Experienced Based Solutions for High Resiliency Cold Foaming
There are two basic methods of making molded flexible foams, the Hot Cure (HC) and Cold Cure/High Resilience (HR) processes, and Chem-Trend has developed products to address the challenges of molding with either method. Thirty years ago, HC was the predominate method of manufacturing molded flexible foam seating, but the HC market has significantly decreased over the years – to the point that there is zero HC molded foam in the NAFTA region and only a minor amount in the EU. The Asia Pacific region still uses some HC, as does South America, but the High Resiliency Cold Foaming process is the most widely used today in the manufacture of molded flexible foams.
The HC process is characterized by using longer cycle times (10 - 20 minutes) and higher molding temperatures (~100° – 125° C / 210° - 260° F) in order to properly cure the polyurethane foam. HC typically uses polyols that are secondary hydroxyl functionality, so they tend to be less reactive than cold cure polyurethanes. Cold cure processes use mostly primary hydroxyl polyols (faster reactivity), lower molding temperatures (~30° - 75° C / 85° - 170° F), and faster cycle times (in the 3 - 5 minute cure time range).
Chem-Trend is the global leader in supplying release agents for the molded flexible, visco-elastic, and high-resiliency (HR) MDI, TDI, and TDI/MDI polyurethane systems for low- to high-density automotive and non-automotive foam markets. De-molding any part can be defined as a point of critical performance in any polyurethane manufacturing process – especially in an HR application, where every second counts during production and there are high standards for finished part quality. In developing our mold release agent technologies for HR applications, we take into account the differences in mold temperature ranges, molded foam densities, time from mold release spray to polyurethane pour, tooling complexity, surface finish (open celled versus closed celled), mold construction, and many other process conditions specific to each customers manufacturing processes.
Mold Release Agents and Other Process Enhancing Products
Chem-Trend's release agents provide excellent release ease, superior part finish, extremely low buildup, and process robustness over a wide molding temperature range. Product offerings also include release agents that reduce the noise inside the automobile (anti-squeak), give controlled open or closed surfaces, and provide surfaces for post-molding bonding to the molded part.
Beyond mold release agents, we offer a full range of products including: mold cleaners, mold preparation/conditioner paste waxes and mold sealers.
We have been able to become the global leader in providing mold release solutions for polyurethane molders around the world through our more than fifty years of experience in the industry. Over that time our work on the shop floor of our customers has proven time and again that Chem-Trend understands their challenges and can work in partnership with them to develop solutions to address those challenges.
To learn more about how our portfolio of products for the polyurethane industry can help you, read our main Polyurethane Molding page, or contact us to speak with one of our polyurethane industry experts.