A low carbon, low odor, low voc high resilience foam and method of making the same

Abstract

The application discloses a kind of low carbon, low VOC high resilience foam and its preparation method, it is characterized in that, by A component and B component according to weight ratio: 100:40-56 is formed, wherein A component is made of the following components by weight fraction: polyether polyol 45-65 parts, polymer polyol 15-25 parts, bio-based polyether 20-30 parts, foaming agent 3.0-3.8 parts, catalyst 0.7-1.2 parts, crosslinking agent 0.8-2.0 parts, silicone oil 0.8-1.2 parts B component is made of the following components by weight fraction: TDI:MDI=50-70 parts:50-30 parts.It has lower odor and VOC, meets industry and national standards, has lower carbon emissions, and can reduce carbon emissions by 50-90%.

Description

Technical Field

[0001] This invention relates to a low-carbon, low-odor, low-VOC, high-resilience foam and its preparation method, belonging to the field of foaming material technology. Background Technology

[0002] Car seats are the main automotive components that drivers and passengers directly come into contact with and perceive, and they have a direct impact on the health of drivers and passengers. The levels of harmful substances such as VOC content, odor, and atomization in car seats must not exceed the levels that would cause harm to drivers and passengers, and must meet industry and national standards.

[0003] From a foam perspective, the VOC content, odor, atomization, and carbon emissions from car seats mainly originate from raw materials such as amine catalysts, stabilizers, repair adhesives, release agents, polyethers, and isocyanates. Current formulations include amine catalysts: 7303 delayed and 7303 balanced; stabilizers: 1231 and 1254; water-based repair adhesive PK-903; solvent-based release agent LP FDC-82; petroleum ether polyethers H45 and 2803L; and isocyanates (T80+M20S). Some indicators of foam odor (grade 3-3.5) and VOCs (pentabenzene and trialdehyde) exceed industry and national standards, posing a certain degree of harm to the health of drivers and passengers, and resulting in high carbon emissions and environmental pollution.

[0004] The following table shows the foam odor and VOC performance of different OEMs, VOC standards, and existing technologies:

[0005]

[0006] Summary of the Invention

[0007] To address the aforementioned problems, the present invention aims to provide a low-carbon, low-odor, low-VOC, and high-resilience foam. A second objective of the present invention is to provide its preparation method, which has even lower odor and VOC, meets industry and national standards, and has lower carbon emissions, reducing carbon emissions by 50-90%.

[0008] To achieve the aforementioned first objective, the technical solution of the present invention is as follows: a low-carbon, low-odor, low-VOC, high-resilience foam, characterized in that it is composed of component A and component B in a weight ratio of 100:40-56, wherein component A is made of the following components in parts by weight: 45-65 parts of polyether polyol, 15-25 parts of polymer polyol, 20-30 parts of bio-based polyether, 3.0-3.8 parts of blowing agent, 0.7-1.2 parts of catalyst, 0.8-2.0 parts of crosslinking agent, and 0.8-1.2 parts of silicone oil; wherein the total mass parts of polyether polyol, polymer polyol, and bio-based polyether are 100.

[0009] Component B consists of the following components in parts by weight: TDI:MDI = 50-70 parts: 50-30 parts.

[0010] In the above scheme, the polyether polyol is selected from a mixture of POP40 and LD83EK from Shandong Lanxing Dongda Chemical Co., Ltd., and mixed in any proportion.

[0011] In the above scheme, the bio-based polyether is selected from Wanhua Chemical Group Co., Ltd.'s bio-based polyether FB350.

[0012] In the above scheme, the catalyst is a mixture of catalysts LE517, LE519 and LED-103 from Huntsman Chemical Trading (Shanghai) Co., Ltd.

[0013] In the above scheme, the proportions of catalyst LE517, catalyst LE519, and catalyst LED-103 are: 0.4-0.7 parts of catalyst LE517, 0.1-0.4 parts of catalyst LE519, and 0.05-0.15 parts of catalyst LED-103.

[0014] In the above scheme, the silicone oil is a mixture of silicone oil 3686L and silicone oil 3682L from Momentive Advanced Materials (Nantong) Co., Ltd., and the amount added is: 0.4-0.7 parts of silicone oil 3686L and 0.4-0.7 parts of silicone oil 3682L.

[0015] In the above scheme, the crosslinking agent is a mixture of crosslinking agents DEOA and TEOA from Nan Ya Chemical Co., Ltd.

[0016] In the above scheme, the isocyanate is a mixture of Covestro renewable TDI and MDI.

[0017] The second objective of this invention is achieved as follows: a method for preparing low-carbon, low-odor, low-VOC, high-resilience foam, characterized in that: component A is premixed, and then component B is mixed and stored separately in storage tanks; then component A and component B are mixed under high pressure using a high-pressure foaming machine, and then injected into a mold for molding.

[0018] In the above scheme, the mold cavity temperature is 55℃-65℃.

[0019] In the above scheme, the temperature of the raw materials in the storage tank is 20℃-26℃.

[0020] In the above scheme, the mold closing reaction takes 3-4 minutes.

[0021] Compared with existing technologies, the beneficial effects of this invention are as follows: It utilizes a specific polyether polyol and 50% isocyanate with a bio-based polyether and renewable material content. The excipients are a low-odor, reactive catalyst, a low-odor, low-atomization silicone oil, and a crosslinking agent. By selecting different brands of bio-based polyethers from various manufacturers and developing different combination formulations, it achieves lower odor and VOC levels, meeting industry and national standards, thus benefiting the health of drivers and passengers; and lower carbon emissions, reducing carbon emissions by 50-90%. It meets the requirements of different OEMs. The VOC content is as low as 2.5-3, and the odor level is 6.0-6.3, meeting industry and national standards, significantly reducing harm to drivers and passengers. Detailed Implementation

[0022] The present invention will be further illustrated below through examples:

[0023] Example 1:

[0024] Low-carbon, low-VOC, high-resilience foam is composed of component A and component B in a weight ratio of 100:40. Component A is made of the following components in parts by weight: 45 parts polyether polyol, 30 parts polymer polyol, 25 parts bio-based polyether, 3.0 parts blowing agent, 0.7 parts catalyst, 0.8 parts crosslinking agent, and 0.8 parts silicone oil.

[0025] Component B consists of the following components in parts by weight: TDI:MDI = 50 parts: 50 parts.

[0026] The polyether polyol was selected from a mixture of POP40 and LD83EK from Shandong Lanxing Dongda Chemical Co., Ltd., with 20 parts of POP40 and 25 parts of LD83EK.

[0027] The bio-based polyether is selected from Wanhua Chemical Group Co., Ltd.'s bio-based polyether FB350.

[0028] The catalyst is a mixture of catalysts LE517, LE519, and LED-103 from Huntsman Chemical Trading (Shanghai) Co., Ltd. The ratio of catalysts LE517, LE519, and LED-103 is 0.4 parts LE517, 0.15 parts LE519, and 0.15 parts LED-103. The silicone oil is a mixture of silicone oil 3686L and silicone oil 3682L from Momentive Advanced Materials (Nantong) Co., Ltd., with an addition amount of 0.4 parts each. The crosslinking agent is a mixture of crosslinking agents DEOA and TEOA from Nan Ya Chemical Co., Ltd.

[0029] The isocyanate is a Covestro renewable TDI and MDI compound.

[0030] The preparation method is as follows: Component A is premixed according to a certain ratio, and then component B is mixed and stored separately in storage tanks; the temperature of the raw materials in the storage tanks is 20℃-26℃. Then, components A and B are mixed under high pressure using a high-pressure foaming machine, and then injected into a mold. The mold cavity temperature is 55℃-65℃. After mold closing reaction, curing and molding are carried out for 3-4 minutes. The foam test results are shown in the table below:

[0031] Actual test results of bio-based foam odor

[0032]

[0033] VOC test results of bio-based polyether foam

[0034]

[0035]

[0036] Example 2

[0037] Low-carbon, low-VOC, high-resilience foam is composed of component A and component B in a weight ratio of 100:56. Component A is made of the following components in parts by weight: 65 parts polyether polyol, 15 parts polymer polyol, 20 parts bio-based polyether, 3.8 parts blowing agent, 1.2 parts catalyst, 2.0 parts crosslinking agent, and 1.2 parts silicone oil.

[0038] Component B consists of the following components in parts by weight: TDI:MDI = 70 parts: 30 parts.

[0039] The polyether polyol was selected from a mixture of POP40 and LD83EK from Shandong Lanxing Dongda Chemical Co., Ltd., specifically a mixture of POP40 and 20 parts of LD83EK and 45 parts of LD83EK.

[0040] The bio-based polyether is selected from 30 parts of Wanhua Chemical Group Co., Ltd.'s bio-based polyether FB350.

[0041] The catalyst is a mixture of catalysts LE517, LE519, and LED-103 from Huntsman Chemical Trading (Shanghai) Co., Ltd. The ratio of catalysts LE517, LE519, and LED-103 is 0.7 parts LE517, 0.4 parts LE519, and 0.1 parts LED-103. The silicone oil is a mixture of silicone oil 3686L and silicone oil 3682L from Momentive Advanced Materials (Nantong) Co., Ltd., with the following amounts added: 0.7 parts silicone oil 3686L and 0.5 parts silicone oil 3682L. The crosslinking agent is a mixture of crosslinking agents DEOA and TEOA from Nan Ya Chemical Co., Ltd.

[0042] The isocyanate is a mixture of Covestro renewable TDI and MDI.

[0043] The preparation method is as follows: Component A is premixed according to a certain ratio, and then component B is mixed and stored separately in storage tanks; the temperature of the raw materials in the storage tanks is 20℃-26℃. Then, components A and B are mixed under high pressure using a high-pressure foaming machine, and then injected into a mold. The mold cavity temperature is 55℃-65℃. After mold closing reaction, curing and molding are carried out for 3-4 minutes. The foam test results are shown in the table below:

[0044] Actual test results of bio-based foam odor

[0045]

[0046] VOC test results of bio-based polyether foam

[0047] Benzene 50 ND qualified Benzene 50 ND qualified Benzene 40 ND qualified Toluene 300 9.517 qualified Toluene 300 7.333 qualified Toluene 200 ND qualified 200 ethylbenzene 7.675 qualified 200 ethylbenzene 10.65 qualified 150 ethylbenzene 11 qualified Xylene 300 34.525 qualified Xylene 300 42.883 qualified Xylene 200 68 qualified Styrene 300 4.042 qualified Styrene 300 135.358 qualified Styrene 100 ND qualified Formaldehyde 200 121.385 qualified Formaldehyde 200 101.146 qualified Formaldehyde 200 299 Unqualified Acetaldehyde 200 3.487 qualified Acetaldehyde 200 5.997 qualified Acetaldehyde 100 34 qualified acrolein 100 0.149 qualified acrolein 100 0.139 qualified acrolein 50 ND qualified TVOC8000 1077.618 qualified TVOC8000 1270.201 qualified TVOC9000 809 qualified

[0048] Example 3 is the same as Example 1, except that:

[0049] Polyether polyols selected from Changhua Chemical Technology Co., Ltd. (CHE-45, 2803L) and Wanhua Chemical's bio-based polyether FB350, TDI from Cangzhou Dahua and MDI from BASF, Huntsman catalysts (LE517, LE519, LED-103) and silicone oils (1231, 1254), and crosslinking agents (DEOA and TEOA) from Jiahe Chemical Co., Ltd. are shown in the table below.

[0050] Actual test results of bio-based foam odor

[0051]

[0052] VOC test results of bio-based polyether foam

[0053]

[0054] Example 4 is the same as Example 1, except that:

[0055] The polyether polyols used were Wanhua Chemical's POP2140, F-3128, and Wanhua Chemical's bio-based polyether FB350; Gansu Baiyin's TDI + BASF MDI; Huntsman's catalysts LE517, LE519, and LED-103; Shandong Dingxin's silicone oils B511 and K511; and Nanya Chemical's crosslinking agents DEOA and TEOA. The test results are shown in the table below:

[0056] Actual test results of bio-based foam odor

[0057]

[0058] VOC test results of bio-based polyether foam

[0059]

[0060]

[0061] Example 5 is the same as Example 1, except that:

[0062] Polyether polyols selected included Tianjin Sanshi Chemical's TEP3600 and TEP330N, Wanhua Chemical's bio-based polyether FB350, Cangzhou Dahua's TDI + BASF MDI, Huntsman's catalysts LE517, LE519, and LED-103, Jiangsu Meiside's silicone oils M-7735LF2 and M-7738LF2, and Nanya Chemical's crosslinking agents DEOA and TEOA. The test results are shown in the table below.

[0063] Actual test results of bio-based foam odor

[0064]

[0065] VOC test results of bio-based polyether foam

[0066] Benzene 50 25.79 qualified Benzene 50 35.57 qualified Benzene 40 54.88 qualified Toluene 300 86.38 qualified Toluene 300 67.17 qualified Toluene 200 98.53 qualified 200 ethylbenzene 41.23 qualified 200 ethylbenzene 83.25 qualified 150 ethylbenzene 105.67 Unqualified Xylene 300 127.69 qualified Xylene 300 311.92 Unqualified Xylene 200 233.05 Unqualified Styrene 300 43.56 qualified Styrene 300 75.26 qualified Styrene 100 25.96 qualified Formaldehyde 200 235.86 Unqualified Formaldehyde 200 165.10 qualified Formaldehyde 200 258.31 Unqualified Acetaldehyde 200 99.37 qualified Acetaldehyde 200 56.38 qualified Acetaldehyde 100 43.28 qualified acrolein 100 15.64 qualified acrolein 100 32.54 qualified acrolein 50 35.23 qualified TVOC8000 8235.75 Unqualified TVOC8000 6523.67 qualified TVOC9000 6321.57 qualified

[0067] This invention is not limited to the above embodiments. Those skilled in the art will understand that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of this invention. The scope of this invention is defined by the claims and their equivalents.

Claims

1. A low carbon, low odor, low VOC high resilience foam characterized in that, The A component and the B component are composed according to the weight ratio: 100:40-56, wherein the A component is made of the following components in parts by weight: polyether polyol 45-65 parts, polymer polyol 15-25 parts, bio-based polyether 20-30 parts, foaming agent 3.0-3.8 parts, catalyst 0.7-1.2 parts, crosslinking agent 0.8-2.0 parts, silicone oil 0.8-1.2 parts; wherein the total of the mass parts of the polyether polyol, the polymer polyol and the bio-based polyether is 100; The B component is composed of the following components in parts by weight: TDI:MDI=50-70 parts:50-30 parts, the catalyst is a mixture of catalyst LE517, catalyst LE519 and catalyst LED-103 of Huntsman Chemical Trade (Shanghai) Co., Ltd., the ratio of the catalyst LE517, the catalyst LE519 and the catalyst LED-103 is: catalyst LE517 0.4-0.7 parts, catalyst LE519 0.1-0.4 parts, catalyst LED-103 0.05-0.15 parts, the TDI and the MDI are selected from renewable TDI and MDI of Covestro, the bio-based polyether is selected from bio-based polyether FB350 of Wanhua Chemical Group Co., Ltd.; the polyether polyol is selected from a mixture of POP40 and LD83EK of Shandong Lansheng Dongda Chemical Co., Ltd.; the silicone oil is a mixture of silicone oil 3686L and silicone oil 3682L of Momentive High New Materials (Nantong) Co., Ltd., and the added amount is: silicone oil 3686L 0.4-0.7 parts, silicone oil 3682L 0.4-0.7 parts; the crosslinking agent is a mixture of crosslinking agent DEOA and crosslinking agent TEOA of Nanya Chemical Co., Ltd.

2. A process for the production of a low carbon, low odor, low VOC high resilience foam characterized by: The A component is premixed according to claim 1, then the B component is mixed and respectively sent into the storage tank for storage; then the A component and the B component are high-pressure mixed by a high-pressure foaming machine, and then injected into a mold for molding.

3. The process for producing a low carbon, low odor, low VOC high resiliency foam according to claim 2, wherein: The temperature of the raw materials in the storage tank is 20-26℃; the temperature of the mold cavity is 55-65℃, and the mold is reacted and cured after molding; the mold is reacted for 3-4 minutes.

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