Introduction
High-resilience flexible polyurethane foams (HR PU) have been a key material in the automotive sector for decades, especially in seating applications, thanks to their excellent combination of comfort and durability.
In recent years, OEM requirements have evolved toward improving indoor air quality (IAQ), focusing on the reduction of volatile organic compounds (VOC), the control of aldehydes such as formaldehyde, and odor improvement.
These requirements are particularly stringent in Asia, driving the development of new low-VOC solutions in which silicone surfactants play a fundamental role.
Objective
To evaluate the impact of replacing a conventional silicone with a low-VOC alternative.
Experimental Methodology
All tests were carried out using the same TM-type HR formulation and molding conditions. The only change was replacing the conventional standard market surfactant (ST1) with a new low-VOC technology surfactant manufactured by Concentrol (STB PU-1254) under the following conditions:
– 1 L bag test
– Conditioning at 23°C
– Analysis at 60°C
– Measurement of TVOC, aromatics, and aldehydes
– Odor evaluation by sensory panel
Results and Discussion
Figure 1: HR foams before the volatile emissions test using sampling bags.
Table 1: Results of the Sampling Bag analyses for volatile compounds and odor.
The results demonstrate a significant reduction in emissions when comparing both solutions. In terms of TVOC, the ST1 system showed values of 11137.998 µg/specimen, while PU-1254 reduced this figure to 8550.035 µg/specimen, representing an approximate reduction of 23%.
Regarding odor, a relevant improvement was also observed, decreasing from a rating of 3.0 with ST1 to 2.5 with PU-1254, equivalent to an improvement of approximately 17%. These data confirm the key role of silicone in emissions and in the final olfactory perception of the material.
From a technical standpoint, changing the silicone directly impacts critical parameters such as VOC emissions, aldehyde formation, and the final odor of the product. In this context, PU-1254 stands out by enabling substantial improvements in these aspects without requiring modifications to either the process or the formulation, acting as a true “drop-in” solution.
Conclusions
The STB PU-1254 surfactant offers clear advantages, including a significant reduction in volatile organic compounds (VOC), close to 23%, as well as an approximate 24% reduction in formaldehyde, thereby contributing to improved environmental quality of the final product. In addition, it provides a remarkable odor improvement, enhancing perceived comfort. Thanks to these benefits, it positions itself as a key solution for the development of HR PU foams.
At the industrial level, this case demonstrates not only the potential of the 1000 Series, but also Concentrol’s capability to provide advanced solutions adapted to increasing market demands. The 1000 Series surfactant range is designed to address all types of HR systems, including TDI-, MDI-, and TM-based formulations, providing low-VOC alternatives capable of meeting the most demanding OEM requirements, especially in Asian markets. This comprehensive approach positions Concentrol as a technological partner capable of supporting its customers in the transition toward lower-emission materials without compromising performance or processability.
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