Melamine sponge and production process thereof

Abstract

The invention relates to the technical field of melamine sponge, in particular to a production process of melamine sponge, which comprises the following steps: step 1, adding melamine, formaldehyde and a buffer agent into a reaction kettle, mixing according to a ratio, and reacting at 80 DEG C for 1 hour to obtain a melamine-formaldehyde prepolymer; 2, adding polyethylene glycol (PEG), a foaming agent and deionized water into the prepolymer, and stirring for 20 minutes by using a high-speed shearing stirrer to form a uniform mixture; and 3, transferring the mixture to a foaming device, and continuously reacting at 70 DEG C for 30 minutes. A buffering agent and an antioxidant are added in the production process of the prepolymer, so that the reaction stability and efficiency are remarkably improved, and the production process of the melamine sponge is optimized. And high-speed shearing stirring and ultrasonic stirring equipment are combined, so that uniform distribution of all components is ensured, and the melamine sponge with various excellent characteristics such as high strength, low density and high elasticity is finally prepared.

Description

Technical Field

[0001] The invention relates to the technical field of melamine sponge, in particular to a melamine sponge and a production process thereof. Background Art

[0002] The existing melamine sponge production process has problems such as low production efficiency, high cost, unstable performance, etc., which makes it difficult to meet the growing market demand. Therefore, it is urgent to develop a new preparation method to improve the production efficiency and performance of melamine sponge. Summary of the invention

[0003] The object of the present invention is to provide a melamine sponge and a production process thereof to solve the problems raised in the above background technology.

[0004] To achieve the above object, the present invention provides the following technical solution: a melamine sponge, the formula of which comprises:

[0005] Melamine: 100 parts, formaldehyde: 250-300 parts, polyethylene glycol (PEG): 15-20 parts, foaming agent: 7-10 parts, curing agent: 2-5 parts, catalyst 1.5-2 parts, stabilizer: 1-3 parts, buffer: 1-2 parts, antioxidant: 0.5-1 part, deionized water: appropriate amount, cross-linking agent 5-10 parts.

[0006] A production process of melamine sponge comprises the following steps:

[0007] Step 1: Add melamine, formaldehyde and a buffer into a reaction kettle, mix them according to a certain proportion, and react them at 80° C. for 1 hour to obtain a melamine-formaldehyde prepolymer.

[0008] Step 2: Add polyethylene glycol (PEG), foaming agent and deionized water to the prepolymer and stir for 20 minutes using a high-speed shear mixer to form a uniform mixture.

[0009] Step 3: Transfer the mixture to a foaming device and continue the reaction at 70°C for 30 minutes to allow the foaming agent to fully act and produce a uniform foam structure.

[0010] Step 4: During the foam formation process, gradually add curing agent, catalyst and stabilizer, use ultrasonic stirring equipment to ensure that the ingredients are evenly distributed, and continue stirring for 10 minutes.

[0011] Step 5: Pour the reacted foam material into a mold preheated to 90°C and cure it for 2 hours.

[0012] Step 6: The solidified melamine sponge is cooled, demoulded and cut to obtain the final product.

[0013] Preferably, in the step, sodium citrate is used as a buffer to stabilize the pH value, and BHT is used as an antioxidant to prevent oxidation, thereby improving the stability of the prepolymer.

[0014] Preferably, the cross-linking modification of polyethylene glycol in step 2 forms a three-dimensional network structure in the sponge, thereby reducing the migration and loss of PEG and enhancing the mechanical strength and water resistance of the sponge.

[0015] The preparation method of polyethylene glycol cross-linking modification comprises the following steps:

[0016] Mix 15-20 parts of PEG with 5-10 parts of a cross-linking agent (glutaraldehyde or diisocyanate), and stir at 60° C. for 30 minutes to ensure that the PEG and the cross-linking agent react fully to form a preliminary three-dimensional network structure.

[0017] Preparation of foaming system;

[0018] Addition of foaming agent and curing agent: Add 7-10 parts of foaming agent and 2-5 parts of curing agent to the prepolymer and stir evenly;

[0019] Addition of catalysts, stabilizers, buffers and antioxidants:

[0020] Add 1.5-2 parts of catalyst, 1-3 parts of stabilizer, 1-2 parts of buffer and 0.5-1 parts of antioxidant and continue stirring to ensure uniform dispersion.

[0021] Mixing and foaming

[0022] Mixed reaction:

[0023] Slowly add the PEG cross-linking mixture into the foaming system, stirring continuously to ensure that all ingredients are fully mixed;

[0024] Foaming reaction:

[0025] The mixture was poured into a mold and allowed to stand at 60°C for 1 hour to undergo a foaming reaction to form a sponge.

[0026] Drying and curing:

[0027] The foamed sponge was taken out and placed in a drying oven at 80° C. for 2 hours.

[0028] The sponge was further placed in a heat treatment furnace at 120° C. and heated for 4 hours for curing to ensure that the cross-linking reaction was complete and a stable three-dimensional network structure was formed.

[0029] Cooling and finishing:

[0030] Allow to cool to room temperature and trim sponge to desired size, removing edges and irregularities.

[0031] Compared with the prior art, the present invention has the following beneficial effects:

[0032] By adding buffers and antioxidants during the prepolymer production process, the stability and efficiency of the reaction are significantly improved, and the production process of melamine sponge is optimized. Combined with high-speed shear stirring and ultrasonic stirring equipment, the components are evenly distributed, and finally a melamine sponge with multiple excellent properties such as high strength, low density and high elasticity is prepared. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] In order to more clearly illustrate the specific implementation methods of the present invention or the technical solutions in the prior art, the drawings required for use in the specific implementation methods or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some implementation methods of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0034] Figure 1 The present invention is a production process flow chart of the melamine sponge;

[0035] Figure 2 This is a formula diagram of high-strength melamine sponge according to Example 1 of the present invention;

[0036] Figure 3 This is a formula diagram of low-density melamine sponge according to Example 2 of the present invention;

[0037] Figure 4 This is a formula diagram of the high elastic melamine sponge according to Example 3 of the present invention. DETAILED DESCRIPTION

[0038] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0039] See also Figures 1 to 4 , the present invention provides a technical solution:

[0040] A melamine sponge, the formula comprising:

[0041] Melamine: 100 parts, formaldehyde: 250-300 parts, polyethylene glycol (PEG): 15-20 parts, foaming agent: 7-10 parts, curing agent: 2-5 parts, catalyst 1.5-2 parts, stabilizer: 1-3 parts, buffer: 1-2 parts, antioxidant: 0.5-1 part, deionized water: appropriate amount, cross-linking agent 5-10 parts.

[0042] A production process of melamine sponge comprises the following steps:

[0043] Step 1: Add melamine, formaldehyde and a buffer into a reaction kettle, mix them according to a certain proportion, and react them at 80° C. for 1 hour to obtain a melamine-formaldehyde prepolymer.

[0044] Step 2: Add polyethylene glycol (PEG), foaming agent and deionized water to the prepolymer and stir for 20 minutes using a high-speed shear mixer to form a uniform mixture.

[0045] Step 3: Transfer the mixture to a foaming device and continue the reaction at 70°C for 30 minutes to allow the foaming agent to fully act and produce a uniform foam structure.

[0046] Step 4: During the foam formation process, gradually add curing agent, catalyst and stabilizer, use ultrasonic stirring equipment to ensure that the ingredients are evenly distributed, and continue stirring for 10 minutes.

[0047] Step 5: Pour the reacted foam material into a mold preheated to 90°C and cure it for 2 hours.

[0048] Step 6: The solidified melamine sponge is cooled, demoulded and cut to obtain the final product.

[0049] Preferably, in the step, sodium citrate is used as a buffer to stabilize the pH value, and BHT is used as an antioxidant to prevent oxidation, thereby improving the stability of the prepolymer.

[0050] Preferably, the cross-linking modification of polyethylene glycol in step 2 forms a three-dimensional network structure in the sponge, thereby reducing the migration and loss of PEG and enhancing the mechanical strength and water resistance of the sponge.

[0051] The preparation method of polyethylene glycol cross-linking modification comprises the following steps:

[0052] Mix 15-20 parts of PEG with 5-10 parts of a cross-linking agent (glutaraldehyde or diisocyanate), and stir at 60° C. for 30 minutes to ensure that the PEG and the cross-linking agent react fully to form a preliminary three-dimensional network structure.

[0053] Preparation of foaming system;

[0054] Addition of foaming agent and curing agent: Add 7-10 parts of foaming agent and 2-5 parts of curing agent to the prepolymer and stir evenly;

[0055] Addition of catalysts, stabilizers, buffers and antioxidants:

[0056] Add 1.5-2 parts of catalyst, 1-3 parts of stabilizer, 1-2 parts of buffer and 0.5-1 parts of antioxidant and continue stirring to ensure uniform dispersion.

[0057] Mixing and foaming

[0058] Mixed reaction:

[0059] Slowly add the PEG cross-linking mixture into the foaming system, stirring continuously to ensure that all ingredients are fully mixed;

[0060] Foaming reaction:

[0061] The mixture was poured into a mold and allowed to stand at 60°C for 1 hour to undergo a foaming reaction to form a sponge.

[0062] Drying and curing:

[0063] The foamed sponge was taken out and placed in a drying oven at 80° C. for 2 hours.

[0064] The sponge was further placed in a heat treatment furnace at 120° C. and heated for 4 hours for curing to ensure that the cross-linking reaction was complete and a stable three-dimensional network structure was formed.

[0065] Cooling and finishing:

[0066] Cool to room temperature and trim the sponge to desired size, removing edges and irregularities;

[0067] Example 1: High-strength melamine sponge

[0068] 1. Ingredients

[0069] Melamine: 100 parts

[0070] Formaldehyde: 300 parts

[0071] Polyethylene glycol (PEG): 20 parts

[0072] Foaming agent: 10 parts

[0073] Curing agent: 3 parts

[0074] Catalyst: 2 parts

[0075] Stabilizer: 2 parts

[0076] Buffer: 1.5 parts

[0077] Antioxidant: 0.8 parts

[0078] Deionized water: 150 parts

[0079] 2. Preparation steps

[0080] Step 1: At 80° C., 100 parts of melamine and 300 parts of formaldehyde are mixed and reacted for 1 hour, and 1.5 parts of a buffer and 0.8 parts of an antioxidant are added to obtain a prepolymer.

[0081] Step 2: Add 20 parts of PEG, 10 parts of foaming agent and 150 parts of deionized water, and stir for 20 minutes using a high-speed shear mixer.

[0082] Step 3: Continue the reaction at 70°C for 30 minutes to produce a uniform foam structure.

[0083] Step 4: Gradually add 3 parts of curing agent, 2 parts of catalyst and 2 parts of stabilizer, and distribute them evenly using ultrasonic stirring equipment.

[0084] Step 5: Pour the foam material into a mold preheated to 90°C and cure for 2 hours.

[0085] Step 6: Cooling, demoulding and cutting to obtain high-strength melamine sponge.

[0086] Example 2: Low density melamine sponge

[0087] 1. Ingredients

[0088] Melamine: 100 parts

[0089] Formaldehyde: 250 parts

[0090] Polyethylene glycol (PEG): 15 parts

[0091] Foaming agent: 8 parts

[0092] Curing agent: 2 parts

[0093] Catalyst: 1.5 parts

[0094] Stabilizer: 1.5 parts

[0095] Buffer: 1 part

[0096] Antioxidant: 0.5 parts

[0097] Deionized water: 180 parts

[0098] 2. Preparation steps

[0099] Step 1: At 75° C., 100 parts of melamine and 250 parts of formaldehyde are mixed and reacted for 1 hour, and 1 part of a buffer and 0.5 parts of an antioxidant are added to obtain a prepolymer.

[0100] Step 2: Add 15 parts of PEG, 8 parts of foaming agent and 180 parts of deionized water, and stir for 15 minutes using a high-speed shear mixer.

[0101] Step 3: Continue the reaction at 65°C for 25 minutes to produce a uniform foam structure.

[0102] Step 4: Gradually add 2 parts of curing agent, 1.5 parts of catalyst and 1.5 parts of stabilizer, and distribute them evenly using ultrasonic stirring equipment.

[0103] Step 5: Pour the foam material into a mold preheated to 85°C and cure for 2 hours.

[0104] Step 6: Cooling, demoulding and cutting to obtain low-density melamine sponge.

[0105] Example 3: Highly elastic melamine sponge

[0106] 1. Ingredients

[0107] Melamine: 100 parts

[0108] Formaldehyde: 280 parts

[0109] Polyethylene glycol (PEG): 25 parts

[0110] Foaming agent: 9 parts

[0111] Curing agent: 4 parts

[0112] Catalyst: 1.8 parts

[0113] Stabilizer: 2.5 parts

[0114] Buffer: 1.2 parts

[0115] Antioxidant: 0.7 parts

[0116] Deionized water: 160 parts

[0117] 2. Preparation steps

[0118] Step 1: At 85° C., 100 parts of melamine and 280 parts of formaldehyde are mixed and reacted for 1 hour, and 1.2 parts of a buffer and 0.7 parts of an antioxidant are added to obtain a prepolymer.

[0119] Step 2: Add 25 parts of PEG, 9 parts of foaming agent and 160 parts of deionized water, and stir for 20 minutes using a high-speed shear mixer.

[0120] Step 3: Continue the reaction at 75°C for 30 minutes to produce a uniform foam structure.

[0121] Step 4: Gradually add 4 parts of curing agent, 1.8 parts of catalyst and 2.5 parts of stabilizer, and distribute them evenly using ultrasonic stirring equipment.

[0122] Step 5: Pour the foam material into a mold preheated to 95°C and cure for 2.5 hours.

[0123] Step 6: Cooling, demoulding and cutting to obtain high elastic melamine sponge.

[0124] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A melamine sponge, characterized in that: The recipe includes: Melamine: 100 parts, formaldehyde: 250-300 parts, polyethylene glycol (PEG): 15-20 parts, foaming agent: 7-10 parts, curing agent: 2-5 parts, catalyst 1.5-2 parts, stabilizer: 1-3 parts, buffer: 1-2 parts, antioxidant: 0.5-1 part, deionized water: appropriate amount, cross-linking agent 5-10 parts.

2. A production process for preparing a melamine sponge according to claim 1, characterized in that: The steps include: Step 1: Add melamine, formaldehyde and a buffer into a reaction kettle, mix them according to a certain proportion, and react them at 80° C. for 1 hour to obtain a melamine-formaldehyde prepolymer; Step 2: Add polyethylene glycol (PEG), a foaming agent and deionized water to the prepolymer, and stir for 20 minutes using a high-speed shear mixer to form a uniform mixture; Step 3: Transfer the mixture to a foaming device and continue to react at 70°C for 30 minutes to allow the foaming agent to fully act and produce a uniform foam structure; Step 4: During the foam formation process, gradually add curing agent, catalyst and stabilizer, use ultrasonic stirring equipment to ensure that the ingredients are evenly distributed, and continue stirring for 10 minutes; Step 5: Pour the reacted foam material into a mold preheated to 90°C and perform a curing treatment for 2 hours; Step 6: The solidified melamine sponge is cooled, demoulded and cut to obtain the final product.

3. The production process of a melamine sponge according to claim 1, characterized in that: In the step, sodium citrate is used as a buffer to stabilize the pH value, and BHT is used as an antioxidant to prevent oxidation, thereby improving the stability of the prepolymer.

4. A melamine sponge and a production process thereof according to claim 2, characterized in that: The cross-linking modification of polyethylene glycol in step 2 forms a three-dimensional network structure in the sponge, reduces the migration and loss of PEG, and enhances the mechanical strength and water resistance of the sponge.

5. The production process of a melamine sponge according to claim 1, characterized in that: The cross-linking and modified preparation method of polyethylene glycol comprises the following steps: Mix 15-20 parts of PEG with 5-10 parts of a cross-linking agent (glutaraldehyde or diisocyanate), and stir at 60° C. for 30 minutes to ensure that the PEG and the cross-linking agent react fully to form a preliminary three-dimensional network structure.

6. The production process of a melamine sponge according to claim 5, characterized in that: The cross-linking and modified preparation method of polyethylene glycol comprises the following steps: preparing a foaming system; Addition of foaming agent and curing agent: Add 7-10 parts of foaming agent and 2-5 parts of curing agent to the prepolymer and stir evenly; Addition of catalyst, stabilizer, buffer and antioxidant: Add 1.5-2 parts of catalyst, 1-3 parts of stabilizer, 1-2 parts of buffer and 0.5-1 parts of antioxidant, and continue stirring to ensure uniform dispersion.

7. The production process of a melamine sponge according to claim 6, characterized in that: The cross-linking and modified preparation method of polyethylene glycol comprises the following steps: mixing and foaming Mixing reaction: Slowly add the PEG cross-linking mixture into the foaming system, stirring continuously to ensure that all ingredients are fully mixed; Foaming reaction: Pour the mixture into a mold and let it stand at 60°C for 1 hour to undergo a foaming reaction to form a sponge.

8. The production process of a melamine sponge according to claim 7, characterized in that: The polyethylene glycol cross-linking modification preparation method comprises the following steps: drying and curing: taking out the foamed sponge and putting it into a drying oven to dry at 80° C. for 2 hours. The sponge was further placed in a heat treatment furnace at 120°C and heated for 4 hours for curing to ensure that the cross-linking reaction was complete and a stable three-dimensional network structure was formed. Cooling and trimming: Cool to room temperature, trim the sponge to the required size, and remove corners and irregular parts.

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