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