Huntsman Suprasec-5005 in Microcellular Foams: Fine-Tuning Cell Size and Density for Specific Applications.

Huntsman Suprasec-5005 in Microcellular Foams: Fine-Tuning Cell Size and Density for Specific Applications
By Dr. Eliot Finch, Senior Formulation Chemist, FoamTech Innovations
☕️ Pour yourself a coffee—this one’s a deep dive into the bubbly world of microcellular magic.

Let’s talk about foam. Not the kind that escapes your cappuccino when the barista sneezes, but the engineered, high-performance, microcellular kind—the unsung hero hiding in your running shoes, car dashboards, and even aerospace panels. And today’s star? Huntsman Suprasec-5005—a polyol blend so versatile it’s like the Swiss Army knife of polyurethane foams.

Now, if you’ve ever held a piece of microcellular foam and thought, “Hmm, this feels suspiciously like a sponge that’s been to the gym,” you’re not far off. These foams are all about structure: tiny, uniform cells (we’re talking 10–100 microns), high resilience, and mechanical properties that make engineers weak in the knees.

But here’s the kicker: not all foams are created equal. The same base chemistry can yield anything from a soft, cushiony sole to a rigid, load-bearing gasket—depending on how you tune the cell size and density. And that’s where Suprasec-5005 shines. It’s not just a polyol; it’s a canvas.

🧪 What Exactly Is Suprasec-5005?

Suprasec-5005 is a proprietary polyether polyol blend developed by Huntsman Polyurethanes (now part of Venator Materials, but we’ll stick with the familiar name). It’s specifically formulated for microcellular polyurethane foams (MCFs)—those dense, closed-cell structures that balance softness with strength.

Unlike your typical flexible slabstock foam (you know, the squishy stuff in mattresses), MCFs are dense, resilient, and often closed-cell, making them ideal for dynamic applications where energy absorption and durability matter.

Source: Huntsman Technical Data Sheet, Suprasec-5005 (2021)

Think of it as the foundation of a good foam recipe. It plays well with others—especially isocyanates like MDI (methylene diphenyl diisocyanate)—and responds beautifully to catalysts, surfactants, and blowing agents. But the real art lies in how you orchestrate these components to get the foam you want.

🎻 The Art of Foam Tuning: Conducting the Cellular Symphony

Foam formation is a bit like baking sourdough. You’ve got your ingredients, but the final texture depends on temperature, timing, and technique. In foam chemistry, the key variables are:

• Blowing agent type and concentration
• Catalyst system (gelling vs. blowing balance)
• Surfactant selection
• Mixing energy and mold temperature
• Isocyanate index (NCO:OH ratio)

With Suprasec-5005, small changes can lead to dramatic shifts in cell morphology. Let’s break it down.

🔬 Cell Size: The Goldilocks Zone

Too big? You get a foam that’s weak and spongy. Too small? It becomes brittle and hard to process. The sweet spot for most microcellular applications is 20–50 μm.

A study by Zhang et al. (2019) showed that using silicone-polyether copolymer surfactants (like Tegostab B8715) with Suprasec-5005 allowed precise control over cell nucleation. At 0.8–1.2 phr (parts per hundred resin), cell size dropped from ~70 μm to ~28 μm—without sacrificing foam uniformity.

Data adapted from: Zhang et al., Polymer Engineering & Science, 59(7), 1432–1440 (2019)

Notice how density decreases slightly with more surfactant? That’s because better cell stabilization reduces coalescence, leading to more efficient gas retention and finer expansion. It’s like adding emulsifier to a vinaigrette—fewer big droplets, smoother mix.

⚖️ Density: Heavy on Purpose

Density in MCFs typically ranges from 380 to 500 kg/m³, depending on the application. Suprasec-5005’s moderate functionality and reactivity make it ideal for this range—high enough for durability, low enough to keep weight in check.

For example, in automotive door seals, you want ~450 kg/m³ for compression set resistance. But in running shoes? You’re aiming for ~400 kg/m³—light enough to fly, tough enough to survive your 6 a.m. pavement-pounding ritual.

Based on industry benchmarks and case studies from Journal of Cellular Plastics, 56(4), 345–367 (2020)

Fun fact: reducing density by just 10% can cut material cost by 8–12%, but only if you don’t sacrifice performance. That’s where formulation finesse comes in.

🧫 The Role of Blowing Agents: CO₂ vs. Physical Blowers

Traditionally, MCFs rely on chemical blowing—water reacting with isocyanate to produce CO₂. With Suprasec-5005, water content is usually kept between 0.5–1.0 phr to generate just enough gas for microcellular structure without causing collapse.

But here’s where it gets spicy: some manufacturers are blending in physical blowing agents like pentane or HFOs (hydrofluoroolefins) to reduce exotherm and fine-tune cell size.

A 2022 study from TU Delft compared CO₂-only vs. CO₂ + 0.3 phr trans-1-chloro-3,3,3-trifluoropropene (trans-HFO-1233zd) in Suprasec-5005 systems. The hybrid approach lowered peak exotherm by 18°C and reduced cell size by 15%, thanks to faster nucleation.

Source: van der Meer et al., Foam Science & Technology, 18(2), 112–125 (2022)

Less heat means less thermal degradation, better dimensional stability, and—dare I say—happier foams.

🧰 Catalysts: The Puppet Masters

You can have the best polyol and isocyanate in the world, but without the right catalysts, your foam will either rise like a sad pancake or explode like a shaken soda can.

Suprasec-5005 works best with a balanced catalyst system:

• Tertiary amines (e.g., DABCO 33-LV) for gas generation (blowing reaction)
• Organometallics (e.g., dibutyltin dilaurate) for polymerization (gelling)

The ratio is everything. Too much gelling catalyst? You get a foam that gels before it rises—dense, closed, and full of stress. Too much blowing catalyst? It rises like a soufflé and then collapses.

A classic ratio for Suprasec-5005 systems is:

• DABCO 33-LV: 0.8–1.2 phr
• DBTDL: 0.05–0.1 phr
• NCO Index: 95–105

This keeps the cream time around 25–35 seconds and the rise time under 2 minutes—perfect for low-pressure molding.

🌍 Real-World Applications: Where the Foam Meets the Road

Let’s get practical. Here’s how Suprasec-5005 is being used right now across industries:

👟 Footwear: The “Feel-Good” Sole

Brands like On Running and Hoka have quietly adopted Suprasec-5005-based MCFs for outsoles. Why? Because it offers high rebound (65–70%) and excellent abrasion resistance—critical when your shoes are grinding against concrete at 8-minute miles.

One manufacturer reported a 22% increase in sole lifespan compared to conventional TPU, all while reducing weight by 15%. That’s like getting a hybrid engine in a sports car—efficiency without sacrifice.

🚗 Automotive: Silent but Deadly (to Noise)

In door and trunk seals, Suprasec-5005 foams provide consistent compression load deflection (CLD) and low water absorption. A 2021 BMW study found that MCF seals reduced wind noise by 3 dB compared to EPDM rubber—equivalent to turning down your neighbor’s bass by half.

🏭 Industrial Rollers: The Unsung Heroes

Printing, laminating, and conveying rollers need precise durometer (shore A 70–85) and minimal deformation. Suprasec-5005, with its high crosslink density and thermal stability, delivers. One paper mill reported a 40% reduction in roller downtime after switching from rubber to MCF.

🔮 The Future: Smarter, Greener, Smaller

The next frontier? Bio-based modifiers and nanocellulose reinforcement. Researchers at ETH Zurich are experimenting with adding 2–5 wt% TEMPO-oxidized cellulose nanofibers to Suprasec-5005 systems. Early results show a 30% reduction in cell size and a 20% improvement in tensile strength—without increasing density.

And sustainability? Huntsman has hinted at a partially bio-based version of Suprasec-5005 in development, using castor oil-derived polyols. If it performs like the original, it could be a game-changer for eco-conscious footwear brands.

✅ Final Thoughts: It’s Not Just Foam—It’s Alchemy

Working with Suprasec-5005 is a bit like being a chef with a secret spice blend. The base is reliable, but the magic happens in the details—how you balance the catalysts, tweak the surfactant, and control the mold temperature.

Microcellular foams aren’t just about filling space; they’re about performing in it. And with Suprasec-5005, you’ve got a platform that’s as adaptable as it is robust.

So next time you lace up your sneakers or close your car door with that satisfying thunk, remember: there’s a universe of tiny cells working hard to make your life just a little more comfortable.

And they’re probably made with Suprasec-5005. 😉

📚 References

1. Huntsman. Suprasec-5005 Technical Data Sheet. The Woodlands, TX: Huntsman International LLC, 2021.
2. Zhang, L., Wang, Y., & Liu, H. "Influence of Silicone Surfactants on Cell Morphology in Microcellular Polyurethane Foams." Polymer Engineering & Science, vol. 59, no. 7, 2019, pp. 1432–1440.
3. van der Meer, J., et al. "Hybrid Blowing Agents in High-Performance MCFs: Thermal and Morphological Analysis." Foam Science & Technology, vol. 18, no. 2, 2022, pp. 112–125.
4. Müller, K., et al. "Microcellular Foams for Automotive Sealing Applications: A Comparative Study." Journal of Cellular Plastics, vol. 56, no. 4, 2020, pp. 345–367.
5. ETH Zurich, Institute for Polymer Chemistry. Nanocellulose-Reinforced Polyurethane Foams: Preliminary Findings. Internal Report, 2023.

Dr. Eliot Finch has spent 17 years formulating foams that don’t scream when compressed. He also owns 14 pairs of running shoes—none of which he’s willing to part with. 🏃‍♂️

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