Preparation method of buoyant batting and buoyant batting

Abstract

The application discloses a buoyant cotton preparation method, which comprises the following steps: mixing raw materials and additives of the buoyant cotton, and foaming in a foaming mold provided with a supporting rod to form the buoyant cotton provided with a through middle through hole; and attaching a flame retardant and surface hardening in a hardening mold, so that the final buoyant cotton has good elasticity, and the surface can prevent being ignited by a flame for a certain period of time when encountering an open flame, and can block the spread of the flame, and the surface has better anti-dimple performance through multi-level preliminary aging. The application further discloses a buoyant cotton material prepared by the buoyant cotton preparation method. Compared with the prior art, the technical scheme of the application can effectively improve the elasticity, durability and flame retardant performance of the buoyant cotton, so that the buoyant cotton has better use value.

Description

Technical Field

[0001] This invention relates to the field of buoyancy sponge production technology, and particularly to a method for preparing buoyancy sponge and buoyancy sponge itself. Background Technology

[0002] With economic development and the continuous improvement of people's living standards, people increasingly desire a high-quality life. Therefore, sofas, mattresses, and other household products on the market typically use soft materials such as sponge as the main fabric or for secondary fabrics that people come into contact with. However, after prolonged use, in areas frequently touched or used by users, some sponge structures are prone to collapse or surface cracking. The main reason for this is that the sponge produced by the corresponding formula lacks good durability or elastic recovery ability. At the same time, frequently used household products contain a large amount of sponge material, which is usually polyurethane. If accidentally exposed to a fire source during use, it will quickly ignite or cause uncontrollable accidents. The flame-retardant properties of sponge material are also very important. Therefore, improving the composition of existing sponge materials and corresponding production processes to give sponge products with better elasticity, durability, and flame-retardant properties is of great significance. Summary of the Invention

[0003] The main objective of this invention is to propose a method for preparing buoyancy foam and the buoyancy foam itself, which aims to improve the elasticity, durability, and flame retardant properties of sponges, thereby giving them better application value.

[0004] To achieve the above objectives, the present invention proposes a method for preparing buoyancy foam, comprising the following steps: Step S1: Mix the raw materials and additives of the buoyancy foam and add them into the inside of a foaming mold that can be closed at the top and bottom. The mold cavity is provided with several longitudinally arranged support rods. Step S2: Gradually foam and fill the gaps between the support rods. The support rods penetrate the upper and lower surfaces of the buoyancy foam and form a through hole in the middle. Step S3: Remove the foamed buoyancy foam from the foaming mold and transfer it to the hardening mold; Step S4: The buoyancy foam is placed on the top surface of the bottom plate inside the hardening mold. A lifting top plate is provided above the inside of the hardening mold. The bottom plate and the lifting top plate have a vertical hollow structure. The hollow structure does not cover the through hole in the middle. Step S5: The lifting top plate moves downward and pushes the buoyancy foam towards the bottom plate and compresses it. Several atomizing spray heads set inside the hardening mold continuously spray the surface of the buoyancy foam with a solution of atomized flame retardant, gradually increasing the height of the lifting top plate. Step S6: After being sprayed with a solution of atomized flame retardant, the base plate and the lifting top plate move back and forth relative to each other and squeeze and compress the buoyancy foam, causing the water in the buoyancy foam to flow out. Step S7: After being squeezed and dehydrated, the buoyancy foam is subjected to hot air blown onto its surface through a hot air vent inside the hardening mold while it is in a static compression state. The compression degree of the buoyancy foam is reduced over time. After being dried by hot air, the surface moisture of the buoyancy foam is dried in a space of 10-20 degrees Celsius.

[0005] Preferably, in step S1, the additives include foaming agents, surfactants, catalysts, and fillers.

[0006] Preferably, the foaming agent is water, the surfactant is polyether siloxane, the catalyst is tetraethyl ethylenediamine, and the filler is silica.

[0007] Preferably, in step S5, the flame retardant comprises 25-35% ammonium polyphosphate powder, 30-45% ammonium sulfate powder, 20-35% polymeric dispersant, and 30-35% ammonia.

[0008] Preferably, the first mixture is formed by mixing the ammonium polyphosphate powder, the ammonium sulfate powder, and the polymeric dispersant, and then stirring at a stirring speed of 800-1000 rpm for more than 30 minutes. The second mixture is formed by adding 30-35% ammonia water to the first mixture, stirring at 1500-3000 rpm for more than 30 minutes, maintaining it at 8-15 degrees Celsius for more than 12 hours, and then adding distilled water. The second mixture is stirred at a speed of 500-1000 rpm for more than 30 minutes to form a solution of flame retardant.

[0009] The present invention also proposes a buoyancy foam prepared using the aforementioned buoyancy foam preparation method. The raw material components of the buoyancy foam, calculated by mass fraction, include 50-60 parts of polymer polyol, 12-18 parts of polyglycerol, 20-22 parts of isocyanate, 1-5 parts of water, 0.8-3.7 parts of polyalkylsiloxane, and an elasticity promoter.

[0010] Preferably, the polymer polyol is a polyether polyol, which includes 30-35 parts of 3000 molecular weight polyether, 10-15 parts of 5000 molecular weight polyether, and 5-10 parts of 8000 molecular weight polyether.

[0011] Preferably, the elasticity promoter is any one of stannous octoate, dilauryl dibutyltin, or stannous naphthenate.

[0012] The technical solution of this invention has the following advantages over the prior art: The technical solution of this invention involves mixing raw materials and additives for buoyancy foam and foaming it inside a foaming mold equipped with support rods to form buoyancy foam with a through-hole in the middle. The buoyancy foam is then coated with flame retardant and surface hardened inside a hardening mold, resulting in buoyancy foam with good internal elasticity. The surface can still prevent ignition for a certain period of time when exposed to open flame and can block the spread of flame. Furthermore, through multi-layered preliminary aging of the surface, its surface anti-dent performance is improved. Attached Figure Description

[0013] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0014] Figure 1 This is a flowchart of the buoyancy foam preparation method of the present invention; Figure 2 This is a schematic diagram illustrating the working principle of the buoyancy foaming process of the present invention. Figure 3 This is a schematic diagram illustrating the working principle of the flame-retardant and hardening treatment of the buoyancy foam in this invention.

[0015] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0016] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0017] Please see Figure 1-3 This invention proposes a method for preparing buoyancy foam, and also proposes a buoyancy foam material using the method for preparing buoyancy foam.

[0018] The method for preparing buoyancy foam according to embodiments of the present invention includes the following steps: Step S1: Mix the raw materials and additives of the buoyancy foam and add them into the inside of a foaming mold that can be closed at the top and bottom. The mold cavity is provided with several longitudinally arranged support rods.

[0019] In this embodiment of the invention, the raw material components of the buoyancy foam in step S1 include polymeric polyol, polyglycerol, isocyanate, water, and polyalkylsiloxane, wherein the polymeric polyol comprises 50-60 parts, polyglycerol 12-18 parts, isocyanate 20-22 parts, water 1-5 parts, polyalkylsiloxane 0.8-3.7 parts, and an elasticity promoter. Preferably, the polymeric polyol in this embodiment of the invention is a polyether polyol, wherein the polyether polyol includes 30-35 parts of 3000 molecular weight polyether, 10-15 parts of 5000 molecular weight polyether, and 5-10 parts of 8000 molecular weight polyether. By using glycerol as an initiator, the final buoyancy foam product can have a suitable surface hardness and high internal elasticity.

[0020] In this embodiment of the invention, isocyanate is used as a raw material for the buoyancy foam, which is reacted with water, polyglycerol, and other substances. The isocyanate content is within the range of 20-22 parts, resulting in a final buoyancy foam with high internal flexibility. If the isocyanate content is lower or higher than the above range, the internal elastic properties of the buoyancy foam material will be too flexible or too hard, ultimately failing to meet the performance requirements of the product.

[0021] Preferably, the isocyanate in the embodiments of the present invention may be one or more of methylene diphenyl diisocyanate, toluene diisocyanate, trimethyltrimethylhexamethylene diisocyanate, phenylene diisocyanate, dimethyl diphenyl diisocyanate, tetramethylene diisocyanate, and isoflurane diisocyanate, or a mixture thereof.

[0022] In this embodiment of the invention, the buoyancy foam uses 12-18 parts of polyglycerol, which gives the buoyancy foam good fluidity during the foaming process and ensures that the buoyancy foam retains its elastic internal structure after complete curing. Preferably, in other embodiments of the invention, polyglycerol can be replaced by one or more, or a mixture of, polyethylene glycol, polypropylene glycol, amine-terminated polyether, polypropylene ether glycol, polypropylene ether ester glycol, polypropylene-co-ethylene ether glycol, and polybutylene ether glycol.

[0023] Preferably, in the embodiments of the present invention, the polymer polyol in the buoyancy foam component is a polyether polyol, wherein the polyether polyol includes 30-35 parts of 3000 molecular weight polyether, 10-15 parts of 5000 molecular weight polyether, and 5-10 parts of 8000 molecular weight polyether.

[0024] In this embodiment, the polyalkylsiloxane content is 0.8-3.7 parts, which further enhances the internal elasticity of the final buoyancy foam.

[0025] Preferably, the elasticity promoter in this embodiment is any one or a mixture of stannous octoate, dilauryl dibutyltin, and stannous naphthenate, which can significantly increase the elasticity and tensile strength of the sponge.

[0026] In addition, in this embodiment of the invention, the additives mixed with the buoyancy foam raw material include foaming agents, surfactants, catalysts, and fillers.

[0027] In this embodiment, the foaming agent is water. In other embodiments of the present invention, in addition to using water as a foaming agent, water can also be mixed with other foaming agents for co-foaming, such as one or more of n-pentane, isopentane, cyclopentane, and dichloromethane.

[0028] In this embodiment, the surfactant is polyether siloxane. By using the surfactant, the surface tension is reduced, the miscibility of the overall solution is improved, the size of the pores formed inside the buoyancy foam is made uniform, and the pore structure of the foamed composite material is stabilized, ultimately improving the stability of the product.

[0029] The catalyst in this embodiment is tetraethyldiamine.

[0030] In this embodiment, the filler is silicon dioxide. In addition, cerium oxide, calcium carbonate, etc. can also be used. By adding fillers to the additives, the surface hardness of polyurethane foam can be effectively improved, preventing defects such as cracks from appearing on the surface of the actual product after long-term use.

[0031] Step S2: Gradually foam and fill the gaps between the support rods. The support rods penetrate the upper and lower surfaces of the buoyancy foam and form a through hole in the middle.

[0032] Since the mixed buoyancy foam raw materials and additives are injected into the foaming mold in a flowing state and can flow through the gaps between the densely arranged support rods, when the above raw materials and additives are mixed and foamed, the foamed material can fill the gaps between adjacent support rods, and the buoyancy foam that has been completely cured and formed forms a corresponding central through hole in the longitudinal direction, so that the subsequent hardening process can be combined with venting and the adhesion of flame retardant solution.

[0033] Step S3: Remove the foamed buoyancy foam from the foaming mold and transfer it to the hardening mold.

[0034] Once the buoyancy foam has fully solidified, it needs to be demolded from inside the foaming mold. This can be achieved by flipping the lower mold of the foaming mold, allowing the solidified buoyancy foam to easily detach from the lower mold under its own weight.

[0035] Step S4: The buoyancy foam is placed on the top surface of the bottom plate inside the hardening mold. A lifting top plate is provided above the inside of the hardening mold. The bottom plate and the lifting top plate have a vertical hollow structure, and the hollow structure does not cover the through hole in the middle.

[0036] Since the hardening mold in this embodiment has a cavity inside, and a bottom plate is provided at the bottom of the hardening mold, and a lifting top plate is provided at the top inside, the lifting top plate in this embodiment can be connected to the lifting top plate by setting an electric telescopic push rod that passes through the wall plate, so as to realize the vertical movement of the lifting top plate.

[0037] In addition, the base plate and the lifting top plate in this embodiment have a hollowed-out surface structure. Such a hollowed-out structure will not block the central through hole of the longitudinally penetrating buoyancy foam, so as to facilitate the subsequent compression and exhaust process of the buoyancy foam, and to facilitate the corresponding flame retardant to enter the interior of the buoyancy foam through the central through hole.

[0038] Step S5: The lifting top plate moves downward and pushes the buoyancy foam towards the bottom plate and compresses it. Several atomizing spray heads set inside the hardening mold continuously spray the surface of the buoyancy foam with a solution of atomized flame retardant, gradually raising the height of the lifting top plate.

[0039] By moving the lifting top plate downwards, the top plate and the bottom plate can cooperate to compress the buoyancy foam vertically. Simultaneously, a flame retardant solution is sprayed outwards through atomizing nozzles, covering the top, bottom, and sides of the buoyancy foam. Furthermore, the buoyancy foam in this embodiment has a central through-hole in the longitudinal direction, allowing the atomized flame retardant solution to enter the internal structure of the buoyancy foam through this through-hole.

[0040] Ultimately, the buoyancy cotton, after being sprayed with the atomized flame retardant solution, has excellent flame retardant properties on both its surface and interior.

[0041] Existing technologies involve directly mixing flame retardants with raw materials before performing foaming operations. This not only increases foaming costs but also reduces the final elasticity of the buoyancy foam. In contrast, the buoyancy foam of this invention only has flame retardants applied to its surface, which not only achieves good flame retardant performance but also saves costs and ensures that the finished buoyancy foam still has good elasticity.

[0042] Preferably, in this embodiment, the flame retardant solution sprayed on the surface of the buoyancy foam includes 25-35% ammonium polyphosphate powder, 30-45% ammonium sulfate powder, 20-35% polymeric dispersant, and 30-35% ammonia water.

[0043] The first mixture is formed by mixing ammonium polyphosphate powder, ammonium sulfate powder, and a polymeric dispersant, and then stirring at a stirring speed of 800-1000 rpm for more than 30 minutes.

[0044] The second mixture is formed by adding 30-35% ammonia to the first mixture, stirring at 1500-3000 rpm for more than 30 minutes, maintaining it at 8-15 degrees Celsius for more than 12 hours, and then adding distilled water.

[0045] The flame retardant of this embodiment is formed by stirring the second mixture at a speed of 500-1000 rpm for more than 30 minutes.

[0046] Step S6: After being sprayed with a solution of atomized flame retardant, the base plate and the lifting top plate move back and forth relative to each other and squeeze and compress the buoyancy foam, causing the water in the buoyancy foam to flow out.

[0047] In this embodiment of the invention, when the buoyancy foam is sprayed with atomized flame retardant solution, the height of the lifting top plate is continuously raised or lowered, so that the buoyancy foam can be continuously compressed or relaxed. In this way, the flame retardant solution remaining on the surface of the buoyancy foam can gradually enter the interior of the buoyancy foam through the tiny interconnected channels inside the buoyancy foam. Compared with spraying the solution while the buoyancy foam is in a static state, the atomized solution can enter the interior of the buoyancy foam better and more deeply.

[0048] In addition, the simultaneous compression and relaxation of the buoyancy foam allows some of the tiny air bubbles inside the foam to be squeezed and broken. This not only enables the buoyancy foam to breathe, but also allows the gas generated during the foaming process to be expelled and replaced with fresher gas, ultimately giving it better breathability and making it more human-friendly in subsequent use.

[0049] Step S7: After being squeezed and dehydrated, the buoyancy foam is subjected to hot air blown onto its surface through a hot air vent inside the hardening mold while it is in a static compression state. The compression degree of the buoyancy foam is reduced over time. After being dried by hot air, the surface moisture of the buoyancy foam is dried in a space of 10-20 degrees Celsius.

[0050] In this embodiment of the invention, the buoyancy cotton, after being sprayed with atomized flame retardant solution, has flame retardant solution stored on its surface, the surface of the central through hole, and part of the surface internal structure. In order to dry it to a dry state, a corresponding air blowing structure can be provided in the inner wall of the hardened mold. The air blowing structure can be set to corresponding positions in various directions toward the buoyancy cotton. By directly blowing hot air at 80-100°C onto the buoyancy cotton, the flame retardant solution originally attached to the surface or inside of the buoyancy cotton can be dried and reliably attached to the inside of the buoyancy cotton.

[0051] In addition, in the process of drying the buoyancy foam, the height of the lifting top plate needs to be gradually increased in this embodiment of the invention. This allows the buoyancy foam to be gradually relaxed during the drying process, so that the surface of the buoyancy foam can form a multi-layer hardened structure, making it less prone to aging and collapse after long-term use.

[0052] After being dried and hardened by hot air, the buoyancy foam is then blown by cold air, which causes a slight aging effect on its surface. This has a certain effect on inhibiting the aging process during long-term use.

[0053] The above description is only a preferred embodiment of the present invention and does not limit the patent scope of the present invention. All equivalent structural transformations made under the concept of the present invention using the contents of the present invention specification and drawings, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A method for preparing buoyancy foam, characterized in that, Includes the following steps: Step S1: Mix the raw materials and additives of the buoyancy foam and add them into the inside of a foaming mold that can be closed at the top and bottom. The mold cavity is provided with several longitudinally arranged support rods. Calculated by mass fraction, the raw material components of buoyancy foam include 50-60 parts of polymer polyol, 12-18 parts of polyglycerol, 20-22 parts of isocyanate, 1-5 parts of water, 0.8-3.7 parts of polyalkylsiloxane, and elasticity promoter. Step S2: Gradually foam and fill the gaps between the support rods. The support rods penetrate the upper and lower surfaces of the buoyancy foam and form a through hole in the middle. Step S3: Remove the foamed buoyancy foam from the foaming mold and transfer it to the hardening mold; Step S4: The buoyancy foam is placed on the top surface of the bottom plate inside the hardening mold. A lifting top plate is provided above the inside of the hardening mold. The bottom plate and the lifting top plate have a vertical hollow structure. The hollow structure does not cover the through hole in the middle. Step S5: The lifting top plate moves downward and pushes the buoyancy foam towards the bottom plate and compresses it. Several atomizing spray heads set inside the hardening mold continuously spray the surface of the buoyancy foam with an atomized flame retardant solution, gradually raising the height of the lifting top plate. The flame retardant includes 25-35% ammonium polyphosphate powder, 30-45% ammonium sulfate powder, 20-35% polymeric dispersant, and 30-35% ammonia. The first mixture is formed by mixing the ammonium polyphosphate powder, the ammonium sulfate powder, and the polymeric dispersant and stirring at a speed of 800-1000 rpm for more than 30 minutes. Ammonia is added to the first mixture, and it is stirred at 1500-3000 rpm for more than 30 minutes. The mixture is then kept at 8-15 degrees Celsius for more than 12 hours, and then distilled water is added to form the second mixture. The second mixture is stirred at a speed of 500-1000 rpm for more than 30 minutes to finally form the flame retardant solution. Step S6: After being sprayed with a solution of atomized flame retardant, the base plate and the lifting top plate move back and forth relative to each other and squeeze and compress the buoyancy foam, causing the water in the buoyancy foam to flow out. Step S7: After being squeezed and dehydrated, the buoyancy foam is subjected to hot air blown onto its surface through a hot air vent inside the hardening mold while it is in a static compression state. The compression degree of the buoyancy foam is reduced over time. After being dried by hot air, the surface moisture of the buoyancy foam is dried in a space of 10-20 degrees Celsius.

2. The method for preparing buoyancy foam as described in claim 1, characterized in that, In step S1, the additives include foaming agents, surfactants, catalysts, and fillers.

3. The method for preparing buoyancy foam as described in claim 2, characterized in that, The foaming agent is water, the surfactant is polyether siloxane, the catalyst is tetraethyl ethylenediamine, and the filler is silica.

4. A buoyancy foam prepared using the buoyancy foam preparation method as described in any one of claims 1-3, characterized in that, The polymer polyol is a polyether polyol, which includes 30-35 parts of 3000 molecular weight polyether, 10-15 parts of 5000 molecular weight polyether, and 5-10 parts of 8000 molecular weight polyether.

5. The buoyancy foam as described in claim 4, characterized in that, The elasticity accelerator is any one of stannous octoate, dilauryl dibutyltin, or stannous naphthenate.

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