Use of Novel Non-Toxic Bismuth Catalyst for the Preparation of Flexible Polyurethane Foam

Foam products are one of the largest markets for polyurethane (PU) and are heavily used in many sectors. However, current PU formulations use highly toxic and environmentally unfriendly production processes. Meanwhile, the increasing environmental concerns and regulations are intensifying the research into green and non-toxic products. In this study, we synthesized flexible polyurethane foam (PUF) using different weight percentages (0.025%, 0.05% and 0.1%) of a non-toxic bismuth catalyst. The bismuth-catalyzed foams presented a well evolved cellular structure with an open cell morphology. The properties of the bismuth-catalyzed flexible PUF, such as the mechanical, morphological, kinetic and thermal behaviors, were optimized and compared with a conventional tin-catalyzed PUF. The bismuth-catalyst revealed a higher isocyanate conversion efficiency than the stannous octoate catalyst. When comparing samples with similar densities, the bismuth-catalyzed foams present better mechanical behavior than the tin-catalyzed sample with similar thermal stability. The high solubility of bismuth triflate in water, together with its high Lewis acidity, have been shown to benefit the production of PU foams.

Download Full-text

Recovery of Flexible Polyurethane Foam Waste for Efficient Reuse in Industrial Formulations

Polymers ◽

10.3390/polym12071533 ◽

2020 ◽

Vol 12 (7) ◽

pp. 1533 ◽

Cited By ~ 2

Author(s):

Gabriel Kiss ◽

Gerlinde Rusu ◽

Francisc Peter ◽

Ionuț Tănase ◽

Geza Bandur

Keyword(s):

Polyurethane Foam ◽

Atmospheric Pressure ◽

Air Permeability ◽

Hydroxyl Number ◽

Pu Foam ◽

Flexible Polyurethane Foam ◽

Flexible Polyurethane ◽

The Relationship ◽

Pu Foams ◽

Glycolysis Process

Ester polyurethane (PU) foam waste was reacted at atmospheric pressure in an autoclave and using microwaves with diethylene glycol (DEG) at different PU/DEG ratios in the presence of diethanolamine as a catalyst to find the glycolysis conditions that allow for the improved recovery of the PU foam waste and enable the recycling of the whole glycolysis product in foam formulations suitable for industrial application. The recycled polyol was characterized by dynamic viscosity, hydroxyl number, water content, and density, while thermal stability was assessed using thermogravimetric analysis. In the PU foam formulation, 1% and 5% of the glycolyzed material was reused. The relationship between the reuse level of the recycled polyol and the physical properties of the foam was thoroughly investigated. It was observed that both hardness and air flow decreased with increasing recycled polyol content, particularly for the polyester type foam, while tensile strength and compression strength increased. Depending on the amount of recycled polyol and catalyst used, polyether-based foams could be obtained with a low air permeability, needed in special applications as sealed foams, or with higher air permeability desirable for comfort PU foams. The results open the way for further optimization studies of industrial polyurethane foam formulations using a glycolysis process without any separation stage.

Download Full-text