As a leading manufacturer of polymer polyols, Changhua Chemical has been committed to developing and producing high-quality products for a wide range of applications, including upholstered furniture, automotive interiors, shoe materials and apparel.With its performance polymer polyols, which are enabled by innovations and advanced technologies, the company is helping to create a healthy and comfortable life for humans.

Innovative initiator

In traditional process for manufacturing polymer polyols, AIBN is often used as the initiator.At high temperatures, however, AIBN would trigger side reaction that produces a carcinogen called tetramethyl succinonitrile, which is difficult to be isolated and highly toxic as it can cause permanent damage to the nervous system.At the same time, solid impurities and excessive residual styrene monomer, which produces high VOC emissions, can be generated.

On the other hand, sponge and mattress products exported to the United States have to obtain the Greenguard Certification UL28212018-04, which is currently the most stringent standard for indoor air quality certification and requires a tetramethyl succinonitrile content of less than 5ug/m³ for sponge and mattress.

In this context, Changhua Chemical uses a novel initiator, which ensures the products’ environmental-friendliness and safety by producing non-toxic decomposition product, increasing the conversion of monomers, reducing vinyl monomer residue and minimizing VOC emissions.

Minimum monomer residue

Besides, by introducing an environmentally friendly production process the company has significantly reduced the production of solid impurities, which helps sponge manufacturers avoid clogging of the filter screens and the screen cloth for swing head and thus increases productivity. And due to the reduced number of foam cells and the improvement in fineness of the cells, the products’ quality and appearance also significantly improve.

Few solid impurities

Macromonomers provide steric stabilization

Macromonomers provide steric stabilization.

Increased molecular weight or functionality can help reduce the agglomeration of particles and thus reduce viscosity.Manufactured using optimized process, Changhua’s Carnol ® P920 has a narrow particle size distribution, which can match that of leading foreign firms’ products.

Narrow particle size distribution

As environmental and safety concerns in polyurethane industry drew considerable attention, in 2017 methylene chloride (MC) was included in the List of Chemicals under Priority Control (first batch) released at the end of the year.Accordingly, relevant government departments have planned to minimize the production and use of MC to address environmental and health risks associated with the chemical.

Thus, environmentally friendly alternatives to MC need to be created through technological innovations.Presently, carbon dioxide and vacuum foaming processes are available on the market.But many foreign sponge manufacturers prefer carbon dioxide foaming over vacuum foaming as the latter increases production costs due to its high energy consumption.

The carbon dioxide foaming, which is high-pressure foaming, requires a particle size of less than 4um for polymer polyols to avoid safety risk associated with sharp rise in pressure resulting from nozzle clogging.

Made from macromonomers with higher molecular weight/functionality and using optimized process, Carnol ® P920 has a narrow particle size distribution, ranging between 0.4 and 4um. thus, it meets this requirement and can support green production of polyurethane sponge.

Excellent foaming properties

Parameters of Carnol ® P920

1.Ultra-low odor and VOC emissions provide customers with healthy and safe production environment.

2.Excellent yellowing resistance helps ensure stable product color and extend the product’s service life.

3.Good fluidity and water solubility helps produce foams with small density gradient and fine and uniform foam cells.

4.Excellent physical properties offer the foams high  tensile and tear strength and good air permeability, which further provides end users with greater comfort.

Foaming formula 

Sponge properties