A polyurethane foam and a method for producing the same

Abstract

The present application relates to the technical field of foam materials, and particularly relates to a polyurethane foam material and a preparation method thereof. Raw materials of the polyurethane foam material include a polyol composition, isocyanate; the polyol composition includes a polyol, a crosslinking agent, silicone oil and water; and the equivalent ratio of NCO content in the isocyanate to OH content in the polyol composition is 0.8-1.1. After the polyol composition and the isocyanate are mixed and stirred, free foaming is carried out, and after foaming is completed, the polyurethane foam material is obtained by pouring into a mold and curing. The polyurethane foam material provided by the present application not only has good flame retardant performance, but also has excellent performance of low formaldehyde, low acetaldehyde and low odor, and meets the standard of GB / T 27630-2011 'Guidelines for the Evaluation of Air Quality in Passenger Cars'.

Description

Technical Field

[0001] This invention relates to the field of foam materials technology, and in particular to a polyurethane foam material and its preparation method. Background Technology

[0002] Polyurethane flexible foam materials possess high resilience, comfort, sound insulation, and vibration absorption properties, making them widely used in automotive interiors and related home furnishing products such as mattresses and sofas. With the rapid development of my country's automotive industry and the improvement of people's consumption levels, more and more consumers are demanding higher quality and environmental protection standards for automobiles. The eight VOCs (benzene, toluene, xylene, ethylbenzene, styrene, formaldehyde, acetaldehyde, and acrolein) in automobiles have become part of automotive standards. In 2011, GB / T 27630-2011, "Guidelines for Air Quality Evaluation in Passenger Cars," was formulated, specifying the concentration requirements for benzene, toluene, xylene, ethylbenzene, styrene, formaldehyde, acetaldehyde, and acrolein (referred to as the new eight VOCs) in the air inside the vehicle. Furthermore, the fire safety issues associated with polyurethane foam have also attracted considerable attention.

[0003] Polyurethane foam materials are generally produced by reacting polyether polyol blends with isocyanates in the presence of catalysts. Among the VOC indicators of foam, aldehyde content is particularly difficult to control. To improve the flame retardant properties of polyurethane materials, solid flame retardants are often added to the polyurethane system. However, the poor dispersibility of these solid flame retardants in the polyurethane foam system results in unsatisfactory flame retardant performance. Summary of the Invention

[0004] To address the aforementioned technical problems, a first aspect of the present invention provides a polyurethane foam material, wherein the raw materials of the polyurethane foam material include a polyol composition and an isocyanate; the polyol composition includes a polyol, a crosslinking agent, a catalyst, silicone oil, and water; and the equivalent ratio of the NCO content in the isocyanate to the OH content in the polyol composition is 0.8 to 1.1.

[0005] As a preferred embodiment of the present invention, the polyol composition comprises, by weight, 90-115 parts of polyol, 0-3.5 parts of crosslinking agent, 1-2.5 parts of catalyst, 0.3-1 parts of silicone oil, and 0.1-0.5 parts of water.

[0006] As a preferred embodiment of the present invention, the catalyst is a tertiary amine catalyst or an organic tertiary amine catalyst containing active hydrogen in its molecular structure.

[0007] As a preferred embodiment of the present invention, at least one of the catalysts contains an ether bond in its molecular structure.

[0008] As a preferred embodiment of the present invention, the polyol composition further includes an aldehyde removal agent.

[0009] As a preferred embodiment of the present invention, the formaldehyde removal agent has a viscosity of 200-1000 mPa·s at 25°C.

[0010] As a preferred embodiment of the present invention, the polyol is (c) and / or (d), wherein (c) is one or more polyols with a hydroxyl value of 15-50 mg KOH / g and a functionality of 2-5, and (d) is a polymer made from one or more polyols with a hydroxyl value of 15-50 mg KOH / g and a functionality of 2-5.

[0011] As a preferred embodiment of the present invention, the weight ratio of the catalyst, the formaldehyde remover and the polyol is (1-2):(0.1-0.5):100.

[0012] As a preferred embodiment of the present invention, the crosslinking agent is a small molecule polyol or polyamine with a functionality of 2 or greater; or one or more of the following: a polyether in which the small molecule polyol or polyamine is used as an initiator and the hydroxyl value is greater than 200 mg KOH / g.

[0013] A second aspect of this invention provides a method for preparing a polyurethane foam material, wherein the raw materials for the polyurethane foam material include a polyol composition and an isocyanate; the polyol composition includes a polyol, a crosslinking agent, silicone oil, and water; and the equivalent ratio of the NCO content in the isocyanate to the OH content in the polyol composition is 0.8 to 1.1. This invention has the following beneficial effects:

[0014] 1. The polyurethane foam material in this invention has a very low odor, almost undetectable;

[0015] 2. The polyurethane foam material in this invention has very low formaldehyde and acetaldehyde content, which meets the standards of GB / T 27630-2011 "Guidelines for Evaluating Air Quality in Passenger Cars";

[0016] 3. The polyurethane foam material in this invention has certain flame retardancy, which effectively solves the shortcoming of poor flame retardancy of polyurethane foam material;

[0017] 4. In this invention, a certain amount of catalyst is selected to catalyze the "gas-generating reaction" between water and isocyanate;

[0018] 5. Adding a certain amount of formaldehyde remover to this invention can reduce the formaldehyde content in polyurethane;

[0019] 6. In this invention, the selection of an appropriate amount of crosslinking agent can effectively control the foaming speed and the strength of the polyurethane foam material during the foaming process;

[0020] 7. This foam material is not only flame-retardant and has a low odor, but also has very low formaldehyde and acetaldehyde content, which can meet the requirements of high-speed rail seats, car seats and other foam materials. It is widely used in high-speed rail seats, car interiors, furniture products and places with high requirements for flame retardancy, odor and VOC. Detailed Implementation

[0021] The first aspect of the present invention provides a polyurethane foam material, wherein the raw materials of the polyurethane foam material include a polyol composition and an isocyanate; the polyol composition includes a polyol, a crosslinking agent, a catalyst, silicone oil, and water; and the equivalent ratio of the NCO content in the isocyanate to the OH content in the polyol composition is 0.8 to 1.1.

[0022] In this invention, "equivalent ratio" refers to the molar ratio of NCO groups in the isocyanate to OH groups in the polyol composition.

[0023] Preferably, the polyol composition comprises, by weight, 90-115 parts polyol, 0-3.5 parts crosslinking agent, 1-2.5 parts catalyst, 0.3-1 parts silicone oil, and 0.1-0.5 parts water.

[0024] More preferably, the polyol composition comprises, by weight, 98-105 parts polyol, 1-2 parts crosslinking agent, 1.2-2 parts catalyst, 0.5-0.8 parts silicone oil, and 0.2-0.4 parts water.

[0025] More preferably, the polyol composition comprises, by weight, 100 parts polyol, 1.5 parts crosslinking agent, 1.4 parts catalyst, 0.7 parts silicone oil, and 0.3 parts water.

[0026] Preferably, the polyol composition further includes an aldehyde remover.

[0027] In one embodiment, the polyol composition further includes 0 to 3.0 wt% of a chain extender; the chain extender is not limited, and examples include small molecule diols and small molecule diamines.

[0028] In one embodiment, the polyol composition further includes 0-0.6 wt% of other additives, including foam openers, antioxidants, and light stabilizers. In this invention, there are no restrictions on the other additives, which can be added as needed.

[0029] catalyst

[0030] The catalyst is a tertiary amine catalyst or an organic tertiary amine catalyst containing active hydrogen in its molecular structure.

[0031] In this invention, the lone electrons on the nitrogen atoms of the tertiary amine catalyst or the organic tertiary amine catalyst containing active hydrogen in its molecular structure can cause the hydrogen atoms in the system to coordinate and complex, catalyzing the "gas-generating reaction" between water and isocyanate.

[0032] Preferably, the catalyst is an organic tertiary amine catalyst containing active hydrogen in its molecular structure.

[0033] The applicant unexpectedly discovered that in the system of the present invention, when the catalyst is an organic tertiary amine catalyst containing active hydrogen in its molecular structure, it has a lower odor. The applicant believes that the possible reason is that the organic tertiary amine catalyst containing active hydrogen has active hydrogen groups in its structure, which can react with -NCO in isocyanate to generate part of polyurethane foam, thereby reducing the odor of polyurethane foam material.

[0034] Further preferably, at least one of the organic tertiary amine catalysts containing active hydrogen in the molecular structure contains an ether bond, preferably N,N,N-trimethyl-N-hydroxyethyl-diaminoethyl ether and / or dimethylaminoethoxyethanol; more preferably N,N,N'-trimethyl-N-hydroxyethyl-diaminoethyl ether.

[0035] The polyether polyols used in the preparation of polyurethane foam materials have a high aldehyde content, leading to excessive levels of aldehydes in the polyurethane materials and affecting human health. During the research process, the applicant unexpectedly discovered that at least one organic tertiary amine catalyst containing active hydrogen contains ether bonds, especially N,N,N-trimethyl-N-hydroxyethyl-diaminoethyl ether and / or dimethylaminoethoxyethanol, which effectively reduces the odor of the polyurethane foam materials.

[0036] More preferably, at least one of the organic tertiary amine catalysts containing active hydrogen in the molecular structure contains a secondary amino group; preferably 3,3'-iminobis(N,N-dimethylpropylamine).

[0037] More preferably, the catalyst is N,N,N'-trimethyl-N-hydroxyethyl-diaminoethyl ether, dimethylaminopropylamine diisopropanol, 3,3'-iminobis(N,N-dimethylpropylamine), or 1-[bis(3-dimethylaminopropyl)amino]-2-propanol, in a weight ratio of (1-5):(4-10):(1-3):(1-3), preferably 3:7:2:2.

[0038] In the system of this invention, N,N,N-trimethyl-N-hydroxyethyl-diaminoethyl ether and / or dimethylaminoethoxyethanol increase the formaldehyde content in the polyurethane foam material to a certain extent. However, the applicant unexpectedly discovered that when the organic tertiary amine catalyst containing ether bonds is N,N,N-trimethyl-N-hydroxyethyl-diaminoethyl ether, and the organic tertiary amine catalyst containing active hydrogen in its molecular structure contains a secondary amino group, especially 3,3'-iminobis(N,N-dimethylpropylamine), and the organic tertiary amine catalyst containing active hydrogen also includes dimethylaminopropylamine diisopropanol and 1-[bis(3-dimethylaminopropyl)amino]-2-propanol, and the weight ratio of N,N,N-trimethyl-N-hydroxyethyl-diaminoethyl ether, dimethylaminopropylamine diisopropanol, 3,3'-iminobis(N,N-dimethylpropylamine), and 1-[bis(3-dimethylaminopropyl)amino]-2-propanol is (1... When the reaction is -5):(4-10):(1-3):(1-3), extremely low formaldehyde content can be obtained. The applicant believes that the possible reason is that the ether bond in the organic tertiary amine catalyst containing the ether bond is oxidized to form aldehyde during the polyurethane reaction, which increases the formaldehyde content in the polyurethane. The numerous side chain steric hindrances in N,N,N-trimethyl-N-hydroxyethyl-diaminoethyl ether and dimethylaminopropylamine diisopropanol, as well as the long carbon side chain of 1-[bis(3-dimethylaminopropyl)amino]-2-propanol, hinder the oxidation process to a certain extent. At the same time, the secondary amine in 3,3'-iminobis(N,N-dimethylpropylamine) reacts with the aldehyde in the polyol during the polyurethane reaction, reducing the formaldehyde content.

[0039] formaldehyde remover

[0040] The formaldehyde removal agent has a viscosity of 200-1000 mPa·s at 25°C.

[0041] Adding a certain amount of formaldehyde remover during the experiment can reduce the formaldehyde content in polyurethane. Currently, the formaldehyde removal effect of existing formaldehyde removers in the formulation system of this application still needs to be improved. Through a series of experiments, research, thinking and improvement, the applicant unexpectedly discovered that when the viscosity of the formaldehyde remover at 25℃ is 200-1000mPa·s, it can improve the formaldehyde and acetaldehyde removal effect to a certain extent. The applicant speculates that this may be because the formaldehyde remover with a viscosity of 200-1000mPa·s is well compatible with the polyol or polyol polyether with a hydroxyl value of 15-50mg KOH / g and a functionality of 2-5 in this application, thus avoiding the oxidation of polyol polyether to aldehydes during the reaction.

[0042] Preferably, the formaldehyde removal agent is selected from one or more of formaldehyde removal agents HPW-700, HPW-725, HPW-800, and HPW-800S.

[0043] More preferably, the formaldehyde removal agent is composed of (a) and (b) in a weight ratio of 1:1, wherein (a) is formaldehyde removal agent HPW-700 and / or formaldehyde removal agent HPW-725, and (b) is formaldehyde removal agent HPW-800 and / or formaldehyde removal agent HPW-800S.

[0044] More preferably, (a) is formaldehyde removal agent HPW-725 and (b) is formaldehyde removal agent HPW-800S.

[0045] Furthermore, the applicant unexpectedly discovered that when the formaldehyde removal agent comprises (a) formaldehyde removal agent HPW-700 and / or formaldehyde removal agent HPW-725 and (b) formaldehyde removal agent HPW-800 and / or formaldehyde removal agent HPW-800S, and the weight ratio of (a) and (b) is 1:1, especially when (a) is formaldehyde removal agent HPW-725 and (b) is formaldehyde removal agent HPW-800S, the removal effect on formaldehyde and acetaldehyde is excellent. The applicant speculates that this may be because formaldehyde removal agents HPW-725 and HPW-800S do not contain water of crystallization, thus not affecting the reaction and removal of aldehydes by the formaldehyde removal agent during the foaming process of polyol and / or polyether polyol reacting with isocyanate.

[0046] polyols

[0047] The polyol is (c) and / or (d), wherein (c) is one or more polyols with a hydroxyl value of 15-50 mg KOH / g and a functionality of 2-5, and (d) is a polymer made from one or more polyols with a hydroxyl value of 15-50 mg KOH / g and a functionality of 2-5.

[0048] Preferably, the polyol is (d); more preferably, the hydroxyl value of (d) is 26-28 mg KOH / g.

[0049] Further preferred, (d) is polyether polyol MC28-02 and / or flame retardant POP FR-28.

[0050] More preferably, the poly(d) is polyether polyol MC28-02 and flame retardant POP FR-28 in a weight ratio of 7:3.

[0051] Preferably, the weight ratio of the catalyst, the formaldehyde remover and the polyol is (1-2):(0.1-0.5):100.

[0052] In the experiment, the applicant unexpectedly discovered that when the hydroxyl value of the polyol (d) is 26-28 mgKOH / g, especially when the polyol (d) is polyether polyol MC28-02 and flame retardant POP FR-28, and the weight ratio of catalyst, formaldehyde remover and polyol is (1-2):(0.1-0.5):100, the polyurethane prepared has an extremely low odor, almost undetectable. The applicant believes that the possible reason is that under these conditions, the catalyst and formaldehyde remover can fully react with the synthesized aldehyde irritating gas or inhibit the formation of aldehydes during the polyurethane synthesis process. At the same time, polyether polyol MC28-02 and flame retardant POP FR-28 are not easily decomposed to generate irritating odor substances during the reaction process. Under the action of a suitable ratio of catalyst and formaldehyde remover, their oxidation is inhibited. On the other hand, under these conditions, the polyurethane foam produced has fine pores, and the very small amount of irritating gas generated can be eliminated in time.

[0053] Crosslinking agent

[0054] The crosslinking agent is a small molecule polyol or polyamine with a functionality of 2 or greater; or one or more of the following: a polyether in which the small molecule polyol or polyamine is used as an initiator and the hydroxyl value is greater than 200 mg KOH / g.

[0055] Crosslinking agents that can be listed include small molecule polyols or polyamines with a functionality of 2 or greater, such as triethanolamine, diethanolamine, glycerol, pentaerythritol, trimethylolpropane, sorbitol, sucrose, and glucose.

[0056] For example, one or more polyethers with a hydroxyl value greater than 200 mg KOH / g, using small molecule polyols or polyamines as initiators, can be generated by reacting ethylene oxide and / or propylene oxide with an initiator having small molecule polyols or polyamines.

[0057] The crosslinking agent contains multiple hydroxyl or amino active groups, which can react with isocyanates to produce a crosslinked network structure. In the system of this invention, a certain amount of crosslinking agent can effectively control the foaming speed and the strength of the polyurethane foam material during the foaming process.

[0058] In this embodiment, the crosslinking agent used is diethanolamine.

[0059] silicone oil

[0060] There are no particular limitations on the silicone oil used; any silicone oil suitable for polyurethane foam systems is applicable to the system of this invention. Adding an appropriate amount of silicone oil to the system of this invention can stabilize the cell structure of the system, resulting in better density of the polyurethane foam, and improving the compatibility between materials in the system, thus preparing a polyurethane foam material with a uniform structure.

[0061] water

[0062] There are no restrictions on the type of water; it can be tap water, distilled water, deionized water, etc.

[0063] In this embodiment, the water used is deionized water.

[0064] Water does not contribute to the greenhouse effect, and its use as a foaming agent in this invention aligns with the concept of green foaming. Furthermore, the selection of an appropriate weight proportion of water within the system of this invention ensures that the polyurethane foam material possesses excellent mechanical properties.

[0065] Isocyanates

[0066] The isocyanate is an aromatic isocyanate or a modified isocyanate.

[0067] In this embodiment, the selected isocyanate is a modified isocyanate.

[0068] The modified isocyanate refers to a modified diphenylmethane diisocyanate (MDI), specifically Huntsman's modified isocyanate 2412.

[0069] A second aspect of the present invention provides a method for preparing polyurethane foam material, wherein a polyol composition is mixed and stirred with isocyanate and then allowed to foam freely. After foaming, the mixture is poured into a mold for curing to obtain polyurethane foam material.

[0070] Mixing and pouring are common techniques in this field.

[0071] The following are some specific embodiments of the present invention, but the present invention is not limited to these embodiments.

[0072] Table 1 lists the manufacturers of the raw materials used in the specific embodiments and examples of this invention, but the invention is not limited to these manufacturers.

[0073] In addition, unless otherwise specified, all raw materials used in this invention are commercially available.

[0074] Table 1

[0075]

[0076]

[0077] Example

[0078] Example 1

[0079] Embodiment 1 of the present invention provides a polyurethane foam material, wherein the raw materials of the polyurethane foam material include a polyol composition and isocyanate; the polyol composition includes a polyol, a crosslinking agent, silicone oil, and water; the equivalent ratio of the NCO content in the isocyanate to the OH content in the polyol composition is 0.8.

[0080] The polyol composition comprises, by weight, 90 parts polyol, 1 part crosslinking agent, 0.3 parts silicone oil, and 0.15 parts water;

[0081] The polyol composition further includes a catalyst; the catalyst is N,N,N'-trimethyl-N-hydroxyethyl-diaminoethyl ether, dimethylaminopropylamine diisopropanol, 3,3'-iminobis(N,N-dimethylpropylamine), or 1-[bis(3-dimethylaminopropyl)amino]-2-propanol, in a weight ratio of 3:7:2:2.

[0082] The polyol composition further includes a formaldehyde remover; the formaldehyde remover has a viscosity of 200 mPa·s at 25°C; the formaldehyde remover is composed of (a) and (b) in a weight ratio of 1:1; (a) is formaldehyde remover HPW-725, and (b) is formaldehyde remover HPW-800S;

[0083] The polyol is (d); the hydroxyl value of (d) is 26-28 mg KOH / g, and (d) is polyether polyol MC28-02 and flame retardant POP FR-28 in a weight ratio of 7:3;

[0084] The weight ratio of the catalyst, formaldehyde remover, and polyol is 1:0.1:100;

[0085] The crosslinking agent is diethanolamine;

[0086] The water is deionized water;

[0087] The isocyanate is Huntsman's modified isocyanate 2412.

[0088] The polyol composition is mixed with isocyanate and stirred to allow it to foam freely. After foaming, it is poured into a mold for curing to obtain polyurethane foam material.

[0089] Example 2

[0090] Embodiment 2 of the present invention provides a polyurethane foam material, wherein the raw materials of the polyurethane foam material include a polyol composition and an isocyanate; the polyol composition includes a polyol, a crosslinking agent, silicone oil, and water; and the equivalent ratio of the NCO content in the isocyanate to the OH content in the polyol composition is 1.1.

[0091] The polyol composition comprises, by weight, 115 parts polyol, 3.5 parts crosslinking agent, 1 part silicone oil, and 0.5 parts water;

[0092] The polyol composition further includes a catalyst; the catalyst is the same as in Example 1;

[0093] The polyol composition further includes a formaldehyde remover; the formaldehyde remover has a viscosity of 1000 mPa·s at 25°C; the formaldehyde remover is composed of (a) and (b) in a weight ratio of 1:1; (a) is formaldehyde remover HPW-725, and (b) is formaldehyde remover HPW-800S;

[0094] The polyol is the same as in Example 1;

[0095] The weight ratio of the catalyst, formaldehyde remover, and polyol is 2:0.5:100;

[0096] The crosslinking agent is the same as in Example 1;

[0097] The water is the same as in Example 1;

[0098] The isocyanate is the same as in Example 1;

[0099] The polyol composition is mixed with isocyanate and stirred to allow it to foam freely. After foaming, it is poured into a mold for curing to obtain polyurethane foam material.

[0100] Example 3

[0101] Embodiment 3 of the present invention provides a polyurethane foam material, wherein the raw materials of the polyurethane foam material include a polyol composition and isocyanate; the polyol composition includes a polyol, a crosslinking agent, silicone oil, and water; and the equivalent ratio of the NCO content in the isocyanate to the OH content in the polyol composition is 1.

[0102] The polyol composition comprises, by weight, 100 parts polyol, 1.5 parts crosslinking agent, 0.7 parts silicone oil, and 0.3 parts water;

[0103] The polyol composition further includes a catalyst; the catalyst is the same as in Example 1;

[0104] The polyol composition further includes a formaldehyde remover; the formaldehyde remover has a viscosity of 600 mPa·s at 25°C; the formaldehyde remover is composed of (a) and (b) in a weight ratio of 1:1; (a) is formaldehyde remover HPW-725, and (b) is formaldehyde remover HPW-800S;

[0105] The polyol is the same as in Example 1;

[0106] The weight ratio of the catalyst, formaldehyde remover, and polyol is 1.4:0.2:100;

[0107] The crosslinking agent is the same as in Example 1;

[0108] The water is the same as in Example 1;

[0109] The isocyanate is the same as in Example 1;

[0110] The polyol composition is mixed with isocyanate and stirred to allow it to foam freely. After foaming, it is poured into a mold for curing to obtain polyurethane foam material.

[0111] Example 4

[0112] Example 4 of the present invention provides a polyurethane foam material, the specific implementation of which is the same as that of Example 3, except that 1-[bis(3-dimethylaminopropyl)amino]-2-propanol in Example 3 is replaced with dimorpholine diethyl ether.

[0113] Example 5

[0114] Example 5 of the present invention provides a polyurethane foam material, the specific implementation of which is the same as that of Example 3, except that it does not contain 3,3'-iminobis(N,N-dimethylpropylamine).

[0115] Example 6

[0116] Example 6 of the present invention provides a polyurethane foam material, the specific implementation of which is the same as that of Example 3, except that it does not contain 1-[bis(3-dimethylaminopropyl)amino]-2-propanol.

[0117] Example 7

[0118] Example 7 of the present invention provides a polyurethane foam material, the specific implementation of which is the same as that of Example 3, except that it does not contain dimethylaminopropylamine diisopropanol.

[0119] Example 8

[0120] Example 8 of the present invention provides a polyurethane foam material, the specific implementation of which is the same as that of Example 3, except that the formaldehyde removal agent is HPW-700.

[0121] Example 9

[0122] Example 9 of the present invention provides a polyurethane foam material, the specific implementation of which is the same as that of Example 3, except that it does not contain the formaldehyde removal agent HPW-800S.

[0123] Example 10

[0124] Example 10 of the present invention provides a polyurethane foam material, the specific implementation of which is the same as that of Example 3, except that it does not contain the formaldehyde removal agent HPW-725.

[0125] Example 11

[0126] Example 11 of the present invention provides a polyurethane foam material, the specific implementation of which is the same as that of Example 3, except that the formaldehyde removal agent is HPW-800.

[0127] Example 12

[0128] Example 12 of the present invention provides a polyurethane foam material, the specific implementation of which is the same as that of Example 3, except that the viscosity of the formaldehyde removal agent at 25°C is 120 mPa·s.

[0129] Example 13

[0130] Example 13 of the present invention provides a polyurethane foam material, the specific implementation of which is the same as that of Example 3, except that the viscosity of the formaldehyde removal agent at 25°C is 120 mPa·s.

[0131] Example 14

[0132] Example 14 of the present invention provides a polyurethane foam material, the specific implementation of which is the same as that of Example 3, except that it is non-flame-retardant POP FR-28.

[0133] Example 15

[0134] Example 15 of the present invention provides a polyurethane foam material, the specific implementation of which is the same as that of Example 3, except that the weight ratio of catalyst, formaldehyde remover and polyol is 0.8:0.08:100.

[0135] Example 16

[0136] Example 16 of the present invention provides a polyurethane foam material, the specific implementation of which is the same as that of Example 3, except that the weight ratio of catalyst, formaldehyde remover and polyol is 2.5:0.6:100.

[0137] Example 17

[0138] Example 17 of the present invention provides a polyurethane foam material, the specific implementation of which is the same as that of Example 3, except that the weight ratio of catalyst, formaldehyde remover and polyol is 0.8:0.6:100.

[0139] Example 18

[0140] Example 18 of the present invention provides a polyurethane foam material, the specific implementation of which is the same as that of Example 3, except that the weight ratio of catalyst, formaldehyde remover and polyol is 2.5:0.08:100.

[0141] Example 19

[0142] Example 19 of the present invention provides a polyurethane foam material, the specific implementation of which is the same as that of Example 3, except that the weight ratio of catalyst, formaldehyde remover and polyol is 0.8:0.6:100.

[0143] Performance testing

[0144] 1. Formaldehyde content: The formaldehyde content in the polyurethane foam in some examples was tested using the general TS-BD-003 bag method;

[0145] 2. Acetaldehyde content: The acetaldehyde content in the polyurethane foam in some examples was tested using the general TS-BD-003 bag method;

[0146] 3. Odor Evaluation: Polyurethane foam samples from the core of selected examples were cut into 50mm × 50mm × 20mm pieces. Each piece was placed in a 1L sealed container and heated at 80℃ for 2 hours. Each sample was evaluated by 5 trained test personnel. Evaluation criteria: No odor, Level 1; slight odor (almost undetectable), Level 2; easily identifiable odor, but without discomfort, Level 3; noticeable odor, causing discomfort, Level 4; strong odor, causing aversion, Level 5; unbearable odor, Level 6. The final average value was taken as the test result.

[0147] 4. Oxygen Index Determination: The oxygen index of polyurethane foam in some examples was tested according to GB / T2406.2-2009 standard.

[0148] The test results are shown in Table 1:

[0149] Table 1

[0150]

[0151]

[0152] As can be seen from the test results in Table 1, the polyurethane foam material provided by the present invention not only has good flame retardant properties, but also has excellent properties such as low formaldehyde, low acetaldehyde, and low odor.

[0153] The foregoing examples are merely illustrative, used to explain some features of the method described in this invention. The appended claims are intended to claim the broadest possible scope, and the embodiments presented herein are merely illustrative of selected implementations based on combinations of all possible embodiments. Therefore, the applicant intends that the appended claims are not limited by the selection of examples illustrating the features of the invention. Some numerical ranges used in the claims also include sub-ranges within them, and variations within these ranges should also be interpreted as being covered by the appended claims where possible.

Claims

1. A polyurethane foam material, characterized in that, The raw materials for the polyurethane foam material include a polyol composition and isocyanate; the polyol composition includes a polyol, a crosslinking agent, a catalyst, silicone oil, and water; the equivalent ratio of the NCO content in the isocyanate to the OH content in the polyol composition is 0.8 to 1.

1. The polyol composition comprises, by weight, 90-115 parts polyol, 0-3.5 parts crosslinking agent, 1-2.5 parts catalyst, 0.3-1 parts silicone oil, and 0.1-0.5 parts water; The catalyst is N,N,N-trimethyl-N-hydroxyethyl-diaminoethyl ether, dimethylaminopropylamine diisopropanol, 3,3'-iminobis(N,N-dimethylpropylamine), and 1-[bis(3-dimethylaminopropyl)amino]-2-propanol, in a weight ratio of 3:7:2:

2. The polyol composition further includes an aldehyde removal agent; the aldehyde removal agent has a viscosity of 200-1000 mPa·s at 25°C; The formaldehyde removal agent is composed of (a) and (b) in a weight ratio of 1:1; (a) is formaldehyde removal agent HPW-725, and (b) is formaldehyde removal agent HPW-800S; The polyol is polyether polyol MC28-02 and flame retardant POP FR-28 in a mass ratio of 7:3; The weight ratio of the catalyst, formaldehyde remover, and polyol is (1-2):(0.1-0.5):100; The crosslinking agent is diethanolamine; the water is deionized water; and the isocyanate is Huntsman's modified isocyanate 2412. The polyol composition is mixed with isocyanate and stirred to allow it to foam freely. After foaming, it is poured into a mold for curing to obtain polyurethane foam material.

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