Publications

TufFoam™: A TDI-free water-blown polyurethane foam

Whinnery, LeRoy L.; Goods, Steven H.; Keifer, Patrick N.

TufFoam™ is a TDI-free, water-blown, closed-cell, rigid polyurethane foam (PU) initially formulated as an electronics encapsulant to mitigate the effects of harsh mechanical environments. Because it contains no TDI, the handling hazards and chemical sensitization associated with exposure during processing of common, commercial PU foams are obviated. The mechanical properties of TufFoam™ have been found to be comparable or superior to conventional TDI-based foams. Beyond its original intent, it has since found use in a variety of additional applications, including as a structural material and as a thermal and electrical insulating material. TufFoam™ constituents are commercially available in commodity quantities and batch processing schedules have been developed for its preparation at densities ranging from 0.03 to 0.70 g/cc (2 to 40 pcf). TufFoam™ has a uniform, fine cell structure over the entire range of density explored. Its Tg is somewhat dependant on the cure temperature, but is approximately 127°C when cured at 65°C. The coefficient of thermal expansion (CTE) is 7x10 -5 °C -1. TufFoam™ is electrically insulating with a volume resistivity of 3x10 17 ohm-cm at a density of 0.1 g/cc.