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Use of Uoropolymer Permanent Release Coatings For Molded Polyurethane Foam Production
Use of Uoropolymer Permanent Release Coatings For Molded Polyurethane Foam Production
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Abstract The problem of adhesion of polyurethane ties, with major applications as coatings, adhesives,
foams to fluoropolymer permanent release mold coatings elastomers, and foams. Typically, they are produced by
was studied. Two coatings, based on polytetrafluoroeth- polycondensation of polyisocyanates with polyalco-
ylene (PTFE) and perfluoroalkoxy polymer (PFA) aque- hols. In the case of PUR foam production, water reacts
ous dispersions, respectively, were applied on aluminum with isocyanate, forming carbamic acid which decom-
plates, and the foam release performance evaluated. The poses to an amine and carbon dioxide which acts as the
PTFE coating displayed gradual loss of antiadhesion foam blowing agent. The amine then reacts with excess
properties with consecutive exposure to the reactive isocyanate resulting in the formation of ureas.
mixture, which was associated with isocyanate surface Flexible foam parts are manufactured industrially in
penetration. Penetrant mass uptake experiments, per- a batch molding process. The reactive components are
formed on free films, indicated that PTFE retains about 10 premixed with catalysts, foam stabilizers, reinforcing
times more isocyanate than PFA, probably because of its agents, and others additives, and then poured into a
porous surface morphology. A synergistic effect was heated aluminum mold. The mold is then closed,
found by applying a very small quantity of a waterborne allowing for foam expansion and cure of the reactive
release agent on the PTFE coating, before every foam mixture. At the end of this step, the molded part is
molding cycle. The release agent formed a protective removed and allowed to cool down.
barrier that minimized contact of the coating with the Permanent release coatings are used in several
reactive mixture, allowing for stable and robust foam industrial molding applications, ranging from food to
release performance. The problem of polyurea build-up, epoxy part manufacture. Fluoropolymers are the most
associated with the use of aqueous release agents, was not common choice for these coatings, since the very low
observed because of the small amounts of compound used. surface energies result in excellent antiadhesion prop-
erties.1–3 However, it is well known in the industry that
Keywords Fluoropolymer coating, Mold release, with PUR-molded foam production, this type of
Polyurethane foam, Isocyanate approach leads to poor results. The permanent coat-
ings tend to lose nonstick performance after relatively
few cycles, causing the foam to tear when removed
Introduction from the mold. The need for short-term coating
replacement is economically unfeasible. For this
Polyurethanes (PURs) include a very extensive group reason, the molded PUR foam industry continues to
of polymers with different compositions and proper- use liquid release agents applied directly to the
uncoated aluminum mold surface in generous quanti-
L. Figueiredo, A. Mendes, M. M. S. M. Bastos, ties.4 These are usually aqueous dispersions typically
F. D. Magalhães (&) composed of tin or amine accelerants, siloxane-based
LEPAE—Departamento de Engenharia Quı́mica, foam stabilizers, polyethylene waxes, and polybutadi-
Faculdade de Engenharia, Universidade do Porto, ene.5 The water present in the release agent is slow to
Rua Dr. Roberto Frias, 4200-465 Porto, Portugal evaporate and, owing to the short cycle times used in
e-mail: fdmagalh@fe.up.pt industrial production, a residue persists when the
reactive mixture is poured into the mold. This residual
P. Bandeira
water reacts with isocyanate producing polyureas that
Flupol, Rua da Central, 401, 4440-043 Campo, Portugal
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J. Coat. Technol. Res., 9 (6) 757–764, 2012
Experimental
Materials
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J. Coat. Technol. Res., 9 (6) 757–764, 2012
FTIR spectroscopy
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J. Coat. Technol. Res., 9 (6) 757–764, 2012
were measured at 60C. Zero uptake was found for antiadhesive performance of this coating along the
polyol, as was expected from its large molecular size. molding cycles, as will be discussed later.
On the other hand, MDI originates measurable uptake, Note that when testing an aluminum plate with no
especially on PTFE, as seen in Fig. 5. After less than applied coating or release agent, the release force
5 h of contact, the penetrant mass uptake for PTFE exceeded the measurement limit of the dynamometer.
rises above 1.5% and then tends to stabilize. On PFA, In addition, a complete removal implied destruction of
uptake increases steadily but at a much slower rate, the foam surface, as some portions still remained
reaching about 0.1% after 60 h of contact. The much adhered to the plate.
higher measurement reproducibility obtained with The results obtained for the PTFE coating are
PFA is probably a consequence of the surface homo- shown in Fig. 7 in terms of maximum release force and
geneity in comparison with PTFE. Values of penetrant release work (area under the force vs distance curve)
mass uptake up to 0.7% have been measured by Park measured after each cycle. Two different situations are
and coworkers for PFA in contact with benzene and compared: with and without post-cure contact time. In
dichloromethane.8 the first case, the plates were left in contact with the
The porous structure of the PTFE coating is the foam for 20 min after removal from the oven, while in
probable cause of the significantly higher MDI pene- the second, the plates were peeled off immediately at
tration observed. The results obtained by Akinci and the end of the oven curing step. In both cases, the
Cobanoglu,9 reporting about 13% decrease in water release force and the release work are seen to increase
contact angle after contacting a PTFE coating with steadily with the number of cycles, denoting a cumu-
isocyanate, and only 1% decrease for a PFA coating, lative degradation of the coating performance. In
are probably a repercussion of this same effect. addition, the values are always higher for the plates
that were detached earlier. This is due to the cure
being incomplete, with the foam still presenting signif-
Foam release performance of PTFE icant tackiness. In industrial production, in-mold cur-
and PFA coatings ing cycles are allowed for only a few minutes, and the
foam is removed immediately afterward. Therefore, in
The force required for detaching the coated plates order to test the coatings performances under the most
from the foam was measured with a digital force gauge. stringent conditions, all the subsequent measurements
Figure 6 shows an example of the force vs linear were performed immediately after removal from the
displacement for the release of a PTFE-coated plate oven. To avoid redundancy, in the remainder of the
after an increasing number of molding cycles. It is article, the plate release results are presented only in
evident that, in this case, the release is increasingly terms of release work, since the maximum force values
difficult, both in terms of maximum force necessary always show an equivalent evolution along the number
and duration of adhesion until full release is attained. of cycles.
This illustrates the successive degradation of the Figure 8 compares the release performance of the
PTFE and PFA coatings, along the same number of
cycles. Unlike PTFE, PFA shows an apparently stable
3 behavior, with the measured values being always
PTFE 0.9
0.8
Penetrant mass uptake/%
2 20
0.7
15
0.6
0.5 10
F /kgf
0.4
1 6
0.3
1
PFA 0.2
0.1
0
0 10 20 30 40 50 60 0
t /h 0 1 2 3 4
Linear displacement/cm
Fig. 5: Penetrant mass uptake, defined as percent weight
increase, for PFA and PTFE films in contact with MDI at Fig. 6: Example of release force vs linear displacement for
60°C. The bars represent 95% confidence intervals. The detachment of a plate coated with PTFE. The number on
high reproducibility for results with PFA originated very each curve indicates the number of foam molding cycles
short bars that are hardly visible in the plot that the plate has been subjected to
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J. Coat. Technol. Res., 9 (6) 757–764, 2012
(a) 0.18
1.2
0.16
1 0.14
0.12
0.8
W /N m
0.1
F /kgf
0.6 0.08
0.06
0.4
0.04
0.2 0.02
0
0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Cycle
Cycle
Fig. 8: Release work along consecutive foam molding
(b) 0.18 cycles for plates coated with PTFE (triangles) and PFA
0.16 (empty squares)
0.14
0.1
performance degradation with PFA. This will probably
0.08 be a slower process than for PTFE, due to the lower
0.06
tendency for isocyanate penetration, as shown in the
penetrant mass uptake measurements. This issue was
0.04 not analyzed further, since the rest of the study was not
0.02 focused on the use of PFA coatings.
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Cycle Performance of PTFE coating combined
with release agent
Fig. 7: Evolution of (a) maximum release force and
(b) release work along consecutive foam molding cycles Except for the observed degradation in antiadhesion
for plates coated with PTFE. Plates were detached imme-
performance, other known properties of the PTFE
diately after the end of foam cure (triangles) or 20 min after
the end of foam cure (empty squares). The points represent coating used in this study, like abrasion resistance,
the average of measurements performed on four plates. make it an appropriate choice for demanding industrial
The bars represent 95% confidence intervals applications. Therefore, the viability of its use as a
foam release coating was investigated further.
The PUR foam industry uses waterborne or solvent-
based release agents applied directly on the uncoated
significantly lower than for the other coating. The aluminum mold surface to provide, upon water evap-
steady increase in release work measured for PTFE oration, an antiadhesion wax layer. Release agents are
indicates the presence of a cumulative phenomenon. formulated so as not to interfere with the physico-
We suggest that the cumulative penetration of MDI on chemical foam expansion/cure process, allowing for the
the PTFE film, much higher than on PFA as discussed formation of a uniform foam surface. However, the
previously, contributes to the observed degradation of large quantities needed for efficient foam release imply
antiadhesion performance. The retention of this highly significant cleaning, maintenance, and residue disposal
reactive substance in the coating potentiates the costs. In the remainder of the study, the synergistic
adhesion of polyol molecules to the surface in combination of low amounts of aqueous release agent
subsequent foam formations, thereby counteracting with the PTFE coating was investigated.
the coating’s antiadhesion properties. It must be noted A value of 20 g/m2 of release agent per area of mold
that SEM images of the plate surfaces after 20 molding was assumed as representative of the value typically
cycles (not shown here) did not show foam residues used in industry on uncoated molds. Successively lower
adhered to it or any evidence of morphologic changes amounts were tested in combination with the PTFE
in the coating. coating. Figure 9 shows the results when the amounts
It must be noted that apparently good results of release agent applied, before each molding cycle, are
obtained with PFA may be deceptive, as it is known 12% and 25% of the reference value. The performance
in the industry that this type of coating also ends up of the PTFE plates with release agent is consistently
adhering to PUR foams after a certain number of better than that of the bare PTFE plates. There is
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J. Coat. Technol. Res., 9 (6) 757–764, 2012
actually a slight initial decrease in the maximum 25% release agent. A continuous film now covers the
release force and work, as the release agent accumu- surface (Fig. 12a). At some points, the film can be seen
lates along the first applications. There is no difference to be broken (Fig. 12b). This release agent residue
in the results for 12% or 25% dosages. The measure- could be easily removed with a sponge and a household
ment reproducibility in each cycle improved signifi- detergent, as long as the mold surface was kept warm
cantly in both cases. It must be noted that if a 12% (50–60C).
dosage is applied to an uncoated aluminum plate, the FTIR analyses were performed to study the nature
foam adheres very strongly right after the first cycle, of the residual film. Three samples were analyzed: the
and its surface is destroyed when detachment is original PTFE coating, the residue obtained after
attempted. This suggests that PTFE is playing a drying the release agent in an oven for 2 days, and
decisive part in the demolding process, working syner- the PTFE-coated plate surface after 20 molding cycles.
gistically with the release agent. The latter acts as a The FTIR spectra obtained are shown in Fig. 13. The
protective barrier that reduces contact between the
reaction mixture and the PTFE coating, therefore
0.06
preserving its performance along several cycles. The
release agent forms both as a physical barrier to
isocyanate penetration into the coating, and as a 0.05
chemical barrier, since its formulation contains a
catalyst that accelerates isocyanate consumption when 0.04
reacting with polyol at the interface between foam and
W /N m
release film. 0.03
Another test was performed in which the release
agent was not applied before every molding cycle.
0.02
Figure 10 shows the obtained results. After the first
application, the release work increases steadily, but
decreases again every time the release agent is reap- 0.01
plied. The release agent residue that remains on the
surface wears out after a short number of cycles and 0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
has to be replenished to maintain low adhesion of the
Cycle
surface. The performance of the coating does not seem
to be irreversibly damaged by these periods of Fig. 10: Release work along consecutive foam molding
‘‘unprotected’’ operation. cycles for plates coated with PTFE. The arrows indicate the
SEM analysis of the surface of a PTFE coating after only three times when release agent was applied, with a
a single application of 25% release agent, before each 12% dosage relative to the reference amount of 20 g/m2
molding cycle, as seen in Fig. 11, shows that a uniform
film has not yet been formed. The release agent forms
scattered drops on the surface. Figure 12, on the other
hand, shows the surface of a PTFE-coated plate that
has undergone 20 molding cycles with application of
0.12
0.1
0.08
W /N m
0.06
0.04
0.02
0
0 1 2 3 4 5 6 7 8 9 10 11
Cycle
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J. Coat. Technol. Res., 9 (6) 757–764, 2012
Fig. 12: SEM images of the surface of a PTFE coating with the application of 25% release agent throughout 20 molding
cycles, with magnifications of (a) 3000 and (b) 100 times
PTFE
RA
Plate
%T
4000,0 3600 3200 2800 2400 2000 1800 1600 1400 1200 1000 800 650
cm–1
Fig. 13: FTIR spectra of the original coating (PTFE), release agent dry residue (RA) and coated plate surface after 20
molding cycles with release agent applied (Plate)
spectrum obtained for the plate surface shows the stretching vibration does not match the characteristic
presence of release agent, as expected, with bands at wavenumber for C=O group on PUR, which should
966 and 911 cm 1, corresponding to (C–H) out-of-plane appear in the range of 1730–1740 cm 1 (free C=O) or
deformation vibration on CH=CH2 and CH=CH 1703–1710 cm 1 (C=OÆÆÆNH).10,11 These bands indicate
polybutadiene units, respectively, and in the the presence of polyureas in the residue film. These are
2850–3000 cm 1 region, corresponding to (C–H) known to be formed by reaction of MDI with the
stretching vibration on CH2 and CH3 groups present in relatively large amount of water present in the release
polybutadiene and waxes. Note that polybutadiene is agent formulation. Polyureas present a serious problem
commonly present in release agent formulations.4 for the conventional PUR-molded foam industry. They
However, other relevant peaks are visible on the plate tend to adhere strongly to the aluminum mold surface,
surface and not on the release agent residue. The creating hard deposits that have to be removed daily by
presence of C=O and N–H groups is indicated by bands manual scraping or using abrasive processes, in a time-
at 1648 and 3315 cm 1, respectively. This value of C=O consuming operation. However, since a much lower
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J. Coat. Technol. Res., 9 (6) 757–764, 2012
amount to release agent is being used in the current deposit. This is easily removed if the surface is warm
approach, the polyureas are expected to form in much enough to soften the film.
lower quantities, becoming incorporated in the release If a solvent-based release agent were used in com-
agent residues and being easily removable. bination with the PTFE coating, instead of an aqueous
Further tests were performed with a Flucoat X32- product, then a similar synergistic effect is anticipated.
coated mold (without release plates) exposed to 100 Even though some degree of solvent penetration in the
molding cycles (typical for a one day work in an industrial coating would be a possibility, it should not present a
production line), with 12% release agent application problem, since the nonreactive solvent does not pro-
before each cycle. Foam release, although not quantified, mote foam adhesion. Formation of a protective barrier
was facile throughout all cycles, and the foam’s surface should again be the decisive factor in preserving the
remained uniform, with no signs of damage associated coating along repeated production cycles.
with detachment from the mold. The film deposit at the
end of the 100 cycles was easily removed by washing the Acknowledgments This study was partly funded by
heated mold with a sponge. Only a few hard residues the Agência de Inovação (project Vale Inovação ref.
remained in the corners of the mold, which were removed 3762). The authors are thankful to Grupo Copo for
by scraping without difficulty. These results validated the supplying raw materials for PUR foam production and
proposed synergistic combination of the PTFE coating a production mold, as well as facilitating the necessary
with a small amount of release agent. industrial validation tests. An expression of our
gratitude is due especially to Arturo González and
Alejandro Plaza, from Grupo Copo, for their useful
Conclusions insights and discussions.
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