New product concept
Seeking Mitigation Of Low Molecular Weight Aldehydes Released From Flexible Polyurethane Foams
ClosedInquiries no longer accepted
Type of Solution sought
- A Material
- A Technology
- A Manufacturing Process modification
Description of Desired Solution
Background
Although it is preferable to prevent the formation of low molecular weight aldehydes in the first place, solutions that would capture, bind, or otherwise prevent their escape into the automobile’s cabin air would also be acceptable.
The SpecialChem Client is a major global provider of raw materials and formulations for manufacturing Polyurethane (PUR) foams for automobile seating applications. The Client has a 30% share globally of the raw materials and formulated systems that go into this market. They are willing to improve their existing products to offer a new grade of PUR foam.
Detailed Solution Description
A typical manufacturing process to make the backbone of PUR/PIR follows these steps:
- Only liquid reactants are used.
- Raw materials are formulated with tertiary amine and organo-tin catalysts, water, auxiliary hydrocarbon blowing agents, and surfactants.
- The backbone of the PUR foam is produced by reacting a low molecular weight aromatic diisocyanate with a saturated polyether polyol.
The foam seat cushion is produced by injecting the reactants into a mold. This is generally done with a 2-stream mixhead, where the isocyanate is one stream and the formulated polyol/additives blend is the second stream. The mold may be open or closed during injection.
The Client is willing to work with the solver to fine-tune the approach and make samples. The Client can also perform any required material characterization, analytical work, and physical testing required to validate the solution.Possible Routes To Investigate
The SpecialChem Client is ready to consider chemical, filler, and foam manufacturing process changes.
- The Client is especially interested in additives to the foam formulation that would prevent the decomposition of the PUR backbone into aldehydes. However, routes to sequester or bind the aldehydes once they form, to prevent their migration into the cabin air, would also be considered.
- If a filler solution is proposed, modifications will also be required to the foam manufacturing process which currently uses all liquid reactants.
- Solutions may also suggest modifications to the isocyanate and/or polyol intermediates used to make the foam.
Solution that are not of interest
- Post application coatings to the foam are not in scope, but a truly novel approach of this nature may be considered, e.g. an in-mold coating.
- Barrier materials, such as modifications to the permeability of the seat cushion fabric or addition of chemicals or films to the textiles of the seat covering, are beyond the control of the Client.
Anticipated Next Steps with Respondents
Type of Outcome expected
- Ready to use solutions
- Approaches suitable for joint development
Company Demographics
- Industry: Chemical Industry
- Annual Revenue: > 10 Billion Euro
- Years in Business: > 50 years
- Headquarters Area: Germany
Business considered
- Buying
- Licensing
- Contractual partnership (R&D, marketing…)
- Funding/Joint-venture