Characterization of polyurethane systems which contain low levels of free TDI

EN-7, EN-8, and EN-9 are polyurethane systems that are used in numerous applications in the Department of Energy complex. These systems contain high levels of toluene diisocyanate (TDI). Currently, TDI is being treated as a suspect human carcinogen within the Department of Energy complex. This report documents the results of a material characterization study of three polyurethane systems that contain low levels of free (potentially airborne) TDI. The characterization has been accomplished by performing a set of statistically designed experiments. The purpose of these experiments is to explore the effects of formulation and cure schedule on various material properties. In general, the material properties (pot life, glass transition temperature, hardness, and tear strength) were relatively insensitive to variation in the cure schedule. On the other hand, variation in curative level had measurable effects on material properties for the polyurethane systems studied. Furthermore, the material properties of the three low-free-TDI polyurethane systems were found to be comparable or superior (for certain curative levels) to commonly-used polyurethane systems. Thus, these low-free-TDI systems appear to be viable candidates for applications where a polyurethane is needed.