Does Polyester resin + catalyst react with uncured polyurethane foam?

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SUMMARY

The discussion centers on the interaction between polyester resin and uncured polyurethane foam. The user observed that after applying polyester resin mixed with cabosil and chopped fiberglass, the polyurethane foam underneath exhibited unusual characteristics, including a strong odor and altered texture. The resin did not cure properly, likely due to inadequate temperature conditions and the inherent variability in resin and foam formulations. The user raises concerns about potential toxic off-gassing resulting from the interaction of these uncured materials.

PREREQUISITES
  • Understanding of polyester resin properties and curing processes
  • Knowledge of polyurethane foam types and their chemical behavior
  • Familiarity with resin additives such as cabosil and fiberglass
  • Basic principles of chemical reactions between uncured compounds
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  • Research the chemical compatibility of different polyester resins with various polyurethane foams
  • Investigate the effects of temperature on the curing process of polyester resin
  • Explore safety protocols for handling uncured resins and foams
  • Learn about the toxicity of off-gassing from mixed uncured compounds
USEFUL FOR

Composite material engineers, resin formulators, and safety professionals involved in the use of polyester resins and polyurethane foams will benefit from this discussion.

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TL;DR
I used some polyurethane spray foam in a cold environment, it did not fully cure and i put polyester resin ontop of it. It never cured.
I left it on for about 3 weeks, most of the time it was in below curing temperature, sometimes below freezing, but i gave it about 15 hours of 20c+ to try to cure it. It never did, and still smelt really bad. I decided to rip off the resin that had hardened. Underneath it, the polyurethane foam looked strange, and smelled very strong of uncured resin. I dug deep into the foam, about 15cm, and the foam seemed different wherever the resin had been on top, as if it absorbed part of the resin and only partially cured.

The resin i used, i mixed with cabosil and chopped fiberglass to give it a peanut butter consistency, so i am not sure how it could have gone that deep into the foam.

Was there a reaction between the two uncured compounds? If so, is the off gassing more toxic then either of the original two compounds could produce?
 
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You would need someone versed in resins, but even then the answer would be largely "it depends". There is no one polyurethane foam, there is no one polyester resin. There are many and they differ in formulations, so I wouldn't expect a single answer to "what happened when I mixed a random foam with a random resin?".
 
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