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POLYURETHANES EXPO 2004October 1 8 - 2 0 , 2004Paris Las VegasLas Vegas, NevadaCONFERENCE PROCEEDINGSSponsored by the Alliance for the Polyurethanes IndustryIlALLIANCE FOR THEPOLYURETHANESINDUSTRYTIB/UB Hannover126 154 104
Table of ContentsSession A — Environment, Health & SafetyEH&S Issues Facing the Polyurethane IndustryJ. Kasakevich, J. Chapman, W. Robert (Bayer MaterialScience)3Biomonitoring of Diisocyanate Exposures: Pitfalls and PromisesR. N. Shiotsuka (Bayer CropScience)5Adventures in TransportationR. C. Blake (Bayer MaterialScience) .10Measurements of Airborne Methylene Diphenyl Diisocyanate (MDI) in the U.S. WorkplaceK. Booth, B. Cummings (Bayer MaterialScience), W. J. Karoly (Huntsman Polyurethanes),S. Mullins, W. P. Robert (BASF Corporation), M. Spence (The Dow Chemical Company),F. W. Lichtenberg (fwl Communications)14Eco-efficiency as an EH&S ToolC. Wall (BASF Corporation), A. Kicherer (BASF Aktiengesellschaft)15Road to PetitionD. E. Miller (Miller Environmental & Safety Services)19Session B — FurnishingsViscoelastic Foam with Enhanced Comfort, Reduced Temperature Sensitivity and a Wide Range of ApplicationsR. Neff, S. Dakin, T. Green, R. Gummaraju, T. Smiecinski (BASF Corporation)Progress Towards the Development of Viscoelastic Polyurethane Foam Producedwith VORANOL VORACTIV PolyolsV. Delk, R. Polk, R. Prange (The Dow Chemical Company) F. Aguirre (Dow Europe GmbH)2735Novel Modifier Polyol for Processing and Performance Enhancement of Slabstock FoamN. Anderson, V. Jividen, S. Hager, G. DePhillipo, J. George (Bayer Polymers LLC)41Discoloration in Fire-Retardant Flexible Polyurethane FoamsS. Levchik (Phosphorus Chemicals LLC), M. P. Luda, P. Bracco, P. Nada,L. Costa (Dipartimento di Chimica IFM dell'Universita)46A Brominated Flame Retardant for Flexible Polyurethane FoamsW. R. Brown (Albemarle Corporation)53Session C — CatalysisPolyurethane Catalysis by Tertiary AminesR. Van Maris (TOSOH EUROPE B.V.), K. M. Gay (TOSOH USA, INC.),Y. Tamano, H. Yoshimura (TOSOH CORPORATION)63A Study of the Reaction Kinetics of Polyisocyanurate Foam Formulations using Real-Time FTIRR. R. Romero, R. A. Grigsby, Jr., E. L. Rister, Jr., J. K. Pratt, D. Ridgway (Huntsman Performance Chemicals)71Innovative Trimerization Catalyst Systems for Polyisocyanurate FoamsK. Tokumoto, Y. Takahashi, Y. Tamano, H. Yoshimura (TOSOH Corporation),R. Van Maris (TOSOH EUROPEB.V.), K. M. Gay (TOSOH USA, Inc.)81The Evaluation of Novel Organometallic Catalysts in Polyurethane FoamsB. Stengel (Johnson Matthey Catalysts)93Tuning of Metal Cyanide Salts in Double Metal Cyanide Catalysts for the Ring-opening Polymerizationof Propylene OxideI. Kim, S. H. Byun, J. T. Ahn, S. H. Lee, C. S. Yang (Pusan National University)100Session D — CombustibilityA History of FPF Fire Prevention and Safety EducationL. H. Peters, R. J. Luedeka (Polyurethane Foam Association)Hi111
Risk Watch Fire Safety Education Program Evaluation117K. M. Ransdell (NC Department of Insurance-Office of State Fire Marshal), P. J. Baughman (West Virginia University)Halogen Free Flame Retardant Technology for Polyurethane FoamN. Tokuyasu, K. Fujimoto, T. Hamada (Daihachi Chemical Industry Co., LTD)118Novel Approaches to Meeting Furniture Foam Fire Safety RequirementsS. Falloon, M. Phillips, R. Rose, J. Holland (Great Lakes Chemical Corporation)128FIRE-LCA MODEL: FURNITURE including Polyurethane and Textile as CASE STUDYS. Landry, L. Tange (EFRA Representatives), P. Blomqvist, L. Rosell, M. Simonson,P. Anderson (SP Sweden and Hakan Stripple)133A Primer of Fire Protection Measures and The Appropriate Selection of Flammability Test Methodsfor Materials and Products for Specific, End-Use ApplicationsJ. T. Chapin, R. Backstrom (Underwriters Laboratories, Inc.)144Session E — ApplianceImproving Initial HFC-245fa Foam Offerings for the Rigid Appliance IndustryC. Martin, B. Obi, S. Moore (The Dow Chemical Company)153CoreFlex: Flexible Core-Changing System for Refrigerated Cabinet Production LinesD. R. Hanne (Hennecke Machinery Group), K. Pieper (HenneckeGmbH)160Balancing Foam System Economics and Performance with Reduced Levels of HFC 245faS. Schilling, E. Ball (Bayer MaterialScience LLC)163Insights into Converting Your Blowing Agent to PentaneS. Willis (Krauss-Maffei Corporation)169Numerical Simulation of PU Foaming Flow in a Refrigerator CabinetY. B. Kim, K. D. Kim, S. E. Hong, J. G. Kim, M. H. Park, J. H. Kim (LG Electronics),J. K. Kweon (Korea Polyol Co., Ltd.)175Comparison of Insulating Agents. Global Warming Analyses Using a New Index of SustainabilityA. Sekiya (National Institute of Advanced Industrial Science and Technology (AIST))182Session F — FundamentalsEffect of Polydispersity of Polymer Glycols on Structure and Properties of Polyurethane ElastomersM. Furukawa, Y. Okuhara, K. Kojio (Nagasaki University)191FTIR Analysis of Thermally Processed Polyurethane FoamsD. W. Hatchett, G. Kodippili, J. M. Kinyanjui (University of Nevada, Las Vegas),L. Sapochak (Pacific Northwest National Laboratory)197Novel Properties of Polyurethane Elastomers Prepared with Ether Based DiisocyanateK. Kojio, T. Fukumaru, M. Furukawa (Nagasaki University)203Cell Morphology, Density, and Mechanical Property Relations in Rigid Polyurethane FoamB. OToole, M. C. Hawkins, D. J. Jackovich (University of Nevada Las Vegas)211HR Moulded Foam Compression Set and Hardness Response to Relative HumidityG. R. Blair, L. Dong, M. Rusan, R. J. Bailey (Woodbridge Foam)227Session G — FootwearFuture Prospects for the Footwear Industry; Production, Style Trends and Soling MaterialsS. Lee (Steve Lee Associates-an InfoDynamix Limited Company)243PU-Lightweight: The New Generation of Midsole MaterialB. Dormann, C. Decker (DESMA)247New Antioxidant and Light Stabilizer Systems for PUR Shoe ApplicationsD. Mader (Ciba Specialty Chemicals Inc.), M. Speer (Ciba Specialty Chemicals Corporation),K. Schrinner (Ciba Specialty Chemicals (Singapore) Pte Ltd.)252Quick Colour Change System for TPU ProcessC. Decker, B. Dormann (DESMA)263iv
Session H — RecyclingISPA Mattress Disposal Task ForceR. Trainer (International Sleep Products Association)273Effect of pH and Buffers on Hydrolysis Rate of TDI and PMDI Based PolyureasI. Sendijarevic, V. Sendijarevic, A. Sendijarevic (Troy Polymers, Inc.), K. A. Reimann (BASF Corporation),R. E. Bailey (Bailey Associates)274Adding Value to Waste PolyolsR. Gerstle (Satellite International)282Chemical Recycling of Mixed Polyurethane Foam Stream Recovered from Shredder Residueinto Polyurethane PolyolsV. Sendijarevic (Troy Polymers, Inc.)284Mobius PU Recycling Technology and Dow's VORANOL VORACTIV PolyolsProduce "Green" Slabstock FoamsP. Berthevas, R. Villwock, B. Martel (Mobius Technologies, Inc), F. Aguirre (Dow Europe GmbH)292Recycling Shredder Residue Containing Plastics and Foam Using a Thermal Conversion ProcessG. R. Winslow (KBS Consulting), B. S. Appel, T. N. Adams (Chaning World Technologies),N. L. Simon (DaimlerChrysler), C. M. Duranceau (Ford Motor Company),C. S. Wheeler (General Motors Corporation), V. Sendijarevic (Troy Polymers, Inc.)298Session I — Blowing AgentsThe Use of Saytex RB-9130/9170 Low Viscosity Brominated Flame Retardant Polyols in HFC-245faand High Water FormulationsB. Feske (Albemarle Corporation)ftwts-l,2-dichloroethyelene As an Additive for HFC-134a Foam SystemsJ. Wu, C. Bertelo (ATOFINA Chemicals, Inc.), V. Enaux (ATOFINA CRRA)Factors Influencing the Vapor Pressure of Polyol Preblends Containing Enovate 3000 Blowing Agentand Methods for Vapor Pressure ManagementD. J. Williams, R. R. Singh, Z. Zhu, J. M. Bowman (Honeywell)309314322Tailored Surfactant Solutions to Optimize Foam Performance in HFC-245fa Blown Appliance SystemsC. Eilbracht, P. Hohl (Degussa)341Safety Measures for Plants Producing Pentane-blown Polyiso Laminate Boardstock InsulationL. A. Ross (Intech Consulting, Inc.)350Survey of Responsible Use Principles Followed for HFC Blowing Agents(Alliance for the Polyurethanes Industry (API))351Session J — Processing InnovationsHennecke's NafpurTec and CompurTec Equipment Technology for Lightweight Automotive MoldingsB. Metzler (Hennecke Machinery Group)361Finished Structural & Aesthetical Parts: Combining Benefits of PU Foaming and Vacuum Forming TechnologiesB. Pile (Cannon USA), C. Cairati (Cannon Afros SpA), G. Furlanetto (GMP SpA)366Polymer Laminate Tools for Polyurethane Foam MoldingC. Majewski, N. Hopkinson (Rapid Manufacturing Research Group)377Innovative Mixing Head Nozzle Controls Ensure Considerable Time Savings When Molding Flexible FoamsW. Sochtig, J. Renkl (Krauss-Maffei Kunststofftechnik GmbH)386Polyurethane Mix Head Technologies and AdvancementsJ. Stout, T. Sherman (Linden Industries)390C-Spray: Innovative Solution for Low Flow-Rate PU Spray Skin ApplicationsB. Biondich (Decker Industries, Inc.)394Session K — ConstructionFoam Plastic Insulations, Fire Testing, Building Codes, and BuildingsJ. R. Hagan (Intech Consulting, Inc.)401
Water-Blown Polyurethane Rigid Foam Modified with MaleateS. Murayama, K. Fukuda, T. Kimura, T. Sasahara (Nippon Polyurethane Industry Co., Ltd.)Dedicated Equipment for the Use of Expandable Graphite: To Improve Flame Retardant Properties of Foamsfor Insulated Sandwich PanelsG. Gula (Cannon USA), C. Cairati (Cannon Afros SpA), R. Verbruggen (Cannon Benelux)402409High Temperature Performance of Cyclopentane Blown Rigid Foam Spray Systems for Pipe InsulationM. A. Dobransky (Bayer MaterialScience)421Impact Equipment Selection and Environmental Conditions on Enovate 3000 Blowing Agent Spray FoamM. Bogdan (Honeywell), D. West (West Roofing), W. Blank, S. Mirasol (The Dow Chemical Company)428Advances in Polyisocyanurate Technology for Metal Faced PanelsF. Pignagnoli (Dow Italia S.r.l.), M. J. Skowronski (The Dow Chemical Company), L. Bertucelli (Dow Italia S.r.l.)436Session L — Coatings, Adhesives & SealantsA Detailed Understanding of Polyurethane Dispersions, Their Process and ApplicationsB. Erdem, D. Bhattacharjee, L.-J. Chen (The Dow Chemical Company)451Innovation and Urethane Chemistry in Materials for CoatingsR. R. Matheson, Jr. (DuPont Performance Coatings)466Tack Measurement of Heat-Activated Polyurethane AdhesivesJ. F. Dormish (Bayer MaterialScience LLC)467Characteristics and Applications of HDI Allophanate DerivativesH. Orito, M. Ikemoto (Nippon Polyurethane Industry Co., Ltd.)476Novel Polyurea Spray Systems with Improved Physical Mechanical PropertiesG. Muller, C. Bruchertseifer, V. M. T. Thiede (Dow Deutschland GmbH & Co. OHG)480Novel C12 Chain Extenders for PolyurethanesB. H. Novak (INVISTA, Inc.), V. Sendijarevic, A. Sendijarevic (Troy Polymers, Inc.)481Session M — AutomotiveNew Isocyanate Technology for the Reduction of Flammability in Low Density Flexible FoamsB. Kaushiva, J. Garrett (Bayer MaterialScience)491Innovative Copolymer Polyol Technologies for Automotive Polyurethane HR MoldingH. R. Van Der Wai (Dow Benelux N.V.), J. M. Sonney, F. M. Casati (Dow Europe GmbH),R. D. Dawe, R. Prange (The Dow Chemical Company)496Morphology Study of HFCs Blown Integral Skin FoamL. Lee, C-C Lai (Industrial Technology Research Institute)504Heat Resistant Flexible FoamT. Iwa, T. Shibata, K. Ohkubo (Mitsui Takeda Chemicals, Inc.)509Studies of Composites Made with Baypreg F: Component Selection for Optimal Mechanical PropertiesR. A. Cageao, J. M. Lorenzo, K. Franken (Bayer MaterialScience LLC)513The Rear Foaming of Leather & Other Substrates for Automobile ComponentsJ. Stout (Linden Industries, Inc.), D. Luthi (ISOTHERM AG)520Poster Session — Coatings, Adhesives & SealantsNovel Cycloaliphatic Chain Extenders for PolyurethanesB. H. Novak (INVISTA)527Measurement of the reaction profile and the Pot Life of PU-CASE materialsE. E. Hofmann (Format Messtechnik GmbH), D. J. Gross (EuroTech Distributors)528PU-Lightweight: The New Generation of Midsole MaterialB. Dormann, C. Decker (DESMA)532An Innovative Process for Manufacturing Polyurethane Structural Composites: Automotive, General Transportationand other Applications533P. Farkas, R. Stanciu, L. Mendoza (Woodbridge Foam Corp.)VI
Poster Session — Flexible Foam/AutomotiveThe Rear Foaming of Leather & Other Substrates for Automobile ComponentsJ. Stout (Linden Industries, Inc.)537Mechanical Properties of Fiber Reinforced Polyurethane CompositesS. Husic, I. Javni, Z. S. Petrovic (Pittsburg State University)538Poster Session — Fundamentals/EquipmentEH&S Issues facing the Polyurethane IndustryJ. Kasakevich, W. Robert (BASF Corporation)547Chemical Recycling of Mixed Polyurethane Foam Stream Recovered from Shredder Residueinto Polyurethane PolyolsV. Sendijarevic (Troy Polymers, Inc.)548Effect of pH and Buffers on Hydrolysis rate of TDI and PMDI Based PolyureasI. Sendijarevic, V. Sendijarevic, A. Sendijarevic (Troy Polymers, Inc.),K. A. Reimann (BASF Corporation), R. E. Bailey (Bailey Associates)556Cell Morphology, Density, and Mechanical Property Relations in a Rigid Polyurethane FoamC. Hawkins, B. J. O'Toole, D. Jackovich, B. J. O'Toole, Ph. D. (University of Nevada Las Vegas)557Cone Calorimeter Evaluations of/ra«s-l,2-dichloroethylene Containing Pentane FoamsJ. Wu, J. Maxwell, C. Bertelo (Atofina Chemicals, Inc.)558Novel Vegetable Oil Polyols and PolyurethanesZ. S. Petrovic, W. Zhang, I. Javni, J. Schlechte (Pittsburg State University)559Polyurethane Mix Head Technologies & AdvancementsJ. E. Stout (Linden Industries, Inc.)560Prediction of Polyol Reactivity Based on Gel Reaction MonitoringL. Brami, V. V. Infiesta (REPSOL YPF VP Quimica)561A Case-Based Tool for Formulating PolyurethanesD. M. Segura, A. D. Nurse, R. Heath (Loughborough University)562ZIKASORB Series: The Innovative Anti-Yellowing Solution for PolyurethaneY. Choi, D. Lee (ZIKO Ltd.)563ecomate Foam Blowing AgentM. Schulte, T. Kalinowski, J. Murphy (Foam Supplies, Inc)566Polydextrose: A High Functionality Polyol and Polyol Initiator for Making Polyurethane FoamC. Nichols, K. Knoblock (Danisco Sweeteners), J. O'Connor, A. McGlocklin (SynUthane International),D. Russell (Akron Polymer Labs)567Did You Know!D. E. Miller (Miller Environment & Safety Services)568Quick Colour Change System for the TPU ProcessB. Dormann, C. Decker (DESMA)571Direct Dosing of PU-Waste, Granulate or Powder at PU Reaction Pouring UnitsB. Dormann, C. Decker (DESMA)572The BayCareSM Online Training Center: An Evolutionary Approach to Safer Handling and Storageof Polyurethane ChemicalsH. Campbell (Bayer MaterialScience LLC)573Mechanical Properties of Fiber Reinforced Polyurethane CompositesS. Husic, I. Javni, Z. S. Petrovic (Pittsburg State University)574Analysis of Polymer Additives in Polyurethane Using GPC ColumnsS. Huang (Noveon Inc.)581Halogen Free Flame Retardant Technology for Polyurethane FoamN. Tokuyasu, K. Fujimoto, T. Hamada (Daihachi Chemical Industry Co., Ltd.)582Polyurethane AllianceT. Thomson (Main Street Technologies)583vii
Dedicated Equipment for the Use of Expandable Graphite to Improve Flame Retardant Propertiesof Foams for Insulated Sandwich PanelsG. Gula (Cannon USA), R. Verbruggen (Cannon Benelux), C. Cairati (Cannon Afros SpA)Finished Structural & Aesthetical Parts Combining Benefits of PU Foaming and Vacuum Forming TechnologiesB. Pile (Cannon USA), G. Furlanetto (GMP SpA), C. Cairati (Cannon Afros SpA)584585Poster Session — Rigid FoamNew Phosphorus-Based Flame Retardant for Rigid PUR FoamsB. Karoleski (Bayer Chemicals Corporation (Soon to be LANXESS Corporation),H. Tebbe (Bayer Chemicals, AG, (Soon to be LANXESS AG)589Innovative Trimerization Catalyst Systems for Polyisocyanurate FoamsK. Tokumoto (TOSOH Corporation)590Evaluation of Various Zero ODP Blowing Agents in a North American Class I Pour-In-Place Panel ApplicationsJ. Hoerter (Honeywell International)591Development of Enovate 3000 Blowing Agent Technology for Rigid Block Foam ApplicationsJ. Hoerter (Honeywell), J. Glorioso (Dyplast)592Low Viscosity Brominated Flame Retardant for Improved Hardness Development in Rigid Polyurethane FoamsR. Sjerps (Albemarle Europe SPRL)593Author Index595viii
K. A. Reimann (BASF Corporation), R. E. Bailey (Bailey Associates) Cell Morphology, Density, and Mechanical Property Relations in a Rigid Polyurethane Foam 557 C. Hawkins, B. J. O'Toole, D. Jackovich, B. J. O'Toole, Ph. D. (University of Nevada Las Vegas) Cone Calorimeter Evaluations of/ra«s-l,2-dichloroethylene Containing Pentane Foams 558
