Process

Flexible polyurethane foam is made by continuous slab stock foaming method. The raw

materials, polyol, isocyanate, blowing agent, catalyst and surfactant are metered

continuousy into a mixer. The mxed reactants are poured continuously into a paper

mold which moving on a conveyer belt. In the paper mold the mxed lquid toams and

expands to form a continuous block of foam. This block is cut and stored for one day to

Cure the foam and cool. The cured are block cuttings are then cut to a variety of

shapes. These foams are having density in the range 15 to 50Kg/m.

Raw materials

The main raw materials are:

1. Polyol

2. Isocyanate

3. Blowing agent

4. Tin and amine catalyst

5. Silicone oil surfactant

6. Color/pigment

7. Fire retardant

Poyo

Flexible slabstock foams are made from polyether polyols. These are condensates of

propylene oxide and ethylene oxide. They are mainly triols. The hydroxyl values of

these polyols are in the range 36-56 mg KOH/9

Isocyanate

Toluene di iso-cyanate is used as raw material for flexible foams. 2.4 & 2.6 isomers are

present in the ration 80:20.

Blowing aents

The primary blowing agent which causes the foam to expand is carbon dioxide. Carbon

dioxide is produced by the reaction of iso-cyanate and added water.

Soft foams with density less than 21kg/m is produced by adding a secondary blowing

agent (trichlorofluoromethane or dichloromethane)

Catalyst

Amine: This type of catalyst (di-methyl amino ethanol or triethylene diamine) is used to

control rate of carbon dioxide formation (water and isocyanate reaction)

Stannous octoate: this catalyst promotes polyol and isocyanate reaction.

SNkcone oil surfactant