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Polyurethane (; often abbreviated PUR and PU) refers to a class of
polymer A polymer (; Greek '' poly-'', "many" + ''-mer'', "part") is a substance or material consisting of very large molecules called macromolecules, composed of many repeating subunits. Due to their broad spectrum of properties, both synthetic a ...
s composed of
organic Organic may refer to: * Organic, of or relating to an organism, a living entity * Organic, of or relating to an anatomical organ Chemistry * Organic matter, matter that has come from a once-living organism, is capable of decay or is the product ...
units joined by
carbamate In organic chemistry, a carbamate is a category of organic compounds with the general formula and structure , which are formally derived from carbamic acid (). The term includes organic compounds (e.g., the ester ethyl carbamate), formally o ...
(urethane) links. In contrast to other common polymers such as
polyethylene Polyethylene or polythene (abbreviated PE; IUPAC name polyethene or poly(methylene)) is the most commonly produced plastic. It is a polymer, primarily used for packaging ( plastic bags, plastic films, geomembranes and containers including bo ...
and
polystyrene Polystyrene (PS) is a synthetic polymer made from monomers of the aromatic hydrocarbon styrene. Polystyrene can be solid or foamed. General-purpose polystyrene is clear, hard, and brittle. It is an inexpensive resin per unit weight. It is a ...
, polyurethane is produced from a wide range of starting materials. This chemical variety produces polyurethanes with different chemical structures leading to many different applications. These include rigid and flexible foams, varnishes and coatings, adhesives, electrical potting compounds, and fibers such as
spandex Spandex, Lycra, or elastane is a synthetic fiber known for its exceptional elasticity. It is a polyether-polyurea copolymer that was invented in 1958 by chemist Joseph Shivers at DuPont's Benger Laboratory in Waynesboro, Virginia, US. The ge ...
and PUL. Foams are the largest application accounting for 67% of all polyurethane produced in 2016. A polyurethane is typically produced by reacting an isocyanate with a
polyol In organic chemistry, a polyol is an organic compound containing multiple hydroxyl groups (). The term "polyol" can have slightly different meanings depending on whether it is used in food science or polymer chemistry. Polyols containing two, thr ...
. Since a polyurethane contains two types of monomers, which polymerize one after the other, they are classed as alternating copolymers. Both the isocyanates and polyols used to make a polyurethane contain two or more
functional group In organic chemistry, a functional group is a substituent or moiety in a molecule that causes the molecule's characteristic chemical reactions. The same functional group will undergo the same or similar chemical reactions regardless of the rest ...
s per molecule. Global production in 2019 was 25 million metric tonnes, accounting for about 6% of all polymers produced in that year. Polyurethane is a commodity plastic.


History

Otto Bayer Otto Bayer (4 November 1902 – 1 August 1982) was a German industrial chemist at IG Farben who was head of the research group that in 1937 discovered the polyaddition for the synthesis of polyurethanes out of poly-isocyanate and polyol. Bay ...
and his coworkers at
IG Farben Interessengemeinschaft Farbenindustrie AG (), commonly known as IG Farben (German for 'IG Dyestuffs'), was a German chemical and pharmaceutical conglomerate (company), conglomerate. Formed in 1925 from a merger of six chemical companies—BASF, ...
in Leverkusen, Germany, first made polyurethanes in 1937. The new polymers had some advantages over existing plastics that were made by polymerizing olefins or by
polycondensation In polymer chemistry, condensation polymers are any kind of polymers whose process of polymerization involves a condensation reaction (i.e. a small molecule, such as water or methanol, is produced as a byproduct). Condensation polymers are form ...
, and were not covered by patents obtained by
Wallace Carothers Wallace Hume Carothers (; April 27, 1896 – April 29, 1937) was an American chemist, inventor and the leader of organic chemistry at DuPont, who was credited with the invention of nylon. Carothers was a group leader at the DuPont Experiment ...
on
polyester Polyester is a category of polymers that contain the ester functional group in every repeat unit of their main chain. As a specific material, it most commonly refers to a type called polyethylene terephthalate (PET). Polyesters include natural ...
s. Early work focused on the production of fibers and flexible foams and PUs were applied on a limited scale as aircraft coating during
World War II World War II or the Second World War, often abbreviated as WWII or WW2, was a world war that lasted from 1939 to 1945. It involved the vast majority of the world's countries—including all of the great powers—forming two opposin ...
.
Polyisocyanate In organic chemistry, isocyanate is the functional group with the formula . Organic compounds that contain an isocyanate group are referred to as isocyanates. An organic compound with two isocyanate groups is known as a diisocyanate. Diisocyan ...
s became commercially available in 1952, and production of flexible polyurethane foam began in 1954 by combining
toluene diisocyanate Toluene diisocyanate (TDI) is an organic compound with the formula CH3C6H3(NCO)2. Two of the six possible isomers are commercially important: 2,4-TDI (CAS: 584-84-9) and 2,6-TDI (CAS: 91-08-7). 2,4-TDI is produced in the pure state, but TDI is oft ...
(TDI) and polyester polyols. These materials were also used to produce rigid foams, gum rubber, and
elastomer An elastomer is a polymer with viscoelasticity (i.e. both viscosity and elasticity) and with weak intermolecular forces, generally low Young's modulus and high failure strain compared with other materials. The term, a portmanteau of ''elastic p ...
s. Linear fibers were produced from
hexamethylene diisocyanate Hexamethylene diisocyanate (HDI) is the organic compound with the formula (CH2)6(NCO)2. It is classified as an diisocyanate. It is a colorless liquid. It has sometimes been called HMDI but this not usually done to avoid confusion with Hydrogenated ...
(HDI) and
1,4-Butanediol 1,4-Butanediol, colloquially known as BD or BDO, is a primary alcohol, and an organic compound, with the formula HOCH2CH2CH2CH2OH. It is a colorless viscous liquid. It is one of four stable isomers of butanediol. Synthesis In industrial sy ...
(BDO).
DuPont DuPont de Nemours, Inc., commonly shortened to DuPont, is an American multinational chemical company first formed in 1802 by French-American chemist and industrialist Éleuthère Irénée du Pont de Nemours. The company played a major role in ...
introduced polyethers, specifically
poly(tetramethylene ether) glycol Polytetrahydrofuran, also called poly(tetramethylene ether) glycol or poly(tetramethylene oxide), is a chemical compound with formula ()''n''OH2 or HO-(-(CH2)4O-)''n''-H. It can be viewed as a polymer of tetrahydrofuran, or as the polyether deriv ...
, in 1956.
BASF BASF Societas Europaea, SE () is a German multinational corporation, multinational chemical company and the List of largest chemical producers, largest chemical producer in the world. Its headquarters is located in Ludwigshafen, Germany. The ...
and
Dow Chemical The Dow Chemical Company, officially Dow Inc., is an American multinational chemical corporation headquartered in Midland, Michigan, United States. The company is among the three largest chemical producers in the world. Dow manufactures plastics ...
introduced polyalkylene glycols in 1957. Polyether polyols were cheaper, easier to handle and more water-resistant than polyester polyols.
Union Carbide Union Carbide Corporation is an American chemical corporation wholly owned subsidiary (since February 6, 2001) by Dow Chemical Company. Union Carbide produces chemicals and polymers that undergo one or more further conversions by customers befor ...
and
Mobay Mobay Chemical Corporation, based in Pittsburgh, Pennsylvania, was a joint venture of Monsanto Company and Bayer to market polyurethanes in the United States. Founded in 1954, Bayer bought out Monsanto's shares in the company in the 1970s. Moba ...
, a U.S.
Monsanto The Monsanto Company () was an American agrochemical and agricultural biotechnology corporation founded in 1901 and headquartered in Creve Coeur, Missouri. Monsanto's best known product is Roundup, a glyphosate-based herbicide, developed in th ...
/
Bayer Bayer AG (, commonly pronounced ; ) is a German multinational corporation, multinational pharmaceutical and biotechnology company and one of the largest pharmaceutical companies in the world. Headquartered in Leverkusen, Bayer's areas of busi ...
joint venture, also began making polyurethane chemicals. In 1960 more than 45,000 metric tons of flexible polyurethane foams were produced. The availability of
chlorofluoroalkane Chlorofluorocarbons (CFCs) and hydrochlorofluorocarbons (HCFCs) are fully or partly halogenated hydrocarbons that contain carbon (C), hydrogen (H), chlorine (Cl), and fluorine (F), produced as volatile derivatives of methane, ethane, and propa ...
blowing agents, inexpensive polyether polyols, and
methylene diphenyl diisocyanate Methylene diphenyl diisocyanate (MDI) is an aromatic diisocyanate. Three isomers are common, varying by the positions of the isocyanate groups around the rings: 2,2′-MDI, 2,4′-MDI, and 4,4′-MDI. The 4,4′ isomer is most widely used, and i ...
(MDI) allowed polyurethane rigid foams to be used as high-performance insulation materials. In 1967, urethane-modified
polyisocyanurate Polyisocyanurate (), also referred to as PIR, polyiso, or ISO, is a thermoset plastic typically produced as a foam and used as rigid thermal insulation. The starting materials are similar to those used in polyurethane (PUR) except that the propor ...
rigid foams were introduced, offering even better thermal stability and
flammability A combustible material is something that can burn (i.e., ''combust'') in air. A combustible material is flammable if it ignites easily at ambient temperatures. In other words, a combustible material ignites with some effort and a flammable mat ...
resistance. During the 1960s, automotive interior safety components, such as instrument and door panels, were produced by back-filling
thermoplastic A thermoplastic, or thermosoft plastic, is any plastic polymer material that becomes pliable or moldable at a certain elevated temperature and solidifies upon cooling. Most thermoplastics have a high molecular weight. The polymer chains associate ...
skins with semi-rigid foam. In 1969, Bayer exhibited an all-plastic car in
Düsseldorf Düsseldorf ( , , ; often in English sources; Low Franconian and Ripuarian: ''Düsseldörp'' ; archaic nl, Dusseldorp ) is the capital city of North Rhine-Westphalia, the most populous state of Germany. It is the second-largest city in th ...
, Germany. Parts of this car, such as the
fascia A fascia (; plural fasciae or fascias; adjective fascial; from Latin: "band") is a band or sheet of connective tissue, primarily collagen, beneath the skin that attaches to, stabilizes, encloses, and separates muscles and other internal organs. ...
and body panels, were manufactured using a new process called
reaction injection molding Reaction injection molding (RIM) is similar to injection molding except thermosetting polymers are used, which requires a curing reaction to occur within the mold. Common items made via RIM include automotive bumpers, air spoilers, and fen ...
(RIM), in which the reactants were mixed and then injected into a mold. The addition of fillers, such as milled glass,
mica Micas ( ) are a group of silicate minerals whose outstanding physical characteristic is that individual mica crystals can easily be split into extremely thin elastic plates. This characteristic is described as perfect basal cleavage. Mica is ...
, and processed mineral fibers, gave rise to reinforced RIM (RRIM), which provided improvements in
flexural modulus In mechanics, the flexural modulus or bending modulus is an intensive property that is computed as the ratio of stress to strain in flexural deformation, or the tendency for a material to resist bending. It is determined from the slope of a stress ...
(stiffness), reduction in coefficient of
thermal expansion Thermal expansion is the tendency of matter to change its shape, area, volume, and density in response to a change in temperature, usually not including phase transitions. Temperature is a monotonic function of the average molecular kinetic ...
and better thermal stability. This technology was used to make the first plastic-body automobile in the United States, the
Pontiac Fiero The Pontiac Fiero is a mid-engine sports car manufactured and marketed by Pontiac (automobile), Pontiac for model years 1984-1988. Designed by George Milidrag and Hulki Aldikacti as a sports car, it was the first two-seater Pontiac (automobile) ...
, in 1983. Further increases in stiffness were obtained by incorporating pre-placed glass mats into the RIM mold cavity, also known broadly as resin injection molding, or structural RIM. Starting in the early 1980s, water-blown microcellular flexible foams were used to mold gaskets for automotive panels and air-filter seals, replacing PVC polymers. Polyurethane foams are used in many automotive applications including seating, head and arm rests, and headliners. Polyurethane foam (including foam rubber) is sometimes made using small amounts of
blowing agent A blowing agent is a substance which is capable of producing a cellular structure via a foaming process in a variety of materials that undergo hardening or phase transition, such as polymers, plastics, and metals. They are typically applied when ...
s to give less dense foam, better cushioning/energy absorption or thermal insulation. In the early 1990s, because of their impact on
ozone depletion Ozone depletion consists of two related events observed since the late 1970s: a steady lowering of about four percent in the total amount of ozone in Earth's atmosphere, and a much larger springtime decrease in stratospheric ozone (the ozone l ...
, the
Montreal Protocol The Montreal Protocol is an international treaty designed to protect the ozone layer by phasing out the production of numerous substances that are responsible for ozone depletion Ozone depletion consists of two related events observed sinc ...
restricted the use of many
chlorine Chlorine is a chemical element with the Symbol (chemistry), symbol Cl and atomic number 17. The second-lightest of the halogens, it appears between fluorine and bromine in the periodic table and its properties are mostly intermediate betwee ...
-containing blowing agents, such as
trichlorofluoromethane Trichlorofluoromethane, also called freon-11, CFC-11, or R-11, is a chlorofluorocarbon (CFC). It is a colorless, faintly ethereal, and sweetish-smelling liquid that boils around room temperature. CFC-11 is a Class 1 ozone-depleting substance ...
(CFC-11). By the late 1990s, blowing agents such as
carbon dioxide Carbon dioxide (chemical formula ) is a chemical compound made up of molecules that each have one carbon atom covalently double bonded to two oxygen atoms. It is found in the gas state at room temperature. In the air, carbon dioxide is transpar ...
,
pentane Pentane is an organic compound with the formula C5H12—that is, an alkane with five carbon atoms. The term may refer to any of three structural isomers, or to a mixture of them: in the IUPAC nomenclature, however, pentane means exclusively the ' ...
,
1,1,1,2-tetrafluoroethane 1,1,1,2-Tetrafluoroethane (also known as norflurane (INN), R-134a, Freon 134a, Forane 134a, Genetron 134a, Green Gas, Florasol 134a, Suva 134a, or HFC-134a) is a hydrofluorocarbon (HFC) and haloalkane refrigerant with thermodynamic properties s ...
(HFC-134a) and 1,1,1,3,3-pentafluoropropane (HFC-245fa) were widely used in North America and the EU, although chlorinated blowing agents remained in use in many developing countries. Later, HFC-134a was also banned due to high ODP and GWP readings, and HFC - 141B was introduced in early 2000s as an alternate blowing agent in developing nations.


Chemistry

Polyurethanes are produced by reacting di
isocyanate In organic chemistry, isocyanate is the functional group with the formula . Organic compounds that contain an isocyanate group are referred to as isocyanates. An organic compound with two isocyanate groups is known as a diisocyanate. Diisocyan ...
s with
polyol In organic chemistry, a polyol is an organic compound containing multiple hydroxyl groups (). The term "polyol" can have slightly different meanings depending on whether it is used in food science or polymer chemistry. Polyols containing two, thr ...
s,''n'' â‰¥ 2 in the presence of a
catalyst Catalysis () is the process of increasing the rate of a chemical reaction by adding a substance known as a catalyst (). Catalysts are not consumed in the reaction and remain unchanged after it. If the reaction is rapid and the catalyst recyc ...
, or upon exposure to ultraviolet light. Common catalysts include tertiary
amine In chemistry, amines (, ) are compounds and functional groups that contain a basic nitrogen atom with a lone pair. Amines are formally derivatives of ammonia (), wherein one or more hydrogen atoms have been replaced by a substituen ...
s, such as
DABCO DABCO (1,4-diazabicyclo .2.2ctane), also known as triethylenediamine or TEDA, is a bicyclic organic compound with the formula N2(C2H4)3. This colorless solid is a highly nucleophilic tertiary amine base, which is used as a catalyst and reagent i ...
, or
metallic soap A metallic soap is a metallic salt of a fatty acid. Theoretically, soaps can be made of any metal, although not all enjoy practical uses. Varying the metal can strongly affect the properties of the compound, particularly its solubility. Alkali, a ...
s, such as
dibutyltin dilaurate Dibutyltin dilaurate (abbreviated DBTDL), also called dibutyltindilaurate or butynorate, is an organotin compound that is used as a catalyst. It is a colourless oily liquid. In terms of its structure, the molecule consists of two laurate groups ...
. The
stoichiometry Stoichiometry refers to the relationship between the quantities of reactants and products before, during, and following chemical reactions. Stoichiometry is founded on the law of conservation of mass where the total mass of the reactants equal ...
of the starting materials must be carefully controlled as excess isocyanate can trimerise, leading to the formation of rigid
polyisocyanurate Polyisocyanurate (), also referred to as PIR, polyiso, or ISO, is a thermoset plastic typically produced as a foam and used as rigid thermal insulation. The starting materials are similar to those used in polyurethane (PUR) except that the propor ...
s. The polymer usually has a highly
crosslink In chemistry and biology a cross-link is a bond or a short sequence of bonds that links one polymer chain to another. These links may take the form of covalent bonds or ionic bonds and the polymers can be either synthetic polymers or natural ...
ed molecular structure, resulting in a
thermosetting In materials science, a thermosetting polymer, often called a thermoset, is a polymer that is obtained by irreversibly hardening (" curing") a soft solid or viscous liquid prepolymer (resin). Curing is induced by heat or suitable radiation and ...
material which does not melt on heating; although some
thermoplastic polyurethane Thermoplastic polyurethane (TPU) is any of a class of polyurethane plastics with many properties, including elasticity, transparency, and resistance to oil, grease, and abrasion. Technically, they are thermoplastic elastomers consisting of linea ...
s are also produced. The most common application of polyurethane is as solid
foam Foams are materials formed by trapping pockets of gas in a liquid or solid. A bath sponge and the head on a glass of beer are examples of foams. In most foams, the volume of gas is large, with thin films of liquid or solid separating the reg ...
s, which requires the presence of a gas, or
blowing agent A blowing agent is a substance which is capable of producing a cellular structure via a foaming process in a variety of materials that undergo hardening or phase transition, such as polymers, plastics, and metals. They are typically applied when ...
, during the polymerization step. This is commonly achieved by adding small amounts of water, which reacts with isocyanates to form CO2 gas and an
amine In chemistry, amines (, ) are compounds and functional groups that contain a basic nitrogen atom with a lone pair. Amines are formally derivatives of ammonia (), wherein one or more hydrogen atoms have been replaced by a substituen ...
, via an unstable
carbamic acid Carbamic acid, which might also be called aminoformic acid or aminocarboxylic acid, is the chemical compound with the formula . It can be obtained by the reaction of ammonia and carbon dioxide at very low temperatures, which also yields an equ ...
group. The amine produced can also react with isocyanates to form
urea Urea, also known as carbamide, is an organic compound with chemical formula . This amide has two amino groups (–) joined by a carbonyl functional group (–C(=O)–). It is thus the simplest amide of carbamic acid. Urea serves an important r ...
groups, and as such the polymer will contain both these and urethane linkers. The urea is not very soluble in the reaction mixture and tends to form separate "hard segment" phases consisting mostly of
polyurea Polyurea is a type of elastomer that is derived from the reaction product of an isocyanate component and a synthetic resin blend component through step-growth polymerization. The isocyanate can be aromatic or aliphatic in nature. It can be monom ...
. The concentration and organization of these polyurea phases can have a significant impact on the properties of the foam. The type of foam produced can be controlled by regulating the amount of blowing agent and also by the addition of various
surfactant Surfactants are chemical compounds that decrease the surface tension between two liquids, between a gas and a liquid, or interfacial tension between a liquid and a solid. Surfactants may act as detergents, wetting agents, emulsifiers, foaming ...
s which change the
rheology Rheology (; ) is the study of the flow of matter, primarily in a fluid ( liquid or gas) state, but also as "soft solids" or solids under conditions in which they respond with plastic flow rather than deforming elastically in response to an appl ...
of the polymerising mixture. Foams can be either "closed-cell", where most of the original bubbles or cells remain intact, or "open-cell", where the bubbles have broken but the edges of the bubbles are stiff enough to retain their shape, in extreme cases
reticulated foam Reticulated foam is a very porous, low density solid foam. 'Reticulated' means like a net. Reticulated foams are extremely open foams i.e. there are few, if any, intact bubbles or cell windows. In contrast, the foam formed by soap bubbles is compo ...
s can be formed. Open-cell foams feel soft and allow air to flow through, so they are comfortable when used in seat cushions or
mattresses A mattress is a large, usually rectangular pad for supporting a lying person. It is designed to be used as a bed, or on a bed frame as part of a bed. Mattresses may consist of a quilted or similarly fastened case, usually of heavy cloth, contain ...
. Closed-cell foams are used as rigid
thermal insulation Thermal insulation is the reduction of heat transfer (i.e., the transfer of thermal energy between objects of differing temperature) between objects in thermal contact or in range of radiative influence. Thermal insulation can be achieved with s ...
. High-density
microcellular Microcellular plastics, otherwise known as microcellular foam, is a form of manufactured plastic fabricated to contain billions of tiny bubbles less than 50 microns wide (typically 0.1–100 micrometers). It is formed by dissolving gas under high p ...
foams can be formed without the addition of blowing agents by mechanically frothing the polyol prior to use. These are tough elastomeric materials used in covering car
steering wheel A steering wheel (also called a driving wheel (UK), a hand wheel, or simply wheel) is a type of steering control in vehicles. Steering wheels are used in most modern land vehicles, including all mass-production automobiles, buses, light and ...
s or
shoe sole A shoe is an item of footwear intended to protect and comfort the human foot. They are often worn with a sock. Shoes are also used as an item of decoration and fashion. The design of shoes has varied enormously through time and from culture to ...
s. The properties of a polyurethane are greatly influenced by the types of isocyanates and polyols used to make it. Long, flexible segments, contributed by the polyol, give soft,
elastic Elastic is a word often used to describe or identify certain types of elastomer, elastic used in garments or stretchable fabrics. Elastic may also refer to: Alternative name * Rubber band, ring-shaped band of rubber used to hold objects togeth ...
polymer. High amounts of
crosslinking Cross-linking may refer to *Cross-link In chemistry and biology a cross-link is a bond or a short sequence of bonds that links one polymer chain to another. These links may take the form of covalent bonds or ionic bonds and the polymers ca ...
give tough or rigid polymers. Long chains and low crosslinking give a polymer that is very stretchy, short chains with many crosslinks produce a hard polymer while long chains and intermediate crosslinking give a polymer useful for making foam. The choices available for the isocyanates and polyols, in addition to other additives and processing conditions allow polyurethanes to have the very wide range of properties that make them such widely used polymers.


Raw materials

The main ingredients to make a polyurethane are di- and tri-
isocyanates In organic chemistry, isocyanate is the functional group with the formula . Organic compounds that contain an isocyanate group are referred to as isocyanates. An organic compound with two isocyanate groups is known as a diisocyanate. Diisocyan ...
and
polyols In organic chemistry, a polyol is an organic compound containing multiple hydroxyl groups (). The term "polyol" can have slightly different meanings depending on whether it is used in food science or polymer chemistry. Polyols containing two, thre ...
. Other materials are added to aid processing the polymer or to modify the properties of the polymer.


Isocyanates

Isocyanates used to make polyurethane have two or more isocyanate groups on each molecule. The most commonly used isocyanates are the
aromatic In chemistry, aromaticity is a chemical property of cyclic ( ring-shaped), ''typically'' planar (flat) molecular structures with pi bonds in resonance (those containing delocalized electrons) that gives increased stability compared to satur ...
diisocyanates,
toluene diisocyanate Toluene diisocyanate (TDI) is an organic compound with the formula CH3C6H3(NCO)2. Two of the six possible isomers are commercially important: 2,4-TDI (CAS: 584-84-9) and 2,6-TDI (CAS: 91-08-7). 2,4-TDI is produced in the pure state, but TDI is oft ...
(TDI) and
methylene diphenyl diisocyanate Methylene diphenyl diisocyanate (MDI) is an aromatic diisocyanate. Three isomers are common, varying by the positions of the isocyanate groups around the rings: 2,2′-MDI, 2,4′-MDI, and 4,4′-MDI. The 4,4′ isomer is most widely used, and i ...
, (MDI). These aromatic isocyanates are more reactive than
aliphatic In organic chemistry, hydrocarbons ( compounds composed solely of carbon and hydrogen) are divided into two classes: aromatic compounds and aliphatic compounds (; G. ''aleiphar'', fat, oil). Aliphatic compounds can be saturated, like hexane, or ...
isocyanates. TDI and MDI are generally less expensive and more reactive than other isocyanates. Industrial grade TDI and MDI are mixtures of isomers and MDI often contains polymeric materials. They are used to make flexible foam (for example slabstock foam for mattresses or molded foams for car seats), rigid foam (for example insulating foam in refrigerators) elastomers (shoe soles, for example), and so on. The isocyanates may be modified by partially reacting them with polyols or introducing some other materials to reduce volatility (and hence toxicity) of the isocyanates, decrease their freezing points to make handling easier or to improve the properties of the final polymers. Aliphatic and cycloaliphatic isocyanates are used in smaller quantities, most often in coatings and other applications where color and transparency are important since polyurethanes made with aromatic isocyanates tend to darken on exposure to light. The most important aliphatic and cycloaliphatic isocyanates are 1,6-hexamethylene diisocyanate (HDI), 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethyl-cyclohexane (
isophorone diisocyanate Isophorone diisocyanate (IPDI) is an organic compound in the class known as isocyanates. More specifically, it is an aliphatic diisocyanate. It is produced in relatively small quantities, accounting for (with hexamethylene diisocyanate) only 3.4% ...
, IPDI), and 4,4′-diisocyanato dicyclohexylmethane (H12MDI or hydrogenated MDI).


Polyols

Polyols In organic chemistry, a polyol is an organic compound containing multiple hydroxyl groups (). The term "polyol" can have slightly different meanings depending on whether it is used in food science or polymer chemistry. Polyols containing two, thre ...
are polymers in their own right and have on average two or more hydroxyl groups per molecule. They can be converted to polyether polyols co-polymerizing
ethylene oxide Ethylene oxide is an organic compound with the chemical formula, formula . It is a cyclic ether and the simplest epoxide: a three-membered Ring (chemistry), ring consisting of one oxygen atom and two carbon atoms. Ethylene oxide is a colorless a ...
and
propylene oxide Propylene oxide is an acutely toxic and carcinogenic organic compound with the molecular formula CH3CHCH2O. This colourless volatile liquid with an odour similar to ether, is produced on a large scale industrially. Its major application is its us ...
with a suitable polyol precursor. Polyester polyols are made by the polycondensation of multifunctional
carboxylic acid In organic chemistry, a carboxylic acid is an organic acid that contains a carboxyl group () attached to an R-group. The general formula of a carboxylic acid is or , with R referring to the alkyl, alkenyl, aryl, or other group. Carboxylic ...
s and polyhydroxyl compounds. They can be further classified according to their end use. Higher molecular weight polyols (molecular weights from 2,000 to 10,000) are used to make more flexible polyurethanes while lower molecular weight polyols make more rigid products. Polyols for flexible applications use low functionality initiators such as
dipropylene glycol Dipropylene glycol is a mixture of three isomeric chemical compounds, 4-oxa-2,6-heptandiol, 2-(2-hydroxy-propoxy)-propan-1-ol, and 2-(2-hydroxy-1-methyl-ethoxy)-propan-1-ol. It is a colorless, nearly odorless liquid with a high boiling point and ...
(''f'' = 2),
glycerine Glycerol (), also called glycerine in British English and glycerin in American English, is a simple triol compound. It is a colorless, odorless, viscous liquid that is sweet-tasting and non-toxic. The glycerol backbone is found in lipids known ...
(''f'' = 3), or a sorbitol/water solution (''f'' = 2.75). Polyols for rigid applications use high functionality initiators such as
sucrose Sucrose, a disaccharide, is a sugar composed of glucose and fructose subunits. It is produced naturally in plants and is the main constituent of white sugar. It has the molecular formula . For human consumption, sucrose is extracted and refined ...
(''f'' = 8),
sorbitol Sorbitol (), less commonly known as glucitol (), is a sugar alcohol with a sweet taste which the human body metabolizes slowly. It can be obtained by reduction of glucose, which changes the converted aldehyde group (−CHO) to a primary alcohol g ...
(''f'' = 6),
toluenediamine Toluenediamine may refer to these isomeric organic compounds with the formula C6H3(NH2)2(CH3): *2,4-Diaminotoluene, precursor to toluene diisocyanate and azo dye Azo dyes are organic compounds bearing the functional group R−N=N−R†...
(''f'' = 4), and
Mannich base A Mannich base is a beta-amino-ketone, which is formed in the reaction of an amine, formaldehyde (or an aldehyde) and a carbon acid. The Mannich base is an endproduct in the Mannich reaction, which is nucleophilic addition reaction of a non-enoliz ...
s (''f'' = 4).
Propylene oxide Propylene oxide is an acutely toxic and carcinogenic organic compound with the molecular formula CH3CHCH2O. This colourless volatile liquid with an odour similar to ether, is produced on a large scale industrially. Its major application is its us ...
and/or
ethylene oxide Ethylene oxide is an organic compound with the chemical formula, formula . It is a cyclic ether and the simplest epoxide: a three-membered Ring (chemistry), ring consisting of one oxygen atom and two carbon atoms. Ethylene oxide is a colorless a ...
is added to the initiators until the desired molecular weight is achieved. The order of addition and the amounts of each oxide affect many polyol properties, such as compatibility, water-solubility, and reactivity. Polyols made with only propylene oxide are terminated with secondary hydroxyl groups and are less reactive than polyols capped with ethylene oxide, which contain primary hydroxyl groups. Incorporating carbon dioxide into the polyol structure is being researched by multiple companies. Graft polyols (also called filled polyols or polymer polyols) contain finely dispersed styrene–acrylonitrile,
acrylonitrile Acrylonitrile is an organic compound with the formula and the structure . It is a colorless, volatile liquid although commercial samples can be yellow due to impurities. It has a pungent odor of garlic or onions. In terms of its molecular ...
, or polyurea (PHD) polymer solids chemically grafted to a high molecular weight polyether backbone. They are used to increase the load-bearing properties of low-density high-resiliency (HR) foam, as well as add toughness to microcellular foams and cast elastomers. Initiators such as
ethylenediamine Ethylenediamine (abbreviated as en when a ligand) is the organic compound with the formula C2H4(NH2)2. This colorless liquid with an ammonia-like odor is a basic amine. It is a widely used building block in chemical synthesis, with approximately ...
and
triethanolamine Triethanolamine, or TEA is a viscous organic compound that is both a tertiary amine and a triol. A triol is a molecule with three alcohol groups. Approximately 150,000 tonnes were produced in 1999. It is a colourless compound although samples m ...
are used to make low molecular weight rigid foam polyols that have built-in catalytic activity due to the presence of nitrogen atoms in the backbone. A special class of polyether polyols,
poly(tetramethylene ether) glycol Polytetrahydrofuran, also called poly(tetramethylene ether) glycol or poly(tetramethylene oxide), is a chemical compound with formula ()''n''OH2 or HO-(-(CH2)4O-)''n''-H. It can be viewed as a polymer of tetrahydrofuran, or as the polyether deriv ...
s, which are made by polymerizing
tetrahydrofuran Tetrahydrofuran (THF), or oxolane, is an organic compound with the formula (CH2)4O. The compound is classified as heterocyclic compound, specifically a cyclic ether. It is a colorless, water-miscible organic liquid with low viscosity. It is ma ...
, are used in high performance coating, wetting and elastomer applications. Conventional polyester polyols are based on virgin raw materials and are manufactured by the direct polyesterification of high-purity diacids and glycols, such as adipic acid and 1,4-butanediol. Polyester polyols are usually more expensive and more viscous than polyether polyols, but they make polyurethanes with better solvent, abrasion, and cut resistance. Other polyester polyols are based on reclaimed raw materials. They are manufactured by transesterification (
glycolysis Glycolysis is the metabolic pathway that converts glucose () into pyruvate (). The free energy released in this process is used to form the high-energy molecules adenosine triphosphate (ATP) and reduced nicotinamide adenine dinucleotide (NADH ...
) of recycled poly(ethyleneterephthalate) (PET) or dimethylterephthalate (DMT) distillation bottoms with glycols such as diethylene glycol. These low molecular weight, aromatic polyester polyols are used in rigid foam, and bring low cost and excellent flammability characteristics to
polyisocyanurate Polyisocyanurate (), also referred to as PIR, polyiso, or ISO, is a thermoset plastic typically produced as a foam and used as rigid thermal insulation. The starting materials are similar to those used in polyurethane (PUR) except that the propor ...
(PIR) boardstock and polyurethane spray foam insulation. Specialty polyols include
polycarbonate Polycarbonates (PC) are a group of thermoplastic polymers containing carbonate groups in their chemical structures. Polycarbonates used in engineering are strong, tough materials, and some grades are optically transparent. They are easily work ...
polyols,
polycaprolactone Polycaprolactone (PCL) is a biodegradable polyester with a low melting point of around 60 Â°C and a glass transition temperature of about −60 Â°C. The most common use of polycaprolactone is in the production of speciality polyure ...
polyols,
polybutadiene Polybutadiene utadiene rubber BRis a synthetic rubber. Polybutadiene rubber is a polymer formed from the polymerization of the monomer 1,3-butadiene. Polybutadiene has a high resistance to wear and is used especially in the manufacture of tir ...
polyols, and
polysulfide Polysulfides are a class of chemical compounds containing chains of sulfur atoms. There are two main classes of polysulfides: inorganic and organic. Among the inorganic polysulfides, there are ones which contain anions, which have the general formu ...
polyols. The materials are used in elastomer, sealant, and adhesive applications that require superior weatherability, and resistance to chemical and environmental attack. Natural oil polyols derived from
castor oil Castor oil is a vegetable oil pressed from castor beans. It is a colourless or pale yellow liquid with a distinct taste and odor. Its boiling point is and its density is 0.961 g/cm3. It includes a mixture of triglycerides in which about ...
and other
vegetable oils Vegetable oils, or vegetable fats, are oils extracted from seeds or from other parts of fruits. Like animal fats, vegetable fats are ''mixtures'' of triglycerides. Soybean oil, grape seed oil, and cocoa butter are examples of seed oils, or fat ...
are used to make elastomers, flexible bunstock, and flexible molded foam. Co-polymerizing
chlorotrifluoroethylene Chlorotrifluoroethylene (CTFE) is a chlorofluorocarbon with chemical formula CFCl=CF2. It is commonly used as a refrigerant in cryogenic applications. CTFE has a carbon-carbon double bond and so can be polymerized to form polychlorotrifluoroethyl ...
or
tetrafluoroethylene Tetrafluoroethylene (TFE) is a fluorocarbon with the chemical formula C2 F4. It is the simplest perfluorinated alkene. This gaseous species is used primarily in the industrial preparation of fluoropolymers. Properties Tetrafluoroethylene is a ...
with vinyl ethers containing hydroxyalkyl vinyl ether produces fluorinated (FEVE) polyols. Two-component fluorinated polyurethanes prepared by reacting FEVE fluorinated polyols with polyisocyanate have been used to make ambient cure paints and coatings. Since fluorinated polyurethanes contain a high percentage of fluorine–carbon bonds, which are the strongest bonds among all chemical bonds, fluorinated polyurethanes exhibit resistance to UV, acids, alkali, salts, chemicals, solvents, weathering, corrosion, fungi and microbial attack. These have been used for high performance coatings and paints.
Phosphorus Phosphorus is a chemical element with the symbol P and atomic number 15. Elemental phosphorus exists in two major forms, white phosphorus and red phosphorus, but because it is highly reactive, phosphorus is never found as a free element on Ear ...
-containing polyols are available that become chemically bonded to the polyurethane matrix for the use as
flame retardants The term flame retardants subsumes a diverse group of chemicals that are added to manufactured materials, such as plastics and textiles, and surface finishes and coatings. Flame retardants are activated by the presence of an ignition source a ...
. This covalent linkage prevents migration and leaching of the organophosphorus compound.


Bio-derived materials

Interest in
sustainable Specific definitions of sustainability are difficult to agree on and have varied in the literature and over time. The concept of sustainability can be used to guide decisions at the global, national, and individual levels (e.g. sustainable livin ...
"green" products raised interest in polyols derived from
vegetable oil Vegetable oils, or vegetable fats, are oils extracted from seeds or from other parts of fruits. Like animal fats, vegetable fats are ''mixtures'' of triglycerides. Soybean oil, grape seed oil, and cocoa butter are examples of seed oils, or fat ...
s. Various oils used in the preparation polyols for polyurethanes include soybean, cotton seed, neem seed, and castor. Vegetable oils are functionalized by various ways and modified to polyetheramide, polyethers, alkyds, etc. Renewable sources used to prepare polyols may be dimer fatty acids or fatty acids. Some biobased and isocyanate-free polyurethanes exploit the reaction between polyamines and cyclic carbonates to produce polyhydroxurethanes.


Chain extenders and cross linkers

Chain extenders (''f'' = 2) and cross linkers (''f'' â‰¥ 3) are low molecular weight hydroxyl and amine terminated compounds that play an important role in the polymer morphology of polyurethane fibers, elastomers, adhesives, and certain integral skin and microcellular foams. The elastomeric properties of these materials are derived from the phase separation of the hard and soft copolymer segments of the polymer, such that the urethane hard segment domains serve as cross-links between the amorphous polyether (or polyester) soft segment domains. This phase separation occurs because the mainly nonpolar, low melting soft segments are incompatible with the polar, high melting hard segments. The soft segments, which are formed from high molecular weight polyols, are mobile and are normally present in coiled formation, while the hard segments, which are formed from the isocyanate and chain extenders, are stiff and immobile. Because the hard segments are covalently coupled to the soft segments, they inhibit plastic flow of the polymer chains, thus creating elastomeric resiliency. Upon mechanical deformation, a portion of the soft segments are stressed by uncoiling, and the hard segments become aligned in the stress direction. This reorientation of the hard segments and consequent powerful hydrogen bonding contributes to high tensile strength, elongation, and tear resistance values. The choice of chain extender also determines flexural, heat, and chemical resistance properties. The most important chain extenders are
ethylene glycol Ethylene glycol (IUPAC name: ethane-1,2-diol) is an organic compound (a vicinal diol) with the formula . It is mainly used for two purposes, as a raw material in the manufacture of polyester fibers and for antifreeze formulations. It is an odo ...
,
1,4-butanediol 1,4-Butanediol, colloquially known as BD or BDO, is a primary alcohol, and an organic compound, with the formula HOCH2CH2CH2CH2OH. It is a colorless viscous liquid. It is one of four stable isomers of butanediol. Synthesis In industrial sy ...
(1,4-BDO or BDO), 1,6-hexanediol,
cyclohexane dimethanol Cyclohexanedimethanol (CHDM) is a mixture of isomeric organic compounds with formula C6H10(CH2OH)2. It is a colorless low-melting solid used in the production of polyester resins. Commercial samples consist of a mixture of cis and trans isomers. ...
and
hydroquinone bis(2-hydroxyethyl) ether Hydroquinone, also known as benzene-1,4-diol or quinol, is an aromatic organic compound that is a type of Phenols, phenol, a derivative of benzene, having the chemical formula C6H4(OH)2. It has two hydroxyl groups covalent bond, bonded to a benze ...
(HQEE). All of these glycols form polyurethanes that phase separate well and form well defined hard segment domains, and are melt processable. They are all suitable for
thermoplastic polyurethanes Thermoplastic polyurethane (TPU) is any of a class of polyurethane plastics with many properties, including elasticity, transparency, and resistance to oil, grease, and abrasion. Technically, they are thermoplastic elastomers consisting of linea ...
with the exception of ethylene glycol, since its derived bis-phenyl urethane undergoes unfavorable degradation at high hard segment levels. Diethanolamine and triethanolamine are used in flex molded foams to build firmness and add catalytic activity. Diethyltoluenediamine is used extensively in RIM, and in polyurethane and polyurea elastomer formulations.


Catalysts

Polyurethane
catalyst Catalysis () is the process of increasing the rate of a chemical reaction by adding a substance known as a catalyst (). Catalysts are not consumed in the reaction and remain unchanged after it. If the reaction is rapid and the catalyst recyc ...
s can be classified into two broad categories, basic and acidic
amine In chemistry, amines (, ) are compounds and functional groups that contain a basic nitrogen atom with a lone pair. Amines are formally derivatives of ammonia (), wherein one or more hydrogen atoms have been replaced by a substituen ...
.
Tertiary amine In chemistry, amines (, ) are compounds and functional groups that contain a basic nitrogen atom with a lone pair. Amines are formally derivatives of ammonia (), wherein one or more hydrogen atoms have been replaced by a substituent such a ...
catalysts function by enhancing the nucleophilicity of the diol component. Alkyl tin carboxylates, oxides and mercaptides oxides function as mild Lewis acids in accelerating the formation of polyurethane. As bases, traditional amine catalysts include triethylenediamine (TEDA, also called
DABCO DABCO (1,4-diazabicyclo .2.2ctane), also known as triethylenediamine or TEDA, is a bicyclic organic compound with the formula N2(C2H4)3. This colorless solid is a highly nucleophilic tertiary amine base, which is used as a catalyst and reagent i ...
, 1,4-diazabicyclo .2.2ctane), dimethylcyclohexylamine (DMCHA),
dimethylethanolamine Dimethylethanolamine (DMAE or DMEA) is an organic compound with the formula (CH3)2NCH2CH2OH. It is bifunctional, containing both a tertiary amine and primary alcohol functional groups. It is a colorless viscous liquid. It is used in skin care produ ...
(DMEA), and bis-(2-dimethylaminoethyl)ether, a blowing catalyst also called A-99. A typical Lewis acidic catalyst is
dibutyltin dilaurate Dibutyltin dilaurate (abbreviated DBTDL), also called dibutyltindilaurate or butynorate, is an organotin compound that is used as a catalyst. It is a colourless oily liquid. In terms of its structure, the molecule consists of two laurate groups ...
. The process is highly sensitive to the nature of the catalyst and is also known to be
autocatalytic A single chemical reaction is said to be autocatalytic if one of the reaction products is also a catalyst for the same or a coupled reaction.Steinfeld J.I., Francisco J.S. and Hase W.L. ''Chemical Kinetics and Dynamics'' (2nd ed., Prentice-Hall 199 ...
. Factors affecting catalyst selection include balancing three reactions: urethane (polyol+isocyanate, or gel) formation, the urea (water+isocyanate, or "blow") formation, or the isocyanate trimerization reaction (e.g., using potassium acetate, to form isocyanurate rings). A variety of specialized catalysts have been developed.


Surfactants

Surfactants Surfactants are chemical compounds that decrease the surface tension between two liquids, between a gas and a liquid, or interfacial tension between a liquid and a solid. Surfactants may act as detergents, wetting agents, emulsion#Emulsifiers , ...
are used to modify the characteristics of both foam and non-foam polyurethane polymers. They take the form of polydimethylsiloxane-polyoxyalkylene block copolymers,
silicone A silicone or polysiloxane is a polymer made up of siloxane (−R2Si−O−SiR2−, where R = organic group). They are typically colorless oils or rubber-like substances. Silicones are used in sealants, adhesives, lubricants, medicine, cooking ...
oils,
nonylphenol Nonylphenols are a family of closely related organic compounds composed of phenol bearing a 9 carbon-tail. Nonylphenols can come in numerous structures, all of which may be considered alkylphenols. They are used in manufacturing antioxidants, lub ...
ethoxylates, and other organic compounds. In foams, they are used to emulsify the liquid components, regulate cell size, and stabilize the cell structure to prevent collapse and sub-surface voids. In non-foam applications they are used as air release and antifoaming agents, as wetting agents, and are used to eliminate surface defects such as pin holes, orange peel, and sink marks.


Production

Polyurethanes are produced by mixing two or more liquid streams. The polyol stream contains catalysts, surfactants,
blowing agent A blowing agent is a substance which is capable of producing a cellular structure via a foaming process in a variety of materials that undergo hardening or phase transition, such as polymers, plastics, and metals. They are typically applied when ...
s (when making polyurethane foam insulation) and so on. The two components are referred to as a polyurethane system, or simply a system. The isocyanate is commonly referred to in North America as the 'A-side' or just the 'iso'. The blend of polyols and other additives is commonly referred to as the 'B-side' or as the 'poly'. This mixture might also be called a 'resin' or 'resin blend'. In Europe the meanings for 'A-side' and 'B-side' are reversed. Resin blend additives may include chain extenders,
cross linker In chemistry and biology a cross-link is a bond or a short sequence of bonds that links one polymer chain to another. These links may take the form of covalent bonds or ionic bonds and the polymers can be either synthetic polymers or natural ...
s,
surfactant Surfactants are chemical compounds that decrease the surface tension between two liquids, between a gas and a liquid, or interfacial tension between a liquid and a solid. Surfactants may act as detergents, wetting agents, emulsifiers, foaming ...
s,
flame retardant The term flame retardants subsumes a diverse group of chemicals that are added to manufactured materials, such as plastics and textiles, and surface finishes and coatings. Flame retardants are activated by the presence of an ignition source a ...
s,
blowing agent A blowing agent is a substance which is capable of producing a cellular structure via a foaming process in a variety of materials that undergo hardening or phase transition, such as polymers, plastics, and metals. They are typically applied when ...
s,
pigment A pigment is a colored material that is completely or nearly insoluble in water. In contrast, dyes are typically soluble, at least at some stage in their use. Generally dyes are often organic compounds whereas pigments are often inorganic compo ...
s, and
fillers In processed animal foods, a filler is an ingredient added to provide dietary fiber, bulk or some other non-nutritive purpose. Products like corncobs, feathers, soy, cottonseed hulls, peanut hulls, citrus pulp, screening, weeds, straw, and cere ...
. Polyurethane can be made in a variety of densities and hardnesses by varying the isocyanate, polyol or additives.


Health and safety

Fully reacted polyurethane polymer is chemically inert. No exposure limits have been established in the U.S. by OSHA (
Occupational Safety and Health Administration The Occupational Safety and Health Administration'' (OSHA ) is a large regulatory agency of the United States Department of Labor that originally had federal visitorial powers to inspect and examine workplaces. Congress established the agenc ...
) or ACGIH (
American Conference of Governmental Industrial Hygienists The American Conference of Governmental Industrial Hygienists (ACGIH) is a professional association of industrial hygienists and practitioners of related professions, with headquarters in Cincinnati, Ohio. One of its goals is to advance worker pr ...
). It is not regulated by OSHA for carcinogenicity. Polyurethanes are combustible. Decomposition from fire can produce significant amounts of carbon monoxide and
hydrogen cyanide Hydrogen cyanide, sometimes called prussic acid, is a chemical compound with the formula HCN and structure . It is a colorless, extremely poisonous, and flammable liquid that boils slightly above room temperature, at . HCN is produced on an ...
, in addition to nitrogen oxides, isocyanates, and other toxic products. Because of the flammability of the material, it has to be treated with
flame retardant The term flame retardants subsumes a diverse group of chemicals that are added to manufactured materials, such as plastics and textiles, and surface finishes and coatings. Flame retardants are activated by the presence of an ignition source a ...
s (at least in case of furniture), almost all of which are considered harmful. California later issued Technical Bulletin 117 2013 which allowed most polyurethane foam to pass flammability tests without the use of flame retardants. Green Science Policy Institute states: "Although the new standard can be met without flame retardants, it does NOT ban their use. Consumers who wish to reduce household exposure to flame retardants can look for a TB117-2013 tag on furniture, and verify with retailers that products do not contain flame retardants." Liquid resin blends and
isocyanate In organic chemistry, isocyanate is the functional group with the formula . Organic compounds that contain an isocyanate group are referred to as isocyanates. An organic compound with two isocyanate groups is known as a diisocyanate. Diisocyan ...
s may contain hazardous or regulated components. Isocyanates are known skin and respiratory sensitizers. Additionally, amines, glycols, and phosphate present in spray polyurethane foams present risks. Exposure to chemicals that may be emitted during or after application of polyurethane spray foam (such as isocyanates) are harmful to human health and therefore special precautions are required during and after this process. In the United States, additional health and safety information can be found through organizations such as the Polyurethane Manufacturers Association (PMA) and the Center for the Polyurethanes Industry (CPI), as well as from polyurethane system and raw material manufacturers. Regulatory information can be found in the
Code of Federal Regulations In the law of the United States, the ''Code of Federal Regulations'' (''CFR'') is the codification of the general and permanent regulations promulgated by the executive departments and agencies of the federal government of the United States. ...
Title 21 (Food and Drugs) and Title 40 (Protection of the Environment). In Europe, health and safety information is available from ISOPA, the European Diisocyanate and Polyol Producers Association.


Manufacturing

The methods of manufacturing polyurethane finished goods range from small, hand pour piece-part operations to large, high-volume bunstock and boardstock production lines. Regardless of the end-product, the manufacturing principle is the same: to meter the liquid isocyanate and resin blend at a specified stoichiometric ratio, mix them together until a homogeneous blend is obtained, dispense the reacting liquid into a mold or on to a surface, wait until it cures, then demold the finished part.


Dispensing equipment

Although the capital outlay can be high, it is desirable to use a meter-mix or dispense unit for even low-volume production operations that require a steady output of finished parts. Dispense equipment consists of material holding (day) tanks, metering pumps, a mix head, and a control unit. Often, a conditioning or heater–chiller unit is added to control material temperature in order to improve mix efficiency, cure rate, and to reduce process variability. Choice of dispense equipment components depends on shot size, throughput, material characteristics such as
viscosity The viscosity of a fluid is a measure of its resistance to deformation at a given rate. For liquids, it corresponds to the informal concept of "thickness": for example, syrup has a higher viscosity than water. Viscosity quantifies the inte ...
and filler content, and
process control An industrial process control in continuous production processes is a discipline that uses industrial control systems to achieve a production level of consistency, economy and safety which could not be achieved purely by human manual control. I ...
. Material day tanks may be single to hundreds of gallons in size and may be supplied directly from drums, IBCs (
intermediate bulk container Intermediate bulk containers (also known as IBC tank, IBC tote, IBC, or pallet tank) are industrial-grade containers engineered for the mass handling, transport, and storage of liquids, semi-solids, pastes, or solids. The two main categories of I ...
s, such as
totes Totes Isotoner Corporation, stylized totes»ISOTONER and often abbreviated to Totes, is an international umbrella, footwear, and cold weather accessory supplier, headquartered in Cincinnati, Ohio, USA. Totes is regularly billed in press reports as ...
), or bulk storage tanks. They may incorporate level sensors, conditioning jackets, and mixers. Pumps can be sized to meter in single grams per second up to hundreds of pounds per minute. They can be rotary, gear, or piston pumps, or can be specially hardened
lance pump A lance is a spear designed to be used by a mounted warrior or cavalry soldier (lancer). In Ancient warfare, ancient and medieval warfare, it evolved into the leading weapon in cavalry charges, and was unsuited for throwing or for repeated thru ...
s to meter liquids containing highly abrasive fillers such as chopped or hammer-milled
glass fiber Glass fiber ( or glass fibre) is a material consisting of numerous extremely fine fibers of glass. Glassmakers throughout history have experimented with glass fibers, but mass manufacture of glass fiber was only made possible with the inventio ...
and
wollastonite Wollastonite is a calcium inosilicate mineral ( Ca Si O3) that may contain small amounts of iron, magnesium, and manganese substituting for calcium. It is usually white. It forms when impure limestone or dolomite is subjected to high temperature a ...
. Image:HighPressureDispenseUnit800x600.png, A high-pressure polyurethane dispense unit, showing control panel, high-pressure pump, integral day tanks, and hydraulic drive unit Image:HighPressureLHeadFront600x800.png, A high-pressure mix head, showing simple controls (front view) Image:HighPressureLHeadRear600x800.png, A high-pressure mix head, showing material supply and hydraulic actuator lines (rear view) The pumps can drive low-pressure (10 to 30 bar, 1 to 3 MPa) or high-pressure (125 to 250 bar, 12.5 to 25.0 MPa) dispense systems. Mix heads can be simple static mix tubes, rotary-element mixers, low-pressure dynamic mixers, or high-pressure hydraulically actuated direct impingement mixers. Control units may have basic on/off and dispense/stop switches, and analogue pressure and temperature gauges, or may be computer-controlled with flow meters to electronically calibrate mix ratio, digital temperature and level sensors, and a full suite of statistical process control software. Add-ons to dispense equipment include nucleation or gas injection units, and third or fourth stream capability for adding pigments or metering in supplemental additive packages. Image:LowPressureMixHead600x800.png, A low-pressure mix head with calibration chamber installed, showing material supply and air actuator lines Image:LowPressureMixChamberComponents800x600.png, Low-pressure mix head components, including mix chambers, conical mixers, and mounting plates Image:LowPressure5GallonDayTanks800x600.png, 5-gallon (20-liter) material day tanks for supplying a low-pressure dispense unit


Tooling

Distinct from pour-in-place, bun and boardstock, and coating applications, the production of piece parts requires tooling to contain and form the reacting liquid. The choice of mold-making material is dependent on the expected number of uses to end-of-life (EOL), molding pressure, flexibility, and heat transfer characteristics. RTV silicone is used for tooling that has an EOL in the thousands of parts. It is typically used for molding rigid foam parts, where the ability to stretch and peel the mold around undercuts is needed. The heat transfer characteristic of RTV silicone tooling is poor. High-performance, flexible polyurethane elastomers are also used in this way. Epoxy, metal-filled epoxy, and metal-coated epoxy is used for tooling that has an EOL in the tens of thousands of parts. It is typically used for molding flexible foam cushions and seating, integral skin and microcellular foam padding, and shallow-draft RIM bezels and fascia. The heat transfer characteristic of epoxy tooling is fair; the heat transfer characteristic of metal-filled and metal-coated epoxy is good. Copper tubing can be incorporated into the body of the tool, allowing hot water to circulate and heat the mold surface. Aluminum is used for tooling that has an EOL in the hundreds of thousands of parts. It is typically used for molding microcellular foam gasketing and cast elastomer parts, and is milled or extruded into shape. Mirror-finish
stainless steel Stainless steel is an alloy of iron that is resistant to rusting and corrosion. It contains at least 11% chromium and may contain elements such as carbon, other nonmetals and metals to obtain other desired properties. Stainless steel's corros ...
is used for tooling that imparts a glossy appearance to the finished part. The heat transfer characteristic of metal tooling is excellent. Finally, molded or milled
polypropylene Polypropylene (PP), also known as polypropene, is a thermoplastic polymer used in a wide variety of applications. It is produced via chain-growth polymerization from the monomer propylene. Polypropylene belongs to the group of polyolefins and ...
is used to create low-volume tooling for molded gasket applications. Instead of many expensive metal molds, low-cost plastic tooling can be formed from a single metal master, which also allows greater design flexibility. The heat transfer characteristic of polypropylene tooling is poor, which must be taken into consideration during the formulation process.


Applications

In 2007, the global consumption of polyurethane raw materials was above 12 million metric tons, and the average annual growth rate was about 5%. Revenues generated with PUR on the global market are expected to rise to approximately US$75 billion by 2022.


Degradation and environmental fate


Effects of visible light

Polyurethanes, especially those made using
aromatic In chemistry, aromaticity is a chemical property of cyclic ( ring-shaped), ''typically'' planar (flat) molecular structures with pi bonds in resonance (those containing delocalized electrons) that gives increased stability compared to satur ...
isocyanates, contain
chromophores A chromophore is the part of a molecule responsible for its color. The color that is seen by our eyes is the one not absorbed by the reflecting object within a certain wavelength spectrum of visible light. The chromophore is a region in the molec ...
that interact with light. This is of particular interest in the area of polyurethane coatings, where
light Light or visible light is electromagnetic radiation that can be perceived by the human eye. Visible light is usually defined as having wavelengths in the range of 400–700 nanometres (nm), corresponding to frequencies of 750–420 tera ...
stability is a critical factor and is the main reason that
aliphatic In organic chemistry, hydrocarbons ( compounds composed solely of carbon and hydrogen) are divided into two classes: aromatic compounds and aliphatic compounds (; G. ''aleiphar'', fat, oil). Aliphatic compounds can be saturated, like hexane, or ...
isocyanates are used in making polyurethane coatings. When PU foam, which is made using aromatic isocyanates, is exposed to visible light, it discolors, turning from off-white to yellow to reddish brown. It has been generally accepted that apart from yellowing, visible light has little effect on foam properties. This is especially the case if the yellowing happens on the outer portions of a large foam, as the deterioration of properties in the outer portion has little effect on the overall bulk properties of the foam itself. It has been reported that exposure to visible light can affect the variability of some physical property test results. Higher-energy UV radiation promotes chemical reactions in foam, some of which are detrimental to the foam structure.


Hydrolysis and biodegradation

Polyurethanes may crumble due to hydrolysis. This is a common problem with shoes left in a closet, and reacting with moisture in the air. Microbial degradation of polyurethane is believed to be due to the action of
esterase An esterase is a hydrolase enzyme that splits esters into an acid and an alcohol in a chemical reaction with water called hydrolysis. A wide range of different esterases exist that differ in their substrate specificity, their protein structure, ...
, urethanase,
hydrolase Hydrolase is a class of enzyme that commonly perform as biochemical catalysts that use water to break a chemical bond, which typically results in dividing a larger molecule into smaller molecules. Some common examples of hydrolase enzymes are este ...
and
protease A protease (also called a peptidase, proteinase, or proteolytic enzyme) is an enzyme that catalyzes (increases reaction rate or "speeds up") proteolysis, breaking down proteins into smaller polypeptides or single amino acids, and spurring the ...
enzymes. The process is slow as most microbes have difficulty moving beyond the surface of the polymer. Susceptibility to fungi is better due to their release of
extracellular enzymes Extracellular enzymes or exoenzymes are synthesized inside the cell and then secreted outside the cell, where their function is to break down complex macromolecules into smaller units to be taken up by the cell for growth and assimilation. These ...
, which are more able to permeate the polymer matrix. Two species of the Ecuadorian fungus ''
Pestalotiopsis ''Pestalotiopsis'' is a genus of ascomycete fungi. ''Pestalotiopsis'' species are known as plant pathogens. The genus name of ''Pestalotiopsis'' is in honour of Fortunato Pestalozza (died 1878), who was an Italian botanist and doctor who worked ...
'' are capable of biodegrading polyurethane in aerobic and anaerobic conditions such as found at the bottom of
landfill A landfill site, also known as a tip, dump, rubbish dump, garbage dump, or dumping ground, is a site for the disposal of waste materials. Landfill is the oldest and most common form of waste disposal, although the systematic burial of the waste ...
s. Degradation of polyurethane items at museums has been reported. Polyester-type polyurethanes are more easily biodegraded by fungus than polyether-type.


See also

*
Passive fire protection Passive fire protection (PFP) is components or systems of a building or structure that slows or impedes the spread of the effects of fire or smoke without system activation, and usually without movement. Examples of passive systems include floor- ...
*
Penetrant (mechanical, electrical, or structural) Penetrants, or penetrating items, are the mechanical, electrical or structural items that pass through an opening in a wall or floor, such as pipes, electrical conduits, ducting, electrical cables and cable trays, or structural steel beams and ...
* Polyaspartic *
Thermoplastic polyurethanes Thermoplastic polyurethane (TPU) is any of a class of polyurethane plastics with many properties, including elasticity, transparency, and resistance to oil, grease, and abrasion. Technically, they are thermoplastic elastomers consisting of linea ...
*
Thermoset polymer matrix A thermoset polymer matrix is a synthetic polymer reinforcement where polymers act as binder or matrix to secure in place incorporated particulates, fibres or other reinforcements. They were first developed for structural applications, such as gla ...


References


External links


Center for the Polyurethanes Industry
information for EH&S issues related to polyurethanes developments

Polymer Science Learning Center,
University of Southern Mississippi The University of Southern Mississippi (Southern Miss or USM) is a public research university with its main campus located in Hattiesburg, Mississippi. It is accredited by the Southern Association of Colleges and Schools to award bachelor's, ma ...

Polyurethane Foam Association
Industry information, educational materials and resources related to flexible polyurethane foam
PU Europe: European PU insulation industry association
(formerly BING): European voice for the national trade associations representing the polyurethane insulation industry
ISOPA: European Diisocyanate & Polyol Producers Association
ISOPA represents the manufacturers in Europe of aromatic diisocyanates and polyols {{Authority control 1937 in Germany 1937 in science Adhesives Building insulation materials Coatings Elastomers Plastics Wood finishing materials German inventions of the Nazi period