Production Of High Quality Foam
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TABLE OF CONTENT
Title page
Approval page
Dedication
Acknowledgement
Table of content
Abstract
CHAPTER ONE
1.0
Introduction
1.1
Problem statement
1.2
Aims and objectives of the project
CHAPTER TWO
2.0
Literature Review
2.1
Origin of foam
2.2
Structure of polyurethane
2.3
Properties of polyurethane foam
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2.4
Classification of polyurethane
2.5
Flexible foam
2.6
Rigid foam
2.7
Basic chemistry of foam production
2.8
Polyurethane chemicals and functions
2.8.1 Man chemicals
2.8.2 Blowing agents
2.8.3 Catalyst
2.9
Foam stabilizers
2.10 Making / Agitation
2.11 Characteristic features of methyl come chloride
2.12 Some possible faults, causes and their remedies.
2.13 Characteristics of fibre foams
2.14 Physical properties of foam polyurethane
2.15 Thermal properties of polyurethane foams
2.16 Foam fibres applications
2.17 Factors that causes defect during process
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CHAPTER THREE
3.0
Foam formulation
3.1
The roles of chemicals in foaming reactors
3.2
Determination of Chemical consumption rates
3.2.1 Water
3.2.2 Tohiene DI – Isocyate
3.2.3 Blowing Agents
3.2.4 Schlone
3.2.5 Amine
3.2.6 Stannous actuate
3.2.7 Colorant
3.3
Summary of the formulation
CHAPTER FOUR
4.0
Production procedure / Analyses
4.1
Essential Raw Materials Used
4.2
Procedures / methods
4.3
Experimental Results / Analysis
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4.4
General Thermal properties
4.5
Chemical properties
4.6
Optical properties
4.7
Electrical properties
4.8
Permanence and service properties
4.9
Characteristic Test
4.10 Sampling and conditioning
4.11 Storage and Handling of urethane raw materials
CHAPTER FIVE
5.0
Discussion
CHAPTER SIX
6.0
Conclusion
6.1
Recommendation
6.2
Cost Analysis
6.3
References
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CHAPTER ONE
INTRODUCTION
Polyurethane foam otherwise known as expanded polymer products are group
of materials developed as gotten by there action between alcohol with two or
more reactive hydroxyl group per molecule. This branch of polymer
technology is finding increasing applications in many field of engineering
including arts and sciences. Foam was discovered as a result of man’s strong
desire in quest to his environment. There are many kinds of foam based on
their inherent features such as high rigidity, stiffness per unit weight of
polymer thermal and acoustical insulating properties. Cushioning properties or
shock absorbency characteristics, low internal stresses of foamed mouldings
and ease of forming. As a result of these, extensive range of materials and
manufactured articles with different applications are produced from polymer.
The three types of foams are flexible, rigid and semi-rigid foams. It’s used in
many structural applications where they form light weight care. Cellular
products contains gas usually air, within their structures, they have lower
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thermal conductivity and are therefore good thermal insulates. Because foams
able to dissipate energy reversible and storage capacity. They are used in
cushions and are exploited in upholstery bedding laminated clothing and
packaging.
Every polymer can be produced in cellular form but these that have been
extensively
used
includes,
polyurethane,
polystyrene,
polyethylene,
polyethylene, poly- (vinyl chloride), cellulose acetate, phenolies epoxides,
urea-formaldehyde resins, silicones naturally rubber e.g. later from which is
made from liquid starting material; sponge rubber and expanded rubber, both
made from solid materials. Cellular plastics are basically of two types, flexible
foam and rigid or structural foam. They may also be classified according to
density as low density foam (< 100kg/m3), medium density foam (6001000kg/m3).
Cellular polymers may have either an open-cell structure in which the cells are
closed separate units (unicellular foams) and may contain gas or air. Materials
with open-cell structures have high permeability’s to liquid and gases but
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because closed – cell structures contain air, their elastic moduli in compression
are higher and they have the best thermal insulations.
Polyethylene foams can be produced by injection moulding or may be
processed by special machines designed to measure the required ratio of
chemical, mixing them together and dispense the reaction mixture in
predetermined amounts. There has been continuous development of machine
for processing along side the development of polyethylene technology.
Based on the environmental impact and protechona, new dimensions to further
challenges in the development of polyethylene technology has taken place
which have contributed to the increasing application of polyethylene in our
daily lives from foam resistant coating.
As a matter of facts, this research project is centered on flexible foam of higher
density and characterization and different types of polymeric reactions could
produce different materials like plastics rubber, filmos, fire surface coating and
adhesive. As a result of variation in reaction hydroxyl groups of alcohol and
isocyanate, senies of polyethylene products have been produced. This ranges
from flexible soft and revilement material to hard, brittle and rigid.
Generally, four bare isocyanates and a range of polyol of different molecular
weight and functionalities are used in the production of whole spectrum of
polyethylene products/materials.
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As the case may be, various types of foams with different characteristics
features are produced by varying the medium, mixing ratio etc.
1.1
PROBLEM STATEMENT
Based on the fact that some raw materials are gotten from out petrochenueal
industries/chemical industries, these unused materials are property channeled
to effective use in producing polymer materials e.g. foam, such materials are
toluenemdi-isocyanata, polyether, resin, polyol, etc.
1.2
AIMS AND OBJECTIVES OF THE PROJECT
This project/research is aimed at producing polyethylene foam that could be
used or applied in various fields to satisfy human wants in Nigeria particularly
and the world in general.
It is expected that if this research project is successful, a medium-layer scale
industries would be established to best foam production.
Thirdly, an employment opportunity would be created for many Nigerians and
would also bring foreign exchange to the country and also attract foreign
investors to come into Nigeria.
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