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Overview of Super-Soft PU Foam
The key characteristics of super-soft polyurethane foam are low density and low compression strength, making it widely used in mattresses, low-load cushions, and pillow cores. The typical production method involves using a low isocyanate index and a high content of auxiliary blowing agents to reduce product stiffness. A typical foaming formulation is shown in the table below.
Foaming Formulations for Super-Soft Polyurethane Foam
|
Formulation |
1 |
2 |
3 |
4 |
|
Polyether Propylan 1 |
80 |
80 |
50 |
30 |
|
Polyether Propylan 3 |
20 |
20 |
50 |
70 |
|
Tin Octoate |
0.05 |
0.08 |
0.10 |
0.18 |
|
Water |
3.6 |
3.6 |
3.6 |
3.6 |
|
Triethylenediamine |
0.2 |
0.2 |
0.2 |
0.2 |
|
Silicone Oil L520 |
1.5 |
2.0 |
1.5 |
2.0 |
|
Auxiliary Blowing Agent |
10 |
20 |
10 |
20 |
|
Toluene Diisocyanate Index |
85 |
90 |
90–95 |
95 |
|
Process Parameters |
1 |
2 |
3 |
4 |
|
Mixing Speed (r/min) |
2250 |
3000 |
2250 |
3000 |
|
Foaming Time (s) |
110–120 |
130–140 |
110–120 |
95–115 |
|
Foaming Temperature (°C) |
22–24 |
22–24 |
22–24 |
22–24 |
|
Product Performance |
1 |
2 |
3 |
4 |
|
Density (kg/m³) |
22.4 |
18.9 |
21.0 |
17.6 |
|
Initial Softness Hardness |
||||
|
25% Compression (N) |
17.7 |
15.6 |
20.5 |
17.0 |
|
50% Compression (N) |
21.5 |
19.1 |
28.3 |
23.7 |
|
65% Compression (N) |
36.3 |
28.3 |
11.5 |
33.1 |
|
Tensile Strength (kPa) |
79 |
16 |
89 |
57 |
|
Elongation (%) |
225 |
220 |
207 |
205 |
|
Tear Strength (kN/m) |
0.57 |
0.22 |
0.23 |
0.24 |
|
Compression Set (70°C, 22h, %) |
5.6 |
6.0 |
4.75 |
7.85 |
|
Resilience (Ball Rebound Rate, %) |
16.2 |
22.0 |
21.0 |
33.0 |
Notes
- Propylan 1: A polyoxypropylene triol with a hydroxyl value of 155–165 mg KOH/g.
- Propylan 3: A polyoxypropylene triol with a hydroxyl value of 53–59 mg KOH/g.
Both are products of Lankro Chemical Company.
Foams with a density lower than 20 kg/m³ are generally classified as ultra-low-density foams. To reduce foam density while maintaining its mechanical strength, lightweight foams are developed to improve cost efficiency and resource savings.
The key to synthesizing such foam is not merely increasing the amount of blowing agent but separately synthesizing hydroxyl-terminated prepolymers and -NCO-terminated prepolymers using polyether.
The purpose of first generating prepolymers is to ensure the polyurethane chains grow to a certain length, which guarantees the mechanical strength and stability of the foam during production.
Additionally, the polyether compound in the -NCO-terminated prepolymer structure should contain more than 15% ethylene oxide segments. This enhances the hydrophilicity of the prepolymer, aiding emulsification and mixing in the presence of a large amount of water.
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