CN115417966A - 一种海绵发泡的配方及其制备方法 - Google Patents
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Abstract
本发明公开了一种海绵发泡的配方及其制备方法,海绵的制备方法包括如下步骤:包括以下步骤:S1、按照聚醚多元醇PPG60~95份、POP 20~30份、催化剂A 0.5~1.5份、催化剂B 0.5~1.0份、硅胶0.5~1.5份、交联剂1.0~3.0份、TDI80 30~50份、水2~5份、二氯甲烷0.5~10份的重量份数称取各原材料;S2、准备一个装有注入装置的罐,向罐内加入聚醚多元醇PPG 60~95份,一边搅拌一边通过注入装置注入CO2;S3、再通过原料泵分别将步骤S2制备好的混合物和其余原材料泵入发泡机形成混合料,然后混合料在温度控制在20~25度状态下发泡,形成海绵体;S4、将海绵体在室内常温状态下冷却48~72小时后,制备得到的海绵成品孔均匀化和低密度化的,延长了使用变形时间,增加海绵使用寿命。
Description
技术领域
本发明涉及一种海绵,尤其涉及一种海绵发泡的配方及其制备方法。
背景技术
海绵是聚氨酯泡沫塑料的一种,属于软质聚氨酯泡沫塑料。因有多孔状蜂窝的结构,所以具有优良的柔软性、弹性、吸水性、耐水性的特点,被广泛用于沙发、床垫、服装、软包装等各个行业。海绵是将聚醚或聚酯树脂、交联剂、发泡剂、催化剂以及表面活性剂混合在一起反应并成型的一种块状软泡,再经过切割、复合等工序加工成各种形状的制品。在海绵的生产过程中,会用到对环境有害的物质二氯甲烷,如何降低二氯甲烷的使用量,使海绵的制造过程天然环保,又使制造出的海绵具有很好的回弹性能仍是目前要解决的问题。
发明内容
为克服上述缺点,本发明的目的在于提供一种海绵发泡的配方及其制备方法,制备方法中减少二氯甲烷的用量,制得的海绵又具有很好的回弹。
为了达到以上目的,本发明采用的技术方案是:一种海绵发泡的配方,包括的原材料按重量份数计有:
进一步地,所述聚醚多元醇PPG为70~80份、催化剂A为0.5~1.0份、催化剂B为0.5~0.8份、硅胶为0.5~1.0份、交联剂为1.5~2.5份、TDI 80为35~45份。
进一步地,所述聚醚多元醇PPG为80份、POP为20份、催化剂A为1.0份、催化剂B为0.8份、硅胶为1.0份、交联剂为2.0份、TDI 80为40份。
进一步地,所述聚醚多元醇PPG为聚醚多元醇PPG3000和聚醚多元醇PPG5000的混合物,其中聚醚多元醇PPG3000为40~60份,聚醚多元醇PPG5000为20~35份。
进一步地,所述原材料还包括:二氯甲烷3~10份和水2~5份。
进一步地,所述原材料还包括:脂肪酸甲酯1~5份;和/或聚氧乙烯聚氧丙烯单丁醚1~10份。
进一步地,所述原材料还包括二氯甲烷0.5~3份。
进一步地,所述的催化剂A为三乙烯二胺,所述的催化剂B为双(二甲氨基乙基)醚,所述交联剂为三羟甲基丙烷。
一种海绵的制备方法,包括以下步骤:
S1、按照聚醚多元醇PPG60~95份、POP 20~30份、催化剂A 0.5~1.5份、催化剂B0.5~1.0份、硅胶0.5~1.5份、交联剂1.0~3.0份、TDI 80 30~50份、水2~5份、二氯甲烷0.5~10份的重量份数称取各原材料;
S2、准备一个装有注入装置的罐,向罐内加入聚醚多元醇PPG 60~95份,一边搅拌一边通过注入装置注入CO2,注入CO2的量约1~10份;
S3、再通过原料泵分别将步骤S2制备好的混合物和其余原材料泵入发泡机形成混合料,然后混合料在温度控制在20~25度状态下发泡,形成海绵体;
S4、将海绵体在室内常温状态下冷却48~72小时后,制备得到海绵成品。
进一步地,向步骤S3中的混合料中加入1~5份脂肪酸甲酯;和/或1~10份聚氧乙烯聚氧丙烯单丁醚。
本发明的有益效果是:
1)、从海绵硬度上看:本发明制得的海绵,40%压陷硬度值达到341.27,可达到再生棉40%压陷硬度值311的标准,甚至更高,这样可以代替高密度的再生棉拥有的硬度品质,让产品硬度达到客户标准且海绵品质提升。
2)、从密度上看,本发明制得的海绵的密度更小,使海绵低密度化。
3)、从永久变形量上看,在压陷75%,测试温度70℃,持续22小时的前提下,本发明制得放的海绵永久性变形量为81%,让海绵使用变形时间延长,增加海绵使用寿命。
4)、本发明能降低具有破坏臭氧层的二氯甲烷的使用量10~90%,使海绵的制造工艺更加环保,并且通过使用不影响硬度和密度的减粘剂,可以提高搅拌效率,抑制了多元醇侧的混合液体粘度增加,并提供稳定的发泡,可以保持现有配方的密度。
具体实施方式
下面对本发明的较佳实施例进行详细阐述,以使本发明的优点和特征能更易于被本领域技术人员理解,从而对本发明的保护范围做出更为清楚明确的界定。
实施例1
一种海绵发泡的配方,包括的原材料按重量计有:
其中:聚醚多元醇PPG是一种有机聚合物,是由起始剂(含活性氢基团的化合物)与环氧乙烷(EO)、环氧丙烷(PO)、环氧丁烷(BO)等在催化剂存在下经加聚反应制得,其为无色透明油状粘稠液体。聚醚多元醇PPG3000是指PPG的分子量在3000左右,聚醚多元醇PPG5000是指PPG的分子量在5000左右。
POP为聚合物多元醇CHP-2045,其主要组分为聚醚多元醇(CAS NO.9082-00-2)和聚醚与乙烯基单体接枝聚合物(CAS NO.57913-80-1),外观为乳白色粘稠液体,羟值(mgKOH/g)为28.61,密度为1.0462g/cm2,粘度为4619mpa.,微溶于水,pH值为7.27。
TDI 80是指甲苯二异氰酸酯(CAS NO.26471-62-5),无色透明或淡黄色易燃液体,有强烈的刺激气味,用于制造聚氨酯泡沫塑料及橡胶、绝缘漆及粘合剂等。
所述的交联剂为三羟甲基丙烷。
所述的催化剂A为三乙烯二胺。
所述的催化剂B为双(二甲氨基乙基)醚。
实施例2
一种海绵的制备方法,包括以下步骤:
S1、按照聚醚多元醇PPG3000 50份、聚醚多元醇PPG5000 30份、POP 20份、催化剂A1.0份、催化剂B为0.8份、硅油1.0份、交联剂2.0份、TDI 8040份、水2份、二氯甲烷10份的重量份数称取各原材料;
S2、将中的各原材料泵入发泡机形成混合料,然后混合料温度控制在20度状态下发泡,形成海绵体;
S3、将海绵体在室内常温状态下冷却48小时后,制备得到海绵成品。
实施例3
一种海绵的制备方法,包括以下步骤:
S1、按照聚醚多元醇PPG3000 50份、聚醚多元醇PPG5000 30份、POP 20份、催化剂A1.0份、催化剂B为0.8份、硅油1.0份、交联剂2.0份、TDI 8040份、水2份、二氯甲烷10份的重量份数称取各原材料;
S2、准备一个装有注入装置的罐,向罐内加入聚醚多元醇PPG3000 50份、聚醚多元醇PPG5000 30份,搅拌混合时通过注入装置注入CO2。注入CO2的量为5份。
S3、再通过原料泵分别将步骤S2制备好的混合物和其余原材料泵入发泡机形成混合料,然后混合料在温度控制在20度状态下发泡,形成海绵体;
S4、将海绵体在室内常温状态下冷却48小时后,制备得到海绵孔均匀化和低密度化的海绵成品。
海绵的发泡,包括以下原因:
①由于水的羟基和异氰酸酯的NCO基之间发生化学反应而产生的CO2发泡;
②由于聚氨酯的反应热而使二氯甲烷蒸发的物理发泡;
③物理发泡:PPG中注入的CO2通过聚氨酯的反应热蒸发而产生的物理发泡。
通常聚氨酯发泡为①和②两种原因导致的,本发明中还包括PPG中注入的CO2通过聚氨酯的反应热蒸发而产生的物理发泡,该方法可以海绵达到低密度化,因此PPG里直接注入CO2可以达到海绵孔的均匀和低密度化。
实施例4
一种海绵的制备方法,包括以下步骤:
S1、按照聚醚多元醇PPG3000 60份、聚醚多元醇PPG5000 35份、POP 25份、催化剂A1.5份、催化剂B 0.5份、硅油0.5份、交联剂3.0份、TDI80为30份、水5份、二氯甲烷5份的重量份数称取各原材料;
S2、准备一个装有注入装置的罐,向罐内加入聚醚多元醇PPG3000 60份、聚醚多元醇PPG5000 35份,搅拌混合时通过注入装置注入CO2。注入CO2的量约5份。
S3、再通过原料泵分别将步骤S2制备好的混合物和其余原材料泵入发泡机形成混合料,然后混合料在温度控制在20度状态下发泡,形成海绵体;
S4、将海绵体在室内常温状态下冷却48小时后,制备得到海绵孔均匀化和低密度化的海绵成品。
实施例5
一种海绵的制备方法,包括以下步骤:
S1、按照聚醚多元醇PPG3000 40份、聚醚多元醇PPG5000 20份、POP 30份、催化剂A0.5份、催化剂B 1.0份、硅油1.5份、交联剂1.0份、TDI80为50份、水5份、二氯甲烷5份的重量份数称取各原材料;
S2、准备一个装有注入装置的罐,向罐内加入聚醚多元醇PPG3000 60份、聚醚多元醇PPG5000 35份,搅拌混合时通过注入装置注入CO2。注入CO2的量约5份。
S3、再通过原料泵分别将步骤S2制备好的混合物和其余原材料泵入发泡机形成混合料,然后混合料在温度控制在20度状态下发泡,形成海绵体;
S4、将海绵体在室内常温状态下冷却60小时后,制备得到海绵孔均匀化和低密度化的海绵成品。
实施例6
一种海绵发泡的配方,包括的原材料按重量计有:
聚醚多元醇PPG3000 60~95份
POP 20-30份
催化剂A 0.5~1.5份
催化剂B 0.5~1.0份
硅0.5~1.5份
交联剂1.0~3.0份
脂肪酸甲酯0.5~5份
聚氧乙烯聚氧丙烯单丁醚1~10份
TDI80 30~50份
水2~5份
二氯甲烷0.5~3份
不加入二氯甲烷时多元醇侧的混合液体粘度达到2000~5000Cps(厘泊·秒),但是加入后粘度降低10~50%。二氯甲烷是一种有机化合物,化学式为CH2Cl2,为无色透明液体,具有类似醚的刺激性气味。2017年10月27日,世界卫生组织国际癌症研究机构公布的致癌物清单初步整理参考,二氯甲烷在2A类致癌物清单中。2019年1月23日,二氯甲烷被列入有毒有害大气污染物名录(2018年),2019年7月23日,二氯甲烷被列入有毒有害水污染物名录。因此今后减少使用具有破坏臭氧层的二氯甲烷是不可避免,本发明通过添加不参加反应的像类似脂肪酸甲酯的低粘度材料可以抑制液体粘度上升、可以达到维持搅拌效率。可是没有末端OH基的脂肪酸甲酯反应后有渗出的可能性,所以添加极限为0.5~5份。因此,可以通过添加末端具有OH基的聚氧乙烯聚氧丙烯单丁基醚或其衍生物来进一步降低粘度。由于该材料末端具有OH基,因此可以添加1~10份而无需担心渗出。
单独或组合使用脂肪酸甲酯和聚氧乙烯聚氧丙烯单丁基醚,可以降低二氯甲烷的使用量10~90%。本发明能降低具有破坏臭氧层的二氯甲烷的使用量10~90%,使海绵的制造工艺更加环保,并且通过使用不影响硬度和密度的减粘剂,可以提高搅拌效率,抑制了多元醇侧的混合液体粘度增加,并提供稳定的发泡,可以保持现有配方的密度。
实施例7
S1、按照聚醚多元醇PPG3000 40~60份、聚醚多元醇PPG3000 70份、POP 30份、催化剂A为1.0份、催化剂B为0.8份、硅油1.0份、交联剂2.0份、TDI 80 40份、水3份、二氯甲烷1份的重量份数称取各原材料;
S2、准备一个装有注入装置的罐,向罐内加入聚醚多元醇PPG3000 70份,搅拌混合时通过注入装置注入CO2,注入CO2的量约5份。
S3、再通过原料泵分别将步骤S2制备好的混合物和其余原材料泵入发泡机形成混合料,向混合料中加入5份脂肪酸甲酯,然后混合料在温度控制在20度状态下发泡,形成海绵体;
S4、将海绵体在室内常温状态下冷却48小时后,制备得到海绵孔均匀化和低密度化的海绵成品。
实施例8
S1、按照聚醚多元醇PPG3000 40~60份、聚醚多元醇PPG3000 70份、POP 30份、催化剂A为1.0份、催化剂B为0.8份、硅油1.0份、交联剂2.0份、TDI 80 40份、水3份、二氯甲烷1份的重量份数称取各原材料;
S2、准备一个装有注入装置的罐,向罐内加入聚醚多元醇PPG3000 70份,搅拌混合时通过注入装置注入CO2,注入CO2的量约5份。
S3、再通过原料泵分别将步骤S2制备好的混合物和其余原材料泵入发泡机形成混合料,向混合料中加入10份聚氧乙烯聚氧丙烯单丁醚。然后混合料在温度控制在20度状态下发泡,形成海绵体;
S4、将海绵体在室内常温状态下冷却48小时后,制备得到海绵孔均匀化和低密度化的海绵成品。
实施例9
S1、按照聚醚多元醇PPG3000 90份、POP 20份、催化剂A为1.5份、催化剂B为1.0份、硅油1.5份、交联剂为3.0份、TDI 80为30份、水2~5份、二氯甲烷0.5份的重量份数称取各原材料;
S2、准备一个装有注入装置的罐,向罐内加入聚醚多元醇PPG3000 90份,搅拌混合时通过注入装置注入CO2,注入CO2的量约5份;
S3、再通过原料泵分别将步骤S2制备好的混合物和其余原材料泵入发泡机形成混合料,向混合料中加入1份脂肪酸甲酯和1份聚氧乙烯聚氧丙烯单丁醚,然后混合料在温度控制在25度状态下发泡,形成海绵体;
S4、将海绵体在室内常温状态下冷却72小时后,制备得到海绵孔均匀化和低密度化的海绵成品。
实施例10
对实施例2中的海绵成品进行性能测试,数据如下:
表1:压陷硬度
表2:基本测试项目
表3:永久变形量:(结果单位%)
对实施例3中制得的海绵成品进行性能测试,数据如下:
表4:压陷硬度
表5:基本测试项目
序号 | 长度(mm) | 宽度(mm) | 厚度(mm) | 重量(g) | 密度(kg/m<sup>3</sup>) |
1 | 382 | 380 | 46 | 132 | 19.87 |
2 | 382 | 380 | 50 | 132 | 18.18 |
3 | 379 | 378 | 51 | 129 | 17.65 |
平均值 | 381 | 380 | 49 | 131 | 18.57 |
表6:永久变形量:(结果单位%)
从表1~6中的测试数据对比得知:
1)、从海绵硬度上看(参见表1和表4):改变配方后实施例3中制得的海绵,40%压陷硬度值达到341.27,对比原有的实施例2中40%压陷硬度值为299.43,硬度增加13%,可达到再生棉40%压陷硬度值311的标准,甚至更高,这样可以代替高密度的再生棉佣有的硬度品质,让产品硬度达到客户标准且海绵品质提升。
2)、从密度上看(参见表2和表5),海绵的密度由原有的19.49kg/m3降低到18.57kg/m3,改变配方后制备的海绵密度更小,使海绵低密度化。
3)、从永久变形量上看(参见表3和表6):在压陷75%,测试温度70℃,持续22小时的前提下,改变配方前永久变形量为58.21%,改变后永久性变形量为81%,让海绵使用变形时间延长,增加海绵使用寿命。
以上实施方式只为说明本发明的技术构思及特点,其目的在于让熟悉此项技术的人了解本发明的内容并加以实施,并不能以此限制本发明的保护范围,凡根据本发明精神实质所做的等效变化或修饰,都应涵盖在本发明的保护范围内。
Claims (10)
2.根据权利要求1所述的海绵发泡的配方,其特征在于,所述聚醚多元醇PPG为70~80份、催化剂A为0.5~1.0份、催化剂B为0.5~0.8份、硅胶为0.5~1.0份、交联剂为1.5~2.5份、TDI 80为35~45份。
3.根据权利要求2所述的海绵发泡的配方,其特征在于,聚醚多元醇PPG为80份、POP为20份、催化剂A为1.0份、催化剂B为0.8份、硅胶为1.0份、交联剂为2.0份、TDI 80为40份。
4.根据权利要求1所述的海绵发泡的配方,其特征在于,所述聚醚多元醇PPG为聚醚多元醇PPG3000和聚醚多元醇PPG5000的混合物,其中聚醚多元醇PPG3000为40~60份,聚醚多元醇PPG5000为20~35份。
5.根据权利要求1所述的海绵发泡的配方,其特征在于,所述原材料还包括:二氯甲烷3~10份和水2~5份。
6.根据权利要求1所述的海绵发泡的配方,其特征在于,所述原材料还包括:脂肪酸甲酯1~5份;和/或聚氧乙烯聚氧丙烯单丁醚1~10份。
7.根据权利要求6所述的海绵发泡的配方,其特征在于,所述原材料还包括:二氯甲烷0.5~3份。
8.根据权利要求1-7任一项所述的海绵发泡的配方,其特征在于,所述的催化剂A为三乙烯二胺,所述的催化剂B为双(二甲氨基乙基)醚,所述交联剂为三羟甲基丙烷。
9.一种海绵的制备方法,包括以下步骤:
S1、按照聚醚多元醇PPG60~95份、POP 20~30份、催化剂A 0.5~1.5份、催化剂B 0.5~1.0份、硅胶0.5~1.5份、交联剂1.0~3.0份、TDI 80 30~50份、水2~5份、二氯甲烷0.5~10份的重量份数称取各原材料;
S2、准备一个装有注入装置的罐,向罐内加入聚醚多元醇PPG 60~95份,一边搅拌一边通过注入装置注入CO2,注入CO2的量为1~10份;
S3、再通过原料泵分别将步骤S2制备好的混合物和其余原材料泵入发泡机形成混合料,然后混合料在温度控制在20~25度状态下发泡,形成海绵体;
S4、将海绵体在室内常温状态下冷却48~72小时后,制备得到海绵成品。
10.根据权利要求9所述的一种海绵的制备方法,其特征在于,向步骤S3中的混合料中加入1~5份脂肪酸甲酯;和/或1~10份聚氧乙烯聚氧丙烯单丁醚。
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