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百折不饶聚氨酯 Polyurethene: the Strength of Flexibility

We use polyurethanes in one form or another every day – at home, in our offices and cars, for sport and leisure activities and on holiday.

Polyurethanes are versatile, modern and safe. They are used in a wide variety of applications to create all manner of consumer and industrial products that play a crucial role in making our lives more convenient, comfortable and environmentally friendly.

我们每天在家中,办公室和汽车上以这样或那样的形式使用聚氨酯,用于运动、休闲和渡假。

聚氨酯是多功能,现代和安全的。 它们被广泛应用于创造各种消费和工业产品,在使我们的生活更方便,舒适和环保方面发挥关键作用。

 

Polyurethane is a plastic material, which exists in various forms. It can be tailored to be either rigid or flexible, and is the material of choice for a broad range of end-user applications such as:

  • insulation of refrigerators and freezers
  • building insulation
  • cushioning for furniture
  • mattresses
  • car parts
  • coatings
  • adhesives
  • rollers and tyres
  • composite wood panels
  • shoe soles
  • sportswear

 

聚氨酯是可以多种形式存在的塑料材料。 它可以被定制为刚性或柔性的,并且是多种多样终端用户应用的首选材料,例如:


  • 冰箱和冷柜的绝缘
  • 建筑保温
  • 家具软垫
  • 床垫
  • 汽车零件
  • 涂层
  • 粘合剂
  • 滚轮和轮胎
  • 复合木板
  • 鞋底
  • 运动装


 

The list of applications is long and getting longer all the time, as new uses are found for this adaptable material. Read more about polyurethanes and their applications.

Polyurethanes are found just about everywhere in modern life; the chair you are sitting on, the bed you sleep in, the house you live in, the car you drive – all these, plus innumerable other items you use every day, probably contain polyurethanes.

实际应用的列表可以很长,并且随着时间的推移越来越长,因为这种多面性材料的新用途会不断被发现。

聚氨酯在现代生活中的任何地方都可见到; 你坐的椅子,你睡的床,你住的房子,你开车的车 - 所有这些,加上你每天使用的无数其他物品,可能都包含聚氨酯。


Polyurethanes were invented back in the 1930s by Professor Dr. Otto Bayer
 (1902-1982). There are various types of polyurethanes, which look and feel very different from each other. They are used in a diversity of products, from coatings and adhesives to shoe soles, mattresses and foam insulation. However, the basic chemistry of each type is essentially the same.


Widespread use of polyurethanes was first seen during World War II, when they were utilised as a replacement for rubber, which at the time was expensive and hard to obtain. During the war, other applications were developed, largely involving coatings of different kinds, from aeroplane finishes to resistant clothing.


By the 1950s, polyurethanes were being used in adhesives, elastomers and rigid foams and, in the latter part of the same decade, flexible cushioning foams similar to those used today.

Subsequent decades saw many further developments and today we are surrounded by polyurethane applications in every aspect of our everyday lives. While polyurethane is a product that most people are not overly familiar with, as it is generally 'hidden' behind covers or surfaces made of other materials, it would be hard to imagine life without polyurethanes.

聚氨酯是由奥托拜耳教授(1902-1982)在二十世纪三十年代发明的。 有各种类型的聚氨酯,其外观和感觉彼此非常不同。 它们用于多种产品,从涂料和粘合剂到鞋底,床垫和泡沫保温。 然而,每种类型的基本化学物质基本相同。

第二次世界大战期间,聚氨酯首次得到广泛使用,被用作橡胶的替代品,当时它既昂贵又难以制取。 战争期间,其它应用也有开发,主要涉及不同类型的涂层,从飞机表面到防护服。


20世纪50年代,聚氨酯被用于粘合剂,弹性体和刚性泡沫塑料中,以及到那十年后半期,也被用作与今日所用类似的软垫泡沫。


随后的几十年里,取得许多进一步的发展,今天我们日常生活的各个方面都被聚氨酯的应用所包围。虽然聚氨酯是大多数人不太熟悉的产品,因为它通常被“隐藏”在其他材料制成的覆盖物或表层下面,但很难想象没有聚氨酯的生活。


Polyurethanes, like all plastics, are polymers made by reacting diisocyanates (MDI and/or TDI) with a range of polyols. Depending on the desired end product, chemical formulations may contain other ingredients such as catalysts, blowing agents and possibly flame retardants. These various combinations allow the manufacture of a range of product types including:

l  rigid and flexible foams

l  rigid and flexible integral skin foams

l  elastomers

l  adhesives

l  coatings

l  sealants

 

聚氨酯像所有塑料一样,是聚合物,其通过使二异氰酸酯(MDI/TDI)与一系列多元醇反应而制成的。根据最终产品的需要,化学配方中可以含有其它成分,例如催化剂,发泡剂,也许或是阻燃剂。 这些多样的组合可以制得一系列产品类型,包括:

l  硬质或柔性泡沫

l  硬质或柔性泡沫片

l  弹性体

l  粘合剂

l  涂层

l  密封剂

 

The density of the product is determined by the amount of blowing agent used, and the flexibility or rigidity by the type of polyols and diisocyanates involved.

Different forms of polyurethane are often combined with other materials to manufacture a variety of end products, for example:

  • insulated building panels
  • mattresses and upholstered furniture
  • car seats
  • domestic refrigerators and freezers
  • composite wood panels
  • truck bodies
  • footwear
  • sportswear

 

产品密度由所用的发泡剂量确定,柔性和刚性则通过所涉及的多元醇和二异氰酸酯的类型来确定。

不同形式的聚氨酯通常与其他材料结合以制造各种最终产品,例如:

l  建筑用隔热面板

l  床垫和软体家具

l  汽车座椅

l  家用冰箱和冷柜

l  复合木板

l  卡车车身

l  鞋类

l  运动装

 

1.6cm-thick polyurethane insulation has the same insulation efficiency as a 1.34m-thick concrete wall!

  • since 2003, all polyurethane foams have been HCFC-free in the EU.
  • the polyurethane industry employs over 800,000 people in the EU.
  • the first polyurethane surfboard was made and used in the 1950s.
  • because of the introduction of polyurethanes into refrigerators, models designated A++ today are 60% more efficient than refrigerators 15 years ago.
  • in 1973, roller skates were improved and popularised by the introduction of thermoplastic polyurethane (TPU) wheels and, later, TPU boots. Today they are known as Rollerblades.
  • the amount of energy used to produce enough polyurethane insulation for one house is subsequently saved in the space of just one year thanks to the insulation provided.
  • polyurethane is often referred to as PU or PUR.
  • since 1995, all polyurethane foams have been CFC-free in the EU. Since 2003, they have been HCFC free as well
  • that renewable raw materials can be used to produce foams for several applications such as mattresses
  • more and more dams and dykes are protected against storms with a PU-based solution

 

1.6cm厚的聚氨酯绝缘层具有与1.34m厚的混凝土墙相同的隔热效果!


  • 2003年以来,欧盟范围内制造的所有聚氨酯泡沫材料都不再含有HCFC氟氯烃。
  • 欧盟聚氨酯行业雇佣超过80万员工。
  • 第一个聚氨酯冲浪板在20世纪50年代制成并使用。
  • 因为采用聚氨酯,今日被认定为A ++的冰箱型号,比15年前的能效高出60%
  • 1973年,因为采用热塑性聚氨酯(TPU)轮子,轮滑板,以及后来的TPU轮滑靴,得以改进并大受欢迎。今天它们被称为滚道Rollerblades
  • 绝热材料的改进,使得为生产一座房屋所需聚氨酯隔热材料耗费的能源在一年内就可省回。
  • 聚氨酯通常称为PUPUR
  • 1995年以后,欧盟范围内生产的所有聚氨酯泡沫不含CFC氟氯化碳。2003年以后,也都不含HCFC氟氯烃。
  • 再生料生产的泡沫可用于多种用途,比如,席梦思床垫。
  • 采用PU基的解决方案,越来越多的水坝和堤坝受到保护,免于风雨侵蚀。


 

For many applications, there's a viable alternative to plastic, metal and rubber - one that many OEMs aren't even aware of. It's called cast polyurethane, and it's among the most versatile, durable materials available in manufacturing.

Originally developed by Otto Bayer early in World War II, polyurethane gained traction with numerous applications in the 1950s. Today, with its comparatively low tooling costs, castable polyurethane elastomers are a perfect alternative to more common materials in a variety of applications.

在许多应用方面,塑料,金属和橡胶,都有一种可行的替代品,许多OEM厂商甚至不了解这一点。它被称为浇注型聚氨酯,生产上,这是可供选用的最通用,耐用的材料之一。

聚氨酯由奥托拜耳最初在二战期间开发,在20世纪50年代吸引了众多应用。今天,由于其相对较低的模具成本,浇注聚氨酯弹性体是多种应用中原常用材料的完美替代品。

 

But many product designers may be surprised to learn of polyurethane's physical versatility. Capable of being as flexible as a rubber band or as rigid as some metals, cast polyurethane is especially appropriate for parts that require toughness and durability, including:

  • Gears
  • Cogs
  • Sprockets
  • Solid wheels of all types

 

许多产品设计师可能会惊讶地发现聚氨酯的物理多用性。浇注聚氨酯既能像橡胶带一样柔韧又能像一些金属一样刚硬,尤其适用于制作需要韧性和耐久性的部件,比如:

齿轮

嵌齿轮

链轮

所有类型的实心轮子

 

Here are some of the advantages cast polyurethane has over other materials in low-volume applications.

Vs. Plastic

Polyurethane can be formulated for superior load-bearing capability, abrasion resistance and impact absorption.
In addition, unlike plastic, cast polyurethane doesn't require highpressure tooling, which allows for quicker turnarounds and lower-cost molds.

  • Tooling costs 1/5 that of plastic
  • Faster, more accurate prototypes
  • More durable and wear resistant

Vs. Metal

One of the most overlooked characteristics of polyurethane is its ability to be formulated for high rigidity, making it often a viable alternative to metal for hardware such as valves and gears. Cast polyurethane's advanced manufacturability also eliminates the need for secondary operations such as stamping, punching and painting, which saves time and costs in production.

  • Lighter weight
  • Faster turnarounds and lower total costs
  • Higher corrosion resistance

Vs. Rubber

Featuring the elastic capability of rubber, while measuring higher on the hardness scale, polyurethane can be a good choice for certain parts because of its:

  • Better wear resistance
  • Higher load-bearing capacity
  • Low-pressure tooling

 

























以下是小批量应用中浇注聚氨酯与其他材料相比的部分优点。

与塑料相比

聚氨酯可配制出优异的承载能力,耐磨性和冲击吸收性。

此外,与塑料不同,浇注聚氨酯不需要高压模具,这样可以实现更快的周转时间和更低成本的模具。

模具成本为塑料的1/5

原型制作更快,更准确

更耐用,更耐磨

 

与金属相比

聚氨酯最被忽视的特征之一是其可配制成高刚性的潜力,使其经常成为各种硬件,如阀门和齿轮,等金属件可行的替代品。浇注聚氨酯高超的可加工性也消除了对冲压,扣压和喷漆等二次加工的需要,节省了生产时间和成本。

重量更轻

周转时间更快总成本更低

耐腐蚀性更高

 

与橡胶相比

具有橡胶的弹性力,同时刚性更高,聚氨酯可以是某些部件的不错选择,因为它:

耐磨性更好

承载能更高

只需低压模具

 

Cast Polyurethane

浇注型聚氨酯预聚体又称浇注型聚氨酯弹性体(CPUE),简称浇注型聚氨酯(CPU)或聚氨酯浇筑胶。顾名思义,浇注型是指制品在成型前物料体系为液体,可浇筑,反应固化直接成型制品的一种化学加工方法,而且该物料体系中原则上不含挥发性液体。因为成型前该物料体系为液体,而TPUMPU制品在成型前为固体,所以也可把CPU称为液体橡胶或液体弹性体。与TPUMPU相比,CPU的原材料选择范围更大,产品硬度范围更宽,特别适合于大中型产品的生产,弥补了TPUMPU制品加工工艺的局限和不足,可最大限度发挥聚氨酯弹性体的性能优势,拓宽聚氨酯弹性体的应用领域。CPU弹性体最早出现于德国。20世纪50年代初世界上第一个CPU产品在德国拜耳公司实现了批量生产,其商品牌号为Vulkollan(瓦尔考兰)。20世纪50年代末美国杜邦公司以PTMGTDI为主要原料推出了商品牌号为Adiprenel的聚醚型CPU,随后出现了MDICPU,为后来聚氨酯弹性体的发展和应用做出了卓越贡献。20世纪70年代后,碳化二亚胺改性的液化MDI、低不饱和度聚醚、低游离TDI预聚物、端氨基聚醚、各种环保型胺类扩链剂等新材料陆续进入市场,反应注射模塑(RIM)和喷涂聚脲弹性体技术相继问世,大大推进了传统CPU制品成型技术,拓宽了CPU产品应用领域。

聚氨酯弹性体除了传统的CPUTPUMPU外,还应包括防水涂料和铺装材料、鞋底原液、合成革浆料、氨纶和胶黏剂,因为它们在室温下均处于高弹态(橡胶态)。其中防水和铺装材料、鞋底原液在制品成型前均为液体,不含溶剂,应归属于CPU。如按此分类统计,2005年我国聚氨酯弹性体消费量约87万吨,接近我国聚氨酯消费总量的40%。在弹性体中CPU消费量36万吨,占41.3%。其中鞋底原液(RIM产品)20万吨,占55%,铺装材料10万吨,占28%,传统的CPU 6万吨,占17%

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