Engineering Materials Laboratory Report: Practicum with expanded polyurethane

Juan Sebastian Beltran(5801302),John Alvaro Diaz Zambrano(5801298),Maria Paula

Fernandez(5801303),Laura Sofia Patiño(5801269),Juan Camilo Prieto(1000707690)

Laboratory Report

Pedro Nel Martinez

Mechanical Engineer

Military University Nueva Granada

Faculty of Engineering

Industrial Engineering

Cajicá,Cundinamarca

2023
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Content
Abstract..............................................................................................................................3
1. Introduction..................................................................................................................4
2. Objectives....................................................................................................................5
General Objective...........................................................................................................5
Specific Objectives..........................................................................................................5
3. Theoretical framework.................................................................................................5
 What is a polyurethane?.......................................................................................5
 For Expanded Polyurethane explain its generalities, make a description of the
components, show examples of application, describe its physical and chemical
properties.....................................................................................................................6
 Determine the curing time of expanded polyurethane..........................................7
 Explain what polymerization consists of...............................................................7
 Give a description of the main precautions to be taken when handling the
chemical components that are the object of the practice............................................8
 Explain why expanded polyurethane foam is used as a thermo-acoustic
insulator.......................................................................................................................8
 To which of the families of engineering materials does expanded polyurethane
belong, give a brief explanation of the generalities of this family (classification,
application, properties)................................................................................................8
4. Methodology................................................................................................................9
Materials:.........................................................................................................................9
Procesure:.......................................................................................................................9
5. Analysis of results......................................................................................................11
6. Conclusions...............................................................................................................12
7.References....................................................................................................................13
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Ilustrations Table
Ilustración 1........................................................................................................................6
Ilustración 2........................................................................................................................9
Ilustración 3........................................................................................................................9
Ilustración 4......................................................................................................................10
Ilustración 5......................................................................................................................10
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Glossary

Foam: The accumulation of bubbles on the surface of a liquid is called foam. In this
gaseous mass, the bubbles clump together with a certain consistency.
Expanded: To change something from a smaller to a larger shape.
Isocyanate: Isocyanates are highly reactive chemicals that are used in many
construction
used in many building products, such as paints, adhesives and foams.
Material: Materials are useful substances that we use to make or fabricate something.
Molecules: A molecule is the smallest part of a substance and determines the
properties of the substance. It is composed of two or more atoms bonded together.
Polymer: Polymers are large molecules composed of long chains of smaller molecules
called monomers. Synthetic polymers are commonly made from petroleum compounds.
Polyol: Polyols are alcohols with more than one hydroxyl group and are one of the main
raw materials for the manufacture of polyurethane.
Polyurethane: Polyurethane is a polymer widely used in numerous industrial
processes. It is the result of a mixture of polyol and isocyanate.
Porous: Porosity is the volume fraction of pores in the material. These pores can be
located on its surface or in its internal structure. Porosity is associated with the density
of the material, and with the nature of its compounds and the existence of empty spaces
between them.
Thermostable: Not easily altered by the action of heat.
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Abstract
This document explains the development of laboratory number one of the third semester
subject of Industrial Engineering, which deals with polyurethane, a plastic material which
is used in industries as a thermal insulator, shoe soles or even mattresses.
One of the objectives of this practice is to observe and design the expanded
polyurethane and create it in a laboratory with different percentages of its components.
And thanks to this, to know the properties, the different applications and the different
forms of this important material of the thermosetting polymers family.
As a result, 3 types of polymers were obtained, with different textures, which can be
commercialized for different industrial purposes.
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1. Introduction
This practice is intended to understand the use of polyurethane, which is a plastic
material that can be rigid or flexible through its manufacture and has several
applications as an insulating product. With this in mind, it is expected to observe and
understand the different handling of different materials for the production of expanded
polyurethane, where it is expected that from the different measures used of polyol and
catalyst, different materials with different textures are created.

2. Objectives
General Objective

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

Specific Objectives

 To observe the design and handling of surfaces for the manufacture of expanded
polyurethane.
 To observe and learn the handling of the materials used for the production of
expanded polyurethane.
 To learn how to handle the elements and to take industrial safety precautions for
its manipulation.
 To observe and analyze the chemical reactions that occur in practice.

3. Theoretical framework

 What is a polyurethane?

Polyurethane is a plastic material that can be seen in different forms for different uses. If
we speak from the chemical knowledge it is polymers and this consists of small
molecules connected to each other, a fairly strong bond that gives stability to this
increasingly used material. The fact that it is an adaptable material means that it can be
flexible or rigid, the different possibilities that this material has make its application have
a very wide range.
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 For Expanded Polyurethane explain its generalities, make a description of

the components, show examples of application, describe its physical and
chemical properties.
General.
Most polyurethanes are thermostable, although there are some thermoplastic
polyurethanes for some special applications.it has a very low heat transmission
coefficient, better than that of traditional insulators, which allows the use of much smaller
thicknesses in equivalent insulation.by means of appropriate equipment its application is
carried out "in situ", which allows a fast execution of the work, obtaining a continuous
insulation layer, without joints or thermal bridges.its duration, properly protected, is
indefinite.it has an excellent adhesion to the materials normally used in construction
without the need of adherents of any kind.it has a high resistance to water absorption.it
has a very good dimensional stability. Its duration, properly protected, is indefinite.it has
an excellent adherence to the materials normally used in construction without the need
of adherents of any kind.it has a high resistance to water absorption.it has a very good
dimensional stability between temperature ranges from -200 ºC to 100 ºC.it reinforces
and protects the insulated surface.it hinders the growth of fungi and bacteria.it has very
good resistance to the attack of acids, alkalis, fresh and salt water, hydrocarbons, etc.
Components.
Polyurethane (PU, also called PUR) liquid presentation, has two components (Polyol -
Isocyanate) that when combined initiate a reaction that causes its expansion, resulting in
a solid porous foam that takes the shape of the container or surface where it is emptied
or applied by people trained to handle polyurethane.
Applications.
Polyurethanes are used in building materials, they provide a very efficient insulation
available in the construction and refrigeration industry, polyurethane can be easily
combined which offers the possibility of producing different compounds (from cooling
chambers to power generators), it can also be used to insulate pipes. In the same way
polyurethane is found in the different industries that manufacture car seats, mattresses
and it is also used for packaging delicate equipment or hospital items.
Polyurethanes are used as adhesives because when it reacts with water, in addition to
the application of polyurethane spray foam it provides excellent thermal insulation, anti-
condensation and waterproofing.
Another great applicability of polyurethane is in the paint and enamel industry since
these paints are very durable, resistant and beautiful.
Physical Properties.
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Ilustración 1

Chemical Properties.
Polyurethanes are capable of perfect hydrogen bonding and thus can be very
crystalline. For this reason they are often used to make block copolymers with polymers
of rubber-like structure. These block copolymers have characteristics of thermoplastic
elastomers.
 Determine the curing time of expanded polyurethane.
The curing time of the polyurethane varies according to the surface, the surface layer of
the compound hardens in 5 to 10 minutes.
A minimum of 90 minutes must pass for the polyurethane to dry completely.
 Explain what polymerization consists of.
Polymerization is a chemical reaction in which low molecular weight compounds, known
as monomers, interact with each other forming chemical bonds in a kind of chain
reaction. This phenomenon allows the formation of large and heavy molecules known as
polymers.
This process has two types:
Addition polymerization.
This type of polymerization occurs when monomers make double bonds between
carbon atoms. The monomers are added to the main nucleus of the polymer by means
of the double bonds.
A remarkable characteristic of this type of polymerization is that the monomers that form
part of the polymer do not lose atoms, i.e., the chemical composition of the carbon chain
generated is equal to the sum of the chemical compositions of the monomers that form
part of the polymer. This type of polymerization does not generate by-products.
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Condensation polymerization.
Condensation polymerization occurs when a water molecule is extracted from the union
of two or more monomers. In other words, the monomers lose atoms when they become
part of the polymer. This type of polymerization generates by-products.
Condensation polymers show repeating units linked together by functional units, such as
esters, urethane, etc. This type of polymerization is carried out in stages, where two
monomers can react with each other to generate macromolecules, whose terminal
groups, in turn, can react with each other to generate linear polymers of high molecular
weights.
Polycondensation is composed of a series of reactions that do not require initiation. Its
monomers are bonded together by the expulsion of small molecules, usually water or
methanol. The monomers must have functional groups at the ends so that they can
react together and thus continue polymerization.
 Give a description of the main precautions to be taken when handling the
chemical components that are the object of the practice.
To manipulate the polyurethane and its components, it is necessary to have some
protective items: mask, overalls, goggles and safety boots. Adequate ventilation should
also be provided in the place where the material is being used so as not to inhale its
odor in such a direct way that it does not produce headaches and dizziness.
If any of the components fall on the skin, wash with abundant water and go to a doctor
because they can cause serious damage to the skin.
 Explain why expanded polyurethane foam is used as a thermo-acoustic
insulator
Polyurethane has a very low thermal conductivity, making it one of the most effective
insulations currently available for a wide range of applications. In addition, it requires
very little space, since the foam contains only a small part of the volume of solid matter.
 To which of the families of engineering materials does expanded
polyurethane belong, give a brief explanation of the generalities of this
family (classification, application, properties).
Polyurethanes are part of the so-called thermosetting polymers, characterized by cross-
linked polymer chains, forming a three-dimensional network that does not melt. They are
also known as thermosetting or thermosetting. They are a type of plastic that can only
melt once and when it cools it cannot be transformed again. Unlike thermoplastics, this
plastic cannot change its structure when heated again, it only burns.
The main characteristic of this type of plastic is that it can only be transformed during its
manufacture, since the molecules remain permanently bonded. Once it is melted and
molded, when it is heated again, it changes from a liquid to a gaseous state.
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This material is rigid, heat resistant, even at extreme temperatures, with high resistance
to impact, solvents and gases. It is not a plastic that can be recycled, but it has good
strength, hardness and formability.
Thermoset materials have a simple structure, such as polyethylene.

Some examples of thermosetting polymers are:

Polyurethane (PUR), which is in the form of insulating foam.
Phenol formaldehyde resins, which are used as electrical insulators.
Polyester resins (UP), which are used for the construction of boats, vehicles and pipes,
among others.
Epoxy coatings, which are found in protective coatings due to the high resistance of the
material.
Some applications of thermosetting polymers are:
Different industries use this material, its applications vary according to the classification
of each polymer. The characteristics of the polymers, especially the excellent stability,
are what have made it a material in trend.
It stands out in the automotive sector, as stators and ashtrays. At the same time, in the
kitchen, as handles and battery handles.
Also, in construction, as containers or cabinets for water, gas and electricity meters;
energetics as light meters, switches or coil holders

4. Methodology
Materials:
 Polyol
 Catalyst or diisocyanate
 Plastic cups
 Wooden tongues
 Release wax
 Garbage bags
 Bisturi
 Gloves
 Masks
Procesure:
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1.Make a mold, with cardboard which to be covered with tape and in the corners add
silicone.
2. With the help of the wax, a coating of the mold was applied so that the mixture can be
disassemble.
3 .Perform the relevant operations which involves removing the volume from the mold
and dividing it into 7, which is the amount of expasion of the reagents when mixed.
4.Make a recognition of the materials to be used, in this case Polyol and Dicyanate, use
the disposable cups in which each reagent is added It is verified that the ratio of the two
reagents was equal to 50:50, and then mix them and through constant stirring, look for
the highest percentage of homogenization and add to the mold.
5.Cover the mold with a flat surface, exert pressure on it. Wait 10 minutes, observe
results.
6.Perform this process with different amounts of each reagent, completing 3 processes
making a ratio of 50-50, 25-50 and 50-25
7.Observe and record results.

Ilustración 2

Ilustración 3
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Ilustración 4

Ilustración 5

5. Analysis of results

First of all, it should be taken into account that a mold was built a little big in size and
area; the volume of the mold was calculated in order to know the amount of components
that had to be applied so that the polyurethane would react in a stable way and cover
the entire surface of the mold.
The volume of the mold was calculated with the formula:(32.4*5)/7=749.82〖cm〗^3
Three polyurethanes were manufactured with different proportions of the components, in
the first manufacture 50% polyol and 50% isocyanate were used and this reaction
resulted in a hard insulating material that had little malleability, while the polyurethane
grew pressure was applied in the corners of the mold and it could be felt that an
exothermic reaction was occurring, this material can be used as thermal or acoustic
insulator thanks to its hardness.

Ilustración 6

In the second manufacture isocyanate was applied and half of polyol isocyanate was
applied, the reaction that occurs is exothermic, the result of this reaction is a material a
little softer than the previous one, less hard and a little more malleable.

Ilustración 7
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In the third fabrication, polyol was applied and half of the polyol was applied to the
isocyanate, the reaction is also exothermic, the product of this reaction is a very soft
material which can be used as a pillow or mattress.

Ilustración 8

It is also possible to analyze that it is necessary to be very precise with the amount of
raw material with which these products are manufactured since a bad calculation of this
one can produce a waste of material or a shortage of material, as it happened in this
occasion since you had to add more of the components in order to fill a little more the
mold.
It should also be noted that the manufactured products did not come out in the best way
due to different factors, such as the pressure, the amount of material, the ignorance of
the percentage in which the polyurethane expands, among others. For this reason, they
could not be marketed because they have many imperfections that make the product is
not useful in the same way as one in perfect condition.
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6. Conclusions
 It was concluded that during practice we could experience an exothermic
reaction; An Exothermic Reaction is a chemical reaction that releases energy in
the form of light or heat. When the polyol reacts with the isocyanate and they mix,
they give off heat and this is what causes the sudden increase in mass.

 In this practice we show that there are different types of moldable materials, we
form a polyurethane from the polyol and the isocyanate.

 Once the reaction was observed, we proceeded to finish the sculpture. We

concluded that during practice we developed new knowledge of these materials,
their properties, and their proper handling restrictions.
 Polyurethane, like the rest of the plastic, are the polymers produced from the
interaction of diisocyanates with different polyols. In the final function of the
product, the chemical formula may contain other compounds, such as incentives,
extended factors; Etc.
 The density of the product is determined by the amount of blowing agent used
and the elasticity or hardness of the polyol and diisocyanate used.

Percentages

Juan Beltrán:28,66%

Jhon Alvaro Díaz:28,66%

Maria Paula Fernandez:28,66%

Laura Patiño:7%

Juan Camilo Priero:7%

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7.References

Anonymous (2019). What is polyurethane and what is it used for.

https://cool-r.es/poliuretano/
Anonymous (2020). Polymerization.
https://www.ingenieriaquimicareviews.com/2020/11/que-es-la-polimerizacion.html
Anonymous. (2019). Thermal insulation. https://blog.blinkergroup.com/es-es/espuma-
de-poliuretano
Anonymous. (2022). Engineering plastics. https://www.aceromafe.com/polimeros-
termoestables/
Anonymous. (2018). Polymers. https://www.dow.com/es-es/
Bezos G. (2016).Polyurethane.https://panelesach.com/blog/poliuretano-propiedades-
aplicaciones/.
Bald B. (2020). Polyurethane foam. https://www.mundodeportivo.com/
Fernandes, Ana (2022). "Molecule." https://www.significados.com/molecula/.
Martinez P.(2018).Laboratory Practice Guides.
Mora M. (2011). Plastics technology.
https://tecnologiadelosplasticos.blogspot.com/2011/06/poliuretano.html
Pérez Porto, J., Merino, M. (2017). Definition of foam - What is, Meaning and Concept.
Definitions. https://definicion.de/espuma/