Technical Advancements and Applications in Predictive Modeling of Polyurethane Foaming Height

Various polyurethane foams (i.e., rigid, flexible, and spray polyurethane foams) offer diverse applications due to their unique properties, including thermal insulation, cushioning, and seamless gap filling. These foams provide solutions across industries such as construction, automotive, and refrigeration. However, the foaming process presents several challenges that may result in various defects in the final products. This work provides innovative predictive techniques for polyurethane foam expansion and applications in advanced manufacturing processes. The foaming height of the third polyurethane foaming agent (PU-3) closely aligned with the experimentally measured values. The relationship between foaming height and time is influenced by the type and concentration of catalysts, as well as the blowing agents used. However, simulations using Moldex 3D Version 2024 revealed a nonlinear relationship between foaming height and time, characterized by three distinct foaming rates. Zone B demonstrated the highest foaming rate, followed by Zone C, while Zone A showed the lowest rate. The foaming height and rate were significantly influenced by the foaming angle, with smaller angles enhancing both parameters. At a mold temperature of 30 °C and with an expansion coefficient of 35, the predicted foaming height of the polyurethane agent achieved an average accuracy of approximately 96% across four foaming angles. Based on these experimental findings, this study introduces three mechanisms involved in the foaming process of polyurethane foam components.