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In Flexible Slabstock Foams PFA – Pt Clear AL 2007.

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Presentation on theme: "In Flexible Slabstock Foams PFA – Pt Clear AL 2007."— Presentation transcript:

1 In Flexible Slabstock Foams PFA – Pt Clear AL 2007

2 ecomate ® advantages  A LIQUID Physical Blowing Agent  Patented: US 6,753,357 w others [WP] Pending  To Replace Acetone  ENVIRONMENTALLY BENIGN  ZERO ODP, Negligible GWP, VOC Exempt [US EPA]  Excellent Solubility  Less Hazardous to Use

3 ecomate ® Blowing Agent Properties  Clear, Colorless, Flammable Liquid  Boiling Pt  Flash Point  LEL \ UEL  LAMBDA, gas ( 25 °C)  Vapor Pressure ( 25 °C)  Auto Ignition Temp  Specific Gravity  Molecular Weight 88.7 F31,5 C -26 F-32 C % , psig586 mm >840 F>450 C ,982 60

4 ecomate ® Blowing Agent - Environmental Characteristics  ecomate blowing agent is an attractive long term environmental option ODPGWP VOC CFC NO CFC NO HCFC 141b0.1630NO HCFC NO HCFC NO HCFC 142b NO HFC 134a01300NO HFC 245fa NO Cyclopentane011YES ecomate0negNO

5 Toxicity U.S.EPA HPV Chemical Challenge Program Revised Test Plan for the Formates Category Formic Acid* CAS#: Sodium Formate CAS#: Calcium Formate CAS#: Methyl Formate CAS#: Submitted by: American Chemistry Council Formic Acid and Formates Panel Submitted to: U.S. Environmental Protection Agency Prepared by: Elmer Rauckman, PhD, DABT Toxicology and Regulatory Affairs Freeburg IL May 27, 2003 * Formic Acid is being reviewed as an ICCA chemical and is not formally a HPV chemical.

6 Toxicity  The acute toxicity of all Formate materials is low with NO special hazards  Methyl Formate [MF] is transformed very rapidly into formic acid and methanol in the body with a half-life on the order of several seconds.  Formic Acid is present in many foods (18)  fruit juices ( ppm),  honey ( ppm),  wines ( ppm),  coffee, roasted ( ppm),  coffee, extracts ( ppm),  evaporated milk ( ppm), and  cheese ( ppm) (19). (20). (page 14)  The 4-hour inhalation LC50 of methyl formate was > 21 mg/L  All found negative in the Ames test  No further testing is recommended.

7 Toxicity  The acute toxicity of all Formate materials is low with NO special hazards  Methyl Formate [MF] is transformed very rapidly into formic acid & methanol in the body with a half-life of several seconds.  Formic Acid is present in many foods (18)  fruit juices ( ppm),  honey ( ppm),  wines ( ppm),  coffee, roasted ( ppm),  coffee, extracts ( ppm),  evaporated milk ( ppm), and  cheese ( ppm) (19). (20). (page 14)  The 4-hour inhalation LC50 of MF was > 21 mg/L  All found negative in the Ames test  No further testing is recommended.

8 Effects of Acetone  Long Term Animal Studies  Kidney Damage  Liver Damage  Nerve Damage  Increased Birth Defects  Lowed Reproduction [Males]

9 Use in Foams  Rigid Pour & Spray  Integral Skinned Foams  Flexible

10 Integral Skin

11  ecomate – best alternative to 141b  Solvates all Raws currently used  BPt. just above ambient [like 141b]  Permits good skin formation  Allows fast demold times  Environmentally Benign  Economical – Mol Wt HALF of 141b  US EPA SNAP Approved

12 Flexible Foams Molded & Slab  Good Solubility  Fine Cells  Less Flammable than Hydrocarbons  Non-VOC  Excellent Hand

13 Flexible Foams Molded & Slab EcomateAcetone Mol Wt6058 B Pt, °C LEL, vol% 52.5 UEL, vol% Heat of Vaporization, BTU/Lb PEL, ppm TLV, ppm  Same MW = Same Density  Lower BPt = More Efficient  Lower HtVap = Lower Density  Higher LEL = Lower Hazard  Higher PEL = Lower Hazard  Lower GWP  NO Baggage – Now or Future !

14 Full Scale Trials  2 Seamless Trials  One MDI, one TDI  Both Successes  MDI Trial  Slabstock and Visco-elastic Foam  As Soft or Softer  Reaches ALL density ranges  More Economical

15 TDI SLAB TRIAL  Pre-Trial Methodology  Visitation  Determine Current BA Handling & Exhaust  Consultation - Storage, Transfer, Use  Safely w/o significant changes or expense  Calculation – Max Emissions = 0.27vol%  Set Up - Fully Engineered, work with local Fire Marshall  Inspection - line monitored during run

16 TDI Trials  Two Systems  System X  High Ecomate loading ~ 4.8% of system  Low Density = 0.90 pcf  System Y  Lower Ecomate Loading ~ 1% of system  Higher Thru-put  Low density = 0.95 pcf

17 Ecomate Monitoring TDI Flex SlabstockSYSTEM X SYSTEM Y Foam Thruput, lbs/min Ecomate Thruput, lbs/min Run Time, min Density, pcf Trough [% of LEL] 2%1% Blow-off [% of LEL] 1% Side rollers [% of LEL] 1%0% Cut-off saw [% of LEL] 2%0%

18 Trial Foams Y X

19 CONCLUSIONS  INTEGRAL SKIN  ecomate - a perfect fit  solubility,  ideal BPt,  Lo MW,  environmentally benign  SLABSTOCK  All the Above  Less Hazardous than Acetone

20 ecomate ® advantages  A True LIQUID Blowing Agent  Good Solubility  Good Foam Properties  Less Hazardous to USE  Cost Competitive  BENIGN to ENVIRONMENT  No Future Baggage!

21 The Next Generation Blowing Agent


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