CN109320682A - 汽车座椅用低密度高回弹泡沫及其制备方法 - Google Patents
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Abstract
本发明属于聚氨酯材料制造领域,具体涉及一种汽车座椅用低密度高回弹泡沫及其制备方法。所述的汽车座椅用低密度高回弹泡沫,由A组分和B组分组成,其中,A组分由以下重量份数的原料制成:多元醇B70~90份;多元醇C10~30份;交联剂1~2份;物理发泡剂2.5~3.5份;化学发泡剂3~4份;匀泡剂1~1.5份;催化剂0.8~1份;开孔剂2~4份;B组分为异氰酸酯。本发明制备的汽车座椅用低密度高回弹泡沫,泡沫密度低于50kg/m3,回弹率在70%左右,性能优于现有传统工艺泡沫;所述的制备方法,简单高效。
Description
技术领域
本发明属于聚氨酯材料制造领域,具体涉及一种汽车座椅用低密度高回弹泡沫及其制备方法。
背景技术
随着汽车行业的快速发展,人们对汽车内饰的要求越来越高,汽车座椅作为汽车内饰的重要组成部分,其内部填充物的性能直接与用户的安全驾驶及舒适度紧密相关。据相关研究结果显示,汽车重量每减少100kg,每百公里可节省燃油0.3L,每公里二氧化碳排放量也将减少7.5g-12.5g,全国二氧化碳排放量减少3000万吨,汽车轻量化、舒适安全、环境友好,已成为汽车用材料发展的三大主题。
汽车轻量化的实现,势必从低密度入手,在当前传统原材料前提下,低密度泡沫的承载性是一大急需解决的问题,通常是通过增加聚合物多元醇占比来实现,然而这种解决办法带来的是VOC含量的升高及物料生产工艺的繁琐。制备传统汽车座椅用聚醚多元醇多为分子量5000左右,环氧乙烷封端高活性聚醚多元醇,受到聚醚多元醇催化工艺的限制影响,分子量很难再继续增大。新型高分子量高活性聚醚多元醇的开发和应用,对解决当前汽车座椅轻量化问题,及提升座椅泡沫的舒适性和环保性有更大的价值。因此,如何能够降低汽车座椅泡沫密度,提升汽车座椅泡沫性能,降低产品VOC的释放,成为了当前重点研究方向和亟待解决的问题。
发明内容
针对现有技术的不足,本发明的目的是提供一种汽车座椅用低密度高回弹泡沫,泡沫密度低于50kg/m3,回弹率在70%左右,性能优于现有传统工艺泡沫;本发明还提供其制备方法,简单高效。
本发明所述的汽车座椅用低密度高回弹泡沫,由A组分和B组分组成,其中,A组分由以下重量份数的原料制成:
B组分为异氰酸酯。
其中:
所述的多元醇B为聚醚多元醇,官能度为3,是环氧乙烷封端的聚氧化丙烯聚醚多元醇,数均分子量为7200~7600;采用磷腈催化剂,甘油为起始剂,在温度90~100℃下制得,优选INOVOL F822(山东一诺威新材料有限公司)。
磷腈催化工艺,兼具KOH催化工艺和DMC催化工艺优点,制备高分子量聚醚产品,产品不饱和度低,反应活性高,制备聚醚产品可进行环氧乙烷封端得到高伯羟基占比产品,本发明采用的INOVOL F822,不饱和度低,伯羟基封端,特别有利于泡沫产品各项性能的提升,降低配方中POP占比。
所述的多元醇C是由聚醚多元醇与乙烯基单体在引发剂作用下接枝共聚而成,羟值为25~29mgKOH/g;多元醇C是一种改性聚醚多元醇,或称为聚合物多元醇或接枝聚醚多元醇,优选POP 36/28。
所述的交联剂为二乙醇胺(DEOA)、三乙醇胺(TEA)或甘油中的一种或多种。
所述的物理发泡剂为CH2Cl2或HCFC-141b,优选HCFC-141b。
所述的化学发泡剂为水。
所述的催化剂为叔胺类催化剂。优选市售的P225、A300、A1或A33中的一种或几种。
所述的匀泡剂为聚硅氧烷-氧化烯烃嵌段共聚物。
优选地,所述的匀泡剂为DC6070(空气化工)或DC2525(空气化工)中的一种或两种。
所述的开孔剂为聚醚类开孔剂,羟值32~36mgKOH/g,优选INOVOL S5000T(山东一诺威新材料有限公司)。
所述的异氰酸酯为甲苯二异氰酸(TDI)与多亚甲基多苯基异氰酸酯(PAPI)的混合物,甲苯二异氰酸与多亚甲基多苯基异氰酸酯的质量比为7:3~9:1。其中,多亚甲基多苯基异氰酸酯(PAPI)优选PM200(万华化学)。
本发明所述的汽车座椅用低密度高回弹泡沫的制备方法,步骤如下:
(1)A组分的制备:常温下,将多元醇B、多元醇C、交联剂、开孔剂、催化剂、匀泡剂、物理发泡剂和化学发泡剂加入到反应釜中,搅拌0.5~1小时,装桶密封;
(2)B组分制备:常温下,将异氰酸酯加入到反应釜中,搅拌0.5~1小时,测试NCO含量为43%~47%后,装桶密封;
(3)使用时,将A组分和B组分在22~26℃下按质量比1:0.4~0.45混合,倒入模具中反应,模温控制在45~55℃,熟化4~5min后开模,取出样件,得到汽车座椅用低密度高回弹泡沫。
与现有技术相比,本发明的有益效果如下:
1、本发明采用新型高分子量高活性聚醚多元醇,相比较330N主聚醚产品,在保持原有性能的前提下,能够将泡沫密度降低到50kg/m3以下,对于汽车行业的轻量化趋势具有积极意义。
2、本发明制备的汽车座椅用低密度高回弹泡沫,回弹率较传统工艺提升8%-10%,最高达到72%,滞后损失率和舒适因子均有较大程度的提升。高分子量高活性聚醚的应用,分子链更长,有利于回弹性的提升,此外,应用在该配方体系中降低POP用量,降低催化剂用量,节省成本,降低VOC的释放。
3、本发明的制备方法,简单高效。
具体实施方式
下面结合实施例对本发明做进一步说明,但不限定本发明。
实施例中用到的所有原料除特殊说明外,均为市购。
实施例1
所述的汽车座椅用低密度高回弹泡沫,由A组分和B组分组成,其中,A组分由以下重量份数的原料制成:
B组分由以下重量份数的原料制成:
T80 70份;
PM200 30份。
制备方法如下:
(1)A组分的制备:常温下,将INOVOL F822、POP 36/28、DEOA、HCFC-141b、水、DC6070、A1、A33、INOVOL S5000T按准确计量加入到反应釜中,搅拌1小时,装桶密封;
(2)B组分制备:常温下,将异氰酸酯按计量加入到反应釜中,搅拌1小时,测试NCO43.04%,合格后,装桶密封;
(3)使用时,将组分A和组分B按重量份在26℃下按质量比1:0.4混合,倒入模具中反应,模温控制在55℃,熟化5min后开模,取出样件,得到汽车座椅用低密度高回弹泡沫。
对制得的汽车座椅用低密度高回弹泡沫进行性能测试,测试结果见表1。
对比例1
将实施例1中的INOVOL F822采用市售的330N(山东一诺威新材料有限公司)代替,其余条件同实施例1。
对制得的泡沫进行性能测试,测试结果见表1。
表1测试结果
项目 | 实施例1 | 对比例1 | 检测标准 |
密度(kg/m<sup>3</sup>) | 45 | 45 | ISO845 |
落球回弹率(%) | 70 | 64 | ISO8307 |
拉伸强度(MPa) | 0.202 | 0.186 | ISO1798 |
撕裂强度(kN/M) | 1.045 | 1.032 | ISO8067 |
断裂伸长率(%) | 120 | 118 | ISO1798 |
舒适因子 | 2.9 | 2.8 | ISO2439 |
滞后损失率(%) | 18.2 | 23.1 | ISO3386-1 |
实施例2
所述的汽车座椅用低密度高回弹泡沫,由A组分和B组分组成,其中,A组分由以下重量份数的原料制成:
B组分由以下重量份数的原料制成:
T80 80份;
PM200 20份。
制备方法如下:
(1)A组分的制备:常温下,将INOVOL F822、POP 36/28、DEOA、HCFC-141b、水、DC6070、DC2525、A1、A33、INOVOL S5000T按准确计量加入到反应釜中,搅拌0.8小时,装桶密封;
(2)B组分制备:常温下,将异氰酸酯按计量加入到反应釜中,搅拌0.8小时,测试NCO44.76%,合格后,装桶密封;
(3)使用时,将组分A和组分B按重量份在25℃下按质量比1:0.43混合,倒入模具中反应,模温控制在50℃,熟化4min后开模,取出样件,得到汽车座椅用低密度高回弹泡沫。
对制得的汽车座椅用低密度高回弹泡沫进行性能测试,测试结果见表2。
对比例2
将实施例2中的INOVOL F822采用市售的330N(山东一诺威新材料有限公司)代替,其余条件同实施例2。
对制得的泡沫进行性能测试,测试结果见表2。
表2测试结果
项目 | 实施例2 | 对比例2 | 检测标准 |
密度(kg/m<sup>3</sup>) | 45 | 45 | ISO845 |
落球回弹率(%) | 71.5 | 65 | ISO8307 |
拉伸强度(MPa) | 0.218 | 0.193 | ISO1798 |
撕裂强度(kN/M) | 1.066 | 1.038 | ISO8067 |
断裂伸长率(%) | 125 | 124 | ISO1798 |
舒适因子 | 3.1 | 2.9 | ISO2439 |
滞后损失率(%) | 17.5 | 22.6 | ISO3386-1 |
实施例3
所述的汽车座椅用低密度高回弹泡沫,由A组分和B组分组成,其中,A组分由以下重量份数的原料制成:
B组分由以下重量份数的原料制成:
T80 90份;
PM200 10份。
制备方法如下:
(1)A组分的制备:常温下,将INOVOL F822、POP 36/28、DEOA、HCFC-141b、水、DC6070、DC2525、A1、A33、INOVOL S5000T按准确计量加入到反应釜中,搅拌0.5小时,装桶密封;
(2)B组分制备:常温下,将异氰酸酯按计量加入到反应釜中,搅拌0.5小时,测试NCO46.48%,合格后,装桶密封;
(3)使用时,将组分A和组分B按重量份在22℃下按质量比1:0.45混合,倒入模具中反应,模温控制在45℃,熟化4.5min后开模,取出样件,得到汽车座椅用低密度高回弹泡沫。
对比例3
将实施例3中的INOVOL F822采用市售的330N(山东一诺威新材料有限公司)代替,其余条件同实施例3。
对制得的泡沫进行性能测试,测试结果见表3。
表3测试结果
Claims (10)
1.一种汽车座椅用低密度高回弹泡沫,其特征在于:由A组分和B组分组成,其中,A组分由以下重量份数的原料制成:
所述的多元醇B为聚醚多元醇,官能度为3,是环氧乙烷封端的聚氧化丙烯聚醚多元醇,数均分子量为7200~7600;
所述的多元醇C是由聚醚多元醇与乙烯基单体在引发剂作用下接枝共聚而成,羟值为25~29mgKOH/g;
B组分为异氰酸酯。
2.根据权利要求1所述的汽车座椅用低密度高回弹泡沫,其特征在于:所述的多元醇B,采用磷腈催化剂,甘油为起始剂,在温度90~100℃下制得。
3.根据权利要求1所述的汽车座椅用低密度高回弹泡沫,其特征在于:所述的交联剂为二乙醇胺、三乙醇胺或甘油中的一种或多种。
4.根据权利要求1所述的汽车座椅用低密度高回弹泡沫,其特征在于:所述的化学发泡剂为水。
5.根据权利要求1所述的汽车座椅用低密度高回弹泡沫,其特征在于:所述的催化剂为叔胺类催化剂。
6.根据权利要求1所述的汽车座椅用低密度高回弹泡沫,其特征在于:所述的匀泡剂为聚硅氧烷-氧化烯烃嵌段共聚物。
7.根据权利要求6所述的汽车座椅用低密度高回弹泡沫,其特征在于:所述的匀泡剂为DC6070或DC2525中的一种或两种。
8.根据权利要求1所述的汽车座椅用低密度高回弹泡沫,其特征在于:所述的开孔剂为聚醚类开孔剂,羟值32~36mgKOH/g。
9.根据权利要求1所述的汽车座椅用低密度高回弹泡沫,其特征在于:所述的异氰酸酯为甲苯二异氰酸与多亚甲基多苯基异氰酸酯的混合物,甲苯二异氰酸与多亚甲基多苯基异氰酸酯的质量比为7:3~9:1。
10.一种权利要求1-9任一所述的汽车座椅用低密度高回弹泡沫的制备方法,其特征在于:步骤如下:
(1)A组分的制备:常温下,将多元醇B、多元醇C、交联剂、开孔剂、催化剂、匀泡剂、物理发泡剂和化学发泡剂加入到反应釜中,搅拌0.5~1小时,装桶密封;
(2)B组分制备:常温下,将异氰酸酯加入到反应釜中,搅拌0.5~1小时,测试NCO含量为43%~47%后,装桶密封;
(3)使用时,将A组分和B组分在22~26℃下按质量比1:0.4~0.45混合,倒入模具中反应,模温控制在45~55℃,熟化4~5min后开模,得到汽车座椅用低密度高回弹泡沫。
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