ABSTRACT
In the last decade, the Liquid CO2 Technology for manufacturing Flexible Polyurethane Foam (FPF) has evolved from a novel experimental technique to an established widely used process. During this development, both the equipment manufacturers and foam producers refined their knowledge to successfully implement liquid CO2 blowing in low density and soft high-density foam grades. In parallel, additive manufacturers also met the specific challenges required of silicone surfactants in support of this technology [1–4]. Regardless of this progress, some drawbacks still remain. Achieving an optimal cell structure and minimizing the distribution of physical properties within the block are still areas that need some improvement. In response to these targets, Goldschmidt has developed two new silicone surfactants, namely TEGOSTAB® B 8050 and TEGOSTAB® B 8250, that exhibit enhanced properties as compared to established products like TEGOSTAB® BF 2370 and TEGOSTAB® B 8240. This development addresses the full latitude of processing and efficiency characteristics that are needed to cover the growing variety of foam grades made with the Liquid CO2 Process.
The performance of these new silicones has been extensively studied on the liquid CO2 pilot line at Goldschmidt, as well as on industrial Novaflex®, CarDio® and Beamech CO-2™ machines, to prove their broad applicability in all processes.
With enhanced nucleation properties, these surfactants allow to make foams that are consistently finer and more regular in cell structure by compensating for disturbing influences caused by variations in production conditions (machine and climate parameters), as well as differences in raw material quality and sources.
Furthermore, the outstanding efficiency and processing latitude of the new silicone surfactants provides opportunities for cost savings by optimizing use level and reducing top-to-bottom density variations.
