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Low- or non-emissive amine catalysts for low density, open-cell spray polyurethane foam

von Bulent Ozbas, PhD, Jean L. Vincent, PhD, James D. Tobias, Joel R. Rogers, Juan J. Burdeniuc, PhD

Polyurethane foam related emissions and odor have been the driving forces for new technologies in flexible and automotive applications, and recently, the increasing use of spray polyurethane foam (SPF) in interior spaces requires new additives that can enable the application of these products without negatively affecting the indoor air quality. Minimizing both applicator exposure and post-foam emissions, or off-gassing, are the key elements for developing safe products with minimal impact to environment and air quality. While worker exposure can be mitigated through proper use of equipment and work practices, safer products for end-users can be achieved by reducing the volatile organic components to acceptable levels.

Eliminating any offensive odors – even though the indoor concentrations of the related chemicals are below safe limits – can help the acceptance of such products by consumers. Over the past years, Air Products has developed non-emissive and reduced-emission amine-catalyst technologies that meet the industry specific emission requirements for a variety of polyurethane market segments. In this paper, we present novel amine catalysts, Polycat 140 and Polycat 141, which are specifically developed for low-density (~0.5 lb/ft3), open-cell, water-blown spray polyurethane foam. Emission and performance data will be presented, and the results will be compared to Polycat 31 (low- or non-emissive), and Bis[2-(N,N-dimetylyamino)ethyl] ether-based products.