Production of Car Seat Cushion Using Palm Oil

8/13/2019 Production of Car Seat Cushion Using Palm Oil

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Prepared by: Umi Nabilah Binti

Borhan Ashraf Alqayyum

Bin Samuri

Saravanan Kumar Seiswaran Pandein Darvindran Kumar Ameerul Naim


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Due to the abundant supply of palm oil inMalaysia, products derived from palm oil and

its derivatives are becoming activelyproduced. Most activities involve the

substitution of palm-based materials from

petrochemical-based material.Plastic industry is one area of interest where

polyurethane derived from renewable

resource is starting to penetrate the market.

INTRODUCTION


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It was found that by substituting halfof the raw material with palm oil,better properties of foams were

produced. The production of this finechemical will ensure a sustainable

development as raw material is fromrenewable resource. Besides that, the

use of water in the production ofpolyurethane will help to preserve the

environment.


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Polyurethanes are linear polymers producedthrough a chemical reaction between a

diisocyanate and a polyol.First developed in late 1930s, polyurethanesare some of the most versatile polymers.

They are used in building insulation, surfacecoatings, adhesives, solid plastics, andathletic apparel.

WHAT IS POLYURETHANE?


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A polyol is an alcohol with more thantwo reactive hydroxyl groups per

molecule.

Most of the commercial polyols are petroleum-based.The structure, molecular weights and functionalgroups of the polyols play vital roles in determiningthe properties of the final urethane polymers.

WHAT IS POLYOL?


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PALM OIL-BASED POLYOL

Extract ing Extracted PalmOil

Palm Oil Emp ty Frui t Bun ch


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Palm oil extractor

The palm oil is extracted using anextractor machine.


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Palm oil extracted from EFB is mixed equallyabout 50% of palm oil and 50% of polyhydricalcohol.The process of making palm-oil based polyolis blended using polyol pilot plant.

These days, palm oil-based polyol has beenprocessed by Malaysia Palm Oil Berhad,(MPOB)


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POLYOL PILOT PLANT

AT MPOB


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Example of extracted palm oil-

based polyol


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Isocynate is a salt or ester of isocyanic

acidThe most widely used isocyanates are toluenediisocyanate (TDI),

That is used in the production of flexible foams

WHAT IS ISOCYNATE?


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A blowing agent is used to generate nucleating gasbubbles in the polymerizing or gelling mixture of

polyol and isocyanate.The blowing agents for polyurethane foamscommonly used are water and low-boiling inertliquids or solvents.Additives also play a vital role in the preparationof polyurethane. These include catalysts, cross-linking agents, fillers (tyres scrap) and colouring

materials.

ADDITIVES AND BLOWING

AGENT


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The ratio between polyol and diisocynate is 1:2 in whichthe amount of palm oil-based polyol needed to producedflexible polyurethane foam is 40%.This type of foam has and can:

1. higher energy absorption characteristic2. able to absorb sound3. mechanical energy better.4. withstand pressure of 2 bar.

These are meant for products like furniture, cushionsand mattresses.


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JJ311 CASE STUDY PALMFRONDS\Polyurethane-

foam-

expansion[www.savevid.com].flv

FOAMING PROCESS
http://localhost/var/www/apps/conversion/tmp/scratch_6/JJ311%20CASE%20STUDY%20PALM%20FRONDS/Polyurethane-foam-expansion[www.savevid.com].flvhttp://localhost/var/www/apps/conversion/tmp/scratch_6/JJ311%20CASE%20STUDY%20PALM%20FRONDS/Polyurethane-foam-expansion[www.savevid.com].flvhttp://localhost/var/www/apps/conversion/tmp/scratch_6/JJ311%20CASE%20STUDY%20PALM%20FRONDS/Polyurethane-foam-expansion[www.savevid.com].flvhttp://localhost/var/www/apps/conversion/tmp/scratch_6/JJ311%20CASE%20STUDY%20PALM%20FRONDS/Polyurethane-foam-expansion[www.savevid.com].flvhttp://localhost/var/www/apps/conversion/tmp/scratch_6/JJ311%20CASE%20STUDY%20PALM%20FRONDS/Polyurethane-foam-expansion[www.savevid.com].flvhttp://localhost/var/www/apps/conversion/tmp/scratch_6/JJ311%20CASE%20STUDY%20PALM%20FRONDS/Polyurethane-foam-expansion[www.savevid.com].flvhttp://localhost/var/www/apps/conversion/tmp/scratch_6/JJ311%20CASE%20STUDY%20PALM%20FRONDS/Polyurethane-foam-expansion[www.savevid.com].flvhttp://localhost/var/www/apps/conversion/tmp/scratch_6/JJ311%20CASE%20STUDY%20PALM%20FRONDS/Polyurethane-foam-expansion[www.savevid.com].flvhttp://localhost/var/www/apps/conversion/tmp/scratch_6/JJ311%20CASE%20STUDY%20PALM%20FRONDS/Polyurethane-foam-expansion[www.savevid.com].flvhttp://localhost/var/www/apps/conversion/tmp/scratch_6/JJ311%20CASE%20STUDY%20PALM%20FRONDS/Polyurethane-foam-expansion[www.savevid.com].flvhttp://localhost/var/www/apps/conversion/tmp/scratch_6/JJ311%20CASE%20STUDY%20PALM%20FRONDS/Polyurethane-foam-expansion[www.savevid.com].flvhttp://localhost/var/www/apps/conversion/tmp/scratch_6/JJ311%20CASE%20STUDY%20PALM%20FRONDS/Polyurethane-foam-expansion[www.savevid.com].flvhttp://localhost/var/www/apps/conversion/tmp/scratch_6/JJ311%20CASE%20STUDY%20PALM%20FRONDS/Polyurethane-foam-expansion[www.savevid.com].flvhttp://localhost/var/www/apps/conversion/tmp/scratch_6/JJ311%20CASE%20STUDY%20PALM%20FRONDS/Polyurethane-foam-expansion[www.savevid.com].flv


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Reaction injection molding:

the process is based on a chemicalreaction. A reactive liquid mixture(usually polyol and diisocyanate) is

injected or poured into a mould where achemical reaction takes place.

After an exothermic (heat generating) reactionoccurs, the finished part is removed from the mold.

REACTION INJECTION

MOULDING


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The materials are continuously circulated at lowpressure by the pumping system and through the

mixing head.When the materials reach the mixing head, they arerecirculated back to the day tanks and then throughthe same path again back out to the mixing head.This low-pressure recirculation can be used tomaintain temperature, nucleation, and will help keepadded ingredients such as fillers or pigments evenlydispersed.

RECIRCULATION


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An immediate chemical reaction occurs inside the mixinghead, with a continued exothermic reaction inside themould cavity as process progresses.When processing foams, significant forces created insidethe mould must be resisted to ensure the integrity of thepart. The clamping pressure required can be up to manytons depending on the size, expansion rates, and thedesired density of the partMounting the mould in a pneumatic or hydraulic pressprovides the force required to keep the mould tightlyclosed during the curing process

MOULDING


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JJ311 CASE STUDY PALMFRONDS\Reaction-

Injection-Molding.mp4

RIM PROCESS
http://localhost/var/www/apps/conversion/tmp/scratch_6/JJ311%20CASE%20STUDY%20PALM%20FRONDS/Reaction-Injection-Molding.mp4http://localhost/var/www/apps/conversion/tmp/scratch_6/JJ311%20CASE%20STUDY%20PALM%20FRONDS/Reaction-Injection-Molding.mp4http://localhost/var/www/apps/conversion/tmp/scratch_6/JJ311%20CASE%20STUDY%20PALM%20FRONDS/Reaction-Injection-Molding.mp4http://localhost/var/www/apps/conversion/tmp/scratch_6/JJ311%20CASE%20STUDY%20PALM%20FRONDS/Reaction-Injection-Molding.mp4http://localhost/var/www/apps/conversion/tmp/scratch_6/JJ311%20CASE%20STUDY%20PALM%20FRONDS/Reaction-Injection-Molding.mp4http://localhost/var/www/apps/conversion/tmp/scratch_6/JJ311%20CASE%20STUDY%20PALM%20FRONDS/Reaction-Injection-Molding.mp4http://localhost/var/www/apps/conversion/tmp/scratch_6/JJ311%20CASE%20STUDY%20PALM%20FRONDS/Reaction-Injection-Molding.mp4http://localhost/var/www/apps/conversion/tmp/scratch_6/JJ311%20CASE%20STUDY%20PALM%20FRONDS/Reaction-Injection-Molding.mp4http://localhost/var/www/apps/conversion/tmp/scratch_6/JJ311%20CASE%20STUDY%20PALM%20FRONDS/Reaction-Injection-Molding.mp4http://localhost/var/www/apps/conversion/tmp/scratch_6/JJ311%20CASE%20STUDY%20PALM%20FRONDS/Reaction-Injection-Molding.mp4http://localhost/var/www/apps/conversion/tmp/scratch_6/JJ311%20CASE%20STUDY%20PALM%20FRONDS/Reaction-Injection-Molding.mp4


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END PRODUCT


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stress-strain diagram obtained after

quasi-static compression testsperformed with a 55-mm initialthickness polyurethane foam sample.

Youngs modulus for the polyurethanefoam is estimated to be 18 kPa.

STRESS-STRAIN

DIAGRAM


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STRESS-STRAIN DIAGRAM


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Palm oil-based polyols are being derived from naturalresources hold the promise of eventually replacing a

substantial portion of petroleum based polyols in thepolyurethane market.These developments indicate that the future for palm oil-based polyol is indeed very bright and thus making theproduction of car seat cushion environmentally safe.Car seat cushion made from palm oil-based polyol is alsobiodegradable and can be made from a renewable source.

CONCLUSION

Production of Car Seat Cushion Using Palm Oil

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