Highly Sophisticated Cell Opener For Viscoelastic Foam (Presentation)

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Highly Sophisticated
Cell Opener for
Viscoelastic Foam
Michael Krebs, Roland Hubel
UTECH Europe 2015
15.04.2015
New Cell Opener for
TDI 80 Viscoelastic Foam
What is Viscoelastic Foam?
15.04.2015 Michael Krebs UTECH Europe 2015

New Cell Opener for
Why is Cell Structure so important?

New Cell Opener for
What is a Cell Opener?

New Cell Opener for
What is special about the new Cell Opener ORTEGOL® VCO?

New Cell Opener for
What is special about the new Cell Opener ORTEGOL® VCO?

• Strong cell opening properties with broad processing lattitude
• Both fine and coarse cell structure possible
• Not hydrolyzable
• Easy handling because of low viscosity
• Low VOC and mild odor

Memory Foam
Slow Recovery Foam
Controlled Recovery Foam
Low Resilience Foam
Viscoelastic Foam
…
Different names, different chemical compositions, no standard visco foam.

Slow Recovery
slow
compression
-
low
resistance
towards
deformation
(foam is soft)
slow recovery
0 5 - 20 s
Low Resiliency
Resiliency by Ball Rebound
Conventional flexible foam: roughly 35 – 45 %

HR-foam: 55 – 70 %
Viscoelastic Foam: < 10 %
Energy is converted into heat

Low resiliency is related to slow recovery
Ball rebound test

Typical Applications
Pillows
Mattresses
Pads

Reasons for Viscoelasticity
Network Effect
deformed PUR network
produces the resilient force
Relaxation Effect
relaxation of PUR network segments
Pneumatic Effect Adhesive Effect
takes time, if the mobility of at least a
air needs time to flow adhesive forces
part of the segments is restricted, result
back into the foam, result from sticky
is a force against fast re-expansion
is a slight under pressure surfaces
(glass transition temperature related)
air
air
Foam needs to have a low resilient force

Relaxation effect, adhesive effect and pneumatic effect need to be
increased

Network Effect
deformed PUR network
produces the resilient force
Relaxation Effect
relaxation of PUR network segments
Pneumatic Effect Adhesive Effect
takes time, if the mobility of at least a
air needs time to flow adhesive forces
part of the segments is restricted, result
back into the foam, result from sticky
is a force against fast re-expansion
is a slight under pressure surfaces
(glass transition temperature related)
air
air
Foam needs to have a low resilient force

Relaxation effect, adhesive effect and pneumatic effect need to be
increased

Macroscopic/ Applies to both Influence Influence Influence

Molecular Compression and of of of
Re-Expansion Temperature Cell Structure Stabilizer
Network
Resilient Molecular Yes Yes, weak Yes, weak No
Effect
Relaxation No, but linked to

Molecular Yes Yes No
Effect adhesion effect
Adhesion Macroscopic
No Yes Yes, strong Yes
Effect and Molecular
Pneumatic
Macroscopic Yes No Yes, strong Yes
Effect


Network
Effect

Pneumatic
Effect


Network
Effect

Pneumatic
Effect


Network
Effect

Pneumatic
Effect

Viscoelastic Foam…
The Importance of Cell Regulation
• All viscoelastic foams based on the

pneumatic or adhesive effect strongly
depend on the cell structure
• The role of the cell structure – cell

fineness & porosity – turns out to be
significant for viscoelastic foams
• Therefore, careful control of cell regulation

and cell opening are the main challenges
in production of viscoelastic foam.

Processing Lattitude
Conventional vs. Visco Foam
conventional flexible foam TDI 80 viscoelastic foam
only stabilizer
shrinkage shrinkage
processing
processing
stabilizer and
satisfying cell opener
foam
satisfying foam
collapse only cell opener collapse
amount of stabilizer amount of additive

Processing Lattitude
Conventional vs. Visco Foam
conventional flexible foam TDI 80 viscoelastic foam
only stabilizer
shrinkage shrinkage
processing
processing
stabilizer and
satisfying cell opener
foam
satisfying foam
collapse only cell opener collapse
amount of stabilizer amount of additive
Foams prepared…
• w/o any stabilizer  collapse
• with a standard stabilizer  shrinkage
 special cell opener is required to
prevent shrinkage

Cell Opening Strategies
special polyether
siloxanes
incompatible micro- & nanoparticles

fluids (fumed silica/aluminia,
(silicone oils, PDMS, …) Cell Opening CaCO3, …)
gas producing
technical options
components (organic
(reduced pressure, …)
peroxides, …)

Cell Opening Strategies
special polyether
siloxanes
incompatible micro- & nanoparticles

fluids (fumed silica/aluminia,
(silicone oils, PDMS, …) Cell Opening CaCO3, …)
gas producing
technical options
components (organic
(reduced pressure, …)
peroxides, …)

TDI 80 Visco Foaming Experiments
Dow Formulation
Identification pphp
VoranolTM CP 755 (OH-number: 238 mg KOH/g) 70
TDI T80 Index <85> 40.3
Water 1.95
TEGOAMIN® 33 0.3
TEGOAMIN® BDE 0.2
TEGOAMIN® DMEA 0.2
KOSMOS® 29 0.07
Silicone stabilizer variable
Cell Opener variable

Dow Formulation
Cell Opener Silicon surfactant Porosity
Foam height Density (not CLD 40% Cells Ball rebound
Competitive ORTEGOL® TEGOSTAB® Remarks
[cm] [kg/m³] crushed) [kPa] [cm-1] [%]
VCO BF 2470 [mm]
[pphp] [pphp] [pphp]
- - - - - - - - - collapse
- - 1.0 - - - - - - shrinkage
0.5 - 1.0 - - - - - - shrinkage
1.0 - 1.0 33.1 43.1 5 0.6 15 13 -
- 1.0 1.0 33.3 43.0 6 0.5 15 12 -
- 0.7 0.7 33.1 43.0 96 0.6 > 15 5 -
- 1.0 0.7 33.0 43.2 43 0.6 14 8 -
- 1.25 0.7 32.9 43.2 12 0.5 13 10 -
- 1.5 0.7 - - - - - - collapse

Dow Formulation
VCO BF 2470 [mm]
- - - - - - - - - collapse
- - 1.0 - - - - - - shrinkage
0.5 - 1.0 - - - - - - shrinkage
1.0 - 1.0 33.1 43.1 5 0.6 15 13 -
- 1.0 1.0 33.3 43.0 6 0.5 15 12 -
- 0.7 0.7 33.1 43.0 96 0.6 > 15 5 -
- 1.0 0.7 33.0 43.2 43 0.6 14 8 -
- 1.25 0.7 32.9 43.2 12 0.5 13 10 -
- 1.5 0.7 - - - - - - collapse

Dow Formulation
VCO BF 2470 [mm]
- - - - - - - - - collapse
- - 1.0 - - - - - - shrinkage
0.5 - 1.0 - - - - - - shrinkage
1.0 - 1.0 33.1 43.1 5 0.6 15 13 -
- 1.0 1.0 33.3 43.0 6 0.5 15 12 -
- 0.7 0.7 33.1 43.0 96 0.6 > 15 5 -
- 1.0 0.7 33.0 43.2 43 0.6 14 8 -
- 1.25 0.7 32.9 43.2 12 0.5 13 10 -
- 1.5 0.7 - - - - - - collapse

Dow Formulation
VCO BF 2470 [mm]
- - - - - - - - - collapse
- - 1.0 - - - - - - shrinkage
0.5 - 1.0 - - - - - - shrinkage
1.0 - 1.0 33.1 43.1 5 0.6 15 13 -
- 1.0 1.0 33.3 43.0 6 0.5 15 12 -
- 0.7 0.7 33.1 43.0 96 0.6 > 15 5 -
- 1.0 0.7 33.0 43.2 43 0.6 14 8 -
- 1.25 0.7 32.9 43.2 12 0.5 13 10 -
- 1.5 0.7 - - - - - - collapse

Dow Formulation
VCO BF 2470 [mm]
- - - - - - - - - collapse
- - 1.0 - - - - - - shrinkage
0.5 - 1.0 - - - - - - shrinkage
1.0 - 1.0 33.1 43.1 5 0.6 15 13 -
- 1.0 1.0 33.3 43.0 6 0.5 15 12 -
- 0.7 0.7 33.1 43.0 96 0.6 > 15 5 -
- 1.0 0.7 33.0 43.2 43 0.6 14 8 -
- 1.25 0.7 32.9 43.2 12 0.5 13 10 -
- 1.5 0.7 - - - - - - collapse

Dow Formulation
VCO BF 2470 [mm]
- - - - - - - - - collapse
- - 1.0 - - - - - - shrinkage
0.5 - 1.0 - - - - - - shrinkage
1.0 - 1.0 33.1 43.1 5 0.6 15 13 -
- 1.0 1.0 33.3 43.0 6 0.5 15 12 -
- 0.7 0.7 33.1 43.0 96 0.6 > 15 5 -
- 1.0 0.7 33.0 43.2 43 0.6 14 8 -
- 1.25 0.7 32.9 43.2 12 0.5 13 10 -
- 1.5 0.7 - - - - - - collapse
ORTEGOL® VCO  Cell openness

 Slightly coarser cell structure
Dow Formulation
VCO B 8002 [mm]
- 0.7 0.7 32.9 43.3 268 0.8 15 3 -
- 1 0.7 32.6 43.3 218 0.8 15 3 -
- 1.25 0.7 32.5 43.3 50 0.6 15 7 -
- 1.5 0.7 32.5 43.4 21 0.5 15 9 -
- 1.75 0.7 32.3 43.4 15 0.5 15 10 -
- 2 0.7 32.2 43.4 5 0.5 15 11 -
- 3 0.7 32.1 43.5 1 0.5 15 12 -

Dow Formulation
VCO B 8002 [mm]
- 0.7 0.7 32.9 43.3 268 0.8 15 3 -
- 1 0.7 32.6 43.3 218 0.8 15 3 -
- 1.25 0.7 32.5 43.3 50 0.6 15 7 -
- 1.5 0.7 32.5 43.4 21 0.5 15 9 -
- 1.75 0.7 32.3 43.4 15 0.5 15 10 -
- 2 0.7 32.2 43.4 5 0.5 15 11 -
- 3 0.7 32.1 43.5 1 0.5 15 12 -

Dow Formulation
VCO B 8002 [mm]
- 0.7 0.7 32.9 43.3 268 0.8 15 3 -
- 1 0.7 32.6 43.3 218 0.8 15 3 -
- 1.25 0.7 32.5 43.3 50 0.6 15 7 -
- 1.5 0.7 32.5 43.4 21 0.5 15 9 -
- 1.75 0.7 32.3 43.4 15 0.5 15 10 -
- 2 0.7 32.2 43.4 5 0.5 15 11 -
- 3 0.7 32.1 43.5 1 0.5 15 12 -
ORTEGOL® VCO  Cell openness

 Consistent fine cell structure
 Broad processing lattitude

Rokita Formulation
Identification pphp
Rokopol® vTec 8020 (OH-number: 185 mg KOH/g) 92
Rokopol® M1170 (OH-number: 34 mg KOH/g) 8
TDI T80 Index <93> 41.8
Water 1.7
TEGOAMIN® 33 0.3
TEGOAMIN® BDE 0.15
ORTEGOL® 204 1.6
KOSMOS® 29 0.03
Silicone stabilizer variable
Cell Opener variable

Rokita Formulation

VCO BF 2370 [mm]
- - 0.5 - - - - - - shrinkage
- 1.0 0.5 33.1 49.0 18 2.0 11 12 -
- 1.0 1.0 33.0 49.0 25 2.0 11 10 -
- 1.0 1.5 33.2 49.3 25 2.1 12 8 -
- 1.0 2 33.1 49.1 31 2.2 15 10 -

Rokita Formulation

VCO BF 2370 [mm]
- - 0.5 - - - - - - shrinkage
- 1.0 0.5 33.1 49.0 18 2.0 11 12 -
- 1.0 1.0 33.0 49.0 25 2.0 11 10 -
- 1.0 1.5 33.2 49.3 25 2.1 12 8 -
- 1.0 2 33.1 49.1 31 2.2 15 10 -

Rokita Formulation

VCO BF 2370 [mm]
- - 0.5 - - - - - - shrinkage
- 1.0 0.5 33.1 49.0 18 2.0 11 12 -
- 1.0 1.0 33.0 49.0 25 2.0 11 10 -
- 1.0 1.5 33.2 49.3 25 2.1 12 8 -
- 1.0 2 33.1 49.1 31 2.2 15 10 -

Rokita Formulation

VCO BF 2370 [mm]
- - 0.5 - - - - - - shrinkage
- 1.0 0.5 33.1 49.0 18 2.0 11 12 -
- 1.0 1.0 33.0 49.0 25 2.0 11 10 -
- 1.0 1.5 33.2 49.3 25 2.1 12 8 -
- 1.0 2 33.1 49.1 31 2.2 15 10 -
TEGOSTAB® BF 2370  Cell fineness

 Consistent open foams

Rokita Formulation

VCO BF 2470 [mm]
- - 0.5 - - - - - - shrinkage
- 0.5 0.5 32.9 49.3 64 2.1 14 8 -
- 0.7 0.7 33.1 49.1 12 2.1 12 10 -
- 1.0 1.0 33.3 49.1 9 2.0 11 10 -
- 1.2 1.2 33.4 49.0 8 2.1 9 9 -
- 1.5 1.5 33.5 49.0 7 2.2 8 11 -

Rokita Formulation

VCO BF 2470 [mm]
- - 0.5 - - - - - - shrinkage
- 0.5 0.5 32.9 49.3 64 2.1 14 8 -
- 0.7 0.7 33.1 49.1 12 2.1 12 10 -
- 1.0 1.0 33.3 49.1 9 2.0 11 10 -
- 1.2 1.2 33.4 49.0 8 2.1 9 9 -
- 1.5 1.5 33.5 49.0 7 2.2 8 11 -

Rokita Formulation

VCO BF 2470 [mm]
- - 0.5 - - - - - - shrinkage
- 0.5 0.5 32.9 49.3 64 2.1 14 8 -
- 0.7 0.7 33.1 49.1 12 2.1 12 10 -
- 1.0 1.0 33.3 49.1 9 2.0 11 10 -
- 1.2 1.2 33.4 49.0 8 2.1 9 9 -
- 1.5 1.5 33.5 49.0 7 2.2 8 11 -

Rokita Formulation

VCO BF 2470 [mm]
- - 0.5 - - - - - - shrinkage
- 0.5 0.5 32.9 49.3 64 2.1 14 8 -
- 0.7 0.7 33.1 49.1 12 2.1 12 10 -
- 1.0 1.0 33.3 49.1 9 2.0 11 10 -
- 1.2 1.2 33.4 49.0 8 2.1 9 9 -
- 1.5 1.5 33.5 49.0 7 2.2 8 11 -
TEGOSTAB® BF 2470 Cell fineness


ORTEGOL® VCO Consistent open foams

Rokita Formulation
0.5 pphp ORTEGOL® VCO 0.7 pphp ORTEGOL® VCO 1.0 pphp ORTEGOL® VCO 1.2 pphp ORTEGOL® VCO 1.5 pphp ORTEGOL® VCO
0.5 pphp TEGOSTAB® BF 2470 0.7 pphp TEGOSTAB® BF 2470 1.0 pphp TEGOSTAB® BF 2470 1.2 pphp TEGOSTAB® BF 2470 1.5 pphp TEGOSTAB® BF 2470
14 cells 12 cells 11 cells 9 cells 8 cells

64 mm 12 mm 9 mm 8 mm 7 mm

Rokita Formulation
0.5 pphp ORTEGOL® VCO 0.7 pphp ORTEGOL® VCO 1.0 pphp ORTEGOL® VCO 1.2 pphp ORTEGOL® VCO 1.5 pphp ORTEGOL® VCO
0.5 pphp TEGOSTAB® BF 2470 0.7 pphp TEGOSTAB® BF 2470 1.0 pphp TEGOSTAB® BF 2470 1.2 pphp TEGOSTAB® BF 2470 1.5 pphp TEGOSTAB® BF 2470
14 cells 12 cells 11 cells 9 cells 8 cells

64 mm 12 mm 9 mm 8 mm 7 mm
 Adjustment of cell structure possible, depending on

 amount of ORTEGOL® VCO
 amount and nature of silicon surfactant
VOC Room Temperature Profile
Dow Formulation
Identification pphp
TDI T80 Index <85> 40.3
Water 1.95
TEGOAMIN® 33 0.3
TEGOAMIN® BDE 0.2
TEGOAMIN® DMEA 0.2
KOSMOS® 29 0.07
TEGOSTAB® BF 2470 1.0
ORTEGOL® VCO 1.0

Test Method
Chamber Test (DIN 16000-9):

• Conditioning at room temperature
• Sampling after 24 h
• 2 L of volume absorbed at absorption tube
• Thermodesorption and analysis via GC-MS
• Quantification as toluene equivalent

Chromatogram - DIN 16000-9
Solvent of competitive Cell Opener

T 80 visco foam
aminoethyl)ether
Bis (2-dimethyl
with
Triethylene diamine
1 pphp competitive Cell Opener
+
1 pphp TEGOSTAB® BF 2470
1-(2-propylenoxy)-2-propanol
N,N-Dimethylethanolamine
Cyclic siloxane D6
Cyclic siloxane D5
1592 µg/m³

15.04.2015
N,N-Dimethylethanolamine
1-(2-propylenoxy)-2-propanol
Michael Krebs
Triethylene diamine
Bis (2-dimethyl
UTECH Europe 2015

aminoethyl)ether
Cyclic siloxane D5
Chromatogram - DIN 16000-9
Cyclic siloxane D6
Solvent of new Cell Opener ORTEGOL® VCO

67 µg/m³
+
with
T 80 visco foam
1 pphp ORTEGOL® VCO
1 pphp TEGOSTAB® BF 2470

Minimized Contribution of ORTEGOL® VCO
Concentration as toluene equivalent [µg/m³]

Identification 1 pphp competitive Cell Opener 1 pphp ORTEGOL® VCO VOC source
1 pphp TEGOSTAB® BF 2470 1 pphp TEGOSTAB® BF 2470
cyclic siloxane D5 30 10 volatile siloxane
cyclic siloxane D6 40 8 volatile siloxane
solvent of comp.
alkylated benzene 1592 0
cell opener
new solvent solvent of new

0 67
ORTEGOL® VCO ORTEGOL® VCO
sum of volatiles 1662 85

Properties of ORTEGOL® VCO
Synthetic route Mild odor

provides reliability
Strong Cell Opening Low VOC
No toxic solvents,
Both fine and coarse Not a dangerous
cell structure possible substance
Easy handling not hydrolyzable

because of low viscosity
Intensive trials
Broad processing
for every batch
lattitude
(quality control)

Properties of ORTEGOL® VCO
Physical Properties
Viscosity (25 °C) 119 mPa•s
Specific gravity (25 °C) 0.922 g/cm³
pH-value (1% aqueous solution) 7–8
OH number 12 mg KOH/g
Acid value < 3 mg KOH/g

Highly Sophisticated Cell Opener For Viscoelastic Foam (Presentation)

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Highly Sophisticated Cell Opener For Viscoelastic Foam (Presentation)

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placeholder title visual

What is Viscoelastic Foam?

15.04.2015 Michael Krebs UTECH Europe 2015

What is Viscoelastic Foam?

Why is Cell Structure so important?

15.04.2015 Michael Krebs UTECH Europe 2015

What is Viscoelastic Foam?

Why is Cell Structure so important?

What is a Cell Opener?

15.04.2015 Michael Krebs UTECH Europe 2015

What is Viscoelastic Foam?

Why is Cell Structure so important?

What is a Cell Opener?

What is special about the new Cell Opener ORTEGOL® VCO?

15.04.2015 Michael Krebs UTECH Europe 2015

What is Viscoelastic Foam?

Why is Cell Structure so important?

What is a Cell Opener?

What is special about the new Cell Opener ORTEGOL® VCO?

15.04.2015 Michael Krebs UTECH Europe 2015

Different names, different chemical compositions, no standard visco foam.

15.04.2015 Michael Krebs UTECH Europe 2015

Resiliency by Ball Rebound

Conventional flexible foam: roughly 35 – 45 %

Energy is converted into heat

Ball rebound test

15.04.2015 Michael Krebs UTECH Europe 2015

15.04.2015 Michael Krebs UTECH Europe 2015

Foam needs to have a low resilient force

15.04.2015 Michael Krebs UTECH Europe 2015

Foam needs to have a low resilient force

15.04.2015 Michael Krebs UTECH Europe 2015

Macroscopic/ Applies to both Influence Influence Influence

Relaxation No, but linked to

15.04.2015 Michael Krebs UTECH Europe 2015

Macroscopic/ Applies to both Influence Influence Influence

Relaxation No, but linked to

15.04.2015 Michael Krebs UTECH Europe 2015

Macroscopic/ Applies to both Influence Influence Influence

Relaxation No, but linked to

15.04.2015 Michael Krebs UTECH Europe 2015

Macroscopic/ Applies to both Influence Influence Influence

Relaxation No, but linked to

15.04.2015 Michael Krebs UTECH Europe 2015

• All viscoelastic foams based on the

• The role of the cell structure – cell

• Therefore, careful control of cell regulation

15.04.2015 Michael Krebs UTECH Europe 2015

conventional flexible foam TDI 80 viscoelastic foam

collapse only cell opener collapse

amount of stabilizer amount of additive

15.04.2015 Michael Krebs UTECH Europe 2015

conventional flexible foam TDI 80 viscoelastic foam

collapse only cell opener collapse

amount of stabilizer amount of additive

15.04.2015 Michael Krebs UTECH Europe 2015

incompatible micro- & nanoparticles

15.04.2015 Michael Krebs UTECH Europe 2015

incompatible micro- & nanoparticles

15.04.2015 Michael Krebs UTECH Europe 2015

VoranolTM CP 755 (OH-number: 238 mg KOH/g) 70

VoranolTM CP 3322 (OH-number: 48 mg KOH/g) 30

VoranolTM CP 1421 (OH-number: 33 mg KOH/g) 7