POLYURETHANE
History
Polyurethane chemistry was first studied by the German
chemist, Friedrich Bayer in 1937. He produced early prototypes by
reacting toluene diisocyanate reacted with dihydric alcohols. From
this work one of the first crystalline polyurethane fibers called
Perlon U, was developed.
In 1953, the first commercial production of a
flexible polyurethane foam was begun in the United States. This
material was useful for foam insulation. In 1956, more flexible, less
expensive foams were introduced. During the late 1950s, moldable
polyurethanes were produced. Over the years, improved
polyurethane polymers have been developed including Spandex
fibers, polyurethane coatings, and thermoplastic elastomers.
What is Polyurethane?
We use polyurethanes in one form or another everyday at a
home, in our offices and cars, for sport ,leisure activities on holiday.
Polyurethanes are versatile, modern & safe. They are used in
wide range of variety of applications to create all manner of
consumer and industrial products that play a crucial role in making
our lives more convenient, comfortable & environmentally friendly.
polyurethane is plastic material which is exist in various
forms. It can be tailored to be either rigid or flexible.
Polyurethanes are linear polymers that have a molecular
backbone containing carbamate groups (NHCO2). These groups,
called urethane,
Design
Polyurethanes can be produced in four
different forms including elastomers, coatings,
flexible foams, and cross-linked foams. Elastomers
are materials that can be stretched but will
eventually return to their original shape. They are
useful in applications that require strength,
flexibility, abrasion resistance, and shock absorbing
qualities. Thermoplastic polyurethane elastomers
can be molded and shaped into different parts.
Manufacturing Process
Their production method can be broken
into three distinct phases. First, the bulk polymer
product is made. Next, the polymer is exposed to
various processing steps. Finally, the polymer is
transformed into its final product and shipped.
Processing
1 At the start of polyurethane foam production,
the reacting raw materials are held as liquids in
large, stainless steel tanks. These tanks are
equipped with agitators to keep the materials
fluid. A metering device is attached to the tanks
so that the appropriate amount of reactive
material can be pumped out. A typical ratio of
polyol to diisocyanate is 1:2. Since the ratio of
the component materials produces polymers
with varying characteristics, it is strictly
controlled.
Processing
The reacting materials are passed
through a heat exchanger as they are
pumped into pipes. The exchanger
adjusts the temperature to the reactive
level. Inside the pipes, the
polymerization reaction occurs. By the
time the polymerizing liquid gets to the
end of the pipe, the polyurethane is
already formed. On one end of the pipe
is a dispensing head for the polymer.
Processing
The dispensing head is
hooked up to the processing
line. For the production of
rigid polyurethane foam
insulation, a roll of baking
paper is spooled at the start
of the processing line. This
paper is moved along a
conveyor and brought under
the dispensing head.
Processing
As the paper passes under, polyurethane is blown onto
it. As the polymer is dispensed, it is mixed with carbon
dioxide which causes it to expand. It continues to rise
as it moves along the conveyor. (The sheet of
polyurethane is known as a bun because it "rises" like
dough.)
Processing
After the expansion reaction begins, a second top layer of
paper is rolled on. Additionally, side papers may also be
rolled into the process. Each layer of paper contains the
polyurethane foam giving it shape. The rigid foam is passed
through a series of panels that control the width and height of
the foam bun. As they travel through this section of the
production line, they are typically dried.
Manufacturing process
At the end of the production line, the foam insulation is
cut with an automatic saw to the desired length. The foam
bun is then conveyored to the final processing steps that
include packaging, stacking, and shipping.
Applications of uses
Is the material of choice for a broad range of end-user
applications such as:
1.Insulation of refrigerators and freezers
2.Building insulations
3.mattresses
4.Car parts
5.coatings
6.Adhesives
7.Rollers
8.Shoe soles
9.Sportswear
physical properties of polyurethane
֎ The physical properties of
polyurethane are considerable.
֎ polyurethane performs well
for hardness, tensile strength,
compression strength, impact
resistance, abrasion resistance &
tear strength.
Chemical Properties of Polyurethane
Advantages of polyurethane
Wide range of hardness.
High load bearing capacity.
Flexibility
Abrasion & impact Resistance.
Tear resistance
Resistance to oil, water, grease.
Good Electrical insulations.
Strong bonding properties.
Fungus resistance.
Wide Color Ranges.
disadvantages of polyurethane
Durability- short life
Odor- emits irritating odor and
flammable fumes.
Health Problems- releases toxic fumes
which is not healthy to inhale
Environmental Issues- Burning of
fumes create greenhouse gases that
affects negative role in atmosphere.
