PRACTICE WITH EXPANDED POLYURETHANE

HENRY ALEJANDRO ZAMORA HERNANDEZ

5801065

IVAN LEONARDO ARIZA GALVEZ

5801062

JUAN SEBASTIAN GARCIA TORRES

5801070

UNIVERSIDAD MILITAR NUEVA GRANADA

INDUSTRIAL ENGINEERING

ENGINEERING MATERIALS

FEBRUARY, 2021

PRACTICE WITH EXPANDED POLYURETHANE

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 PRACTICE WITH EXPANDED POLYURETHANE

HENRY ALEJANDRO ZAMORA HERNANDEZ

5801065

IVAN LEONARDO ARIZA GALVEZ

5801062

JUAN SEBASTIAN GARCIA TORRES

5801070

CONSULTANT LIC. PEDRO NEL MARTINEZ HENAO

UNIVERSIDAD MILITAR NUEVA GRANADA

INDUSTRIAL ENGINEERING

ENGINEERING MATERIALS

FEBRUARY, 2021

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 TABLE OF CONTENTS

ABSTRACT …………………………………………………..………………………………………. 4

OBJECTIVES ……………………………………………………………….………………………... 4

INTRODUCTION ………………...……………………………..…………………………………… 4

OBJECTIVES …………………………………………………………………………..…………….. 4

QUESTIONS TO BE ANSWERED IN THE REPORT ……………………………………………... 5

CONCLUSIONS …………………………………………………………………………………….. 16

REFERENCES ……………………………………………………………………………………… 17

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 ABSTRACT

Polyurethane Foam is a polymer widely used in numerous industrial processes, synthetic and
hard material, highly cross-linked and non-fixable, which is obtained from the mixture of two
components generated by chemical processes from oil and sugar: isocyanate and polyol. This material
is used in different industries thanks to its thermal insulation properties, acoustic insulation,
impermeability and moisture control, fire behavior, health, sustainability, mechanical resistance,
adhesion.

INTRODUCTION

The following work was carried out with the purpose of knowing, differentiating, and mainly
knowing when to use the different polyurethane foams in today's industry, consulting each of the
questions raised in the laboratory guide corresponding to the practice with expanded polyurethane,
with the help of experimental videos and databases taken from the internet, in order to familiarize this
material as a thermal and acoustic insulator in a residential and industrial context.

OBJECTIVES

GENERAL OBJECTIVE

● How to choose polyurethane foams and their different applications for surface sealing,
thermal insulation and acoustic insulation thermal insulation and acoustic insulation.

SPECIFIC OBJECTIVES

● To observe the design and handling of surfaces for the manufacture of expanded polyurethane.
● To observe the handling of materials used to produce expanded polyurethane.
● To learn how to manipulate the elements and to have the industrial safety precautions for them
● for bits manipulation.
● To observe and analyze the chemical reactions that occur in practice.

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 QUESTIONS TO BE ANSWERED IN THE REPORT

1. What is polyurethane foam?

Polyurethane is a substance created from a chemical reaction. It is a combination of polyol and

isocyanate that allows this material to be shaped and handled without losing its physiology. This
material can be crushed, scratched and stretched without any problem, being a tremendously resistant
material that can be used in solid, liquid or foam format. In the present case it is used in its liquid state
and after application it tends to expand until it acquires its solid form.

Polyurethane has a multitude of properties that work very well in the construction sector: water-
repellent insulator, thermal insulator and as a moisture-resistant material. In this way, the polyurethane
foam acts as a thermal bridge and, in addition to strengthening the structure, eliminates the transmission
of cold and heat. This means considerable savings in terms of cooling and heating.

2. What is expanded polyurethane, what are its components, what are its physical and chemical
properties?

Expanded polyurethane foam is one of the main materials currently used in various branches,
such as building houses, buildings, boats or boats, airplanes, among others. This material is the main
insulator in the construction industry. Polyurethane is a compound of "isocyanate" and "polyol" through
a chemical reaction. This material is the main insulator in the construction industry. Thanks to its
properties, it is used as a thermal insulator, water-repellent insulator and as an anti-moisture material.

The polyurethane foam is white is a light and low-density material, can be in liquid, solid or
foam this has a high insulating capacity due to the low thermal conductivity possessed by the foam gas
of its closed cells, which can be set at 10 ºC according to UNE 92202, although this value rises slightly
over time until it finally stabilises. The polyurethane foam has a high resistance to the effects of the
passage of time and has a long service life, maintaining without deteriorating for more than 50 years. It
is also highly recommended for its waterproof properties.

The polyurethane foam is an intermediate continuous coating because it meets the aspects
established in the DB-HS1 for these materials related to tightness, resistance to cracking, adhesion,
permeability, and physico-chemical stability. In the face of moisture, polyurethane foam, unlike other
products used, has two very important characteristics for a material used in insulation because it is
waterproof and allows perspiration, in any climate and without the need for a vapor barrier. There are
some varieties of polyurethane foam with fire protection.

3. How is the process of curing expanded polyurethane, what is the curing time of expanded
polyurethane?

1. Shake the spray vigorously (approx. 15 times).

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 2. Insert the applicator nozzle into the container.

3. Before reversing the packaging, some gas/propellant should be removed from the product....
Once this activity is done, we are ready to apply the product!

4. Reverse the spray and you should press gently. Test for cord width and pressure.

5. Fill in spaces at 50%. When the thickness to be applied exceeds 5 cm, apply in several
layers/passes waiting for the previous layer to expand and harden. The hardening process can
be accelerated by spraying the foam with water.

6. Once the foam is hardened, it can be cut, sanded and painted. If the entire container is not
used, clean the valve and cannula thoroughly with acetone.

The top layer dries literally in 20 minutes, the complete configuration occurs within 24 hours.
In this case, the excess material can be cut after 4 hours from the time of application.

4. Explain what is the polymerization process?

Polymerization is a chemical reaction by which reagents, monomers (low molecular weight

compounds), form chemical bonds between themselves, to give rise to a molecule of high molecular
weight (macromolecule), either linear chain or three-dimensional structure, so-called polymer.

5. Describe precautions when handling polyurethane chemical components.

For the use of polyurethane chemical components follow the following recommendations with
great caution. Stay away from heat, heat sources, sparks, open flame, and other sources of ignition.
Avoid smoking. Do not spray on an open flame or other ignition source. Do not puncture or burn, even
after use. Do not breathe dust, smoke, gas, fog, fumes, aerosol. Use respiratory protection. If you have
inadequate ventilation, use breathing protection. Wear protective gloves. Avoid releasing it to the
environment.

6. To which of the engineering material families does expanded polyurethane belong? Record
its classification, applications and properties.

Polyurethanes are part of the so-called thermostable polymers, which are characterized by
having cross-linked polymer chains, forming a three-dimensional net that does not melt. This
differentiates them from thermoplastic polymers. In addition, polyurethanes irreversibly polymerize
with heat or pressure to form a rigid, hard mass. Polyurethanes are the best-known polymers for making
foams. But polyurethanes are more than foams. These polymers have a reticular structure based on
covalent bonds, with cross-linking of chains produced by heat or by a combination of heat and pressure
during the polymerisation reaction. Thermostable polymers are often obtained in the form of two liquid
resins.

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 Thermostable polymers are often obtained in the form of two liquid resins. One contains curing
agents, hardeners and plasticizers, the other fillers and/or reinforcing materials that can be organic or
inorganic. When these two components are mixed, the cross-linking reaction is initiated, just as in others
it is initiated by heat and/or pressure. Because of this, thermosets cannot be reheated and recast like
thermoplastics. This is a disadvantage as the fragments produced during the process cannot be recycled
and used.

In general, the advantages of thermostable plastics for engineering applications are:

➢ High thermal stability.

➢ High rigidity.
➢ High dimensional stability.
➢ Resistance to temperature creep and deformation under load.
➢ Light weight.
➢ High electrical and thermal insulation properties.

Table 1. Structure, properties and applications of different industrial thermostable polymers.

Polímero Estructura Carga rotura Alarg. Módulo de Densidad Aplicaciones

(MPa) (%) elasticidad (Mg/m3)
(GPa)

Fenólicos 34-62 0-2 2.8-9.0 1.27 Adhesivos,

revestimientos, laminados.

Aminas Melamina 34-69 0-1 6.9-11.0 1.50 Adhesivos,

almacenamiento de
alimentos, moldeados
eléctricos.

Urea

Poliéstere 41-90 0-3 2.1-4.5 1.28 Moldeados eléctricos,

s laminados decorativos,
matrices para refuerzo con
fibra de vidrio.

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 Epoxis 28-103 0-6 2.8-3.4 1.25 Adhesivos, moldeados
eléctricos, matriz para
laminados aeronáuticos.

Uretanos 34-68 3-6 1.30 Fibras, revestimientos,

espumas, aislantes.

Furanos 21-31 0 10.9 1.75 Aglomerantes para

moldeado en arena.

Siliconas 21-28 0 8.3 1.55 Adhesivos, juntas y

cierres estancos.

Fuente: Recuperada de https://www.upv.es/materiales/Fcm/Fcm15/fcm15_6.html

7. What is the procedure for removing the stain generated in the polyurethane foam?

This method is recommended if the recent and small stain, such as a drop. Remove all excess
expandable polyurethane using a thin board as a spatula. Soak a clean cloth in acetone* and touch the
stain until it disappears. Remove any remaining acetone with a cloth soaked in water. *When using
acetone, keep in mind that there are some materials, such as paint or some plastics, that are not
compatible with it.

If the stain is extensive it is better to let it dry, so as not to aggravate the problem if trying to
remove it we rub it even more. For tough metal surfaces: With the help of a cutter, cut dry foam as close
to the base as possible. Soak a scrubber in undiluted bleach and rub the stain vigorously until it
disappears. Don’t forget to put on gloves to handle the bleach. Wipe with a damp cloth to remove any
traces of dry foam and bleach.

For stains on delicate surfaces: Cut the leftover dry foam with a cutter. Impregnate a cloth in
dimethylformamide and moisten the stain. Wear neoprene gloves and goggles to handle the solvent.
Leave on for 5 minutes and then brush the area with a clean, dry cloth to remove the foam. Repeat the
process until the stain has disappeared

8. Explain why polyurethane foam is also used as a thermo-acoustic insulator

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 Polyurethane foam is a good choice as a noise insulator, as it is an excellent acoustic insulator.
It achieves a great effectiveness in the absorption of noise and soundproofing of the house

According to a study by the Eduardo Torroja Institute of Construction Sciences, under the
Superior Council for Scientific Research, Science and Research (CSIC), its acoustic properties are
mainly due to its sealing capacity, which provides very good results in insulation from airborne noise,
no longer only in dwellings in urban centres, but also in discotheques, cafes, factories, and other places
where high noise levels are reached.

9. What is the service life of expanded polyurethane?

The durability of polyurethane will depend on the application and use of the product. For
example, under normal circumstances of wear and tear, a durability of more than 50 years can be
expected in insulating products for construction, more than 25 years in refrigerators, more than 20 years
in bumpers. Polyurethane normally outlasts the product in which it is used in terms of durability. [5]

10. What is low, medium and high-density polyurethane?

High density polyurethane is a type of foam that has a higher level of rigidity, which is due to
its high density, which in turn maintains a good thermal insulation, high mechanical strength. They also
stand out for their light weight and easy machinability, on the other hand, the properties of low and
medium density polyurethane vary according to the density in a proportional relationship.

More specifically, when we talk about high density polyurethane foams, we should refer to
materials with more than 35 kg/m3, medium density foams would range from 25 to 30 kg/m3 and low-
density foams would be those with 10 to 23 kg/m3 density. [6]

11. What temperature can polyurethane foam withstand?

Polyurethane foam has a good dimensional stability in a temperature range of -50ºC and +110ºC
and can reach 250ºC in short periods of time. [12]

12. How long does polyurethane foam take to dry?

Skin formation time: approx. 10 minutes.

Drying/hardening time: approximately 1.5 hours.

* Drying time will depend on the type of surface, amount of product used, humidity level and
ambient temperature. [13]

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 13. What are the characteristics of thermoplastic polyurethane?

Thermoplastic polyurethane is an elastomer characterized by:

❏ High wear and abrasion resistance.

❏ High tensile and tear strength.
❏ Very good damping capacity.
❏ Very good flexibility at low temperatures.
❏ High resistance to grease, oil, oxygen and ozone.
❏ Tenacious.
❏ Excellent elastic recovery.
❏ Light fastness (aliphatic). [14]

14. List and explain the different types of polyurethane available on the market.

Foams

Its formulation is based on low hydroxyl number (OH) polyols combined with isocyanates of
low functional group (NCO) content, coupled with special propellants and a precisely measured amount
of water. The formula is stoichiometrically designed to achieve a fast curing material (foamed or not)
with a density between 10 and 80 kg/m³.

The most widely used applications in the flexible polyurethanes segment are the manufacture
of mattresses, pillows and seats for both the household industry (chairs and armchairs) and the industrial
industry (seats and seats for cars, buses, etc.). In this segment, foams of between 18-50 kg/m3 are
usually used. Other applications are in the packaging industry, where foams are used as anti-impact
protectors for packaging delicate parts. Their main characteristic is that they are open-cell and low
density (12-15 kg/m³).

Rigid polyurethanes of density 30-60 kg/m³ are widely used as thermal insulators. Their main
applications are thermal insulation of refrigerators, freezers, cold rooms and sheets for sheds and
industrial roofs (foam molded into a matrix). They are also used as projected thermal insulation for
industrial sheds already built (for example, to insulate farms where chickens, pigs, etc. are raised).

Flexible Foams

Flexible polyurethanes are mainly used in the manufacture of soft foams, elastomers and paints.
Their mechanical properties can vary greatly due to the use of different isocyanates or diols such as
polyethylene glycol. The addition of varying amounts of water causes the generation of a greater or
lesser amount of carbon dioxide, which increases the volume of the product in the form of bubbles, in
different ways depending on the case. Unlike natural sponges, these are usually materials with
somewhat more closed pores.

Solid materials

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 Rigid non-porous or high-density polyurethanes (500-1200 kg/m³) are used to manufacture
automobile components, shoe soles, yacht parts, skateboard parts or furniture and decorated by injection
molding, casting or even RIM (Reaction Injection Molding) techniques. In copolymer form,
polyurethanes are also produced as fibers for the textile industry, such as elastane or lycra.

Liquid materials

Some polyurethanes are used in the manufacture of insulating paints, abrasion resistant coatings
or media insulating coatings, or glues or adhesives that are marketed in liquid form.

Industrial polyurethane

Industrial polyurethane is generally a mixture of two components or two-component systems,

A and B, in a stoichiometric proportion defined by the chemist who designs the formula.

There are also single-component polyurethanes, formulated for ease of application, such as
those commonly used in the construction industry. [15]

15. What forms or procedures exist to apply polyurethane, record it with a picture of each
application procedure. a picture of each application procedure.

If the polyurethane is applied outdoors it should be covered by an elastomeric acrylic, as UV

rays and other natural conditions can degrade it. There must be a good ambient temperature and the
substrate must be completely clean of grease, dust and any residue that affects the adhesion of the foam.

The projection of polyurethane requires a series of conditions, resources and knowledge for the
result to be professional. With its application a relevant energy saving is achieved, since it is an excellent
thermal insulation, as well as acoustic. Knowing how to project polyurethane correctly is key to achieve
maximum performance of the installation.

Also known as polyurethane foam, it is a material widely used in construction because it is

economical, versatile, effective, durable and sustainable.

To achieve optimum insulation, polyurethane foam spraying equipment is required, designed

to pump the components in the right doses and at the right pressure and temperature.

To achieve different performances, it can be applied in two ways: projection or injection. These
two types of polyurethane are a material applied in situ, which offers great advantages on site. [16]

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 16. What can be done with polyurethane? Describe the different types of applications and uses.

of application and uses. attach a picture

Polyurethane is a plastic material resulting from the polymerization of many urethane

structures. In terms of physical appearance, there are two types of polyurethane: pressurized liquid and
foam.

Pressurized liquid has the property that it expands as it is applied. It starts as a viscous liquid,
and when it is injected into an empty space or sprayed on a surface, its volume begins to increase,
covering much more. It is because of this property that it is ideal for sealing.

Polyurethane foam is a soft and consistent material, the one we know in synthetic sponges. It
is an excellent filler for furniture as it has a fairly acceptable degree of firmness.

The most important uses of polyurethane are

● Insulation to conserve heat

● Insulation to prevent heat from entering
● Acoustic insulation
● Liquid absorber
● Sealant
● Void filler
● Furniture foam
● Foam for mattresses
● Cushioning for shoes
● Waterproofing of electrical components
● Rollers and wheels
● Automotive components
● Footwear soles
● Insulating products for construction
● Coatings and adhesives
● Sportswear [17]

17. What are the monomers of polyurethane and what is the monomer formula?

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 Polyurethane is a polymer obtained from hydroxyl bases combined with diisocyanates
(generally TDI or MDI). [15]

18. Does polyurethane foam suffer from any kind of degradation outdoors?

Rigid polyurethane foam applied in-situ by projection does not degrade outdoors. What's more,
it has excellent behavior against atmospheric agents such as water, wind or extreme temperature
variations.

It is only attacked by prolonged exposure to ultraviolet radiation, contained in direct sunlight.

The attack by exposure to UV rays results in a dusty and orange appearance on the surface of
the foam, which produces a decrease in thickness at a regime of 1 or 2 millimeters per year, depending
on the combined effect of rain and wind. [18]

19. Is polyurethane a material harmful to the ozone layer?

Insulation systems help reduce or prevent energy losses in buildings, resulting in energy savings
and increased energy efficiency.

For this reason, they have acquired an essential role in the construction or renovation of
buildings that seek to have moderate energy consumption, such as passive houses or near-zero energy
buildings.

On the other hand, thanks to its excellent durability, it is most likely that it is not necessary to
replace polyurethane-based insulation throughout the life of the building, so it will be greater energy
and resource savings. [19]

20. What materials can polyurethane be projected on?

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 Polyurethane usually adheres perfectly to many materials that are generally used in construction

Polyurethane is an easy, fast and inexpensive way to insulate all kinds of spaces, including the
most difficult to access

One of the types of materials on which polyurethane can be projected are:

● Smooth metallic materials such as steel or aluminum.

● Galvanized sheet metal.
● Poor or sandy mortar layer.
● Concrete surfaces.
● Asphalt fabric. [20]

21. Does polyurethane be attacked by solvents or any other chemical?

Polyurethane is resistant to all chemicals usually used in construction.

Polyurethane is a very resistant material and stands out in the following aspects.

● Resistant to solvents normally used in adhesives, paints, bituminous pastes, wood preservatives
and sealant putty
● Resistant to aging, to the action of the roots, and is biochemically inert against fungi
● Is stable against fuels, mineral oil, diluted acids and alkalis
● Resists the action of exhaust gases or the most aggressive industrial atmosphere
● Is imputrescible (does not rot easily), stable against detritus (result of decomposition of a solid
mass) and odorless (no odor)
● It's chemically neutral [21]

22. What is polyurethane paint?

They are known polyurethane paints that are made from urethane type resin, its main feature is
that it has excellent adhesive properties and dyes.

Using this type of paint can create a durable, uniform, and glossy coating. [22]

23. What density is appropriate for a walkable floor or roof?

In soil two types of density are considered: apparent density and actual density.

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 Apparent density (da): is the mass contained in a unit of volume of a soil sample as it is,
including the volume occupied by pores. To determine this, the weight of a given volume of wood dried
to stove is divided by that volume of soil, and the result is expressed in kg/m3

The apparent density of the soils varies depending on the texture and structure between 1,100
and 1,900 kg/m3.

Actual density (dr) is the density of solid soil particles. It is determined by dividing the weight
of the stove-dried floor by the volume occupied by the solids

The actual density of the most common mineral soils varies from 2,500 to 2,700 kg/m3.

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 CONCLUSIONS

Polyurethane is one of the materials that we as engineers will use or see in any work and
social environment, a good material that lends itself to anything, so to speak. It is very good that we
learn about its properties, capabilities and most importantly the precautions and first aid that must be
provided for the health of the handler.

Polyurethanes, like all other plastics, are chemically polymeric chains of three-dimensional
structures formed by repeated links called polyol and isocyanate monomers. These monomers are
made up of hydrogen, carbon, nitrogen, and oxygen. To make the chains, said links are polymerized
by condensation, that is, they join each other.

Polyurethane is undoubtedly the material with which we live most in our daily lives, from the
moment we get up to the moment we go to sleep, so it is vital to know its origins, types and certainly
where it is used in the industry, in order to familiarize ourselves with it for a professional environment
nearby.

Many specific aspects were studied according to the polyurethane foam, in order to know how
to choose which one, in a situation of professional work or simply entrepreneurship in a field that we
believe relevant.

Through the help of didactic material such as videos, blogs and web pages we developed this
extensive laboratory, with the objective of understanding this material from all its daily ambits.

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sustancias químicas? aisla con poliuretano! https://aislaconpoliuretano.com/al-poliuretano-le-
atacan-los-disolventes-o-cualquier-otra-substancia-quimica/

[22] 5 pasos para lograr un acabado reluciente con pintura de poliuretano. (2021).
pintura de poliuretano. https://www.axalta.com/blog_mx/es_ES/repintado-
automotriz/proceso-repintado/como-lograr-acabado-con-
poliuretano.html#:%7E:text=Se%20le%20conoce%20como%20pintura,revestimiento%20dur
adero%2C%20uniforme%20y%20brillante.

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