAT WITH
POLYURETHANE FOAM POLYVINYL CHLORIDE (40kg/m3 density) FOAM (96kg/m3 density)
Time = 3.5 seconds Time = 3.5 seconds
Power = 70 per cent Power = 70 per cent
Dwell = 4.0 seconds Dwell = 3.0 seconds
BOND SEPARATIONS (TESTED USING PU FOAM PVC FOAM
INSTRON 1026) ACROSS 40MM PRODUCT PRODUCT (1) Bar Weld 23N 28N (2) Tear/seal weld +50N +50N
The polyurethane foam of the present invention therefore provides similar bar weld properties as the
PVC foam while providing equivalent tear/seal weld properties.
It is to be understood that the above described examples are by way of illustration only. Many modifications and variations are possible.
Claims (16)
1. A weldable polyurethane foam having a hydroxyl value in the range from 60 to 300.
2. A weldable polyurethane foam as claimed in claim 1 having a hydroxyl value in the range from 100 to 200.
3. A weldable polyurethane foam as claimed in claim 1 or claim 2, comprising a polyol having a molecular weight of substantially 3000 or below and having a hydroxyl value in the range from 56 to 100.
4. A weldable polyurethane foam as claimed in any preceding claim, comprising a polyol having a molecular weight in the range from 3000 to 6500 in combination with a cross linking agent.
5. A weldable polyurethane foam as claimed in claim 4, wherein the molecular weight of the cross linking agent is less than or equal to 1000.
6. A weldable polyurethane foam as claimed in claim 4 or claim 5, wherein the amount of cross linking agent included in the foam composition is in the range from 1 to 35 parts per hundred parts of polyol.
7. A weldable polyurethane foam as claimed in claim 6, wherein the amount of cross linking agent included in the foam composition is in the range from 10 to 25 parts per hundred of polyol.
8. A weldable polyurethane foam as claimed in any of claims 2 to 7, wherein the foam composition comprises a plasticiser in an amount in the range from 0 to 200 parts per hundred of polyol.
9. A weldable polyurethane foam as claimed in claim 8, wherein the amount of plasticiser is in the range from 50 to 150 parts per hundred of polyol.
10. A weldable polyurethane foam as claimed in claim 8 or claim 9, wherein the plasticiser comprises any of the following either alone or in combination: dialkyl phthalate, phosphate, sebacate, polymeric, epoxidised oil, chlorinated paraffin, fatty acid ester or oxalate plasticicer.
11. A weldable polyurethane foam as claimed in any of claims 2 to 10, wherein a thermoplastic filler is present in an amount in the range from 0 to 120 parts per hundred parts of polyol.
12. A weldable polyurethane foam as claimed in claim 11, wherein the amount of thermoplastic filler is in the range from 30 to 120 parts per hundred parts of polyol.
13. A weldable polyurethane foam as claimed in claim 11 or claim 12, wherein the amount of thermoplastic filler is in the range from 40 to 100 parts per hundred parts of polyol.
14. A weldable polyurethane foam as claimed in any preceding claim having a foam density in the range from 15 to 100 Kg/m3.
15. A weldable polyurethane foam as claimed in any preceding claim having a foam density in the range from 25 to 65 Kg/m3.
16. A weldable polyurethane foam substantially as described herein with reference to the example.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB9213191A GB2256871A (en) | 1991-06-20 | 1992-06-22 | Weldable polyurethane foam |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB919113325A GB9113325D0 (en) | 1991-06-20 | 1991-06-20 | Weldable polyurethane foam |
| GB9213191A GB2256871A (en) | 1991-06-20 | 1992-06-22 | Weldable polyurethane foam |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB9213191D0 GB9213191D0 (en) | 1992-08-05 |
| GB2256871A true GB2256871A (en) | 1992-12-23 |
Family
ID=26299098
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB9213191A Withdrawn GB2256871A (en) | 1991-06-20 | 1992-06-22 | Weldable polyurethane foam |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2256871A (en) |
Citations (17)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE1245117B (en) * | 1958-05-03 | 1967-07-20 | Erich Schickedanz | Process for the production of thermally deformable and weldable foams |
| JPS4213554Y1 (en) * | 1964-08-20 | 1967-08-02 | ||
| JPS4317599Y1 (en) * | 1965-07-08 | 1968-07-20 | ||
| GB1233004A (en) * | 1967-06-13 | 1971-05-26 | ||
| GB1345265A (en) * | 1970-05-06 | 1974-01-30 | Koepp Co Chem Fab Ag Rudolph | Weldable polyurethane foams |
| GB1395754A (en) * | 1971-04-02 | 1975-05-29 | Pohl G | Weldability of articles made from plastics foam |
| JPS53440A (en) * | 1976-06-23 | 1978-01-06 | Nippon Sekiyu Hanbai Kk | Combustion method for liquid fuel |
| CA1042599A (en) * | 1973-02-03 | 1978-11-14 | Morey Weisman | Dielectrically modified polyurethane foam material |
| US4348489A (en) * | 1973-02-03 | 1982-09-07 | Morey Weisman | Dielectrically modified polyurethane foam material |
| EP0078478A1 (en) * | 1981-11-04 | 1983-05-11 | Bayer Ag | High-frequency weldable polyurethane foams, and process for preparing the same |
| JPS58201835A (en) * | 1982-05-20 | 1983-11-24 | Asahi Chem Ind Co Ltd | Aqueous dispersion composition having improved high frequency bonding property |
| JPS5956421A (en) * | 1982-09-27 | 1984-03-31 | Mitsui Toatsu Chem Inc | Production of polyurethane foam |
| EP0105607A2 (en) * | 1982-09-03 | 1984-04-18 | Morey Weisman | Modified polyurethane product having improved load-bearing characteristics |
| JPS60130630A (en) * | 1983-12-17 | 1985-07-12 | Toyo Rubber Chem Ind Co Ltd | Production of polyurethane foam |
| JPS60133020A (en) * | 1983-12-20 | 1985-07-16 | Sanyo Chem Ind Ltd | Urethane foam and its use |
| EP0170206A1 (en) * | 1984-07-26 | 1986-02-05 | Ikeda Bussan Co., Ltd. | Production of polyurethane foam |
| GB2236106A (en) * | 1989-09-21 | 1991-03-27 | British Vita | Weldable polyurethane foam |
-
1992
- 1992-06-22 GB GB9213191A patent/GB2256871A/en not_active Withdrawn
Patent Citations (17)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE1245117B (en) * | 1958-05-03 | 1967-07-20 | Erich Schickedanz | Process for the production of thermally deformable and weldable foams |
| JPS4213554Y1 (en) * | 1964-08-20 | 1967-08-02 | ||
| JPS4317599Y1 (en) * | 1965-07-08 | 1968-07-20 | ||
| GB1233004A (en) * | 1967-06-13 | 1971-05-26 | ||
| GB1345265A (en) * | 1970-05-06 | 1974-01-30 | Koepp Co Chem Fab Ag Rudolph | Weldable polyurethane foams |
| GB1395754A (en) * | 1971-04-02 | 1975-05-29 | Pohl G | Weldability of articles made from plastics foam |
| US4348489A (en) * | 1973-02-03 | 1982-09-07 | Morey Weisman | Dielectrically modified polyurethane foam material |
| CA1042599A (en) * | 1973-02-03 | 1978-11-14 | Morey Weisman | Dielectrically modified polyurethane foam material |
| JPS53440A (en) * | 1976-06-23 | 1978-01-06 | Nippon Sekiyu Hanbai Kk | Combustion method for liquid fuel |
| EP0078478A1 (en) * | 1981-11-04 | 1983-05-11 | Bayer Ag | High-frequency weldable polyurethane foams, and process for preparing the same |
| JPS58201835A (en) * | 1982-05-20 | 1983-11-24 | Asahi Chem Ind Co Ltd | Aqueous dispersion composition having improved high frequency bonding property |
| EP0105607A2 (en) * | 1982-09-03 | 1984-04-18 | Morey Weisman | Modified polyurethane product having improved load-bearing characteristics |
| JPS5956421A (en) * | 1982-09-27 | 1984-03-31 | Mitsui Toatsu Chem Inc | Production of polyurethane foam |
| JPS60130630A (en) * | 1983-12-17 | 1985-07-12 | Toyo Rubber Chem Ind Co Ltd | Production of polyurethane foam |
| JPS60133020A (en) * | 1983-12-20 | 1985-07-16 | Sanyo Chem Ind Ltd | Urethane foam and its use |
| EP0170206A1 (en) * | 1984-07-26 | 1986-02-05 | Ikeda Bussan Co., Ltd. | Production of polyurethane foam |
| GB2236106A (en) * | 1989-09-21 | 1991-03-27 | British Vita | Weldable polyurethane foam |
Also Published As
| Publication number | Publication date |
|---|---|
| GB9213191D0 (en) | 1992-08-05 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| WAP | Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1) |