Technology

September 28, 2017

PFA Papers

Polyurethane Foam Association Sets Technical Presentations For November 2017 Meeting

LOUDON, TN (September 26, 2017)— The Polyurethane Foam Association has finalized its slate of presentations for its fall Technical Program, to be held in conjunction with its annual Fall meeting, October 31-November 2, at the Wyndham Bayside Hotel in San Diego, CA.

Following are abstracts for the presentations to be made during the Technical Program on November 2:

Introducing SlabProcessing and SlabExpert Digital Tools
Covestro LLC
Presenter: Stephen Hoskins

This paper introduces Covestro i4ptO™ 24/7 online digital services to support flexible polyurethane foam R&D and manufacturing initiatives. Under the i4ptO™ “umbrella,” SlabExpert software allows slabstock foamers to more efficiently and effectively formulate using Covestro raw materials, while SlabProcessing provides a custom-service that helps slab manufacturers more effectively collect, monitor and compare production data and processes.  Covestro digital tools serve as self-technical service improvement opportunities that interpret thousands of data points to provide new, precise perspectives to the development and processing of slab foam. Through the creation of cloud-based, low-cost, flexible, and scalable products, we are excited to introduce these tools to support the slabstock foam industry.

Flammability Standards for Upholstered Furnishings and Vehicles: Past, Present, and Future
Fire Science and Technology Inc.
Presenter: Vytenis Babrauska

 

Since the 1970s, flammability standards for furnishings and vehicle interiors have led to use of flame retardants (FRs) in FPF. Research continues to demonstrate exposures and health risks from the use of FRs. Despite recent progress in California, voluntary standards organizations (VSOs) continue to work towards new flammability requirements for furniture; and federal motor vehicle flammability requirements remain and are outdated. Europe currently does not have a unified flammability requirement for residential upholstered furniture; however, a petition was filed in 2016 asking the E.U. government to consider a mandatory smolder standard for European furniture based on TB117-2013. This presentation will demonstrate that the most effective way to reduce harm from flame retardants is to improve flammability standards. To enhance fire safety, benign strategies should be considered that have a proven track record of success and do not lead to widespread exposures to hazardous chemicals. These include improvements in smoke alarm technology, wider introduction of automatic fire sprinklers, and enhanced public education efforts.

Vertifoam Variable Pressure Foaming, VPF-V: Full-scale Production Insights
OPUS Technical Ltd
Presenter: Brian Blackwell

The Vertifoam Variable Pressure Foaming Machine, VPF-V, is now in full commercial production. This paper gives insights into the operation of the VPF-V process and shows how the VPF-V equipment and process have been developed and refined to produce highly successful new foam that has opened up new profitable markets for the PU foam industry. The paper explains how a number of both formulation and equipment developments have given improved cell structure and bun yields. It explains how a unique high pressure technology has been applied to the process giving multiple advantages, and how a brand new technique was employed to allow extended runs (over 5 hours) of highly reactive formulations without the problems normally associated with build-up. Formulation savings will be explained, as well as the efficiency of peeling large diameter, near perfect round buns, to produce a new range of foams that can outperform polyester fiber in both cost and performance for bedding and furniture applications.

Case Study in TDI Detection Using IMS Instruments in Foam Plants
Bruker Detection Corporation
Presenter: Frank Thibodeau

Ion Mobility Spectrometry (IMS) is a scientific technique of measuring ions across a uniform electric field. It is based on the principle that when different charged molecules (ions) are accelerated through an electric field (with a “drift flow” of gas slightly opposing them); they will travel at different speeds and reach a detector at different times. The advantages of IMS instruments are: designed in relatively small packages, fairly inexpensive, rugged, extremely fast and extremely sensitive.   The effectiveness of the IMS technology has been assessed in numerous foam plants under field conditions.   TDI was monitored in foam plants which produced automotive and slab products.  A handheld IMS instrument surveyed in and around production lines, hot & cold foam, storage tanks, transfer lines, and transfer operations.   The IMS instrument was programmed with a TDI library fixed to detect and alarm at or below 1 ppb.  Spectra were also collected at various locations at all foam plants for more detailed post analysis.  Findings, lessons learned and conclusions will be discussed in the technical paper and presentation.

Antimicrobial Treatment of Polyurethane Foams
Lonza Microbial Control
Presenter: Tom Robitaille

The use of antimicrobials in polyurethane foam applications continues to grow as the number of antimicrobial options continue to shrink. End-users and component manufacturers are specifying very rigorous performance characteristics.  Identifying the right antimicrobial product can be a daunting task. There are many factors to consider when identifying the best antimicrobial product and loading. The EPA only allows certain registered products to be used in specific applications and substrates; these regulations should be understood. Characterization of possible reactivity changes must also be understood as well as the impact on air flow and cell size. Depending on the physical nature of the antimicrobial product to be used, solid dispersion or liquid, and viscosity, processes used to add and pump the antimicrobial into the foam should be reviewed. The intent of this paper will be to educate those that may be considering the addition of an antimicrobial for the first time or maybe considering switching to a different antimicrobial product. This paper can serve as a guide for consideration as you prepare to make the change to an antimicrobially treated polyurethane foam.

Why Is An Ultra-Open-Cell-Window Structure Important For Cooler Sleep In Memory Foam Mattresses?
The Dow Chemical Company
Presenter: Wenbo Xu

Viscoelastic memory foams are widely used as an important material for mattress constructions, due to their pressure relieving capability.  A characteristic of memory foam mattresses early on has been that they can “sleep hot” as described by a mattress OEM in patent literature.  A new ultra-high air flow memory foam technology was introduced in 2016.  Simulation and materials testing capabilities at Dow Chemical were used to evaluate the various materials and their contribution to cooling effects: gas convection, gas/solid conduction, and gas diffusivity.  The simulations are multiphysical in nature, taking into account thermal & mass transfer, and feedback loop from human body via the ASHRAE Human Comfort model.  The same simulation capabilities are able to support the development of new generation of foam material that improve on thermal comfort.

Registration for the meeting is open, with a discounted room rate cutoff date of October 9. To register, visit www.pfa.org.

Because the program includes at least six technical papers, the presentations will be scored to compete for a $500 Technical Excellence Award provided by the Herman Stone Family Endowment.

September 28, 2017

PFA Papers

Polyurethane Foam Association Sets Technical Presentations For November 2017 Meeting

LOUDON, TN (September 26, 2017)— The Polyurethane Foam Association has finalized its slate of presentations for its fall Technical Program, to be held in conjunction with its annual Fall meeting, October 31-November 2, at the Wyndham Bayside Hotel in San Diego, CA.

Following are abstracts for the presentations to be made during the Technical Program on November 2:

Introducing SlabProcessing and SlabExpert Digital Tools
Covestro LLC
Presenter: Stephen Hoskins

This paper introduces Covestro i4ptO™ 24/7 online digital services to support flexible polyurethane foam R&D and manufacturing initiatives. Under the i4ptO™ “umbrella,” SlabExpert software allows slabstock foamers to more efficiently and effectively formulate using Covestro raw materials, while SlabProcessing provides a custom-service that helps slab manufacturers more effectively collect, monitor and compare production data and processes.  Covestro digital tools serve as self-technical service improvement opportunities that interpret thousands of data points to provide new, precise perspectives to the development and processing of slab foam. Through the creation of cloud-based, low-cost, flexible, and scalable products, we are excited to introduce these tools to support the slabstock foam industry.

Flammability Standards for Upholstered Furnishings and Vehicles: Past, Present, and Future
Fire Science and Technology Inc.
Presenter: Vytenis Babrauska

 

Since the 1970s, flammability standards for furnishings and vehicle interiors have led to use of flame retardants (FRs) in FPF. Research continues to demonstrate exposures and health risks from the use of FRs. Despite recent progress in California, voluntary standards organizations (VSOs) continue to work towards new flammability requirements for furniture; and federal motor vehicle flammability requirements remain and are outdated. Europe currently does not have a unified flammability requirement for residential upholstered furniture; however, a petition was filed in 2016 asking the E.U. government to consider a mandatory smolder standard for European furniture based on TB117-2013. This presentation will demonstrate that the most effective way to reduce harm from flame retardants is to improve flammability standards. To enhance fire safety, benign strategies should be considered that have a proven track record of success and do not lead to widespread exposures to hazardous chemicals. These include improvements in smoke alarm technology, wider introduction of automatic fire sprinklers, and enhanced public education efforts.

Vertifoam Variable Pressure Foaming, VPF-V: Full-scale Production Insights
OPUS Technical Ltd
Presenter: Brian Blackwell

The Vertifoam Variable Pressure Foaming Machine, VPF-V, is now in full commercial production. This paper gives insights into the operation of the VPF-V process and shows how the VPF-V equipment and process have been developed and refined to produce highly successful new foam that has opened up new profitable markets for the PU foam industry. The paper explains how a number of both formulation and equipment developments have given improved cell structure and bun yields. It explains how a unique high pressure technology has been applied to the process giving multiple advantages, and how a brand new technique was employed to allow extended runs (over 5 hours) of highly reactive formulations without the problems normally associated with build-up. Formulation savings will be explained, as well as the efficiency of peeling large diameter, near perfect round buns, to produce a new range of foams that can outperform polyester fiber in both cost and performance for bedding and furniture applications.

Case Study in TDI Detection Using IMS Instruments in Foam Plants
Bruker Detection Corporation
Presenter: Frank Thibodeau

Ion Mobility Spectrometry (IMS) is a scientific technique of measuring ions across a uniform electric field. It is based on the principle that when different charged molecules (ions) are accelerated through an electric field (with a “drift flow” of gas slightly opposing them); they will travel at different speeds and reach a detector at different times. The advantages of IMS instruments are: designed in relatively small packages, fairly inexpensive, rugged, extremely fast and extremely sensitive.   The effectiveness of the IMS technology has been assessed in numerous foam plants under field conditions.   TDI was monitored in foam plants which produced automotive and slab products.  A handheld IMS instrument surveyed in and around production lines, hot & cold foam, storage tanks, transfer lines, and transfer operations.   The IMS instrument was programmed with a TDI library fixed to detect and alarm at or below 1 ppb.  Spectra were also collected at various locations at all foam plants for more detailed post analysis.  Findings, lessons learned and conclusions will be discussed in the technical paper and presentation.

Antimicrobial Treatment of Polyurethane Foams
Lonza Microbial Control
Presenter: Tom Robitaille

The use of antimicrobials in polyurethane foam applications continues to grow as the number of antimicrobial options continue to shrink. End-users and component manufacturers are specifying very rigorous performance characteristics.  Identifying the right antimicrobial product can be a daunting task. There are many factors to consider when identifying the best antimicrobial product and loading. The EPA only allows certain registered products to be used in specific applications and substrates; these regulations should be understood. Characterization of possible reactivity changes must also be understood as well as the impact on air flow and cell size. Depending on the physical nature of the antimicrobial product to be used, solid dispersion or liquid, and viscosity, processes used to add and pump the antimicrobial into the foam should be reviewed. The intent of this paper will be to educate those that may be considering the addition of an antimicrobial for the first time or maybe considering switching to a different antimicrobial product. This paper can serve as a guide for consideration as you prepare to make the change to an antimicrobially treated polyurethane foam.

Why Is An Ultra-Open-Cell-Window Structure Important For Cooler Sleep In Memory Foam Mattresses?
The Dow Chemical Company
Presenter: Wenbo Xu

Viscoelastic memory foams are widely used as an important material for mattress constructions, due to their pressure relieving capability.  A characteristic of memory foam mattresses early on has been that they can “sleep hot” as described by a mattress OEM in patent literature.  A new ultra-high air flow memory foam technology was introduced in 2016.  Simulation and materials testing capabilities at Dow Chemical were used to evaluate the various materials and their contribution to cooling effects: gas convection, gas/solid conduction, and gas diffusivity.  The simulations are multiphysical in nature, taking into account thermal & mass transfer, and feedback loop from human body via the ASHRAE Human Comfort model.  The same simulation capabilities are able to support the development of new generation of foam material that improve on thermal comfort.

Registration for the meeting is open, with a discounted room rate cutoff date of October 9. To register, visit www.pfa.org.

Because the program includes at least six technical papers, the presentations will be scored to compete for a $500 Technical Excellence Award provided by the Herman Stone Family Endowment.

September 22, 2017

BASF and Brooks Create PU Cushioned Running Shoe

BASF polyurethane powers high energy return in new Brooks Levitate running shoes

New DNA AMP midsole using BASF technology delivers high energy return for leading performance running shoes

Polyurethane cushioning system is tailor-made for Brooks Running

null

WYANDOTTE, MI, September 20, 2017 – BASF’s polyurethane-based cushioning system is powering the latest innovation for runners with the launch of the all-new Brooks Levitate with DNA AMP performance running shoe available starting September 30.

Based on seven years of run research and in partnership with BASF, the Brooks Levitate is the first to feature the DNA AMP midsole, which is made from a new blend of BASF’s Elastopan® Sports Light material. By refining the formula and making modifications to polyurethane on a molecular level, the DNA AMP midsole offers enhanced comfort and durability and provides runners 72 percent of energy return for every foot-pound of force (per Brooks‘ test method).

“Brooks Running is widely recognized as a leader in performance running shoes,” said Chau Nguyen, footwear market manager for BASF in North America. “Through our partnership to develop the all-new Levitate, BASF used its performance materials expertise to create a polyurethane midsole that is tailor-made for Brooks.”

This new cushioning material expands under the runner’s foot, returning more energy as force is applied; leading to less energy expended during a run. In addition, compared to traditional midsole materials such as ethylene-vinyl-acetate, BASF’s high performance polyurethane formulations improve the compression set effectiveness – the ability of the midsole to retain its original thickness – providing lasting wear and functionality during the life of the shoe.

“We are seeing two key trends within the athletic shoe market: consumer demand for lightweight, comfortable and durable shoes and increased focus on automating the footwear production process,” said Nguyen. “The result is renewed interest in and use of high performance polyurethane for athletic shoes.”

For more than forty years, footwear manufacturers have relied on BASF’s material expertise and innovations in custom-tailored polyurethane systems and thermoplastic polyurethane elastomers for making all types of soles. As consumers continue to seek high-quality products that can improve their experience, BASF collaborates directly with leading brands throughout the entire development process, enhancing existing technologies or developing new technologies to meet performance demands.

“The Brooks Levitate with DNA AMP is engineered from the ground up to deliver runners an infinitely energetic experience,” said Zach Boteilho, senior innovation developer at Brooks Running. “We are excited to partner with BASF to bring to life the revolutionary new DNA AMP midsole technology that releases energy straight back to the runner, making the experience so fun they can run forever.”

https://www.basf.com/us/en/company/news-and-media/news-releases/2017/09/P-US-17-098.html

September 22, 2017

BASF and Brooks Create PU Cushioned Running Shoe

BASF polyurethane powers high energy return in new Brooks Levitate running shoes

New DNA AMP midsole using BASF technology delivers high energy return for leading performance running shoes

Polyurethane cushioning system is tailor-made for Brooks Running

null

WYANDOTTE, MI, September 20, 2017 – BASF’s polyurethane-based cushioning system is powering the latest innovation for runners with the launch of the all-new Brooks Levitate with DNA AMP performance running shoe available starting September 30.

Based on seven years of run research and in partnership with BASF, the Brooks Levitate is the first to feature the DNA AMP midsole, which is made from a new blend of BASF’s Elastopan® Sports Light material. By refining the formula and making modifications to polyurethane on a molecular level, the DNA AMP midsole offers enhanced comfort and durability and provides runners 72 percent of energy return for every foot-pound of force (per Brooks‘ test method).

“Brooks Running is widely recognized as a leader in performance running shoes,” said Chau Nguyen, footwear market manager for BASF in North America. “Through our partnership to develop the all-new Levitate, BASF used its performance materials expertise to create a polyurethane midsole that is tailor-made for Brooks.”

This new cushioning material expands under the runner’s foot, returning more energy as force is applied; leading to less energy expended during a run. In addition, compared to traditional midsole materials such as ethylene-vinyl-acetate, BASF’s high performance polyurethane formulations improve the compression set effectiveness – the ability of the midsole to retain its original thickness – providing lasting wear and functionality during the life of the shoe.

“We are seeing two key trends within the athletic shoe market: consumer demand for lightweight, comfortable and durable shoes and increased focus on automating the footwear production process,” said Nguyen. “The result is renewed interest in and use of high performance polyurethane for athletic shoes.”

For more than forty years, footwear manufacturers have relied on BASF’s material expertise and innovations in custom-tailored polyurethane systems and thermoplastic polyurethane elastomers for making all types of soles. As consumers continue to seek high-quality products that can improve their experience, BASF collaborates directly with leading brands throughout the entire development process, enhancing existing technologies or developing new technologies to meet performance demands.

“The Brooks Levitate with DNA AMP is engineered from the ground up to deliver runners an infinitely energetic experience,” said Zach Boteilho, senior innovation developer at Brooks Running. “We are excited to partner with BASF to bring to life the revolutionary new DNA AMP midsole technology that releases energy straight back to the runner, making the experience so fun they can run forever.”

https://www.basf.com/us/en/company/news-and-media/news-releases/2017/09/P-US-17-098.html

August 29, 2017

Polyurethane Football Helmet Shell

Ex-New York Jets Lineman Looks To Make Game Safer With Helmet Tech

NCAA Football, Sports Science August 29, 2017August 29, 2017 Max Rettig

In December 2015, Will Smith took to the big screen to play a forensic pathologist who took on the NFL about traumatic brain injuries and subsequent diseases, especially chronic traumatic encephalopathy. At the same time, a product was in development that now is poised to reduce the chance of these brain injuries.

That product, ProTech, is a shell that can be attached to a variety of football helmets, primarily those models produced by Riddell and Schutt. Created by Defend Your Head, a Pennsylvania-based company founded by two former football players, John Roman and Glenn Tilley, the ProTech shell is designed to absorb and redistribute the impact of a hit to the head. The two joined forces over a shared desire to make football safer.

The shell is made of a polyurethane foam, as opposed to the polycarbonate material used to make helmets. This design aligns with proven science that a soft object, when impacted by a harder object, diffuses kinetic energy. ProTech’s polyurethane composition also means that it is slicker than a normal helmet, preventing dangerous blows from the side from having greater impact with the head. The shell moves over the helmet as it is impacted to deflect hits away from the head.

“We’re making a difference, and that’s what’s driven all of us to come together,” Roman, who was an offensive lineman for the New York Jets, told SportTechie. “We’re seeing evidence and feedback from players in the field that our product has the ability to reduce helmet collision force.”

 

Such evidence can be found at Holy Cross in Massachusetts. In May, the college’s athletic department moved to continue a two-year relationship with Defend Your Head after seeing the effectiveness of ProTech on its football team’s safety. Holy Cross was one of ProTech’s first users, and has since recommended the product to other teams in the Patriot League.

“At Holy Cross we are always looking for ways to improve the student-athlete experience,” Holy Cross athletic director Nathan Pine said in a statement. “ProTech has helped us do that by providing a safer environment for our student-athletes in the sport of football—which is important because that improves their experience not only on the gridiron but also in the classroom.”

According to Tilley, ProTech will be widely used this fall among youth, high school, and college football markets in an approach that seeks to gain feedback and traction to break into the NFL. Currently, Defend Your Head is in talks with the NFL, and certain players have come to the company to ask about using ProTech, Tilley said.

Currently, ProTech is used by players at Western Carolina University and, for the second season in a row, Penn State, where ProTech’s presence has grown from 10 players to about 40, according to Roman. It is also present at other schools as well. Defend Your Head is now in its third year of getting feedback and talking with coaches, equipment managers and trainers at a number of college football programs.

“This year, we’ve taken a little bit more of an aggressive step, and I think we’re in a good place to speak from substance, to say that we’re now out there,” Tilley said. “We’re on the field at different levels, and we’re doing our part to help make the game safer— and that feels very good.”

Down the line, Roman sees opportunities to partner with the major helmet manufacturers. Roman said that one undisclosed helmet maker has already approached Defend Your Head. Eventually, when teams order helmets, ProTech could very well be included as standard safety technology.

“Having played the game professionally for over a decade I have seen the damage that can be done first hand,” Roman said in a statement after research was published showing 110 of 111 deceased former NFL players who had their brains examined were shown to have CTE. “My post-football life has been spent addressing the issue of head trauma in football, which is what compelled me to establish Defend Your Head. We have made great progress in our effort to make the game safer for football players of all ages as evidenced by over 100 organizations utilizing our technology nationwide this year, but more work needs to be done.”

https://www.sporttechie.com/new-york-jets-lineman-helmet-technology/