High-comfort low-TVOC (total volatile organic compound) common furniture sponge and continuous production method thereof

Abstract

The invention relates to a high-comfort low-TVOC (total volatile organic compound) common furniture sponge and a continuous production method thereof, and mainly solves the problems in the prior art that the TVOC of a product is high due to high residual TVOC in a polyurethane raw material; in addition, an intermittent foaming process has the defects of low foaming efficiency, thick and large foam holes and poor product stability, so that the problem that the comfort level of the product is reduced is solved. The problem is well solved by adopting the technical scheme that the high-comfort low-TVOC common furniture sponge is prepared from the following components in parts by weight: 35 to 80 parts of common polyether polyol, 10 to 55 parts of grafted polyether polyol, 5 to 10 parts of macromolecular chain polyether polyol, 2.6 to 3.7 parts of foaming agent, 0.7 to 1.3 parts of foam stabilizer, 0.1 to 0.3 part of foaming catalyst, 0.05 to 0.20 part of gel catalyst and 38 to 51 parts of isocyanate. The method can be used for industrial application of producing common furniture sponge.

Description

Technical Field

[0001] The invention relates to a common furniture sponge with high comfort and low TVOC and a continuous production method thereof. Background Art

[0002] Among the categories of polyurethane foam products, polyurethane soft foam products are used the most among all polyurethane products. Soft foam polyurethane, commonly known as polyurethane sponge, is mostly open-cell structure, with advantages such as softness, breathability, low density, and sound absorption. It is usually used for filtering, sound insulation, shockproof, decoration, packaging and heat insulation. In daily life, it is mainly used for the manufacture of soft furniture such as furniture cushions, mattresses, and vehicle seats. With the improvement of people's material living standards, more and more attention is paid to furniture products, especially mattresses. The two most important requirements for ordinary furniture sponges are: good comfort and low TVOC. The comfort of sponges is generally characterized by comfort factors. The larger the comfort factor, the better the comfort; TVOC is a general term for indoor organic gaseous substances, including alkanes, aromatic hydrocarbons, alkenes, halogenated hydrocarbons and other compounds. The smaller the TVOC value, the better. Once it exceeds the standard, it will have a serious impact on human health and may cause symptoms such as skin and mucous membrane irritation, headache, nausea, etc. Long-term exposure may also lead to more serious health problems, such as cancer.

[0003] Common sponges generally use toxic dichloromethane as a foaming agent to a greater or lesser extent. The residue of this foaming agent will have an adverse effect on the TVOC of sponge products, and the residual TVOC in the raw materials will also have a very large impact on the TVOC of the final product. For example, Chinese patent CN115417966B discloses a sponge foaming formula and a preparation method thereof, according to the weight parts of polyether polyol PPG 60-95 parts, POP 20-30 parts, catalyst A 0.5-1.5 parts, catalyst B 0.5-1.0 parts, silicone oil 0.5-1.5 parts, crosslinking agent 1.0-3.0 parts, TDI80 30-50 parts, water 2-5 parts, and dichloromethane 0.5-10 parts. This formula uses the volatile toxic foaming agent methylene chloride, and the main raw materials, polyether polyols PPG and POP, are conventional raw materials with high TVOC residues. Catalyst A is an ordinary catalyst, and the TVOC residue after foaming will also affect the TVOC of the product.

[0004] In addition, with the same formula, the comfort and TVOC of ordinary furniture sponges produced under different foaming processes are also different. Ordinary furniture sponges are usually produced in two ways: box-type intermittent foaming and assembly line-type continuous foaming. The ordinary furniture sponges produced by box-type intermittent foaming have the disadvantages of low efficiency, coarse pores, and poor stability, while continuous foaming can efficiently produce ordinary furniture sponges with fine pores and stability. Therefore, it is very necessary to develop an ordinary furniture sponge with high comfort and low TVOC and its continuous production method. Summary of the invention

[0005] One of the technical problems to be solved by the present invention is that the residual TVOC in the polyurethane raw material in the prior art is high, resulting in high TVOC of the product. At the same time, ordinary furniture sponges produced by intermittent foaming have the problem of poor comfort. An ordinary furniture sponge with high comfort and low TVOC is provided. The composition has the advantages of good comfort and low TVOC.

[0006] The second technical problem to be solved by the present invention is to provide a continuous production method of high-comfort, low-TVOC ordinary furniture sponge corresponding to the first technical problem to be solved.

[0007] In order to solve one of the above technical problems, the technical solution adopted by the present invention is as follows: a high-comfort and low-TVOC common furniture sponge, comprising: by weight, 35-80 parts of common polyether polyol, 10-55 parts of grafted polyether polyol, 5-10 parts of high molecular chain polyether polyol, 2.6-3.7 parts of foaming agent, 0.7-1.3 parts of uniform foaming agent, 0.1-0.3 parts of foaming catalyst, 0.05-0.20 parts of gel catalyst, and 38-51 parts of isocyanate; the initial TVOC content of the common polyether polyol is greater than 0.5 mg / m 3 After low-temperature vacuum evaporation, the residual TVOC content is ≤0.3mg / m 3 , functionality is 3, wherein EO and PO copolymer structure, hydroxyl value is 50-60 mgKOH / g, viscosity is 400-600 cps; the initial TVOC content of the grafted polyether polyol is> 0.5 mg / m 3 After low-temperature vacuum evaporation, the residual TVOC content is ≤0.3mg / m 3 , functionality is 3, hydroxyl value is 26-30 mgKOH / g, solid content is 44-49%, viscosity is 3000-4500 cps; the initial TVOC content of the polymer chain polyether polyol is> 0.5 mg / m 3 After low-temperature vacuum evaporation, the residual TVOC content is ≤0.3mg / m 3 , functionality is 3, molecular weight is 7000-8000, hydroxyl value is 21-24 mgKOH / g, viscosity is 1400-1700 cps; the TVOC content of the high-comfort low-TVOC ordinary furniture sponge is ≤0.25 mg / m 3 .

[0008] In the above technical scheme, the common polyether polyol is selected from at least one of CHE-5602, SC56-16S, and F3156; the grafted polyether polyol is selected from at least one of CHP-2045, NJ-2045, and POP2045; the high molecular chain polyether polyol is selected from at least one of CHE-822P and TEP-240; and the isocyanate is 80% 2,4-isomer and 20% 2,6-isomer T80.

[0009] In the above technical solution, the foaming agent is tap water filtered through a filter element of at least 40 μm.

[0010] In the above technical solution, the foam leveling agent is soft foam silicone oil, selected from at least one of L-580, L-595, and HC580.

[0011] In the above technical solution, the foaming catalyst is a reactive high-boiling-point foaming catalyst, the main component of which is 2-hydroxymethyltriethylenediamine, and the boiling point is 281°C.

[0012] In the above technical solution, the gel catalyst is an organic tin catalyst selected from one of T-9 and T-12.

[0013] In order to solve the second technical problem mentioned above, the technical solution adopted by the present invention is as follows: a continuous production method of high-comfort and low-TVOC common furniture sponge, comprising the following steps:

[0014] (1) Accurately measure each component through its own metering pump, according to weight parts, 35-80 parts of ordinary polyether polyol, 10-55 parts of grafted polyether polyol, 5-10 parts of high molecular chain polyether polyol, 2.6-3.7 parts of foaming agent, 0.7-1.3 parts of uniform foaming agent, 0.1-0.3 parts of foaming catalyst, 0.05-0.20 parts of gel catalyst, and 38-51 parts of isocyanate;

[0015] (2) The foaming agent component is transported to a high-speed stirring mixing head through a metering pump, wherein the foaming agent component is introduced into 100-120 L / h of high-purity nitrogen at a speed of 5000-6500 rpm through an independent high-speed stirrer, and then enters the foaming stirring mixing head after premixing. The main stirring speed of the foaming stirring mixing head is 4600-5200 rpm, and the mixing head pressure is 2.5-3.0 kg / cm 2 , the discharge port is wrapped with 3 layers of 1mm pore size elastic cloth;

[0016] (3) The mixed foaming material is evenly distributed on the foaming kraft paper moving forward through the elastic cloth. In the process of moving forward, it gradually foams and rises and finally becomes a long piece of foam, which is cut into large pieces of foam of required size by the knife belt.

[0017] By adopting the technical scheme of the present invention, a common furniture sponge with high comfort and low TVOC can be prepared, and the advantages of the technical scheme are as follows: first, the three polyether polyols used in the present invention are all subjected to low-temperature vacuum evaporation treatment, and the foaming agent is filtered water, which reduces the residual TVOC content in the raw materials, thereby reducing the TVOC of the product; second, the foaming catalyst used in the present invention is a reactive high-boiling point foaming catalyst, which has a reactive active hydrogen group, which will participate in the reaction during the foaming process and combine with the sponge skeleton molecular chain, and the organic matter will not volatilize out, and the high boiling point and low volatility make it difficult to produce volatile organic matter and affect the TVOC of the product; third, the use of high molecular chain polyether polyol has the advantages of softness, comfort and good support due to its relatively long molecular chain and good flexibility and resilience; fourth, the use of 80% 2,4-body T80 has moderate rigidity and reactivity, which is conducive to the stable formation of moderately soft and hard comfortable foam; finally, the present invention uses continuous foaming in an assembly line to produce fine bubbles in the product, further improving the comfort of the product. The common furniture sponge prepared by the present invention has low TVOC (0.18-0.25 mg / m 3 ) and good comfort (the comfort factor is 2.64~2.81), and achieved better technical results. DETAILED DESCRIPTION

[0018] The present invention is further described below in conjunction with specific embodiments. The described embodiments are only a part of the embodiments of the present invention, but not all of the embodiments.

[0019] Table 1 List of raw materials

[0020]

[0021]

[0022] Example 1

[0023] (1) Accurately measure each component by its own metering pump, according to the weight parts, ordinary polyether polyol SC56-16S 45 parts, grafted polyether polyol CHP-204545 parts, high molecular chain polyether polyol 10 parts, filtered water 3.2 parts, foam leveling agent L-5801.0 parts, foaming catalyst RZETA 0.2 parts, gel catalyst T90.1 parts, isocyanate T-8045 parts;

[0024] (2) The foaming agent component is transported to a high-speed stirring mixing head through a metering pump, wherein 110 L / h of high-purity nitrogen is introduced into the foaming stirring mixing head at a speed of 5500 rpm through an independent high-speed stirrer, and then enters the foaming stirring mixing head after premixing. The main stirring speed of the foaming stirring mixing head is 4800 rpm, and the mixing head pressure is 2.7 kg / cm 2, the discharge port is wrapped with 3 layers of 1mm pore size elastic cloth;

[0025] (3) The mixed foaming material is evenly distributed on the foaming kraft paper moving forward through the elastic cloth. In the process of moving forward, it gradually foams and rises and finally becomes a long piece of foam, which is cut into large pieces of foam of required size by the knife belt.

[0026] Embodiments 2 to 5

[0027] Examples 2 to 5 are carried out according to the steps in Example 1, except that the reaction raw materials, raw material ratios and process conditions in the foaming formula are different, as shown in Table 2; the performance index data of the obtained high-comfort, low-TVOC ordinary furniture sponge are shown in Table 4.

[0028] Table 2 Weight fractions and process conditions of each component in the foaming formula of common furniture sponge with high comfort and low TVOC in Examples 1 to 5

[0029]

[0030]

[0031] Comparative Examples 1-2

[0032] (1) Prepare the raw materials according to the weight proportions of the components in Table 3;

[0033] (2) Preparation of component A: Add the weighed components in the container in order according to the weight proportions in step (1), and pre-stir at 300 rpm for 15 min;

[0034] (3) Add isocyanate T80 and component A into a foaming mixing barrel according to the proportion, stir at a speed of 1300 rpm for 5 to 10 seconds, and then pour into a foaming box of fixed size, and gradually rise to form large foams of the required size. The performance index data are shown in Table 4.

[0035] Comparative Example 3

[0036] (1) Prepare the raw materials according to the weight proportions of the components in Table 3;

[0037] (2) The foaming agent component is transported to a high-speed stirring mixing head through a metering pump, wherein 110 L / h of high-purity nitrogen is introduced into the foaming stirring mixing head at a speed of 5500 rpm through an independent high-speed stirrer, and then enters the foaming stirring mixing head after premixing. The main stirring speed of the foaming stirring mixing head is 4800 rpm, and the mixing head pressure is 2.7 kg / cm 2 , the discharge port is wrapped with 3 layers of 1mm pore size elastic cloth;

[0038] (3) The mixed foamed material is evenly distributed on the foamed kraft paper moving forward through the elastic cloth. In the process of moving forward, it gradually foams and rises and finally becomes a long piece of foam. It is cut into large pieces of foam of required size by the knife belt. Its performance index data is shown in Table 4.

[0039] Table 3 Weight parts of each component in the foaming formula of ordinary furniture sponge in Comparative Examples 1 to 3

[0040] Component name Comparative Example 1 Comparative Example 2 Comparative Example 3 SC56-16S - 35 - CHE-5602 65 - 65 CHP-2045 35 50 35 CHE-822P - 15 - water 3.1 3.7 3.1 Dichloromethane 2 - 2 L-580 1.3 1.3 1.3 33LV 0.25 - 0.25 RZETA - 0.2 - T9 0.1 0.2 0.1 T-80 45 50 45

[0041] Table 4 Performance test data of common furniture sponges with high comfort and low TVOC in Examples 1 to 5 and Comparative Examples 1 to 3

[0042]

[0043] Comparative Example 1 is an ordinary furniture sponge obtained by a common formula using a box-type intermittent foaming process, Comparative Example 2 is an ordinary furniture sponge obtained by a box-type intermittent foaming process using the formula of Example 1, and Comparative Example 3 is an ordinary furniture sponge obtained by a common formula using a continuous production process.

[0044] As shown in Table 4, the present invention uses three polyether polyols treated by low-temperature vacuum evaporation, filtered water and reactive high-boiling point foaming catalyst to cooperate with each other, so that the TVOC of ordinary furniture sponge (0.18-0.25 mg / m 3 ) and comparative example (0.3~0.57mg / m 3 ) is about 56% lower than that of the previous year.

[0045] Comparative Example 3 and the embodiment both adopt continuous production processes, but because the raw materials of the embodiment use high molecular chain polyether polyols and 80% 2,4-body T80, the sponge comfort factor is larger and the product comfort is better; although the formula of Comparative Example 2 is the same as that of Example 1, the present invention adopts a continuous production process, the comfort factor is large, the bubbles are fine and uniform, and the comfort is good; the present invention combines the formula with the continuous production process to obtain an ordinary furniture sponge with high comfort and low TVOC, and achieves good technical results.

Claims

1. A high-comfort and low-TVOC common furniture sponge, comprising: In terms of weight ratio, the common polyether polyol comprises 35 to 80 parts, the grafted polyether polyol comprises 10 to 55 parts, the high molecular weight chain polyether polyol comprises 5 to 10 parts, the foaming agent comprises 2.6 to 3.7 parts, the uniform foaming agent comprises 0.7 to 1.3 parts, the foaming catalyst comprises 0.1 to 0.3 parts, the gelling catalyst comprises 0.05 to 0.20 parts, and the isocyanate comprises 38 to 51 parts; the initial TVOC content of the common polyether polyol is greater than 0.5 mg / m 3 After low-temperature vacuum evaporation, the residual TVOC content is ≤0.3mg / m 3 , functionality is 3, wherein EO and PO copolymer structure, hydroxyl value is 50-60 mgKOH / g, viscosity is 400-600 cps; the initial TVOC content of the grafted polyether polyol is> 0.5 mg / m 3 After low-temperature vacuum evaporation, the residual TVOC content is ≤0.3mg / m 3 , functionality is 3, hydroxyl value is 26-30 mgKOH / g, solid content is 44-49%, viscosity is 3000-4500 cps; the initial TVOC content of the polymer chain polyether polyol is> 0.5 mg / m 3 After low-temperature vacuum evaporation, the residual TVOC content is ≤0.3mg / m 3 , functionality is 3, molecular weight is 7000-8000, hydroxyl value is 21-24 mgKOH / g, viscosity is 1400-1700 cps; the TVOC content of the high-comfort low-TVOC ordinary furniture sponge is ≤0.25 mg / m 3 .

2. A high-comfort, low-TVOC common furniture sponge according to claim 1, characterized in that: The common polyether polyol is selected from at least one of CHE-5602, SC56-16S, and F3156; the grafted polyether polyol is selected from at least one of CHP-2045, NJ-2045, and POP2045; the high molecular chain polyether polyol is selected from at least one of CHE-822P and TEP-240; the isocyanate is 80% 2,4-isomer and 20% 2,6-isomer T80.

3. A high-comfort, low-TVOC common furniture sponge according to claim 1, characterized in that: The foaming agent is tap water filtered through a filter element with a diameter of at least 40 μm.

4. The high-comfort, low-TVOC common furniture sponge according to claim 1, characterized in that: The foam leveling agent is soft foam silicone oil, which is selected from at least one of L-580, L-595 and HC580.

5. The high-comfort, low-TVOC common furniture sponge according to claim 1, characterized in that: The foaming catalyst is a reactive high-boiling-point foaming catalyst, the main component of which is 2-hydroxymethyltriethylenediamine, and the boiling point is 281°C.

6. The high-comfort, low-TVOC common furniture sponge according to claim 1, characterized in that: The gel catalyst is an organic tin catalyst selected from one of T-9 and T-12.

7. The continuous production method of a high-comfort, low-TVOC common furniture sponge according to claim 1 comprises the following steps: (1) Accurately measure each component through its own metering pump, according to weight parts, 35-80 parts of ordinary polyether polyol, 10-55 parts of grafted polyether polyol, 5-10 parts of high molecular chain polyether polyol, 2.6-3.7 parts of foaming agent, 0.7-1.3 parts of uniform foaming agent, 0.1-0.3 parts of foaming catalyst, 0.05-0.20 parts of gel catalyst, and 38-51 parts of isocyanate; (2) The foaming agent component is transported to a high-speed stirring mixing head through a metering pump, wherein the foaming agent component is introduced into 100-120 L / h of high-purity nitrogen at a speed of 5000-6500 rpm through an independent high-speed stirrer, and then enters the foaming stirring mixing head after premixing. The main stirring speed of the foaming stirring mixing head is 4600-5200 rpm, and the mixing head pressure is 2.5-3.0 kg / cm 2 , the discharge port is wrapped with 3 layers of 1mm pore size elastic cloth; (3) The mixed foaming material is evenly distributed on the foaming kraft paper moving forward through the elastic cloth. In the process of moving forward, it gradually foams and rises and finally becomes a long piece of foam, which is cut into large pieces of foam of required size by the knife belt.

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