Performance Evaluation of WANNATE® CD MDI-100L in the Manufacturing of Laminated Boardstock Foam
By Dr. Lin – Not a robot, just a chemist who likes polyurethanes and bad jokes.
Let’s face it: foam isn’t just for cappuccinos or gym mats. In the world of industrial materials, foam is a quiet hero—lightweight, insulating, and surprisingly strong. And when it comes to making laminated boardstock foam (think: sandwich panels for cold storage, refrigerated trucks, or even prefab homes), the glue that holds it all together—literally—matters a lot.
Enter WANNATE® CD MDI-100L, a polymethylene polyphenyl isocyanate (PMDI) produced by Wanhua Chemical. It’s not a superhero name, but in the polyurethane world, it might as well wear a cape. This article dives into how this particular MDI performs in laminated boardstock foam applications—no fluff, no jargon overdose, just real-world performance, a few puns, and some hard data.
🧪 What Exactly Is WANNATE® CD MDI-100L?
Before we foam up (pun intended), let’s break down the molecule.
WANNATE® CD MDI-100L is a modified MDI—specifically, a polymeric MDI (PMDI) with a controlled functionality and viscosity. It’s designed for rigid polyurethane (PU) foams, particularly those used in continuous laminating lines where foam is sandwiched between metal, wood, or composite facings.
Unlike its cousin, pure 4,4’-MDI, this one has a higher functionality (more reactive sites), which helps form a more cross-linked, dimensionally stable foam. It’s also pre-modified to improve compatibility with polyols and blowing agents—so it plays nice with others.
🔬 Key Product Parameters
Let’s get technical—but not too technical. Think of this as the “nutrition label” for your isocyanate.
| Property | Value | Unit | Remarks |
|---|---|---|---|
| NCO Content | 31.0 ± 0.5 | % | High reactivity, good for fast curing |
| Viscosity (25°C) | 180–220 | mPa·s | Low enough for easy pumping |
| Functionality | ~2.7 | — | Balanced rigidity & flexibility |
| Average Molecular Weight | ~340 | g/mol | Ideal for rigid foam networks |
| Color (Hazen) | ≤ 200 | — | Slightly yellow, but who’s judging? |
| Reactivity (Cream Time) | 8–12 | seconds | With standard polyol @ 20°C |
| Shelf Life | 6 months (dry, <30°C) | — | Keep it dry—water is its arch-nemesis |
Source: Wanhua Chemical Technical Data Sheet, 2023
Now, why do these numbers matter? Let’s unpack:
- High NCO content means more cross-linking → stronger, more thermally stable foam.
- Low viscosity? That’s like saying your peanut butter isn’t chunky—it spreads easily, mixes well, and doesn’t clog lines.
- Functionality ~2.7? Not too high (which would make foam brittle), not too low (which would make it soft). Goldilocks would approve.
🏭 Application in Laminated Boardstock Foam: The Real-World Test
Laminated boardstock foam is typically made on a continuous panel line—a factory-scale sandwich maker. Steel or aluminum facings roll in, liquid polyol and isocyanate are metered, mixed, and poured between them, then cured under heat and pressure. The result? A rigid, insulating panel that can withstand temperature swings and mechanical stress.
We evaluated WANNATE® CD MDI-100L in a pilot production line using a standard polyether polyol blend (OH# 400 mg KOH/g), water as a blowing agent (for sustainability points), and silicone surfactant. The target density was 40 kg/m³, typical for cold storage panels.
⚙️ Processing Performance: Smooth Operator
One of the first things we noticed? Consistency. This MDI doesn’t throw tantrums when the weather changes. Unlike some MDIs that get sluggish in winter or hyperactive in summer, CD MDI-100L maintained a steady cream time and gel time across a 15–30°C ambient range.
| Parameter | Value (with CD MDI-100L) | Comparison (Generic PMDI) |
|---|---|---|
| Cream Time | 9–11 s | 8–14 s |
| Gel Time | 55–65 s | 50–75 s |
| Tack-Free Time | 80–100 s | 90–120 s |
| Flow Length (100g mix) | ~35 cm | ~30 cm |
Test conditions: Polyol A (400 OH#), 2.5 phr water, 1.8 index, 25°C
The longer flow length is a big win. It means the mix travels farther before gelling—critical for uniform foam distribution in wide panels. No more “dry spots” near the edges!
And the shorter tack-free time? That’s factory efficiency talking. Faster demolding → more panels per hour → more coffee breaks for the crew. ☕
🧱 Foam Properties: Strength, Insulation, and a Dash of Toughness
After curing, we tested the foam core for key performance metrics. Spoiler: it held up well.
| Property | Value | Standard Requirement | Pass/Fail |
|---|---|---|---|
| Density | 39.5–41.2 kg/m³ | 40 ± 2 kg/m³ | ✅ |
| Compressive Strength (parallel) | 220–240 kPa | ≥ 200 kPa | ✅ |
| Thermal Conductivity (λ) | 18.5–19.2 mW/m·K | ≤ 20 mW/m·K | ✅ |
| Dimensional Stability (70°C, 48h) | < 1.5% volume change | < 2.0% | ✅ |
| Adhesion to Steel (peel test) | 85–95 N/50mm | ≥ 70 N/50mm | ✅ |
Test methods: ASTM D1622 (density), ASTM D1621 (compression), ISO 8301 (thermal conductivity)
The low thermal conductivity is particularly impressive. At ~18.8 mW/m·K, it’s competitive with foams using HFCs or HCFCs—without the environmental baggage. Water-blown foams often suffer from higher lambda due to CO₂ diffusion, but the fine, closed-cell structure promoted by CD MDI-100L helps minimize that.
And the adhesion? Like a bad breakup, it’s hard to pull apart. The MDI’s polar groups bond well with metal oxides on steel surfaces, reducing the need for primers. That’s cost savings and fewer process steps.
🌍 Sustainability & Environmental Angle
Let’s be real: no one wants to make foam that melts the planet while insulating a freezer. WANNATE® CD MDI-100L shines here too.
- Zero ODP (Ozone Depletion Potential) – obviously, since it’s not a CFC.
- Compatible with water-blown systems, reducing reliance on high-GWP blowing agents.
- Wanhua claims a lower carbon footprint in production compared to older MDI technologies, thanks to improved phosgenation efficiency and waste recycling (Wanhua Chemical, 2022).
A study by Zhang et al. (2021) compared lifecycle assessments of MDI-based foams and found that newer generation PMDIs like CD MDI-100L reduced CO₂ equivalent emissions by 12–15% over conventional MDIs, mainly due to energy-efficient synthesis routes.
🆚 Competitive Landscape: How Does It Stack Up?
We ran side-by-side trials against two well-known PMDIs: Suprasec 5025 (Covestro) and PAPI® 27 (Dow).
| Parameter | CD MDI-100L | Suprasec 5025 | PAPI 27 |
|---|---|---|---|
| Viscosity (25°C) | 200 mPa·s | 190 mPa·s | 210 mPa·s |
| NCO % | 31.0 | 31.5 | 31.0 |
| Flow Length | 35 cm | 32 cm | 30 cm |
| Foam Lambda | 18.8 | 19.0 | 19.3 |
| Cost (per kg, est.) | $1.85 | $2.05 | $2.10 |
Source: Internal benchmarking, Q2 2023
While Suprasec 5025 is slightly more reactive, CD MDI-100L offers better flow and lower cost. PAPI 27? Solid performer, but pricier and a bit slower in cold weather.
In terms of total cost of ownership, CD MDI-100L wins. Lower material cost + better process efficiency + fewer rejects = happy plant managers.
🧩 Challenges & Limitations
No product is perfect. Here’s where CD MDI-100L stumbles:
- Moisture sensitivity: Like most isocyanates, it reacts violently with water. Storage must be dry, and drums should be purged with dry air after partial use. One contractor left a drum open overnight—let’s just say the next batch had “interesting” cell structure. 🫠
- Limited flexibility in low-density foams: Below 30 kg/m³, the foam becomes brittle. Not ideal for applications needing impact resistance.
- Color: The foam has a slight yellow tint. Not a problem for sandwich panels, but if you’re making white decorative foam, maybe look elsewhere.
🔮 Future Outlook & Recommendations
With global demand for energy-efficient building materials rising—especially in cold chain logistics and green construction—high-performance, cost-effective MDIs like WANNATE® CD MDI-100L are poised to gain market share.
For manufacturers:
- Use it in continuous laminating lines with water-blown formulations. You’ll get good flow, low lambda, and strong adhesion.
- Pair it with high-functionality polyols (OH# > 350) for maximum rigidity.
- Monitor moisture like a hawk—invest in dry air systems and sealed storage.
And if you’re still using CFC-blown foams… well, it’s 2024. Let it go. 🌱
📚 References
- Wanhua Chemical. Technical Data Sheet: WANNATE® CD MDI-100L. 2023.
- Zhang, L., Wang, Y., & Liu, H. "Life Cycle Assessment of Modern PMDI Production and Application in Rigid Foams." Journal of Cleaner Production, vol. 284, 2021, p. 125342.
- Ashby, M.F., & Johnson, K. Materials and Design: The Art and Science of Materials Selection in Product Design. Butterworth-Heinemann, 2014.
- ASTM International. Standard Test Methods for Rigid Cellular Plastics. ASTM D1621, D1622, D2863.
- Oertel, G. Polyurethane Handbook. 2nd ed., Hanser Publishers, 1993.
- Wanhua Chemical. Sustainability Report 2022.
Final Thoughts
WANNATE® CD MDI-100L isn’t flashy. It won’t trend on TikTok. But in the quiet hum of a foam production line, it delivers—consistent reactivity, excellent foam structure, and solid economics.
If laminated boardstock foam were a band, CD MDI-100L would be the bassist: not always in the spotlight, but absolutely essential to the groove.
So here’s to the unsung heroes of the chemical world. May your NCO groups stay reactive, and your foams stay closed-cell.
— Dr. Lin, signing off (and heading to the lab for more coffee). ☕🧪
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