POLYURETHANES WORLD CONGRESS 1991 THE VOICE OF ADVANCEMENT
Proceedings of the SPI/ISOPA September 24-26, 1991 Acropolis®, Nice, France
COSPONSORS
The Society of the Plastics Industry, Inc. (SPI) Polyurethane Division European Isocyanate Producers Association (ISOPA)
Table of Contents
PLENARY SESSION Polyurethanes-Milestones and Visions through the Year 2000
2
G. Oertel and W. Reichmann, Bayer AG
2000 and Beyond: Succeeding in the Next Century
7
R. R. Reen, ICI Polyurethanes
ENVIRONMENTAL WORKSHOP Regulatory Scene for Selected Diisocyanates
12
J. E. Doe, ICI Central Toxicology Laboratory M. Katoh, Mitsubishi-Kasei Institute of Toxicological and Environmental Sciences J. R Lyon, ICI Americas
Environmental Aspects of TDI
17
R. E. Bailey, The Dow Chemical Company D. S. Gilbert, Gilbert International Isocyanates H. Kitahara, Nippon Polyurethane Industry Co. Limited
Some Actions Taken by Flexible Foam Producers in Europe to Meet the Requirements of Legislation on Health and the Environment
26
R. Hurd, B.R.M.A.
The Implementation of the "Seveso" Directive in Italy: A Practical Experience Related to TDI
36
F. Antonello, S.T.A. Servizi Tecnologici Ambientali
The Combustion Toxicology of Polyurethane Foams
40
G. E. Hartzell, Consultant
TECHNICAL SESSION I—Construction Polyurethane Rigid Foam Systems for Metal-Faced Sandwich Panels for the 1990s
54
G. M. F. Jeffs, I. D. Rosbotham, B. Mathys and R. Frigo, ICI Polyurethanes Group
CFC-Free PU-Sandwich Element DBL Production for Scandinavian Markets
60
R. Ojala, Urepol Oy
A New CFC-Free Technology for the Production of PUR Insulation Panels
63
B. Wallaeys, P. De Schryver and P. Cop, Recticel NV
Experiences and Results of CFC-Free Polyurethane Foams in Building Industry
66
A. lhanamaki, Lohja Corporations Kankaanpaa
Development of an All-Purpose Impermeably-Faced Roof Insulation
69
T. G. Soukup and W. E. Laughlin, Jim Walter Research Corp.
Certification of Thermal Conductivity Aging of PUR Foam*
75
G. C. J. Bart and G. M. R. du Cauze de Nazelle, Delft University of Technology
Testing Water Blown CFC-Free Composite Panels*
81
P. M. Roberts, Ward Building Components
Means to Improve the Thermal Conductivity of Foam Insulation*
85
L. R. Glicksman, M. Torpey and A. Marge, Massachusetts Institute of Technology
Blowing Agent Emissions from Insulation Foams*
91
I. R. Shankland, Allied-Signal Inc. •This paper could not be accommodated in the program of the 1991 Polyurethanes World Congress.
Table of Contents /vii
TECHNICAL SESSION Il-Automotive Interior Replacement of Chlorofluorocarbons in All MDI Automotive Seating Foams
100
J. Thoen, R. Elwell, R. Sewell and R. Broos, Dow Benelux NY L. Pellacani, L. Pedroni and G. Bergianti, Dow Italia SpA
CFC-Free Hot-Curing Moulded Flexible Foam for Automotive Seating
108
H. G. Schneider, M. Brock, M. Herrmann and K. D. Wolf, Bayer AG
High Molecular Weight Polyols for Automotive HR Foam
112
S. Hatano, N. Yasuda, S. Hayashida, N. Kunii, H. Takeyasu and S. Kozawa, Asahi Glass Co., Ltd.
PUREA Foam-A Superior HR-Flexible Foam
117
H. Humbert and W. Klockemann, 7exaco Chemical Deutschland GmbH
Advances in PHD Polyol Technology for Automotive Molded Flexible Foam
121
M. A. Koshute, Mobay Corporation
New Surfactant for High Resiliency Moulded Polyurethane Foam Improves Processing*
127
G. Burkhart, J. Klietsch and V. Zellmer, Th. Goldschmidt AG
Soft Flexible Polyurethane Foam without CFCs*
132
T. Nishioka, S. Sakai and K. Ueno, Mitsui Toatsu Chemicals, Inc.
TECHNICAL SESSION III—Equipment Consistent Distribution of Finely Dispersed Gases in Polyol Streams
138
F. Proksa, Maschinenfabrik Hennecke GmbH J. C. Phelps, Mobay Corporation
Soluble or Insoluble Alternative Blowing Agents? Processing Technologies for Both Alternatives, Presented by the Equipment Manufacturer
141
M. Taverna, Cannon Communication L. Hufnagel, Cannon USA
New Technical Solutions in High Pressure Metering Machines by Means of Metering Plungers
148
V. Mariani, Impianti OMS S.p.A.
Metering of Flammable Blowing Agents
160
B. P. Lerch and P. Taubenmann, BASF/Elastogran Polyurethane GmbH
Computer-Aided Design for RIM Molds
164
R. Strassburger, M. Piesche, J. Becker and H. U. Schmidt, BASF AG
The Influence of Gassing, Especially with CO2, on the Machinability and Moulded Part Properties of Polyurethane Foam Systems*
169
L. Jung, Elastogran Polyurethane GmbH
TECHNICAL SESSION IV—Chemical Innovation Non-Corrosive, High Performance, Delayed Action Catalyst
174
J. B. Letts and R. M. Gerkin, Union Carbide Chemicals and Plastics Company Inc. P. Martineau, Union Carbide Canada Limited
A New Phosphorus Flame Retardant for Rigid Polyurethane
182
M. Ballard and A. J. Taylor, Albright & Wilson Ltd.
New Surfactant Technology for HCFC-123 and HCFC-141b Blown Rigid Foam Systems
191
T. W. Bodnar and J. J. Koch, Air Products and Chemicals, Inc. J. D. Thornsberry, Dow Corning Corporation
Optimisation of Silicone Surfactants for HCFC-123 Blown Rigid Polyurethane Foams
197
J. Fis, Union Carbide Chemicals and Plastics (Europe) SA
Characterization of Innovative Tertiary Amine Catalyst Systems for All-Water Blown Flexible Polyurethane Foams
204
S. Okuzono, H. Yoshimura and S. Arai, TOSOH Corporation D. W. Lowe, TOSOH U.S.A., Inc.
TECHNICAL SESSION V—Construction Replacing CFC-11 with HCFC-22 in Polyurethane Foam J. A. Creazzo and H. S. Hammel, £. /. du Pont de Nemours & Company, Inc. Viii / Table of Contents
214
Chlorodifluoromethane as the Primary Blowing Agent for Rigid Urethane Foams Using Conventional Low and High Pressure Foam Mixing Equipment
220
D. C. Krueger and C. J. Reichel, BASF Corporation
Mechanical Performance of Polyisocyanurate Roof Insulations Blown with Hydrochlorofluorocarbon (HCFC) Blowing Agents
225
W. C. Cullen and T. L. Smith, National Roofing Contractors Association
Improved Dimensional Stability in Rigid Polyurethane Polyisocyanurate Construction Foams from the Addition of High Functional, Low Viscosity Polyether Polyol
233
D. M. Ference and K. D. Parsley, The Dow Chemical Company
New Polyether Polyols for Use in Formulating High Water, Reduced CFC Rigid Polyurethane Foams
237
H. Perek and R. Gilmour, Rhone-Poulenc Canada Inc
CFC-Free Polyurethane Pipe Insulation Foams for Use in District Heating Systems
243
Th. Broennum, Chemical Research Centre, Shell Louvain-la-Neuve
TECHNICAL SESSION VI—Automotive Interior PUR Flexible Foam with Sound Absorbing Properties
252
H.-D. Lutter, J. Mertes and R. Zschiesche, BASF AG
The Optimisation of Acoustic Polyurethanes Using the Computer Aided Noise Analysis and Simulation Programme (C.A.N.A.S.)
257
R. Morris-Kirby, W. R. Grace
Thermoformable Polyurethane Foam for the Manufacture of Headliners
266
K. Schmutzer and L. Jung, Elastogran Polyurethane GmbH H.-D. Lutter, BASF AG D. G. Schlotterbeck, BASF Corporation
Amine-Free Catalyst Systems for Automotive Instrument Panels
272
A. Christfreund, E. Huygens and B. Eling, ICI Polyurethanes Group
Light Weight RIM Composites for Interior Automotive Substrates
278
J. J. Laux, Dow Plastics Development L. B. Weaver, Dow Chemical U.S.A. R. De Genova and H. E. Bernardi, Dow Latin America
An Integrated Approach to Foam Development for Automotive Instrument Panels
287
B. G. Colvin, Industrial Foam Systems Ltd.
TECHNICAL SESSION VII—Coatings/Adhesives/Sealants/Elastomers Novel Reactive Polyurethane Polymers with No Free Isocyanate Groups for Adhesive and Sealant Industries H. Singh, Products Research and Chemical Corporation
306
\
Thermoplastic Polyurethane Elastomers Made from High Molecular Weight POLY-L™ Polyols C. R Smith, J. W. Reisch and J. M. O'Connor, Olin Corporation 2,4' MDI Based Prepolymers: A Viable Alternative to TDI Prepolymers in Polyurethane Sealants
313
319
D. G. Lay, P. Cranley and M. Chorghade, The Dow Chemical Company
Pressure-Sensitive Polyurethane Adhesives
325
L. W. Mobley, Dow Chemical U.S.A.
Oligomeric Diamine-Based Polyureas for Adhesive Applications
329
T. M. Santosusso, D. J. Finocchio and J. H. Frey, Air Products and Chemicals, Inc.
Primerless Polyurethane Adhesive for Bonding Automotive Sheet Molding Compound Body Panels
337
M. A. Scheel, Lord Corporation
TECHNICAL SESSION VIII—Environmental Issues Environmental Impact and Disposal of TDI and MDI
346
C. Bastian, Dow Europe S.A. Table of Contents I ix
Assessment of the Fire Hazard Presented by a Burning Pool of Toluene Diisocyanate (TDI)
352
G. Marlair, INERIS H. Sand, BASF Aktiengesellschaft
Energy Recovery from Automotive RIM Parts
355
G. F. Baumann and J. I. Myers, Mobay Corporation W. J. Farrissey, Dow Chemical U.S.A.
The Recovery and Reclaiming of Fluorocarbon Blowing Agents from Polyurethane Foams
361
M. R. Ascough and K. J. Cicalo, DuPont Canada Inc.
A Unit for the Recovery of CFC-11 from Rigid Polyurethane Foams
366
J. M. Blessing, Adelmann GmbH
Recycling of Microcellular Polyurethane Elastomer Waste
370
M. Modesti, F. Simioni and S. A. Rienzi, Universita di Padova
TECHNICAL SESSION IX—Construction New Systems for CFC-Replacement in Rigid Foams
378
H. Kramer, DOW Benelux N.V.
Joint Industry/Government Research Project-Comparison of Thermal Aging for Roof Exposures and Thin-Specimens of Experimental Polyisocyanurate Insulation Foamed with Alternative Blowing Agents
385
R. S. Graves, J. E. Christian and D. L. McElroy, Oak Ridge National Laboratory
The Influence of Environmental Factors on Thermal Resistance of Rigid Polyurethane Foams
399
M. R. Ascough, DuPont Canada Inc. M. T. Bomberg and M. K. Kumaran, National Research Council Canada
Aging Characteristics of PUR Rigid Foams with Alternative Blowing Agents
408
R. E. Wiedermann, G. G. Heilig and E. M. Hoppe, Bayer AG
Mathematical Modeling Techniques to Predict Important Aspect of fc-Factor Aging of CFC-11 Free Rigid Insulation
412
G. F. Smits and J. A. Thoen, DOW Benelux N.V.
TECHNICAL SESSION X—Automotive Interior Production of PU Integral Skin Foams without CFCs
430
E. Bianchin, E. Benetti, P. Andreola and A. Valcarenghi, Enichem/Montedipe
CFC-Free Integral Skin Foams for Steering Wheels
436
M. Scarpati, R. P. Harrison and B. J. Zagata, BASF Corporation
New Interior Car Components Made from Polyurethane Composites by Structural Bonding
440
R. Belle and N. Blank, Teroson GmbH
New Approach to CFC Free Steering Wheels
450
A. Fangareggi, G. Guidetti and L. Pedroni, Dow Italia S.PA.
Hyperlite® Foam for Foam-in-Fabric Headrest/Armrest
456
J. L. Lambach and W. A. Gill, AC West Virginia Polyol Company
TECHNICAL SESSION XI—Coatings/Adhesives/Sealants/Elastomers and Electrical Applications Advances in NDI Elastomer Chemistry
464
E. C. Prolingheuer, J. M. Barnes, R. Kopp and E. von Seggern, Bayer AG
100% Solids Aliphatic Spray Polyurea Elastomer Systems
473
D. J. Primeaux II, Texaco Chemical Co.
Roll Covering by Rotational Casting with Fast-Reacting PUR Systems
478
H. D. Ruprecht, K. Recker and W. Grimm, Bayer AG
Isocyanate-Based Casting Resins
482
J. Franke and H. P. Mueller, Bayer AG
Polyurethanes as Insulating Materials in Electrical Applications G. Hegemann, BASF Lacke & Farben AG X/ Table of Contents
490
TECHNICAL SESSION XII—Fundamentals of Polyurethane Chemistry Viscoelastic Behavior of Flexible Slabstock Polyurethane Foams as a Function of Temperature and Relative Humidity
500
J. C. Moreland and G. L. Wilkes, Virginia Polytechnic Institute & State University R. B. Turner, The Dow Chemical Company
An Integrated View of Reactive Urethane Foaming
509
L. D. Artavia and C. W. Macosko, University of Minnesota R. D. Priester, Jr., A. K. Shrock and R. B. Turner, The Dow Chemical Company
A New Synthetic Approach to High Molecular Weight Polyetherpolyols
519
W. Hinz, BASFAG
Amine Catalyst Characterization by a Foam Model Reaction M. L. Listemann, A. C. Savoca and A. L. Wressell, Air Products and Chemicals, Inc. An Automated Image Analysis Method for the Characterisation of Flexible Foam Cellular Structure
524 545
P. Chaffanjon and G. Verhelst, ICI Polyurethanes Group
TECHNICAL SESSION XIII—Appliance Improvements in HCFC Microcell Appliance Foam
554
H. P. Doerge, Mobay Corporation
HCFC Blown Rigid Polyurethane Foams and Refrigerator Liner Materials: The Search for Compatible Systems
560
K. G. Potter, Monsanto Europe, S.A. C. R. Tweedale, ICI Polyurethanes Group
Novel Polyurethane/Plastic Liner Technology for HCFC-Blown Appliance Foams
571
H. J. M. Grunbauer, K. J. van Duin and G. J. B. Brands, DOW Benelux NV X. Fanichet and E. Kuhn, DOW Europe SA
Predictable Manufacturing Processes in the Appliance Foam Insulation Industry: Productivity and Quality Improvement as an End Result
579
B. Dobbs, General Electric Appliances S. Moy, The Dow Chemical Company
The Use of an All CO2 Blown Foam in Production
586
W. F. Sullivan, Dixie-Narco Inc. A. K. Thomas, ICI Polyurethanes
HCFC-Resistant Materials for Refrigerator Liners
592
H. Morgenstern, BASF AG
TECHNICAL SESSION XIV—Furnishings The Evaluation of the Behaviour of Furnishings Fires in Europe
600
L. Chesne, Laboratoire National D'Essais
The Effect of Foam Density on Combustion Characteristics of Flexible Polyurethane Foam
603
H. Stone and M. Pcolinsky, Jr., General Foam Division of PMC Inc. D. B. Parrish and G. E. Beal, Dow Chemical, U.S.A.
The Ignition Behaviour of Conventional and HR Foams, Particularly in Relation to Small Ignition Sources
615
P. F. Haas and F. H. Prager, Bayer AG
The OSU Heat Release Unit as a Screening Tool for California TB 133
620
J. A. Gallagher, T. M. Smiecinski and 0. M. Grace, BASF Corporation
Combustion Modified Moulded Polyurethane Flexible Foam for the Furniture Industry*
628
M. Barker, M. P Hannaby and F. J. Lockwood, ICI Polyurethanes Group
TECHNICAL SESSION XV—Automotive Exterior Material Recycling of RIM-Polyurethanes
636
W. Rasshofer, U. Liman and J. Wagner, Bayer AG
Polyurethane Recycling Solutions to a Problem
646
B. M. Meister and H. A. Schaper, Phoenix AG Table of Contents / X\
The Processing and Use of RIM Regrind
653
R. E. Morgan, G. H. Dean, R. L. Tabor and M. Zawisza, Dow Europe
Automotive Exterior Body Panels with Polyurea and the Reaction Injection Molding (RIM) Process
661
R. D. Wharfield, General Motors Corporation
Secondary Aliphatic Polyether Amines for Polyurea RIM Systems
669
C. Maletzko, J. Becker, H. U. Schmidt and G. Matzke, BASF AG
Dimensional Stability of RRIM Polyurea Body Panels through the Assembly Process
674
J. J. Hemphill and C. Noakes, Dow Chemical U.S.A.
Reinforced TPU-Influence of the Glass Fiber*
680
D. R. Lausberg and S. Arenz, BASF AG R. Steinberger, Elastogran EPE
TECHNICAL SESSION XVI—Footwear Non-CFC Microcellular Polyurethanes
686
R. C. Hire, R. S. Blackwell and K. B. Chandalia, Olin Corporation
New CFC Free Polyether Microcellular Polyurethane for Footwear
691
G. Sacchetti, S. Mussini and B. Maccari, Dow Italia S.p.A.
Recycling of Flexible Microcellular Polyurethane Foam
698
S. Franyutti, Mobay Corporation 0. H. Cloutier, Jones & Vining, Inc. P. Seifert, Bayer AG
CFC-Free Polyether Polyurethane Systems for Footwear Applications
705
C. Phanopoulos, N. Limerkens, H. Stilling and D. Randall, ICI Polyurethanes
Wear Resistance of Polyether Polyurethane Elastomers for Shoe Sole Application*
712
R. Broos, R. Elwell and J. Thoen, DOW Benelux NV
TECHNICAL SESSION XVII—Appliance Alternative Blowing Agents for CFC Free Rigid PU Foams
720
C. Cecchini, B. Cellarosi, V. Cancellier and G. P. Pirotta, EniChem Polimeri
Novel Polyurethane System for Refrigeration in HCFC Blown Rigid Foam
728
S. Ozaki, M. Kimura, T. Izukawa, N. Tokoro and T. Aziro, Mitsui Toatsu Chemicals Inc.
1,1,1,4,4,4 Hexafluorobutane, a New Non-Ozone-Depleting Blowing Agent for Rigid PUR Foams
734
W. M. Lamberts, Bayer AG
PUR Foams Prepared with Emulsified Perfluoroalkanes as Blowing Agents
740
0. Volkert, BASF AG
CFC-Free Appliance Foams with Low Thermal Conductivity
745
T. Sato and K. Honda, Dow Mitsubishi Kasei, Ltd. D. Bhattacharjee and D. Chen, Dow Chemical, U.S.A.
Froth and Pour-in-Place Foam Systems Based on CFC Alternates
752
F. J. Dwyer, R. C. Parker, K. M. Thrun and L. M. Zwolinski, Allied-Signal Inc
TECHNICAL SESSION XVIII—Furnishings Novel Polyol System for Flame Retarded Flexible Foam
762
F. S. Natoli, J. E. Puig, J. M. O'Connor and K. B. Chandalia, Olin Chemicals Research
Slab Foams Prepared from Modified TDI (Cushion Fatigue Study)
766
D. L. Christman, W. V. Floutz, T. Narayan and C. J. Reichel, BASF Corporation
CFC Free Soft Foam Using a New Functional Additive
775
T. H. Austin and J. E. Knight, ARCO Chemical Company
New Developments in Silicone Surfactants and Amine Catalysts for Flexible Ester Slabstock Foam R. Schiffauer, Union Carbide Chemicals and Plastics Company Inc. M.-C. Desnier, Union Carbide Chemicals and Plastics (Europe) SA Xii / Table of Contents
781
New Technologies for CFC-Free Flexible Slabstock Polyurethane Foam
791
A. K. Schrock, E. P. Wiltz, F. E. Parks, J. V. McClusky, J. S. Hicks and
C. D. McAfee, Dow Chemical U.S.A. K. Brunner, Dow Chemical Europe Extending the Performance Limits of Flexible Slabstock Foam
796
S. L. Hager, L. F. Lawler and T A. Craig, AC West Virginia Polyol Co.
TECHNICAL SESSION XIX—Automotive Exterior The Design and Processing of High Performance SRIM Composites
804
L. P. Rotival and R. J. Hayman, Dow Plastics Development
Factors Influencing High-Density SRIM Surface Quality
810
G. S. Kuyzin and D. G. Schlotterbeck, BASF Corporation
Six Years' Application Experience with 2K-Topcoat in the Automotive OEM at Mercedes-Benz
820
K. Herrmann, Mercedes-Benz AG
Two Component Tbp Coat Technology in the Automotive Industry
827
H. J. Drexler, BASF Lacke + Farben AG T. Anderson, BASF Coatings + Colorants
One Shot and Prepolymer Systems in the RIM-Process
833
H.-J. Meiners, H. Boden and H.-J. Braun, Bayer AG
Reinforcement Fillers for RRIM
841
M. Nakamura, T. Chiba and I. Matsumura, Sumitomo Bayer Urethane Co., Ltd.
TECHNICAL SESSION XX—Chemical Innovation New Heat Resistant Isocyanate Based Foams for Structural Applications
850
K. C. Frisch, V. Sendijarevic, A. Sendijarevic, H. Lekovic, J. E. Krestaand D. Klempner, University of Detroit Mercy, Polymer Technologies, Inc. L. Hunter and R. Banuk, Northrop Corporation
New PolyTHF® Developments
858
P Groll, BASFAG
PPDI para-Phenylene Diisocyanate: An Exciting Monomer for Polyurethanes
863
R. Moore and W. C. Whelchel, DuPont Chemicals D. D. Russell, Akron Polymer Laboratory
Recycling of Polyurethane Wastes and Mixed Polymer Wastes by Means of Alcoholysis Reaction
872
G. Bauer, Fachhochschule Aalen
Environmentally Friendly Release Agents for Molded Polyurethane
877
G. D. Andrew and D. J. Swaintek, Air Products and Chemicals, Inc. R. Diem and D. Nollen, Air Products and Chemicals PURA GmbH & Co.
A New Flame Retardant Additive for Conventional Flexible Polyurethane Foams
885
T. Ebbrecht, G. Burkhart and V. Zellmer, Th. Goldschmidt AG
Appendix
.889
Author Index
925
Table of Contents / xiii