CN108864395A - 聚氨酯泡沫的制备方法 - Google Patents
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Abstract
本发明涉及一种聚氨酯泡沫的制备方法,主要解决现有技术中生产聚氨酯板材材料成本高和劳动强度大的问题。本发明通过采用一种聚氨酯泡沫的制备方法,包括以下步骤:1、准备发泡箱:发泡箱呈四方体形状,在发泡箱内的所需位置设置异形模腔,采用高分子复合纸布或高分子膜覆盖发泡箱内表面和异形模腔外表面;2、制备聚氨酯泡沫:向发泡箱内注入聚氨酯发泡材料,采用压顶工装工艺自由发泡得中间所需位置含异形孔的聚氨酯泡沫,较好地解决了该问题,可用于汽车顶篷材料中。
Description
技术领域
本发明涉及一种聚氨酯泡沫的制备方法。
背景技术
聚氨酯泡沫在汽车内饰件中占有重要地位,汽车的顶蓬采用了聚氨酯半硬泡。目前传统的聚氨酯发泡行业中采取全尺寸发泡形式,即整体式全尺寸的长方体发泡形状,但是目前汽车行业中带天窗的车型占比近70%,其中汽车顶棚成型中使用的聚氨酯车顶板材为整体的全尺寸板材,成型后天窗部分为多余的废料,裁剪后直接采取报废的处理方式,针对聚氨酯泡沫板材而言造成比较严重的材料浪费增加材料成本,同时裁剪聚氨酯板材时需要消耗大量的劳动力成本。
CN201710806820.3涉及一种箱式聚氨酯泡沫的制备方法,采用发泡箱压顶工装,在发泡箱压顶工装顶盖打孔,同时采用高分子膜覆盖压顶工装顶盖内表面的技术方案。在现有技术中采用发泡箱全尺寸发泡,得到的聚氨酯泡沫是全尺寸聚氨酯泡沫形状,需要成型裁剪天窗部分多余的废料,增加材料成本和劳动力成本。
发明内容
本发明所要解决的技术问题是现有技术中生产聚氨酯板材材料成本高和劳动强度大的问题,提供一种新的聚氨酯泡沫的制备方法,采用该制备方法具有材料成本低和劳动强度小的优点。
为解决上述技术问题,本发明采用的技术方案如下:一种聚氨酯泡沫的制备方法,包括以下步骤:
1)准备发泡箱:发泡箱呈四方体形状,在发泡箱内的所需位置设置异形模腔,采用高分子复合纸布或高分子膜覆盖发泡箱内表面和异形模腔外表面;
2)制备聚氨酯泡沫:向发泡箱内注入聚氨酯发泡材料,采用压顶工装工艺自由发泡得中间所需位置含异形孔的聚氨酯泡沫。
上述技术方案中,优选地,在采用压顶工装工艺自由发泡时,发泡箱设置有压顶工装顶盖,且在顶盖上,与异形模腔接触的相应位置开设使异形模腔穿过顶盖的异形孔Ⅰ,在顶盖上其余部分开设有小孔Ⅱ。
上述技术方案中,优选地,异形模腔的高度大于发泡箱的高度;在发泡箱的异形压顶工装顶盖上开设小孔Ⅱ,小孔Ⅱ的间距为20~40cm,小孔Ⅱ的孔径为1~4cm,小孔Ⅱ的开孔率即面积百分比为15~30%。
上述技术方案中,优选地,发泡箱的高度为0.8~1.2m,异形模腔的高度为0.9~1.3m。
上述技术方案中,优选地,步骤2)中向发泡箱中注入聚氨酯发泡材料时,先将发泡箱倾斜,倾斜角度α为1~15°,待聚氨酯发泡材料注入完毕后放平;异形模腔呈长方体、立方体或圆形柱状;高分子复合纸布选自聚丙烯复合纸布、聚乙烯复合纸布或聚酰胺复合纸布中的至少一种;高分子膜选自聚丙烯膜、聚乙烯膜或聚酰胺膜中的至少一种。
上述技术方案中,更优选地,发泡箱的高度为1m,异形发泡腔的高度为1.1m。
上述技术方案中,更优选地,发泡箱的异形压顶工装顶盖上开设小孔Ⅱ,小孔Ⅱ的间距为25~35cm,小孔Ⅱ的孔径为2~3cm,小孔Ⅱ的开孔率即面积百分比为20~25%。
上述技术方案中,更优选地,步骤2)中向发泡箱中注入聚氨酯发泡材料时,先将发泡箱倾斜,倾斜角度α为5~10°,待聚酯发泡材料注入完毕后放平。
上述技术方案中,优选地,聚氨酯发泡材料由组分A和组分B组成,组分A为白料,组分B为黑料,组分A和组分B的重量百分比为1:0.9~1.4;组分A中:以重量百分比计包括:聚醚多元醇Ⅰ:10~40%,聚醚多元醇Ⅱ:10~50%,聚酯多元醇:10~50%,泡沫稳定剂:1~4%,催化剂:1~5%,物理发泡剂:10~20%,水:0.1~1.5%,助剂:0.1~1%;聚醚多元醇Ⅰ为4~5.5官能度,数均分子量为300~500的聚醚多元醇;聚醚多元醇Ⅱ为2~3官能度,数均分子量为200~2000的聚醚多元醇,聚酯多元醇为2~3官能度,羟值为240~400的聚酯多元醇;泡沫稳定剂为非水解硅碳类表面活性剂、聚硅氧烷型表面活性剂中的至少一种;物理发泡剂为氟化烷烃;催化剂为胺类催化剂或金属催化剂中的至少一种;助剂选自色浆、抗氧剂或分散剂中的至少一种;组分B为多次甲基多苯基多异氰酸酯。
上述技术方案中,优选地,物理发泡剂选自一氟二氯乙烷、1,1,1,3,3-五氟丁烷、1,1,1,3,3-五氟丙烷、1,1,1,2-四氟乙烷、二氟乙烷或七氟丙烷中的至少一种;助剂中色浆为TEGOCOLOR公司的Black HI、Blue2或宝美施公司的031-9NN015中的至少一种;抗氧剂为抗氧剂245、抗氧剂1010或抗氧剂1035中的至少一种;分散剂为OMG Borchers公司的Gen0451或Ger0851中的至少一种;催化剂为乙酸钾、异辛酸钾、三乙烯二胺、二月桂酸二丁基锡、N,N’,N”-三(二甲基氨基丙基)六氢三嗪、三-3-二甲基氨基丙胺、五甲基二乙三胺、五甲基二丙三胺、三甲基氨基乙基乙醇胺、二甲基氨基乙氧基乙醇或2,4,6-三(二甲基氨基乙基)苯酚中的至少一种。
本发明中,在聚氨酯发泡箱内所需位置设置异形模腔,采用该具有异形模腔的发泡箱,采用压顶工装工艺进行发泡,得到中间具有所需异形孔的聚氨酯泡沫材料,该聚氨酯泡沫材料在成型聚氨酯顶棚材料时,无需去除天窗部位多余的材料,降低了材料成本,降低了工人的劳动强度;在发泡箱中注入聚氨酯发泡材料时,先倾斜注料,倾斜角度α为1~15°,待聚酯发泡材料注入完毕后放平,得到该聚氨酯泡沫材料密度均匀,上下密度差异小于2kg/m3,取得了较好的技术效果。
下面通过实施例对本发明作进一步的阐述,但不仅限于本实施例。
附图说明
附图1是设置有异形模腔的发泡箱示意图。
附图2是设置有α倾斜角度的异形模腔发泡箱示意图。
附图3是发泡箱异形压顶工装顶盖俯视图示意图。
其中,附图1或附图2中,1是异形模腔,2是发泡箱箱体,α是发泡箱倾斜线与平面的倾斜角度;附图3中,3是小孔Ⅱ,4是孔Ⅰ。
具体实施方式
实施例1
(1)准备发泡箱:发泡箱呈长方体形状,高度为1m,在发泡箱内的所需位置设置长方体模腔,高度为1.1m,采用聚丙烯复合纸布覆盖发泡箱内表面和异形模腔外表面;
(2)准备聚氨酯发泡材料:将以下组分混合制得组分A,组分A:50kg;聚醚多元醇Ⅰ(官能度为4,数均分子量为300):10kg,聚醚多元醇Ⅱ(官能度为2,数均分子量为200):15kg,聚酯多元醇(官能度为2,数均分子量为240):10kg,水解硅碳类表面活性剂:2kg,N”-三(二甲基氨基丙基)六氢三嗪:2kg,七氟丙烷:10kg,水:0.75kg,Black HI(TEGOCOLOR公司):0.25kg;制备组分B,多次甲基多苯基多异氰酸酯:75kg;
(3)制备压顶工装:在发泡箱的压顶工装顶盖上与异形模腔接触的相应位置开设使异形模腔穿过顶盖的异形孔Ⅰ,同时在顶盖上打小孔Ⅱ,小孔Ⅱ间距为20cm,小孔Ⅱ孔径为1cm,小孔Ⅱ开孔率即面积百分比为15%;在压顶工装顶盖内表面覆盖聚丙烯复合纸布;
(4)制备聚氨酯泡沫:向发泡箱内注入聚氨酯发泡材料,先倾斜注料,倾斜角度α为10°,待所有聚酯发泡材料注入完毕后放平;采用压顶工装工艺自由发泡得中间所需异形孔的聚氨酯泡沫。得到中间具有异形孔的聚氨酯泡沫,降低15%的原材料成本,降低了工人手工裁剪聚氨酯天窗部门的劳动强度。所得到聚氨酯泡沫的产品质量如表1所示。
实施例2
(1)准备发泡箱:发泡箱呈长方体形状,高度为1.1m,在发泡箱内的所需位置设置长方体模腔,高度为1.2m,采用聚丙烯膜覆盖发泡箱内表面和异形模腔外表面;
(2)准备聚氨酯发泡材料:将以下组分混合制得组分A,组分A:50kg;聚醚多元醇Ⅰ(官能度为4,数均分子量为300):10kg,聚醚多元醇Ⅱ(官能度为2,数均分子量为200):20kg,聚酯多元醇(官能度为2,数均分子量为240):10kg,水解硅碳类表面活性剂:2kg,N,N’,N”-三(二甲基氨基丙基)六氢三嗪:2kg,七氟丙烷:5kg,水:0.75kg,Black HI(TEGOCOLOR公司):0.25kg;制备组分B,多次甲基多苯基多异氰酸酯:75kg;
(3)制备压顶工装:在发泡箱的压顶工装顶盖上与异形模腔接触的相应位置开设使异形模腔穿过顶盖的异形孔Ⅰ,同时在顶盖上打小孔Ⅱ,小孔Ⅱ间距为30cm,小孔Ⅱ孔径为3cm,小孔Ⅱ开孔率即面积百分比为30%;在压顶工装顶盖内表面覆盖聚丙烯膜;
(4)制备聚氨酯泡沫:向发泡箱内注入聚氨酯发泡材料,先倾斜注料,倾斜角度α为15°,待所有聚酯发泡材料注入完毕后放平;采用压顶工装工艺自由发泡得中间所需异形孔的聚氨酯泡沫。得到中间具有异形孔的聚氨酯泡沫,降低12%的原材料成本,降低了工人手工裁剪聚氨酯天窗部门的劳动强度。所得到聚氨酯泡沫的产品质量如表1所示。
实施例3
(1)准备发泡箱:发泡箱呈长方体形状,高度为1.1m,在发泡箱内的所需位置设置长方体模腔,高度为1.2m,采用聚乙烯复合纸布覆盖发泡箱内表面和异形模腔外表面;
(2)准备聚氨酯发泡材料:将以下组分混合制得组分A,组分A:50kg;聚醚多元醇Ⅰ(官能度为4,数均分子量为300):10kg,聚醚多元醇Ⅱ(官能度为2,数均分子量为200):20kg,聚酯多元醇(官能度为2,数均分子量为240):10kg,水解硅碳类表面活性剂:2kg,N,N’,N”-三(二甲基氨基丙基)六氢三嗪:2kg,七氟丙烷:5kg,水:0.75kg,Black HI(TEGOCOLOR公司):0.25kg;制备组分B,多次甲基多苯基多异氰酸酯:75kg;
(3)制备压顶工装:在发泡箱的压顶工装顶盖上与异形模腔接触的相应位置开设使异形模腔穿过顶盖的异形孔Ⅰ,同时在顶盖上打小孔Ⅱ,小孔Ⅱ间距为30cm,小孔Ⅱ孔径为3cm,小孔Ⅱ开孔率即面积百分比为30%;在压顶工装顶盖内表面覆盖聚乙烯复合纸布;
(4)制备聚氨酯泡沫:向发泡箱内注入聚氨酯发泡材料,先倾斜注料,倾斜角度α为5°,待所有聚酯发泡材料注入完毕后放平;采用压顶工装工艺自由发泡得中间所需异形孔的聚氨酯泡沫。得到中间具有异形孔的聚氨酯泡沫,降低12%的原材料成本,降低了工人手工裁剪聚氨酯天窗部门的劳动强度。所得到聚氨酯泡沫的产品质量如表1所示。
实施例4
(1)准备发泡箱:发泡箱呈正方体形状,高度为0.9m,在发泡箱内的所需位置设置正方体模腔,高度为1m,采用聚酰胺膜覆盖发泡箱内表面和异形模腔外表面;
(2)准备聚氨酯发泡材料:将以下组分混合制得组分A,组分A:50kg;聚醚多元醇Ⅰ(官能度为4,数均分子量为300):10kg,聚醚多元醇Ⅱ(官能度为2,数均分子量为200):20kg,聚酯多元醇(官能度为2,数均分子量为240):10kg,水解硅碳类表面活性剂:2kg,N,N’,N”-三(二甲基氨基丙基)六氢三嗪:2kg,七氟丙烷:5kg,水:0.75kg,Black HI(TEGOCOLOR公司):0.25kg;制备组分B,多次甲基多苯基多异氰酸酯:75kg;
(3)制备压顶工装:在发泡箱的压顶工装顶盖上与异形模腔接触的相应位置开设使异形模腔穿过顶盖的异形孔Ⅰ,同时在顶盖上打小孔Ⅱ,小孔Ⅱ间距为30cm,小孔Ⅱ孔径为3cm,小孔Ⅱ开孔率即面积百分比为30%;在压顶工装顶盖内表面覆盖聚酰胺膜;
(4)制备聚氨酯泡沫:将发泡箱放平,向发泡箱内注入聚氨酯发泡材料,α为0°,采用压顶工装工艺自由发泡得中间所需异形孔的聚氨酯泡沫。得到中间具有异形孔的聚氨酯泡沫,降低10%的原材料成本,降低了工人手工裁剪聚氨酯天窗部门的劳动强度。所得到聚氨酯泡沫的产品质量如表1所示。
比较例1
(1)准备发泡箱:发泡箱呈长方体形状,高度为1m,,采用聚丙烯复合纸布覆盖发泡箱内表面;
(2)准备聚氨酯发泡材料:将以下组分混合制得组分A,组分A:50kg;聚醚多元醇Ⅰ(官能度为4,数均分子量为300):10kg,聚醚多元醇Ⅱ(官能度为2,数均分子量为200):20kg,聚酯多元醇(官能度为2,数均分子量为240):10kg,水解硅碳类表面活性剂:2kg,N,N’,N”-三(二甲基氨基丙基)六氢三嗪:2kg,七氟丙烷:5kg,水:0.75kg,Black HI(TEGOCOLOR公司):0.25kg;制备组分B,多次甲基多苯基多异氰酸酯:75kg;
(3)制备压顶工装:在发泡箱的压顶工装顶盖上上打小孔,小孔间距为20cm,小孔孔径为1cm,开孔率即面积百分比为15%;在压顶工装顶盖内表面覆盖聚丙烯复合纸布;
(4)制备聚氨酯泡沫:向发泡箱内注入聚氨酯发泡材料,α为0°,采用压顶工装工艺自由发泡得聚氨酯泡沫。得到中间不具有异形孔的聚氨酯泡沫,在汽车顶棚成型过程,需要去除天窗位置,增加了10%的原材料成本,增加了工人手工裁剪聚氨酯天窗部门的劳动强度。所得到聚氨酯泡沫的产品质量如表1所示。
Claims (8)
1.一种聚氨酯泡沫的制备方法,包括以下步骤:
1)准备发泡箱:发泡箱呈四方体形状,在发泡箱内的所需位置设置异形模腔,采用高分子复合纸布或高分子膜覆盖发泡箱内表面和异形模腔外表面;
2)制备聚氨酯泡沫:向发泡箱内注入聚氨酯发泡材料,采用压顶工装工艺自由发泡得中间所需位置含异形孔的聚氨酯泡沫。
2.根据权利要求1所述的聚氨酯泡沫的制备方法,其特征在于在采用压顶工装工艺自由发泡时,发泡箱设置有压顶工装顶盖,且在顶盖上,与异形模腔接触的相应位置开设使异形模腔穿过顶盖的异形孔Ⅰ,在顶盖上其余部分开设有小孔Ⅱ。
3.根据权利要求2所述的聚氨酯泡沫的制备方法,其特征在于异形模腔的高度大于发泡箱的高度;在发泡箱的异形压顶工装顶盖上开设小孔Ⅱ,小孔Ⅱ的间距为20~40cm,小孔Ⅱ的孔径为1~4cm,小孔Ⅱ的开孔率即面积百分比为15~30%。
4.根据权利要求3所述的聚氨酯泡沫的制备方法,其特征在于发泡箱的高度为0.8~1.2m,异形模腔的高度为0.9~1.3m。
5.根据权利要求1所述的聚氨酯泡沫的制备方法,其特征在于步骤2)中向发泡箱中注入聚氨酯发泡材料时,先将发泡箱倾斜,倾斜角度α为1~15°,待聚氨酯发泡材料注入完毕后放平;异形模腔呈长方体、立方体或圆形柱状;高分子复合纸布选自聚丙烯复合纸布、聚乙烯复合纸布或聚酰胺复合纸布中的至少一种;高分子膜选自聚丙烯膜、聚乙烯膜或聚酰胺膜中的至少一种。
6.根据权利要求4所述的聚氨酯泡沫的制备方法,其特征在于发泡箱的高度为1m,异形发泡腔的高度为1.1m。
7.根据权利要求3所述的聚氨酯泡沫的制备方法,其特征在于发泡箱的异形压顶工装顶盖上开设小孔Ⅱ,小孔Ⅱ的间距为25~35cm,小孔Ⅱ的孔径为2~3cm,小孔Ⅱ的开孔率即面积百分比为20~25%。
8.根据权利要求5所述的聚氨酯泡沫的制备方法,其特征在于步骤2)中向发泡箱中注入聚氨酯发泡材料时,先将发泡箱倾斜,倾斜角度α为5~10°,待聚酯发泡材料注入完毕后放平。
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