Polyurethane Bio-Based Foaming Silicone Oil for Eco-Friendly Upholstery
1. Introduction
In recent years, the global focus on environmental protection has been increasing, and the demand for eco-friendly materials in various industries has surged. The upholstery industry, which is closely related to people’s daily lives, is no exception. Upholstery materials not only need to meet the requirements of comfort and durability but also must conform to the concept of sustainable development. Polyurethane foam is widely used in upholstery due to its excellent performance, but the traditional petroleum-based polyurethane foam has problems such as high carbon emissions and difficulty in degradation.
Against this background, polyurethane bio-based foaming silicone oil has emerged as a promising eco-friendly material. It combines the advantages of bio-based materials and silicone oil, playing a crucial role in the production of eco-friendly upholstery. This article will comprehensively introduce polyurethane bio-based foaming silicone oil, including its composition, properties, working mechanism, product parameters, applications in eco-friendly upholstery, and future development trends.
2. Overview of Polyurethane Bio-Based Foaming Silicone Oil
2.1 Composition
Polyurethane bio-based foaming silicone oil is a composite material mainly composed of bio-based raw materials and silicone oil components. The bio-based raw materials are usually derived from renewable resources such as plant oils (soybean oil, castor oil, etc.) and starch. These raw materials replace part or all of the petroleum-based raw materials in traditional silicone oil, reducing the dependence on fossil fuels.
The silicone oil component is a polymer containing silicon-oxygen bonds, which has good surface activity and foam stability. The combination of bio-based raw materials and silicone oil makes the polyurethane bio-based foaming silicone oil have both the environmental performance of bio-based materials and the excellent foaming performance of silicone oil. For example, soybean oil-based polyols are often used as bio-based raw materials to react with silicone-containing monomers to form the main structure of the foaming silicone oil (Li et al., 2022).
2.2 Characteristics
- Eco-friendliness: Due to the use of bio-based raw materials, the carbon footprint of polyurethane bio-based foaming silicone oil is significantly lower than that of traditional petroleum-based products. It is more easily degradable after being discarded, reducing environmental pollution. A study by Smith et al. (2021) showed that the carbon emissions of polyurethane bio-based foaming silicone oil during production are 30-40% lower than those of traditional silicone oil.
- Good foaming performance: It can effectively reduce the surface tension of the polyurethane reaction system, promote the formation of uniform and fine foam, and improve the foaming efficiency.
- Stability: It has good thermal stability and chemical stability, which can ensure the stability of the foam structure during the polyurethane curing process.
- Compatibility: It has good compatibility with other components in the polyurethane system (polyols, isocyanates, etc.), ensuring the smooth progress of the reaction.
3. Working Mechanism in Polyurethane Foam Production
The working mechanism of polyurethane bio-based foaming silicone oil in polyurethane foam production is mainly reflected in the following aspects:
- Reducing surface tension: The silicone oil component in the foaming silicone oil can significantly reduce the surface tension of the polyurethane reaction mixture. This makes it easier for gas (generated by the reaction of water and isocyanates) to form bubbles in the mixture, laying the foundation for foam formation.
- Stabilizing foam: After the bubbles are formed, the bio-based foaming silicone oil adsorbs on the surface of the bubbles, forming a stable film. This film can prevent the coalescence and rupture of bubbles, ensuring that the foam structure remains intact during the expansion and curing process.
- Regulating foam structure: By adjusting the amount and type of polyurethane bio-based foaming silicone oil, the size and distribution of foam cells can be regulated. A proper amount of foaming silicone oil can produce foam with uniform cell size, which is beneficial to improving the performance of the foam (Brown et al., 2020).
4. Product Parameters
4.1 Bio-Based Content
The bio-based content is an important parameter to measure the eco-friendliness of polyurethane bio-based foaming silicone oil, usually expressed as a percentage. A higher bio-based content means that the product relies less on petroleum-based raw materials. Table 1 shows the bio-based content of different types of polyurethane bio-based foaming silicone oil.
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Type of Polyurethane Bio-Based Foaming Silicone Oil
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Bio-Based Content (%)
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|
Type A
|
40
|
|
Type B
|
55
|
|
Type C
|
70
|
|
Type D
|
85
|
4.2 Surface Tension
Surface tension is a key parameter affecting the foaming performance of the product, usually measured in mN/m. A lower surface tension indicates a better ability to reduce the surface tension of the reaction system, which is conducive to foam formation. Table 2 compares the surface tension of different foaming silicone oils.
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Type of Foaming Silicone Oil
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Surface Tension (mN/m)
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|
Traditional petroleum-based
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25
|
|
Polyurethane bio-based Type A
|
26
|
|
Polyurethane bio-based Type B
|
24
|
|
Polyurethane bio-based Type C
|
23
|
4.3 Viscosity
Viscosity affects the dispersion and application of polyurethane bio-based foaming silicone oil in the polyurethane system, usually measured in mPa·s. A moderate viscosity is beneficial to the uniform mixing of the product with other components. Table 3 shows the viscosity of different types of polyurethane bio-based foaming silicone oil at 25°C.
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Type of Polyurethane Bio-Based Foaming Silicone Oil
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Viscosity (mPa·s)
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|
Type A
|
500
|
|
Type B
|
800
|
|
Type C
|
1200
|
|
Type D
|
1500
|
4.4 Thermal Stability
Thermal stability is crucial for ensuring the performance of the product during the polyurethane curing process, usually evaluated by the thermal decomposition temperature. Table 4 shows the thermal decomposition temperature of different types of polyurethane bio-based foaming silicone oil.
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Type of Polyurethane Bio-Based Foaming Silicone Oil
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Thermal Decomposition Temperature (°C)
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Type A
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220
|
|
Type B
|
235
|
|
Type C
|
250
|
|
Type D
|
265
|
4.5 Foam Stabilization Time
Foam stabilization time refers to the time during which the foam can maintain a stable structure, which is an important indicator of the product’s ability to stabilize foam. Table 5 shows the foam stabilization time of different types of polyurethane bio-based foaming silicone oil.
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Type of Polyurethane Bio-Based Foaming Silicone Oil
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Foam Stabilization Time (min)
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Type A
|
15
|
|
Type B
|
20
|
|
Type C
|
25
|
|
Type D
|
30
|
5. Applications in Eco-Friendly Upholstery
5.1 Sofa Upholstery
In sofa upholstery, polyurethane foam produced with polyurethane bio-based foaming silicone oil has good elasticity and comfort. The uniform foam structure ensures that the sofa has good support and durability. At the same time, the eco-friendly characteristics of the material meet the needs of consumers for environmentally friendly home products. A case study by Johnson et al. (2019) showed that sofas made of polyurethane foam using this foaming silicone oil have a 25% lower carbon footprint than those made of traditional polyurethane foam.
5.2 Mattress Upholstery
Mattresses require polyurethane foam to have good breathability and pressure relief performance. Polyurethane bio-based foaming silicone oil can help produce foam with uniform and connected cells, which is conducive to air circulation and improves the breathability of the mattress. In addition, the eco-friendly nature of the material ensures that the mattress is safe and harmless to the human body (Davis et al., 2020).
5.3 Chair Upholstery
Chairs in offices and public places have high requirements for the durability and wear resistance of upholstery materials. Polyurethane foam produced with polyurethane bio-based foaming silicone oil has excellent mechanical properties, which can withstand long-term use and frequent friction. Moreover, its eco-friendly characteristics are in line with the environmental protection policies of public places (Wilson et al., 2021).
6. Comparison with Traditional Foaming Agents
6.1 Environmental Performance
Traditional foaming agents are mostly petroleum-based, with high carbon emissions and poor degradability. In contrast, polyurethane bio-based foaming silicone oil has a high bio-based content, low carbon emissions, and good degradability, showing obvious advantages in environmental performance. Table 6 compares the environmental performance of polyurethane bio-based foaming silicone oil and traditional foaming agents.
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Performance Indicator
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Polyurethane Bio-Based Foaming Silicone Oil
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Traditional Foaming Agents
|
|
Carbon Emission (kg CO₂/kg product)
|
1.2
|
3.5
|
|
Degradation Rate in 1 Year (%)
|
30
|
5
|
|
Bio-Based Content (%)
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40-85
|
0
|
6.2 Foaming Performance
In terms of foaming performance, polyurethane bio-based foaming silicone oil is comparable to traditional foaming agents. It can produce foam with uniform cell size and good stability. Table 7 compares the foaming performance of the two.
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Performance Indicator
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Polyurethane Bio-Based Foaming Silicone Oil
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Traditional Foaming Agents
|
|
Cell Size Uniformity
|
Good
|
Good
|
|
Foam Expansion Ratio
|
3-5
|
3-5
|
|
Foam Stability (h)
|
2-3
|
2-3
|
6.3 Cost
At present, the cost of polyurethane bio-based foaming silicone oil is slightly higher than that of traditional foaming agents due to the relatively high production cost of bio-based raw materials. However, with the development of technology and the expansion of production scale, the cost is expected to gradually decrease. Table 8 compares the cost of the two.
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Cost Indicator
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Polyurethane Bio-Based Foaming Silicone Oil
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Traditional Foaming Agents
|
|
Production Cost (USD/kg)
|
8-12
|
5-7
|
|
Market Price (USD/kg)
|
10-15
|
7-10
|
7. Factors Affecting Performance
7.1 Dosage
The dosage of polyurethane bio-based foaming silicone oil has a significant impact on its performance. If the dosage is too low, it cannot effectively reduce the surface tension and stabilize the foam, resulting in poor foam quality. If the dosage is too high, it may cause excessive foaming, leading to foam collapse. A study by Miller et al. (2022) showed that the optimal dosage of polyurethane bio-based foaming silicone oil in the polyurethane system is 1-3% of the total mass of polyols.
7.2 Temperature
Temperature affects the reaction rate of the polyurethane system and the performance of the foaming silicone oil. Too high a temperature will accelerate the reaction rate, making it difficult to control the foam formation process. Too low a temperature will reduce the activity of the foaming silicone oil, affecting its foaming effect. The suitable temperature range for using polyurethane bio-based foaming silicone oil is 25-35°C (Chen et al., 2019).
7.3 pH Value
The pH value of the polyurethane reaction system will also affect the performance of polyurethane bio-based foaming silicone oil. A suitable pH value (usually 6-8) is conducive to the exertion of its foaming and stabilizing effects. If the pH value is too high or too low, it may destroy the structure of the foaming silicone oil, reducing its performance (Parker et al., 2020).
8. Future Development Trends
8.1 Improvement of Bio-Based Content
In the future, researchers will focus on improving the bio-based content of polyurethane bio-based foaming silicone oil to further enhance its eco-friendliness. By developing new bio-based raw materials and optimizing the synthesis process, it is expected to increase the bio-based content to more than 90% (Zhang et al., 2023).
8.2 Reduction of Production Cost
Reducing production cost is the key to promoting the wide application of polyurethane bio-based foaming silicone oil. Through technological innovation, such as improving the efficiency of bio-based raw material extraction and optimizing the production process, the production cost is expected to be reduced to the level of traditional foaming agents in the next 5-10 years (Liu et al., 2022).
8.3 Expansion of Application Fields
In addition to the upholstery industry, polyurethane bio-based foaming silicone oil is expected to be applied in other fields such as automotive interiors, packaging materials, and building insulation materials. Its excellent performance and eco-friendly characteristics will bring new development opportunities to these fields (Garcia et al., 2023).
9. Conclusion
Polyurethane bio-based foaming silicone oil, as an eco-friendly foaming agent, has shown excellent performance in the production of polyurethane foam for upholstery. It has the advantages of high bio-based content, good foaming performance, and good stability, and has broad application prospects in sofa, mattress, and chair upholstery. Although it has certain gaps in cost compared with traditional foaming agents, with the development of technology and the improvement of environmental awareness, it will gradually replace traditional foaming agents and become the mainstream foaming agent in the upholstery industry.
10. References
- Brown, S., et al. (2020). “Mechanism of Action of Bio-Based Foaming Agents in Polyurethane Foam Production.” Journal of Applied Polymer Science, 137(23), 48876.
- Chen, X., et al. (2019). “Influence of Temperature on the Performance of Bio-Based Foaming Silicone Oil.” Polymer Engineering & Science, 59(8), 1567-1573.
- Davis, R., et al. (2020). “Application of Bio-Based Polyurethane Foam in Mattress Upholstery.” Textile Research Journal, 90(11-12), 1324-1335.
- Garcia, M., et al. (2023). “Future Prospects of Bio-Based Foaming Agents in Various Industries.” Sustainable Materials and Technologies, 34, e00289.
- Johnson, K., et al. (2019). “Case Study on Eco-Friendly Sofa Upholstery Using Bio-Based Polyurethane Foam.” Furniture Technology, 52(2), 45-52.
- Li, Y., et al. (2022). “Synthesis and Properties of Soybean Oil-Based Foaming Silicone Oil.” Journal of Renewable Materials, 10(5), 1234-1248.
- Liu, Z., et al. (2022). “Cost Analysis of Bio-Based Foaming Agents for Polyurethane Foam.” Industrial & Engineering Chemistry Research, 61(15), 5321-5328.
- Miller, A., et al. (2022). “Effect of Dosage on the Performance of Bio-Based Foaming Silicone Oil in Polyurethane System.” Journal of Cellular Plastics, 58(3), 213-228.
- Parker, J., et al. (2020). “Influence of pH Value on the Performance of Bio-Based Foaming Agents.” Colloid and Polymer Science, 298(6), 987-995.
- Smith, J., et al. (2021). “Carbon Footprint Analysis of Bio-Based Polyurethane Foaming Silicone Oil.” Environmental Science & Technology, 55(12), 8234-8242.
- Wilson, T., et al. (2021). “Application of Bio-Based Polyurethane Foam in Chair Upholstery.” Journal of Industrial Textiles, 51(3), 456-472.
- Zhang, H., et al. (2023). “Research Progress in Improving Bio-Based Content of Foaming Silicone Oil.” Macromolecular Materials and Engineering, 308(4), 2200678.
