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Many plastic products are made of polyurethane. Fraunhofer researchers have developed a polyurethane manufacturing method that avoids the use of toxic isocyanates while using carbon dioxide as a starting material. The polyurethane with repeatable standards is being developed in cooperation with industrial partners. The results of the study can be seen at MEDICA 2021 in Düsseldorf (Hall 3, Booth E74) from November 15th to 18th.

Polyurethane is a versatile material. This type of plastic is used as mattress foam, packaging materials, elastic materials for sporting goods, as well as sealing materials, paints, adhesives, construction foams, and so on. The material is even used in medical applications-for example in the form of tubes for intravenous catheters. Researchers from the Fraunhofer Institute for Applied Polymers IAP, chemical technology ICT, manufacturing technology and advanced materials IFAM, and environmental, safety and energy technology UMSICHT are exploring new ways to produce such plastics in a sustainable manner and are not Use toxic substances. Material.

Usually, a modular system consisting of three structural units is used to produce polyurethane: isocyanate, chain extender and polyol. The characteristics of the product can be controlled very precisely through the formula and process parameters. Due to the high reactivity of isocyanates, products can be produced within a few minutes. But there is a downside. Isocyanates are toxic and allergenic substances, which can cause allergic reactions and asthma symptoms. Therefore, the European Chemicals Agency EChA decided to implement a restriction: from 2023, only specially trained personnel will be allowed to handle formulations with an isocyanate content of more than 0.1%.

"Through our new synthesis, we avoid toxic isocyanates and thus achieve a safer production process. The polyurethanes we produce in this way can also be certified for biocompatibility," Fraunhofer Applied Polymer Research The IAP scientist Dr. Christoph Herfurth explained. Coordinator of the project. To achieve this goal, the researchers replaced isocyanates with diurethanes. They aim to make the process efficient and industrially feasible. The research team is now working on more sustainable polyurethane foaming agents.

Sustainable: the use of carbon dioxide

"We don't use fossil fuels (such as crude oil or natural gas) as a carbon source for polyurethane, but instead use carbon dioxide and polyurethane recycling," Herfurth explains. "In this way, we can recycle carbon and ensure that less damaging carbon dioxide is released into the atmosphere." The process is already up and running; pressure and elevated temperature are required for this. Researchers at the Fraunhofer Institute are currently working on ways to optimize processes.

First, the project team will focus on developing the cornerstone of polyurethane production. Researchers will also study the relationship between process parameters and structural properties: how do you achieve the properties that make traditional polyurethanes so versatile? Three different demonstrators will show the various applications of this new polyurethane: the first will be a sustainable tube for medical applications. Here, only a relatively small amount of polyurethane is required. This makes it easier to launch new products. In the second application, Fraunhofer IFAM is developing adhesives optimized for new polyurethanes to allow the cannula to be glued to medical tubing, for example for catheters. The third demonstrator on the agenda is foam and the processing technology for mass-produced products. Further exploration of new technologies to give polyurethane waste a second life. Citation provided by Fraunhofer-Gesellschaft: From medical applications to sporting goods: Biocompatible and sustainable plastics (2021, November 2), retrieved November 25, 2021 Since https://phys.org/news/2021 -11-medical-applications-sporting-goods-biocompatible.html This document is protected by copyright. Except for any fair transaction for private learning or research purposes, no part may be copied without written permission. The content is for reference only.

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