CN111295403A - 导电氨酯泡沫 - Google Patents

导电氨酯泡沫 Download PDF

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CN111295403A
CN111295403A CN201880070947.6A CN201880070947A CN111295403A CN 111295403 A CN111295403 A CN 111295403A CN 201880070947 A CN201880070947 A CN 201880070947A CN 111295403 A CN111295403 A CN 111295403A
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埃里克·科兹洛夫斯基
布鲁诺·卡拉罗
安德鲁·M·维维安
卡莱布·康
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Abstract

高耐久性的导电氨酯泡沫充当可变电阻器，使得当泡沫弯曲时，导电颗粒变得更加靠近在一起而引起电阻降低。导电泡沫还被整合到车辆座椅传感器系统中。

Description

导电氨酯泡沫
相关申请的交叉引用
本申请要求于2017年11月3日提交的美国临时申请第62/581,189号的优先权。
发明背景
1.技术领域
本发明涉及具有导电特性的聚氨酯泡沫。更特别地，本发明涉及具有改善的耐久性并且与车辆座椅介电常数传感器整合的导电氨酯泡沫。
2.背景技术
整合到车辆座椅中的各种传感器系统在本领域中是已知的。一种用于识别座椅的占用的已知系统包括穿过座垫并且连接至用于评估的计算机的导电聚氨酯的测量带。
其他使用导电多孔泡沫材料或相似材料的层的传感器在本领域中也是已知的。示例性的已知触觉传感器部分地包括：包括电极的第一层、具有根据泡沫的变形而变化的电阻的导电多孔泡沫材料的第二层、以及具有弹性体特性的导电第三层。另一种已知的触觉传感器部分地包括：与导电泡沫弹性体的下层组装的上层、与上层的顶表面接触的第一电极、以及与下层的底表面接触的第二电极。
然而，由于可用的导电泡沫的特性，所有这些实例在车辆座椅应用中可能具有有限的耐久性和性能。目前的导电泡沫可能具有差的聚氨酯基础结构。目前的泡沫可能经历快速的机械破坏，使得这些泡沫可能不适用于车辆座椅。这些泡沫可能具有差的滞回(hysteresis)并且可能具有厚度变形。此外，当用于车辆座椅和相似应用时，这些特性通常可能导致差的耐久性。
因此，期望改善导电泡沫的特性。如果实现足够的导电性和耐久性，则新的新颖应用是可能的。还期望具有这样的泡沫：其可以被构造成充当可变电阻器，使得当泡沫弯曲时，导电颗粒变得更加靠近在一起而引起电阻降低。此外，期望改善泡沫的耐久性，使得可以将可变电阻泡沫用于高负载应用例如车辆座椅中。最后，期望将导电泡沫整合为车辆座椅传感器系统的一部分。
发明内容
高耐久性导电氨酯泡沫充当可变电阻器，使得当泡沫弯曲时，导电颗粒变得更加靠近在一起而引起电阻降低。导电泡沫还被整合到车辆座椅传感器系统中。
附图说明
由于当结合附图考虑时，通过参照以下详细描述而使本发明的优点变得更好理解，因此本发明的优点将容易理解，其中：
图1是根据本发明的一个实施方案的介电常数传感器的侧面透视图；
图2是示出根据本发明的一个实施方案的导电泡沫的电性能的图；
图3是根据本发明的一个实施方案的车辆座椅的侧视图；以及
图4是根据本发明的实施方案的具有介电常数传感器的座垫的第一实施方案和第二实施方案的示意图。
具体实施方式
图1至4示出了根据本文中描述的实施方案的整合到车辆座椅传感器系统中的导电泡沫。在说明书、附图或权利要求书中采用或示出的方向性参照，例如顶部、底部、上部、下部、向上、向下、纵向、横向、左侧、右侧等是为了便于描述而采用的相对的术语，而并不旨在在任何方面限制本发明的范围。此外，示出了车辆座垫组合件、柔性印刷电路组合件和泡沫的截面图以示出它们的层和部件，但是这样的图不一定是按比例的。参照附图，在整个几个图中，相似的数字指示相似或对应的部分。
图1示出了根据本公开的一个实施方案的整合到车辆座椅介电常数传感器20中的导电泡沫10的侧面透视图。介电常数传感器20提供了测量用于车辆中的车辆座椅30(示于图3中)的压缩的量的方式。如图1所示，介电常数传感器20部分地包括与柔性印刷电路40组装在一起的导电泡沫10。柔性印刷电路40可以包括通常印刷在合适的基础膜48(例如聚对苯二甲酸乙二醇酯膜(PET)或聚酰亚胺膜(PI))上的电路44。
导电氨酯泡沫为这样的聚氨酯泡沫：其可以表现出导电特性并且在许多应用中是非常期望的。泡沫可以分为绝缘的、适度的静电传导的和导电的中的一种。泡沫的制备和加工决定电导率特性。对于绝缘泡沫不需要特殊的制备。适度的静电传导可以通过在泡沫中嵌入和/或涂覆导电颗粒来获得。这些颗粒通常是离子盐。为了获得导电泡沫，通过在泡沫的表面上涂覆并粘结特殊颗粒来获得非常高的导电性。用这种方法可以实现3欧姆至3,000欧姆的电阻水平。
一些示例性导电泡沫为用于电子工业中的静电导体。这些已知的导电泡沫可以用于保护集成芯片免于由于错误的静电荷而短路，并且可以用作芯片制造工厂中的制造助剂。这些泡沫可以为能够具有超过10×106欧姆的非常高的电阻水平的，并且可以为表面被涂覆的泡沫和/或可以具有浸渍到泡沫中的离子盐。
然而，目前的导电泡沫可能具有差的聚氨酯基础结构。目前的泡沫可能经历快速的机械破坏，使得这些泡沫可能不适用于车辆座椅。这些泡沫可能具有差的滞回并且可能具有厚度变形。此外，当用于车辆座椅和相似应用时，这些特性通常可能导致差的耐久性。
如果实现足够的导电性和耐久性，则新的新颖应用是可能的。如以上所讨论的，这些导电泡沫可以构造成充当可变电阻器。当导电泡沫弯曲时，导电颗粒变得更加靠近在一起而引起电阻降低。具有足够的耐久性的情况下，可变电阻泡沫可以用于高负载应用(即，车辆座椅)。由于泡沫的弯曲与泡沫正经历的负载直接相关，因此本公开的导电泡沫现在可以用作车辆座椅用压力感测系统中的关键元件。根据本公开的导电泡沫具有高回弹性、高耐久性，可以对压力变化非常敏感，并且可以在毫秒时间帧(timeframe)内回弹/响应。
根据本发明的一个实施方案的新颖的导电泡沫是具有非常低的滞回、高的回弹性、非常低的压缩永久变形的高耐久性泡沫，并且在车辆的使用寿命中保持这些特性。此外，这种新颖的导电泡沫具有随弯曲而变化的高电导率。特殊的导电颗粒与基础泡沫牢固地粘结。独特的粘合剂负载使附着的导电颗粒保持，但不影响泡沫柔软性和导电性能。
当按照ASTM D3574-11-13测试时，该新颖的导电泡沫的优选实施方案表现出非常高的耐久性，其中在恒定力打击下的滞后负载损失(hysteresis load loss)为约6.4％以及通过寿命测试的高度损失低于约1％。此外，当按照ASTM D3574-11-H用305mm球回弹测试进行测试时，该导电泡沫具有高回弹性。
参照以下所示的表1，优选的基础泡沫配方以每一百份多元醇的份数(PPHP)计包含约95PPHP的高反应性6000分子量封端的三醇聚醚多元醇例如由
Figure BDA0002473618390000041
制造的
Figure BDA0002473618390000042
CP-6001、约3PPHP的甘油/蔗糖引发的聚醚多元醇例如由
Figure BDA0002473618390000043
制造的
Figure BDA0002473618390000044
GSP-355、约2PPHP的甘油引发的聚醚多元醇例如由
Figure BDA0002473618390000045
制造的
Figure BDA0002473618390000046
GP-5171、约0.425PPHP的有机硅表面活性剂例如由
Figure BDA0002473618390000047
制造的
Figure BDA0002473618390000048
B-8734、以及约0.33PPHP的胺催化剂1,4-二氮杂双环[2.2.2]辛烷溶液例如由
Figure BDA0002473618390000049
制造的
Figure BDA00024736183900000410
33LX、约0.175PPHP的在二丙二醇中的胺催化剂双-(2-二甲基氨基乙基)醚例如由
Figure BDA00024736183900000411
制造的
Figure BDA00024736183900000412
ZF-22、约0.055PPHP的由已被甲酸部分中和的二丙二醇中的双-(2-二甲基氨基乙基)醚形成的延迟作用催化剂例如由
Figure BDA00024736183900000413
制造的
Figure BDA00024736183900000414
ZF-54、和约1.85PPHP的水。该优选配方的(A+B)比率@100指数为约38.6。优选的基础泡沫配方还包含具有约29.4％的游离NCO含量和约2.15的官能度的二苯基甲烷二异氰酸酯，例如由
Figure BDA00024736183900000415
制造的
Figure BDA00024736183900000416
7007。优选的基础泡沫使用通常已知的聚氨酯泡沫制造方法来制造。
Figure BDA00024736183900000417
根据本公开，导电泡沫的一个优选实施方案通过使用胶乳粘合剂将高导电颗粒粘结至基础泡沫来制备。优选的导电颗粒具有电导率高的小的亚微米尺寸，使得需要低负载水平来实现期望的导电性。优选的导电颗粒的实例为非常纯的炭黑，例如由
Figure BDA0002473618390000051
制造的
Figure BDA0002473618390000052
EC-600JD。优选的胶乳粘合剂为羧化苯乙烯-丁二烯乳液，以使导电颗粒牢固地粘合至基础泡沫并且在产品的使用寿命中保持柔性。合适的胶乳粘合剂的优选来源为由Mallard Creek
Figure BDA0002473618390000053
制造的
Figure BDA0002473618390000054
4180。优选的分散剂部分地包含1-甲氧基-2-丙基乙酸酯和正丁醇。合适的分散剂的优选来源为由
Figure BDA0002473618390000055
制造的
Figure BDA0002473618390000056
PX 4310。
用于增强的导电涂料的一个优选实施方案的导电粘结剂配方包含：约100份的水、约1.75份的胶乳粘合剂例如
Figure BDA0002473618390000057
4180、约1份的导电颗粒例如
Figure BDA0002473618390000058
EC-600JD、和约0.5份的分散剂例如
Figure BDA0002473618390000059
PX4310。优选的导电涂料使用通常已知的用于混合涂料的制造方法来制备。
根据本发明的一个实施方案的导电泡沫通过将增强的导电涂料湿法附加施加法至基础泡沫直至基础泡沫完全浸透(饱和，saturated)来形成。可以对浸透的基础泡沫进行夹送辊压(pinch-rolled)以除去过量的涂料材料。用于约6mm厚的基础泡沫部件的剩余湿法附加为约259g/英尺2(2788g/m2)。可以使浸透的基础泡沫在约180℉下进行烘箱固化直至干燥。
如图2所示，在根据以上优选实施方案制备时，根据以上公开内容制备的导电泡沫具有改善的电性能。图2示出了在通过压缩减小导电泡沫的厚度(mm)时电阻(欧姆)的变化。这产生适用于车辆应用的导电泡沫。此外，如以下实施方案中所述，根据本公开的导电泡沫可以整合到座椅传感器中。
车辆座椅的一个实施方案具有其中泡沫衬垫的一部分填充有导电颗粒的垫子。图3所示的示例性车辆座椅30通常包括座椅靠背50和座垫60，并且可以配置为车辆的前座椅和/或后座椅。座垫60可以由其中泡沫衬垫70的一部分填充有导电颗粒的泡沫衬垫70构成。如图4示意性所示，介电常数传感器20可以与车辆座椅30组装并且可以与泡沫衬垫70相接。如图4所示，介电常数传感器20可以包括附接至PET/PI柔性印刷电路40的导电泡沫的层80。优选地，导电泡沫的层80包括本公开的涂覆有增强导电涂料的具有如表1所示的基础泡沫配方的导电泡沫。PET/PI柔性印刷电路40可以包括适合于预期应用的任意柔性印刷电路配置。示例性柔性印刷电路可选方案40A和40B示于图4中。PET/PI柔性印刷电路40、40A、40B通常包括印刷在聚对苯二甲酸乙二醇酯膜(PET)或聚酰亚胺膜(PI)100上的电路90。
如图4所示，根据本公开的座垫60的第一实施方案包括安装在形成介电常数传感器20的上层130的导电泡沫衬垫80的上表面120上的第一聚氨酯(PU)泡沫板110。座垫60还包括第二聚氨酯(PU)泡沫衬垫140，所述第二聚氨酯泡沫衬垫140与介电常数传感器20的下层160的下表面150组装，即与PET/PI柔性印刷电路40、40A、40B的下表面150相邻地进行组装。
图4中还示出了根据本公开的座垫60A的第二实施方案。座垫60A包括安装在介电常数传感器20A的上表面180上的导电聚氨酯(PU)泡沫板170。介电常数传感器20A可以包括附接至PET/PI柔性印刷电路40的导电聚氨酯泡沫板170的层(如图4中对于介电常数传感器20相似地示出的)。座垫60A还包括聚氨酯(PU)泡沫衬垫190，所述聚氨酯(PU)泡沫衬垫190与介电常数传感器20A的下表面200组装，即，与PET/PI柔性印刷电路40的下表面200相邻地组装。如在座垫60的第一实施方案中，座垫60A的第二实施方案的PET/PI柔性印刷电路40可以包括适合于预期应用的任意柔性印刷电路构造，例如图4所示的示例性柔性印刷电路可选方案40A和40B。
根据以上公开内容制备的导电泡沫的一个益处是与高回弹性结合的改善的耐久性。所公开的导电泡沫的第二个益处是改善的电导率。与高回弹性结合的改善的电导率产生可以对压力变化非常敏感并且可以在毫秒时间帧内回弹/响应的泡沫。这些益处产生了适合于车辆座椅应用的导电泡沫，因为这些应用需要高耐久性以及高回弹性。
另外的益处是将根据以上公开内容制备的这种改善的导电泡沫整合到用于车辆座椅的座椅传感器例如介电常数传感器中。此外，公开了部分地包括介电常数传感器和导电泡沫的座垫组合件，其受益于改善的导电泡沫的性能特性。
已经以举例说明的方式描述了本发明，并且应理解，使用的术语旨在为描述而不是限制的词语的类型。根据上述教导，本发明的许多修改和变化是可能的。因此，应理解，在所附权利要求的范围内，本发明可以以不同于具体描述的方式实施。

Claims (20)

1.一种用于车辆座椅组合件的导电泡沫，所述导电泡沫包括：
基础聚氨酯泡沫；
所述基础泡沫利用湿法附加施加法而用导电粘结剂涂覆和/或浸透；
所述经浸透的基础泡沫被烘箱固化直至干燥；以及
其中所述导电粘结剂包含炭黑导电颗粒、羧化苯乙烯-丁二烯乳液胶乳粘合剂、和分散剂。
2.根据权利要求1所述的导电泡沫，其中所述基础泡沫包含约95PPHP(相对每一百份多元醇的份数)的高反应性6000分子量封端的三醇聚醚多元醇、约3PPHP的甘油/蔗糖引发的聚醚多元醇、约2PPHP的甘油引发的聚醚多元醇、和约0.425PPHP的有机硅表面活性剂。
3.根据权利要求2所述的导电泡沫，其中所述基础泡沫包含约0.33PPHP的胺催化剂1,4-二氮杂双环[2.2.2]辛烷溶液、约0.175PPHP的在二丙二醇中的胺催化剂双-(2-二甲基氨基乙基)醚、约0.055PPHP的由已被甲酸部分地中和的在二丙二醇中的双-(2-二甲基氨基乙基)醚形成的延迟作用催化剂、和约1.85PPHP的水。
4.根据权利要求3所述的导电泡沫，其中所述基础泡沫包含具有约29.4％的游离NCO含量和约2.15的官能度的二苯基甲烷二异氰酸酯。
5.根据权利要求4所述的导电泡沫，其中所述导电粘结剂包含约100份的水、约1.75份的胶乳粘合剂、约1份的导电颗粒、和约0.5份的分散剂。
6.根据权利要求5所述的导电泡沫，其中车辆座椅包括所述导电泡沫的层。
7.根据权利要求6所述的导电泡沫，其中所述车辆座椅包括介电常数传感器，所述介电常数传感器具有与柔性印刷电路的上表面组装的所述导电泡沫的所述层。
8.根据权利要求7所述的导电泡沫，其中所述车辆座椅包括与所述柔性印刷电路的下表面组装的第一聚氨酯泡沫层。
9.根据权利要求8所述的系统，其中所述车辆座椅包括与所述导电泡沫的上表面组装的第二聚氨酯泡沫层。
10.一种介电常数传感器，包括：
聚氨酯导电泡沫的层；
印刷在聚对苯二甲酸乙二醇酯膜(PET)或聚酰亚胺膜(PI)上的柔性电路；以及
其中所述导电泡沫包括用导电涂料涂覆和/或浸透并烘箱固化直至干燥的聚氨酯基础泡沫，所述导电涂料含约100份的水、约1.75份的胶乳粘合剂、约1份的导电颗粒、和约0.5份的分散剂。
11.根据权利要求10所述的介电常数传感器，其中所述基础泡沫包含约95PPHP(相对每一百份多元醇的份数)的高反应性6000分子量封端的三醇聚醚多元醇、约3PPHP的甘油/蔗糖引发的聚醚多元醇、约2PPHP的甘油引发的聚醚多元醇、和约0.425PPHP的有机硅表面活性剂。
12.根据权利要求11所述的介电常数传感器，其中所述基础泡沫包含约0.33PPHP的胺催化剂1,4-二氮杂双环[2.2.2]辛烷溶液、约0.175PPHP的在二丙二醇中的胺催化剂双-(2-二甲基氨基乙基)醚、约0.055PPHP的由已被甲酸部分地中和的二丙二醇中的双-(2-二甲基氨基乙基)醚形成的延迟作用催化剂、和约1.85PPHP的水。
13.根据权利要求12所述的介电常数传感器，其中所述介电常数传感器为车辆座椅传感器。
14.根据权利要求13所述的介电常数传感器，其中所述介电常数传感器的下表面与第一聚氨酯泡沫层组装以形成车辆座垫的一部分。
15.根据权利要求14所述的介电常数传感器，其中所述导电泡沫的上表面与第二聚氨酯泡沫层组装。
16.一种具有介电常数传感器的车辆座垫，所述车辆座垫包括：
所述介电常数传感器，所述介电常数传感器包括与具有聚对苯二甲酸乙二醇酯膜(PET)或聚酰亚胺膜(PI)的柔性印刷电路的上表面组装的导电泡沫的层；
其中所述导电泡沫包括利用湿法附加施加法而用导电粘结剂涂覆和/或浸透的基础聚氨酯泡沫，以及所述经浸透的基础泡沫被烘箱固化直至干燥；以及
其中所述导电粘结剂包含炭黑导电颗粒、羧化苯乙烯-丁二烯乳液胶乳粘合剂、和分散剂。
17.根据权利要求16所述的车辆座垫，还包括与所述介电常数传感器的下表面组装的第一聚氨酯泡沫衬垫。
18.根据权利要求17所述的车辆座垫，还包括与所述导电泡沫的上表面组装的第二聚氨酯泡沫衬垫。
19.根据权利要求18所述的车辆座垫，其中所述基础聚氨酯泡沫包含约95PPHP(每一百份多元醇的份数)的高反应性6000分子量封端的三醇聚醚多元醇、约3PPHP的甘油/蔗糖引发的聚醚多元醇、约2PPHP的甘油引发的聚醚多元醇、以及约0.425PPHP的有机硅表面活性剂、约0.33PPHP的胺催化剂1,4-二氮杂双环[2.2.2]辛烷溶液、约0.175PPHP的在二丙二醇中的胺催化剂双-(2-二甲基氨基乙基)醚、约0.055PPHP的由已被甲酸部分地中和的二丙二醇中的双-(2-二甲基氨基乙基)醚形成的延迟作用催化剂、和约1.85PPHP的水。
20.根据权利要求19所述的车辆座垫，其中所述导电粘结剂包含约100份的水、约1.75份的胶乳粘合剂、约1份的导电颗粒、和约0.5份的分散剂。
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