Polyurethane foam material as well as preparation method and application thereof

Abstract

The invention relates to a polyurethane foam material as well as a preparation method and application thereof, and mainly solves the problems of low peel strength, no high-temperature yellowing resistance and high odor of the polyurethane foam material in the prior art. The novel polyurethane foam material is composed of a component A and a component B, the weight part ratio of the component A to the component B is 100: (40-60), the component A comprises the following components in parts by weight: 0-60 parts of polyether polyol A, 30-40 parts of polymer polyol B, 10-65 parts of polyether carbonate C, 2.5-4 parts of water, 1-2.5 parts of a foam stabilizer, 0.2-0.5 part of an amine catalyst, 0.05-0.2 part of a metal catalyst, 3-10 parts of a flame retardant and 2-6 parts of a fire composite agent; with the adoption of the technical scheme, the problems are well solved, and the composition can be applied to automobile roofs, seats and interiors.

Description

Technical Field

[0001] The invention relates to a polyurethane foam material and a preparation method and application thereof. Background Art

[0002] As automobile technology matures, the performance of core components such as engines and gearboxes is becoming more and more perfect, and the competitiveness of automobiles is gradually shifting to the interior. The information that consumers come into contact with and feel in the shortest time comes from the interior of the car. Therefore, improving the quality of automobile interiors has become one of the focuses of OEMs. Polyurethane foam material is one of the important materials that cannot be ignored in modern automobile manufacturing. Due to its characteristics of light weight, heat insulation, good resilience, good comfort, good low-temperature performance, durability, safety and high vibration absorption, it has been more and more widely used in the field of automobile interiors. It is one of the important materials that cannot be ignored in modern automobile manufacturing.

[0003] Polyurethane materials are widely used in the production of car seats, dashboards, steering wheels, armrests, floor mats, window frame seals, ceilings and door panels.

[0004] Car seats are mainly composed of frames, seat foams, seat covers and plastic parts. Among them, the seat covers are made of composite fabrics, mainly leather, artificial leather + polyether / polyester sponge. Generally, polyester sponge has strong composite adhesion with leather, good mechanical properties, high temperature resistance, strong tensile strength, and uniform and regular pores with few bean holes, but poor hydrolysis resistance, high volatility of volatile organic compounds (VOC), and the feel of its products is not as soft as polyether sponge. Polyether sponge has good flexibility, excellent hydrolysis resistance, good feel, excellent molding performance, good air permeability, but poor peel strength and breaking strength. Due to factors such as poor hydrolysis, high VOC and high raw material costs of polyester sponge, more and more manufacturers have begun to develop half-ester half-ether polyether, which combines the performance advantages of polyester and polyether structures while reducing the cost of sponge.

[0005] Carbon dioxide (CO 2 ) as a major greenhouse gas, it always makes people think of a series of environmental problems caused by it. However, from another perspective, CO 2 In fact, it is a very rich carbon resource. 2 The polyether carbonate polyol was prepared from this process. The polyether has both ester bonds and ether bonds. Its application in the process of preparing polyurethane products not only solves the problem of flame composite sponge, but also utilizes the cheap and readily available CO 2 , responding to the call of atomic economy, and having a far-reaching impact on alleviating the greenhouse effect.

[0006] Patent CN201811467843.7 discloses a waterproof coating for building waterproofing and a preparation method thereof. During the preparation process, polyether polyol and polyester polyol are mixed. The waterproof coating used for building waterproofing has good flexibility, low temperature resistance and high bonding strength. However, its formula system is a two-component polyurethane waterproof coating, component A is polyether polyol, polyester polyol and isocyanate, and component B is a defoamer, a curing agent, a modified nano calcium carbonate filler, a silane coupling agent modified nano silicon dioxide, a thickener, a dispersant and water. This method uses a physical mixing method to improve the bonding strength of the material, but the odor and anti-yellowing properties of the material still need to be improved.

[0007] Patent CN114369236 A discloses a high-performance polyester ether polyol and its preparation method and application. The high-performance polyester ether polyol is obtained by polymerizing a diol with a side group with an alkylene oxide to obtain an intermediate refined polyether polyol, and then mixing the intermediate refined polyether polyol with anhydride and polymerizing with alkylene oxide; the diol with a side group is one or more of 2,2,4-trimethyl-1,3-pentanediol, 2,4-diethyl-1,5-pentanediol, 2-butyl-2-ethyl-1,3-propanediol, and 3-methyl-1,5-pentanediol. The one-component polyurethane waterproof coating prepared by this method has the excellent properties of both polyether and polyester, good flexibility, hydrolysis resistance and high mechanical strength, but poor yellowing resistance. Summary of the invention

[0008] One of the technical problems to be solved by the present invention is that the polyurethane foam material in the prior art has the problems of low peel strength, yellowing resistance at high temperature and high odor, and provides a new polyurethane foam material, which has the advantages of high peel strength, yellowing resistance and low odor.

[0009] The second technical problem to be solved by the present invention is to provide a method for preparing a polyurethane foam material corresponding to the first technical problem to be solved.

[0010] The third technical problem to be solved by the present invention is to provide an application of a polyurethane foam material corresponding to solving the first technical problem.

[0011] In order to solve one of the above technical problems, the technical solution adopted by the present invention is as follows: a polyurethane foam material, comprising component A and component B, wherein the weight ratio of component A to component B is 100:40-60, wherein, by weight ratio, component A: 0-60 parts of polyether polyol A, polymer polyol B 30-40 parts, polyether carbonate C10-65 parts, water 2.5-4 parts, foam stabilizer 1-2.5 parts, amine catalyst 0.2-0.5 parts, metal catalyst 0.05-0.2 parts, flame retardant 3-10 parts, fire-recovery agent 2-6 parts; component B is isocyanate; wherein the polyether polyol A is at least one of glycerol, trimethylolpropane and triethanolamine as an initiator, a polyether polyol of ethylene oxide-propylene oxide copolymer with a molecular weight of 2800-3200, ethylene oxide accounts for 10%-15% of the molecular weight of polyether polyol A, the functionality is 3, the viscosity is 400-600mpa·s, and the hydroxyl value is 50-60mgKOH / g; the molecular weight of the polymer polyol B is 5 The invention discloses a polymer polyol having a molecular weight of 500 to 7000, a functionality of 3, a solid content of 44 to 48%, a viscosity of 3700 to 5000 mpa·s, and a hydroxyl value of 20 to 30 mgKOH / g; the polyether carbonate polyol C is a polyether carbonate polyol obtained by polymerizing propylene oxide with a molecular weight of 2800 to 3200 and carbon dioxide, with at least one of glycerol, trimethylolpropane, and triethanolamine as an initiator, a functionality of 3, and a hydroxyl value of 50 to 60 mgKOH / g; the amine catalyst is a tertiary amine catalyst containing a hydroxyl group; the foam stabilizer is a polysiloxane-olefin oxide block or graft copolymer; and the isocyanate is selected from at least one of toluene diisocyanate, crude MDI, or carbodiimide modified isocyanate.

[0012] In the above technical solution, preferably, the weight proportion of the polyether polyol A is 0 to 46 parts, and the molecular weight is 2900 to 3100; the weight proportion of the polyether carbonate polyol C is 19 to 65 parts, and the molecular weight is 2900 to 3100.

[0013] In the above technical scheme, preferably, the amine catalyst is selected from at least one of a foaming tertiary amine catalyst, a gel tertiary amine catalyst or a balanced tertiary amine catalyst; the foaming tertiary amine catalyst is selected from at least one of dimethylaminoethyl ether, trimethylhydroxyethylethylenediamine or N,N,N'-trimethyl-N'-hydroxyethylbisaminoethyl ether; the gel tertiary amine catalyst is selected from at least one of N,N-bis(dimethylaminopropyl)isopropanolamine or triethylenediamine; and the balanced tertiary amine catalyst is selected from dimethylethanolamine.

[0014] In the above technical solution, preferably, the foam stabilizer is selected from at least one of L-580, L-595 or DC5950.

[0015] In the above technical solution, preferably, the metal catalyst is selected from at least one of dibutyltin dilaurate, stannous octoate and dibutyltin diacetate.

[0016] In the above technical solution, preferably, the flame retardant is selected from YK68LE.

[0017] In the above technical solution, preferably, the fire-restoring agent is selected from 500LF.

[0018] In the above technical solution, preferably, the isocyanate is selected from one of TDI-80, 3133 or 8122.

[0019] In order to solve the second technical problem mentioned above, the technical solution adopted by the present invention is as follows: a method for preparing a polyurethane foam material, comprising the following steps in sequence:

[0020] (1) Add 0-60 parts of polyether polyol A, 30-40 parts of polymer polyol B, 10-65 parts of polyether carbonate C, 2.5-4 parts of water, 1-2.5 parts of foam stabilizer, 0.2-0.5 parts of amine catalyst, 0.05-0.2 parts of metal catalyst, 3-10 parts of flame retardant, and 2-6 parts of fire-retardant agent to container A in accordance with weight parts, add them to the container in sequence, stir and mix thoroughly, stirring at a speed of 2000-3000 rpm and a stirring temperature of 22-25°C;

[0021] (2) Add component B isocyanate into container A, the mass ratio of component B to component A is 40-60:100, stir for 4-6 seconds to obtain a material, the stirring speed is 2000-5000 rpm, and the stirring temperature is 20-30° C.;

[0022] (3) The material is quickly poured into a foaming box for aging for 10 to 72 hours, and a polyurethane foam material is prepared after aging.

[0023] To solve the third of the above technical problems, the technical solution adopted by the present invention is as follows: application of a polyurethane foam material in automobile ceilings, seats and interior decorations.

[0024] The preparation method of the present invention adopts three polyol compositions, namely, polyether polyol A, polymer polyol B and polyether carbonate polyol C, to foam a polyurethane foam material with high peeling force, high anti-yellowing ability and low odor, wherein the hydroxyl value of polyether polyol A is 54-58 mgKOH / g, and polyether polyol A is obtained by copolymerization of propylene oxide and ethylene oxide, and its structure ensures the foaming activity and hand feel of the sponge and can provide a certain resilience; the polymer polyol B improves the hardness of the sponge and simultaneously improves the pore opening degree of the sponge and adjusts the thickness of the pores; the polyether carbonate polyol C ensures that the sponge has high tensile tearing performance and improves the peeling force and anti-yellowing performance; the amine catalyst can balance the starting and gelling of the sponge and will not cause the sponge to start too fast or too slow; stannous octoate or dibutyltin diacetate is a commonly used tin catalyst, which ensures the gelling reaction during the reaction process, avoids the collapse or air stagnation of the foam, and can further improve the air permeability of the sponge, thereby achieving a good technical effect. DETAILED DESCRIPTION

[0025] The present invention is further described below in conjunction with specific embodiments. The described embodiments are only a part of the embodiments of the present invention, but not all of the embodiments.

[0026] Table 1 List of raw materials

[0027]

[0028] Example 1

[0029] (1) Add 33 parts of polyether polyol A, 35 parts of polymer polyol B, 32 parts of polyether polyol C, 3.3 parts of water, 0.35 parts of triethylene diamine A33, 0.08 parts of stannous octoate T9, 1 part of foam stabilizer L-580, 8 parts of flame retardant YK68LE and 2 parts of fire-retardant 500LF to container A by weight; stir evenly at a speed of 3000 rpm and a temperature of 22 to 25°C.

[0030] (2) Add 46.5 parts by weight of TDI-80 into container A and stir for 4 to 6 seconds to obtain a material at a stirring speed of 3000 rpm and a stirring temperature of 25° C.;

[0031] (3) The material is quickly poured into a foaming box for aging for 48 hours, and a polyurethane foam material is prepared after aging.

[0032] Examples 2 to 6 and Comparative Examples 1 to 2

[0033] Examples 2 to 6 and Comparative Examples 1 to 2 were carried out according to the steps of Example 1, except for the types of reaction raw materials, ratios and reaction parameters, as shown in Table 2. The conventional physical property test data of the prepared polyurethane foam materials are shown in Table 3.

[0034] Table 2 Weight parts of raw materials of each component in Examples 1 to 6 and Comparative Examples 1 to 2

[0035]

[0036]

[0037] Note: The increase in the amount of polyether carbonate polyol used will lead to a decrease in the reaction activity of the sponge and insufficient sponge opening rate, so it is necessary to adjust the amount of catalyst and additives used in the formula.

[0038] Table 3 Performance test data of polyurethane foam materials prepared in Examples 1 to 6 and Comparative Examples 1 to 2

[0039]

[0040] As can be seen from Tables 2 and 3, in Examples 1 to 4, the amount of polyether carbonate polyol C is gradually increased, and the prepared polyurethane foam material has a small high-temperature odor (3.1 to 4.1) under controlled conditions, and the peeling force can reach up to 8N, while the b value does not change much, indicating that the polyurethane foam material has low odor, strong peeling force, and good anti-yellowing performance; Comparative Example 1 is a polyurethane foam material prepared without using polyether carbonate polyol, and Comparative Example 2 is a polyurethane foam material prepared by the polyester ether polyol used before. It can be seen that under the same density, the peeling force, high-temperature odor and anti-yellowing of the material are not as good as those of the present invention.

[0041] In summary, the present invention prepares a polyurethane foam material with high peeling force, strong anti-yellowing ability and low odor by foaming three polyol compositions of polyether polyol A, polymer polyol B and polyether carbonate polyol C, and achieves good technical effects.

Claims

1. A polyurethane foam material, comprising component A and component B, wherein the weight ratio of component A to component B is 100:40-60, wherein: In terms of weight ratio, component A comprises: 0-60 parts of polyether polyol A, 30-40 parts of polymer polyol B, 10-65 parts of polyether carbonate C, 2.5-4 parts of water, 1-2.5 parts of foam stabilizer, 0.2-0.5 parts of amine catalyst, 0.05-0.2 parts of metal catalyst, 3-10 parts of flame retardant, and 2-6 parts of fire-retardant; component B is isocyanate; wherein the polyether polyol A is a polyether polyol of ethylene oxide-propylene oxide copolymer with at least one of glycerol, trimethylolpropane, and triethanolamine as an initiator, and has a molecular weight of 2800-3200, the weight percentage of ethylene oxide in the molecular weight of polyether polyol A is 10%-15%, the functionality is 3, the viscosity is 400-600mpa·s, and the hydroxyl value is 50-60mgKOH / g; the molecular weight of the polymer polyol B is 5 The invention discloses a polymer polyol having a molecular weight of 500 to 7000, a functionality of 3, a solid content of 44 to 48%, a viscosity of 3700 to 5000 mpa·s, and a hydroxyl value of 20 to 30 mgKOH / g; the polyether carbonate polyol C is a polyether carbonate polyol obtained by polymerizing propylene oxide with a molecular weight of 2800 to 3200 and carbon dioxide, with at least one of glycerol, trimethylolpropane, and triethanolamine as an initiator, a functionality of 3, and a hydroxyl value of 50 to 60 mgKOH / g; the amine catalyst is a tertiary amine catalyst containing a hydroxyl group; the foam stabilizer is a polysiloxane-olefin oxide block or graft copolymer; and the isocyanate is selected from at least one of toluene diisocyanate, crude MDI, or carbodiimide modified isocyanate.

2. A polyurethane foam material according to claim 1, characterized in that: The weight proportion of the polyether polyol A is 0 to 46 parts, and the molecular weight is 2900 to 3100; the weight proportion of the polyether carbonate polyol C is 19 to 65 parts, and the molecular weight is 2900 to 3100.

3. The polyurethane foam material according to claim 1, characterized in that: The amine catalyst is selected from at least one of a foaming tertiary amine catalyst, a gel tertiary amine catalyst or a balanced tertiary amine catalyst; the foaming tertiary amine catalyst is selected from at least one of dimethylaminoethyl ether, trimethylhydroxyethylethylenediamine or N,N,N'-trimethyl-N'-hydroxyethylbisaminoethyl ether; the gel tertiary amine catalyst is selected from at least one of N,N-bis(dimethylaminopropyl)isopropanolamine or triethylenediamine; and the balanced tertiary amine catalyst is selected from dimethylethanolamine.

4. The polyurethane foam material according to claim 1, characterized in that: The foam stabilizer is selected from at least one of L-580, L-595 or DC5950.

5. The polyurethane foam material according to claim 1, characterized in that: The metal catalyst is selected from at least one of dibutyltin dilaurate, stannous octoate and dibutyltin diacetate.

6. The polyurethane foam material according to claim 1, characterized in that: The flame retardant is selected from YK68LE.

7. The polyurethane foam material according to claim 1, characterized in that: The fire-restoring agent is selected from 500LF.

8. The polyurethane foam material according to claim 1, characterized in that: The isocyanate is selected from one of TDI-80, 3133 or 8122.

9. The method for preparing a polyurethane foam material according to claim 1, comprising the following steps in sequence: (1) Add 0-60 parts of polyether polyol A, 30-40 parts of polymer polyol B, 10-65 parts of polyether carbonate C, 2.5-4 parts of water, 1-2.5 parts of foam stabilizer, 0.2-0.5 parts of amine catalyst, 0.05-0.2 parts of metal catalyst, 3-10 parts of flame retardant, and 2-6 parts of fire-retardant agent to container A in accordance with weight parts, add them to the container in sequence, stir and mix thoroughly, stirring at a speed of 2000-3000 rpm and a stirring temperature of 22-25°C; (2) Add component B isocyanate into container A, the mass ratio of component B to component A is 40-60:100, stir for 4-6 seconds to obtain a material, the stirring speed is 2000-5000 rpm, and the stirring temperature is 20-30° C.; (3) The material is quickly poured into a foaming box for aging for 10 to 72 hours, and a polyurethane foam material is prepared after aging.

10. Use of the polyurethane foam material according to claim 1 in automobile roofs, seats and interior decorations.

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