Recent advances in All-MDI flexible moulded foam

Since the large scale introduction of CFC-free MDI flexible foams in 1989, ICI Polyurethanes has continuously reduced the density of MDI flexible foam while maintaining or improving foam performance. The most recent MDI prepolymer based polyurethane systems make it possible to produce low density flexible foams in large and increasingly complex molds. The new technology displays very robust processing and can be used in conventional cold-cure as well as in typical hot-cure molds for seat cushions, seat backs, headrests and sound insulation applications. The inherent fast reactivity of MDI prepolymers leads to rapid cure and short cycle times, ideally suited for foam-in-fabric applications. In addition, the new systems require low levels of catalyst and other additives resulting in excellent fogging and emission performance. As seating cushions require high comfort performance, development efforts concentrated on foam with improved dynamic comfort. ICI's new prepolymer technology can yield foams with an enhanced height (i.e., H-point) and dynamic modulus retention under load, especially under hot and humid conditions.