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existence in the year 1979 and closed down in the year 1983. As of
then, they were into conversion i.e. they buy foam block from vita
mattresses.
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The Company’s Organogram, is as shown below:
Board of
Directors
Managing
Director
Production Sales
Manager manager
Craftmen Marketers
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CHAPTER 1
matter how tiny they could be, that has a wide variety of
mattresses and cushion to name but a few. Owing to the vast use
materials.
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Polyurethane foam;
foam, and will often not return to its original form. Most
Evlon foam;
buoyant.
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Used in most types of expensive furniture including yachting
and resilient.
Supreme foam;
Rebond foam;
impact / usage.
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Memory foam;
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In all the foam types mentioned above, one thing is common and
that is, that they all emanate from the polyurethanes. The
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CHAPTER 2
backbone.
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Synthetic polymers, like polyurethane, are produced by reacting
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toluene diisocyanate reacted with dihydric alcohols. From this
garments.
foam was begun in the United States. This material was useful for
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THE CHEMISTRY OF POLYURETHANE
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form polyureas. Commercially, polyurethanes are produced by
side' and 'B-side' are reversed. Resin blend additives may include
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diisocyanate (TDI); or aliphatic, such as hexamethylene
diols, those with three hydroxyl groups are called triols, et cetera.
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(DEG), glycerine, and trimethylolpropane (TMP). Polyols are
weight of the polyol greatly affect its physical state, and the
viscosity.
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carbon dioxide gas formed by reacting water and
isocyanate
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dimethylaminoethyl)ether, or specifically drive the isocyanate
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segment" phases consisting mostly of polyurea. The concentration
volatilize into a gas during the reaction process. They fill and
important to know that the blowing gas does not create the cells
into bubbles that are nucleated or stirred into the system at the
during the foaming process. They are used to emulsify the liquid
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designed to produce very fine cells and a very high closed cell
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Softer, elastic, and more flexible polyurethanes result when linear
An even more rigid foam can be made with the use of specialty
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There are then two main foam variants: one in which most of the
trapped, the other being systems which have mostly open cells,
did not form, or became open too soon, foam would not be
The opposite is the case with most rigid foams. Here, retention of
the cell gas is desired since this gas (especially the fluorocarbons
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RAW MATERIALS FOR POLYURETHANE FOAM PRODUCTION
Additives
o Surfactants
o Blowing agents
o Flame retardant
o Light retarders
o Fillers.
Isocyanates
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important building blocks for polyurethane materials, but in much
smaller volumes. There are a number of reasons for this. First, the
properties are required for the final product. For example, light
isomers.
Polyols
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The other reacting species required to produce polyurethanes are
polyols, which are polymers formed from cyclic ethers. They are
polyols were the most used reacting species for the production of
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polyurethanes. However, polyether polyols became significantly
Catalysts
power or efficiency.
polyurethane catalysts.
Surfactants
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foams, they are used to emulsify the liquid components, regulate
cell size, and stabilize the cell structure to prevent collapse and
sink marks.
diisocyanate.
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3. METHLY CHLORIDE;
4. SILICONE;
5. AMINE;
This is used for curing. Curing is the ability of foam to dry easily.
6. COLORANT;
what is needed.
7. Tin;
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This is acting as a binding agent in foam production.
8. WATER;
1. Pumping of chemicals
5. Cutting
1. Pumping of chemicals
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In the production of foam, there are three major chemicals used
which are;
Polypropylene glycol(polyol)
Toluene Diisocynate(TDI)
Methyl chloride
Zinc
Silicone
Colorants
Tin
Amine
Water
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These various elements, compounds and chemicals have various
discussed later.
tank. Here, the major chemicals are concerned i.e. TDI, polyol and
methyl chloride.
The other elements and compounds are not kept in the chemical
room rather, they are kept very close to the foam plant machine
in a smaller container.
2. Cooling of chemical
very important, owing to the fact that a fire outbreak could occur,
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Diisocynate. To each of the tanks, is a pump attached to enhance
machine
machine known as the mixer head, where they all mix together.
distance at which a particular foam must have set. Here, the rising
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point was between 95cm-98cm. This is continuous until the whole
5. Cutting
At one part of the conveyor, few centimeters away from the rising
operated .the cutter or blade cuts the long foam block in blocks of
has finished.
Finally, the work place is cleared and the mixer head is flushed
with methyl chloride and the trough through which the chemicals
course of the production. Then, the production room is left till the
next day In order to allow all the toxic gases escape before the
final arrangement.
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The foam blocks are sent to the conversion unit in order to be
polyol
Mixer head
conveyor
TDI Output(foam)
MeCl
pump
pieces and mixes them up with a gum like liquid as to enable them
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bond with each other. Then the machine has a large compressing
flat surface which compresses the foam pieces which are now in a
container that has the desired shape. When the flat surface
compresses the foam, they are bonded together into the desirable
shape. Then you have the rebond foam widely known in this part
In an ideal foam production firm, there are three major units and
they are:
Production unit
This is the unit in which the actual production of the foam block
takes place. All the production machineries like the omega mass
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The conversion unit
This is the next important unit after the production unit. Here the
machines. Here, the bare foam blocks are given beautiful and
attractive coverings.
This unit is also known as the sales unit. This unit is where finished
The first to unit can be combined in one to give two major units.
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CHAPTER 3
Machines include
Compressing machine
machine
Charts
Polypropylene glycol(polyol)
Toluene Diisocynate(TDI)
Methyl chloride
Zinc
Silicone
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Colorants
Tin
Amine
Water
below.
1. Pumping of chemicals
machine
5. Cutting
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CHAPTER 4
foam plant machine due to the fact that the process is continuous
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As we said before, the machine is computerized. Hence, the
given conveyor speed and the mixer speed. All these could be
leads to loss and wastage of raw materials. This is the reason why
system.
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CONCLUSION
finished product.
the need for him in a foam manufacturing plant can never be over
alcohol group.
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achieve this, he monitors the product during all phases of
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In conclusion, a foam process plant is purely based on various
chemicals, to the mixing and finally the output (the foam block).
Hence, from this we could see that some unit operations like
chemical process.
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REFERENCE
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APPENDIX
CONVEYOR SPEED……………..…………………………………4.0m/s
MIXER SPEED………………………………………………………..3569rpm
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