CN109851843B - Soft polyurethane foam with excellent density distribution - Google Patents

Soft polyurethane foam with excellent density distribution Download PDF

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CN109851843B
CN109851843B CN201811585757.6A CN201811585757A CN109851843B CN 109851843 B CN109851843 B CN 109851843B CN 201811585757 A CN201811585757 A CN 201811585757A CN 109851843 B CN109851843 B CN 109851843B
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polyurethane foam
polyether
polyol
foam
weight ratio
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洪满心
李丰富
朱建军
何运伟
孙宇
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Nanjing Maysta New Materials Co ltd
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Abstract

The invention discloses a soft polyurethane foam with excellent density distribution, belongs to the technical field of polyurethane, and solves the problems of uneven density distribution, poorer foam holes and unstable foaming process of the foam in the prior art. According to the invention, the organosilicon surfactant which is synthesized in advance and has relatively low density and density gradient is applied to the preparation of the polyurethane foam, so that the density distribution of the synthesized polyurethane foam is more uniform, the foam holes are more excellent, the emulsifying property is better, and the foaming process is more stable.

Description

Soft polyurethane foam with excellent density distribution
Technical Field
The invention relates to polyurethane foam, in particular to soft polyurethane foam with excellent density distribution, belonging to the technical field of polyurethane.
Background
Polyurethane foam is mainly prepared by generating gas in the polymerization process of raw materials such as polyether (or polyester) polyol, isocyanate, water, a catalyst, a foam stabilizer and other additives, wherein the generated gas enables a reaction mixture to generate foam so as to form uniform and fine cells.
In modern general polyurethane technology, a foam stabilizer (a common organosilicon surfactant) is an indispensable component, plays roles of emulsifying a foam material, stabilizing foam and regulating foam cells, increases the intersolubility of all components, contributes to the formation of bubbles, controls the size and uniformity of the foam cells, promotes the balance of gel tension of the foam cells, enables the cell walls to have elasticity so as to retain gas and prevent the foam from collapsing, and has important influence on the cell size, structure, physical properties and manufacturing process of a foam body although the dosage of the foam stabilizer is not large.
The flexible polyurethane foam has two production modes, namely a batch method and a continuous method. Batch processes are prepared by pouring the mixed reactants into a stationary mold; whereas the continuous process is prepared by precipitating the reaction mixture on a conveyor with an interleaving paper. The soft polyurethane foam has wide application, including daily life such as sofa, bedding, clothes and the like, and industrial application such as industrial packaging, filtration and the like.
Polyurethane foams are generally prepared by reacting di (or poly) isocyanates under certain conditions with active hydrogen compounds, usually polyether (or polyester) polyols, water and alcohols. In the preparation of polyurethane foams, three reaction types are mainly involved, namely: the chain extension reaction, the gas generation reaction and the crosslinking reaction all proceed simultaneously at a relatively fast rate in the production of polyurethane foam.
After the 21 st century, liquid CO was successively developed by Henry corporation of the Italian Congon group and Germany Bayer group, with the exclusion of CFC-11 and methylene chloride for the protection of the ozone layer2A foaming technique; Rectical/Beamech developed a pressure swing foaming technique; forced cooling foaming technology and the like were developed by Cannon-ViKing corporation.
The foam stabilizers used at present belong to the organosilicon surfactants, and the main structure of the foam stabilizers is polysiloxane-polyoxyalkylene block copolymer. In the copolymer, the polyoxyalkylene is a polar segment, and the polysiloxane is a non-polar segment, so the components can be well mixed and emulsified together to form a homogeneous system, reactants are fully contacted, and various reactions can be carried out in a relatively balanced manner. The polysiloxane with low surface tension can effectively reduce the surface tension of a reaction system; the polyoxyalkylene has excellent emulsifying performance, and the combination of the polyoxyalkylene and the polyoxyalkylene results in the foam stabilizer with excellent effect. In the actual production process, the molecular weight of the polysiloxane and the composition of the polyoxyalkylene can be adjusted for better results.
In the production process of the flexible polyurethane foam in the prior art, the density gradient of the foam is large, the problem is usually solved through a process, a formula or other auxiliary agents, the density gradient is improved, the internal cracking of the foam and the rough cell structure can be caused sometimes, and the large foam density gradient exists as a common problem all the time, so that the high-efficiency organosilicon surfactant is required to have good cell structure and excellent foam density gradient.
Disclosure of Invention
The invention mainly aims to solve the problems of uneven density distribution, poorer foam holes and unstable foaming process of the foam in the prior art, and provides the flexible polyurethane foam with excellent density distribution.
The purpose of the invention can be achieved by adopting the following technical scheme:
a flexible polyurethane foam having excellent density distribution comprising a silicone copolymer surfactant of the general formula:
MDxD'yM
wherein M represents (CH)3)3SiO1/2Or (CH)3)2RSiO1/2And D represents (CH)3)2SiO2/2And D' represents (CH)3)RSiO2/2X + y is 50-150, y is at least 3, x/y is 3-15, and R is a polyether.
R is three polyethers as follows:
i) a general formula is-CnH2n(C2H4O)α(C3H6O)bPolyoxyalkylene polyether of OR':
the number average molecular weight is 2500-5000, wherein n is 2-4, a is a number, the weight ratio of polyoxyethylene group in polyoxyalkylene polyether is 20-60%, b is a number, the weight ratio of polypropylene oxide group in polyoxyalkylene polyether is 40-80%, R' represents alkyl group with 1-4 carbon atoms or-C (O) CH3
ii) a compound of the formula-Cn'H2n'(C2H4O)α'(C3H6O)b'Polyoxyalkylene polyether of OR':
the number average molecular weight is 300-800, wherein n 'is 2-4, a' is a number, the weight ratio of polyoxyethylene group in the polyoxyalkylene polyether is 60-90%, b 'is a number, the weight ratio of polypropylene oxide group in the polyoxyalkylene polyether is 10-40%, R' represents alkyl with 1-4 carbon atoms or-C (O) CH3
iii) a compound of the formula-Cn″H2n″(C2H4O)α″(C3H6O)b″Polyoxyalkylene polyether of OR ":
the number average molecular weight is 1000-2000, n 'is 2-4, a' is a number, the weight ratio of polyoxyethylene group in polyoxyalkylene polyether is 20-60%, b 'is a number, the weight ratio of polypropylene oxide group in polyoxyalkylene polyether is 40-80%, R' represents alkyl group with 1-4 carbon atoms or-C (O) CH3
a is an integer of 12 to 69, b is an integer of 18 to 69, a 'is an integer of 5 to 17, b' is an integer of 1 to 6, a 'is an integer of 5 to 28, and b' is an integer of 7 to 28.
The component i) accounts for 35-60% of the total weight of the polyether, the number average molecular weight is 3000-4500, and the weight ratio of the ethylene oxide to the propylene oxide is 2: 3;
the component ii) accounts for less than 30 percent of the total weight of the polyether, the number average molecular weight is 400-700, and the weight ratio of the ethylene oxide to the propylene oxide is 2: 3;
the component iii) accounts for 10-60% of the total amount of the polyether, the number average molecular weight is 1100-1600, the weight ratio of the ethylene oxide to the propylene oxide is 2:3, and the premise is that x + y is 96, and x/y is 15.
The component ii) accounts for 11 to 30 percent of the total weight of the polyether.
The number average molecular weight of the total amount of the polyether is 1500-2200; the weight ratio of ethylene oxide to propylene oxide in the polyether was 2: 3.
The diluent is one or more of dipropylene glycol, diethylene glycol propyl ether, 5-ethyl-1, 3-dioxane-5-methanol, propylene carbonate and low molecular weight polyether with a terminal group of n-butyl.
The flexible polyurethane foam also comprises at least one polyol, at least one polyisocyanate and at least one polyurethane foam reaction catalyst, and also comprises at least one of a filler, a foaming agent, a coloring agent, a flame retardant and an antioxidant.
The polyol is at least one of a polyether polyol, a polyester polyol, a polycaprolactone polyol, a polycarbonate polyol, a polybutadiene polyol, a hydroxyl-terminated polyolefin polyol, a graft polyol, and a polyol derived from a natural source;
the polyisocyanate is at least one of 4,4 '-diphenylmethane diisocyanate, 2' -diphenylmethane diisocyanate, 2, 4-toluene diisocyanate and 2, 6-toluene diisocyanate;
the polyurethane foam reaction catalyst is at least one of nickel acetylacetonate, stannous octoate, tin-based catalyst, bismuth-based catalyst, zinc-based catalyst, potassium octoate, potassium acetate, sodium octoate and quaternary ammonium carboxylate.
The polyurethane foam has a density gradient of not more than 2kg/m3
The invention has the beneficial technical effects that:
according to the soft polyurethane foam with excellent density distribution, the silicone surfactant is added in the process of synthesizing the polyurethane foam, so that the prepared foam is more uniform in density distribution, more excellent in foam holes and more stable in foaming process.
Drawings
FIG. 1 is a schematic diagram showing a cut front structure of a flexible polyurethane foam prepared according to the present invention cut into a rectangular parallelepiped having a bottom surface of 22X 22 cm;
FIG. 2 is a schematic view showing a cut side structure of a flexible polyurethane foam prepared according to the present invention cut into a rectangular parallelepiped having a bottom surface of 22X 22 cm.
Detailed Description
The present invention will be described in further detail below in order to make the technical solutions of the present invention more clear and definite to those skilled in the art, but the embodiments of the present invention are not limited thereto.
Example 1:
to a 500ml four-necked flask equipped with a mechanical stirrer and a dry nitrogen line, 83.5g of polysiloxane (average formula MD) was added90D'6.0M) and 182.0g of an allyl-initiated, ester-terminated polyalkylene oxide having an average molecular weight of 4000, containing 40% by weight ethylene oxide groups and 60% by weight propylene oxide groups (referred to herein as polyether A); 34.5g of allyl-initiatedAn ester-terminated polyoxyalkylene having an average molecular weight of 550 containing 40% by weight of ethylene oxide groups and 60% by weight of propylene oxide groups (herein, referred to as polyether B).
Adding 80 mu L of dibutylethanol through a liquid-transferring gun, stirring, heating the mixture to 90-95 ℃, stirring for about 10min, adding 8ppm of Pt (chloroplatinic acid ethanol solution), maintaining the mixture in a bottle at 90-95 ℃, measuring the content of Si-H in the mixture to be less than 0.2mL/g after one hour, removing low molecular weight products in vacuum, adding 3.9g of hydrogen peroxide after two hours, stirring for half an hour, heating to 95-100 ℃, and removing excessive hydrogen peroxide in vacuum to obtain light yellow transparent viscous liquid, wherein the viscous product is the surfactant in example 1.
The silicone-polyether surfactants of examples 6-12 and comparative examples 2-5 were prepared in exactly the same manner as example 1, using different polyether combinations as shown in Table 1:
TABLE 1 preparation of examples 6 to 12 and comparative examples 2 to 5 with different polyether combinations
Figure GDA0003297938360000051
Polyether A:
CH2=CH-CH2(C2H4)a(C3H6O)bOC(O)CH3
EO/POwt%=2:3;Mn4000g/mol;
polyether B:
CH2=CH-CH2(C2H4)a'(C3H6O)b'OC(O)CH3
EO/POwt%=2:3;Mn550g/mol;
polyether C:
CH2=CH-CH2(C2H4)a″(C3H6O)b″OC(O)CH3
EO/POwt%=2:3;Mn1200g/mol;
polyether D:
CH2=CH-CH2(C2H4)a'(C3H6O)b'OC(O)CH3
EO/POwt%=2:3;Mn300g/mol;
polyether E:
CH2=CH-CH2(C2H4)a″(C3H6O)b″OH;
EO/POwt%=2:3;Mn1200g/mol;
the examples were mixed with different solvents in different weight ratios, specifically using different solvent combinations as shown in table 2.
TABLE 2 different solvent combinations
Example 1 Dipropylene glycol Diethylene glycol propyl ether Propylene carbonate *P-1000
Example A 60 40 0 0 0
example-B 56 30 5 0 9
Example C 55 30 0 15 0
Polyether with n-butyl end group, EO/POwt% ═ 2: 3; mn1000 g/mol;
preparing flexible polyurethane foam:
comparative examples 9 and 10 were prepared using commercially available surfactants L580 and L-618, respectively, and the results of using silicone surfactants of examples 1A-C and comparative examples 2 and 3 to prepare polyurethane foams of formulation I are shown in Table 3 below;
table 3 different examples of formulation I
Figure GDA0003297938360000061
Figure GDA0003297938360000071
L580 and L-618 are silicone surfactants commercially available as Michigan advanced materials.
The data in Table 3 show that the silicone surfactants of examples 1-A-C of the present invention provide relatively lower densities and density gradients without loss of air permeability as compared to the silicone surfactants of comparative examples 9-10.
In comparison of examples 6 to 8 and examples 1 to 5, the mixing was carried out using the mass ratio of example-B, and polyurethane flexible foams were produced using preparation II, with the results shown in Table 4 below:
table 4 different examples of formulation II
Figure GDA0003297938360000072
The data presented in Table 3 serves as evidence that surfactant example 1-B of the present invention provides relatively low density and density gradient without loss of air permeability. Comparative example 6-B and comparative example 7-B, although having smaller foam density and density gradient, have severe loss of air permeability and coarse cells.
Preparation of flexible slabstock polyurethane foam: the silicone surfactants of examples 1-A to C were compared to comparative examples 9 and 10, (i.e., L-580 and L-618 respectively) as formulation iii), and the results are shown in Table 5 below:
TABLE 5 different examples of formulation III
Figure GDA0003297938360000081
Table 5 clearly shows that the hydroxyl terminated polyether modified silicone surfactants of examples 1-A-C of the present invention still provide relatively low density and density gradient in low density polyurethane foams, as in Table 5, comparative examples 9 and 10, using commercially available surfactants L-580, L-600 and B-8123, respectively, are less effective than the surfactants of examples 1-A-C of the present invention, as represented by the greater density gradient.
Preparation of silicone copolymer surfactant: the copolymer is a non-hydrolytic copolymer connected by Si-C, and is prepared by the addition reaction of polyoxyalkylene with C ═ C unsaturated bond at the end group and polysiloxane with Si-H at the end group or side group, the mole number of the polyoxyalkylene is 130-150% of the mole number of the Si-H group of the polysiloxane, so as to make the reaction complete as possible, the catalyst used in the addition reaction is platinum catalyst, such as chloroplatinic acid, and the temperature used in the addition reaction is 90-100 ℃.
Preparation of high density flexible polyurethane foam: the flexible polyurethane foam described below had a density of 30.0kg/m3 and was prepared according to the following formulation i).
TABLE 6 formulation i)
Raw materials Proportioning (wt%)
PPG 100.0
Water (W) 3.2
Amine A33 0.16-0.18
Stannous octoate 0.17-0.19
TDI80/20 (index 108) 42.79
Organic silicon surfactant 0.8-1
Wherein: the polyol PPG is prepared from a mixture of 84-88% by weight of propylene oxide and 12-16% by weight of ethylene oxide, and has a hydroxyl number of 56.
TDI80/20 is a mixture of 80% by mass of 2, 4-toluene diisocyanate and 20% by mass of 2, 6-toluene diisocyanate.
A33 is a mixture of 33% by mass of triethylenediamine and 67% by mass of dipropylene glycol from air chemical.
Preparation of medium density flexible polyurethane foam: the flexible polyurethane foam described below had a density of about 25.0kg/m3 and was prepared according to formulation ii) described below.
TABLE 7 formulation ii)
Raw materials Proportioning (wt%)
PPG 100.0
Water (W) 3.8
Amine A33 0.14-0.15
Stannous octoate 0.19-0.20
TDI80/20 (index 110) 49.97
Organic silicon surfactant 1.0-1.1
Preparation of a Low Density Flexible polyurethane foam: the flexible polyurethane foam having a density of about 15.0kg/m3 was prepared according to the formulation iii) described below.
TABLE 8 formulation iii)
Raw materials Proportioning (wt%)
PPG 70.0
POP 30.0
Calcium powder 30.0
Water (W) 6.4
Methylene dichloride 16.0
Amine A33 0.28-0.30
Stannous octoate 0.30-0.32
TDI80/20 (index 120) 83.12
Organic silicon surfactant 2.3-2.5
Calcium powder is ground calcium carbonate sieved with 300 mesh.
POP is styrene/acrylonitrile graft polyether polyol with a solid content of 42%.
The flexible polyurethane foam of formulation i) was foamed as follows: adding 600.0 +/-0.5 g of PPG (PPG) polyol into a 2000ml plastic cup, and controlling the temperature of the polyol to be 21.5-22.5 ℃; adding 19.20 + -0.02 g of water, 4.8-6.0g of organosilicon surfactant and 0.96-1.08gA-33, stirring the mixture at 2000r/min for 20 s; adding 1.02-1.14g of stannous octoate, and stirring at 2000r/min for 20 s; toluene diisocyanate 256.74 + -0.20 g maintained at 21.5-22.5 deg.C was poured in and stirred at 2000r/min for 7s, the mixture was poured into a cube 28.5cm, the cup was kept inverted and pouring was continued for 7 s. And (3) starting the reaction of the foam, continuously rising, recording the highest rising height of the foam, the foam jumping time and the height after retraction, and standing the foam. Starting from the step of mixing toluene diisocyanate, curing the foam for 1 hour in an oven at the temperature of 80-100 ℃ for a total of 300 s; the foam was taken out of the oven and cooled for at least 0.5 h.
The flexible polyurethane foam of formulation ii) was foamed as follows: adding 500.0 +/-0.5 g of PPG (PPG) polyol into a 2000ml plastic cup, and controlling the temperature of the polyol to be 21.5-22.5 ℃; adding 19.00 +/-0.02 g of water, 5.00-5.50g of organosilicon surfactant and 0.70-0.75g of A-33, and stirring the mixture at 2000r/min for 20 s; adding 0.95-1.00g of stannous octoate, and stirring at 2000r/min for 20 s; toluene diisocyanate 249.85 + -0.20 g maintained at 21.5-22.5 deg.C was poured in and stirred at 2000r/min for 7s, the mixture was poured into a cube 28.5cm, the cup was kept inverted and pouring was continued for 7 s. And (3) starting the reaction of the foam, continuously rising, recording the highest rising height of the foam, the foam jumping time and the height after retraction, and standing the foam. After the step of mixing toluene diisocyanate, the total time is 200s, and the foam is put into an oven with the temperature of 80-100 ℃ for curing for 1 h; the foam was taken out of the oven and cooled for at least 0.5 h.
Formulation iii) Flexible polyurethane foam the foaming procedure was as follows: adding 140.0 +/-0.1 g of PPG and 60.00 +/-0.05 g of POP into a 20000ml plastic cup, adding 60.00 +/-0.05 g of heavy CaCO3, mixing and stirring, and controlling the temperature of the mixture to be 28.0-29.0 ℃; adding 12.80 + -0.02 g of water, 16.00 + -0.02 g of dichloromethane, 4.60-5.00g of organosilicon surfactant, and 0.56-0.60gA-33 to the mixture, and stirring the mixture at 2000r/min for 20 s; adding 0.60-0.64g of stannous octoate, and stirring at 2000r/min for 20 s; pouring toluene diisocyanate maintained at 27.0-28.0 deg.C, stirring at 2000r/min for 7s, pouring into a cube mold of 28.5cm, and inverting the plastic cup for 7 s. And (3) starting the reaction of the foam, continuously rising, recording the highest rising height of the foam, the foam jumping time and the height after retraction, and standing the foam. After the step of mixing toluene diisocyanate, the total time is 150s, and the foam is put into an oven with the temperature of 80-100 ℃ for curing for 1 h; the foam was taken out of the oven and cooled for at least 0.5 h.
The foam was actually prepared with the same chemistry as described above, the main difference between the examples being the surfactant difference.
The flexible slabstock foam was evaluated with the performance test described below:
the terms have the following definitions:
and (3) detecting the size: as shown in FIGS. 1 and 2 below, the prepared flexible polyurethane foam was cut into a rectangular parallelepiped having a bottom surface of 22X 22cm, and further cut into foam pieces having a thickness of 4.0cm and 2.5cm, respectively, and each property of each foam was tested.
Maximum rise height: the maximum height in centimeters during the rise of the foam.
The complete molding height: cm of the final height of the foam after 12-24 hours of standing at room temperature.
Air permeability: a foam sample of 22X 2.5cm in size was selected from all comparative foams at the same level and position. These tests were designed to directly compare key process parameters of foam in nearly equivalent locations in the foam. Specifically, all foams were measured for porosity using air permeability instruments and air flow was read at standard per cubic meter per minute.
Density: kg/m3And selecting a foam sample with the size of 22 multiplied by 4.0cm in the foam, and measuring to obtain an average value.
Density gradient: a foam sample with the size of 22X 4.0cm in the foam is selected, and the density difference between the topmost layer and the bottommost layer is taken.
In this embodiment, the flexible polyurethane foam with excellent density distribution provided by the present invention is obtained by applying the silicone surfactant with relatively low density and density gradient synthesized in advance to the preparation of the polyurethane foam, so that the density distribution of the synthesized polyurethane foam is more uniform, the foam cells are more excellent, the emulsifying property is better, and the foaming process is more stable.
The above description is only for the purpose of illustrating the present invention and is not intended to limit the scope of the present invention, and any person skilled in the art can substitute or change the technical solution of the present invention and its conception within the scope of the present invention.

Claims (6)

1. A flexible polyurethane foam having an excellent density distribution, comprising a silicone copolymer surfactant and a diluent, the silicone copolymer surfactant having the general formula:
MDxD'yM
wherein M represents (CH)3)3SiO1/2Or (CH)3)2RSiO1/2And D represents (CH)3)2SiO2/2And D' represents (CH)3)RSiO2/2X + y is 50-150, y is at least 3, x/y is 3-15, and R is the following three polyethers:
i) a general formula is-CnH2n(C2H4O)α(C3H6O)bPolyoxyalkylene polyether of OR':
the number average molecular weight is 2500-5000, wherein n is 2-4, a is a number, and the weight ratio of polyoxyethylene group in polyoxyalkylene polyether is 20 to 60%, b is a number, the weight ratio of polypropylene oxide groups in the polyoxyalkylene polyether is 40 to 80%, R' represents an alkyl group having 1 to 4 carbon atoms or-C (O) CH3
ii) a compound of the formula-Cn'H2n'(C2H4O)α'(C3H6O)b'Polyoxyalkylene polyether of OR':
the number average molecular weight is 300-800, wherein n 'is 2-4, a' is a number, the weight ratio of polyoxyethylene group in the polyoxyalkylene polyether is 60-90%, b 'is a number, the weight ratio of polypropylene oxide group in the polyoxyalkylene polyether is 10-40%, R' represents alkyl with 1-4 carbon atoms or-C (O) CH3
iii) a compound of the formula-Cn″H2n″(C2H4O)α″(C3H6O)b″Polyoxyalkylene polyether of OR ":
the number average molecular weight is 1000-2000, n 'is 2-4, a' is a number, the weight ratio of polyoxyethylene group in polyoxyalkylene polyether is 20-60%, b 'is a number, the weight ratio of polypropylene oxide group in polyoxyalkylene polyether is 40-80%, R' represents alkyl group with 1-4 carbon atoms or-C (O) CH3
The diluent is one or more of dipropylene glycol, diethylene glycol propyl ether, 5-ethyl-1, 3-dioxane-5-methanol, propylene carbonate and low molecular weight polyether with a terminal group of n-butyl;
the polyurethane foam has a density gradient of not more than 2kg/m3
2. The flexible polyurethane foam according to claim 1, wherein a is an integer of 12 to 69, b is an integer of 18 to 69, a 'is an integer of 5 to 17, b' is an integer of 1 to 6, a "is an integer of 5 to 28, and b" is an integer of 7 to 28.
3. The flexible polyurethane foam according to claim 1, wherein the component i) is 35 to 60 mol% based on the total amount of polyether, has a number average molecular weight of 3000 to 4500, and has a weight ratio of ethylene oxide to propylene oxide of 2: 3;
the component ii) accounts for less than 30 percent of the total weight of the polyether, the number average molecular weight is 400-700, and the weight ratio of the ethylene oxide to the propylene oxide is 2: 3;
the component iii) accounts for 10-60% of the total amount of the polyether, the number average molecular weight is 1100-1600, the weight ratio of the ethylene oxide to the propylene oxide is 2:3, and the premise is that x + y is 96, and x/y is 15.
4. A flexible polyurethane foam having an excellent density distribution as claimed in claim 1, wherein the component ii) is 11 to 30 mol% based on the total amount of the polyether.
5. A flexible polyurethane foam having an excellent density distribution as claimed in claim 1, wherein said flexible polyurethane foam further comprises at least one polyol, at least one polyisocyanate and at least one polyurethane foam reaction catalyst, and further comprises at least one of a filler, a blowing agent, a colorant, a flame retardant and an antioxidant.
6. A flexible polyurethane foam having an excellent density distribution as set forth in claim 5 wherein the polyol is at least one of a polyether polyol, a polyester polyol, a polycaprolactone polyol, a polycarbonate polyol, a polybutadiene polyol, a hydroxyl terminated polyolefin polyol, a graft polyol, and a polyol derived from natural sources;
the polyisocyanate is at least one of 4,4 '-diphenylmethane diisocyanate, 2' -diphenylmethane diisocyanate, 2, 4-toluene diisocyanate and 2, 6-toluene diisocyanate;
the polyurethane foam reaction catalyst is at least one of nickel acetylacetonate, stannous octoate, tin-based catalyst, bismuth-based catalyst, zinc-based catalyst, potassium octoate, potassium acetate, sodium octoate and quaternary ammonium carboxylate.
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