Foaming sponge as well as preparation method and application thereof
By adding modified concave and convex rod soil to the foamed sponge and using its internal porous structure for grafting reaction, the problem of density exceeding the standard when increasing the strength of the foamed sponge is solved, and the effect of low density and high strength is achieved.
Patent Information
- Application Number
- CN202510064612.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-01-15
- Publication Date
- 2025-04-29
AI Technical Summary
While the existing foamed sponges increase tensile strength and 40% cast hardness, the density is prone to exceed the standard, resulting in an increase in weight.
By adding modified concave and convex rod soil and grafting hydroxyl groups in its internal porous structure, the polyol reacts with the hydroxyl groups in the concave and convex rod soil when reacting with isocyanate, thereby forming several concave and convex rod soil centers in the foaming sponge, improving the uniformity of foaming, reducing the overall density, and improving the internal strength.
A foamed sponge with low density and high strength is achieved, with significant increase in tensile strength and 40% casting hardness, while the density is kept at a low level.
Abstract
Description
Technical Field
[0001] The present application relates to the technical field of foam sponges, and in particular to a foam sponge and a preparation method and application thereof. Background Art
[0002] Sponge is a kind of polyurethane foam plastic, belonging to soft polyurethane foam plastic. Due to its porous honeycomb structure, it has excellent softness, elasticity, water absorption and water resistance, and is widely used in sofas, mattresses, clothing, soft packaging and other industries.
[0003] Among them, automobile interior is also one of the important application fields. The foam sponge used in automobile interior requires high strength and is not easy to collapse. In order to meet its performance requirements, it is often necessary to increase the density of the foam sponge to increase the tensile strength and 40% compression hardness, which will cause the weight to exceed the standard. Therefore, how to improve the strength of the foam sponge and the 40% compression hardness while ensuring that the density does not exceed the standard is a problem that needs to be solved at present. Summary of the invention
[0004] In order to solve at least one of the above technical problems and develop a foam sponge with low density and high strength, the present application provides a foam sponge and a preparation method and application thereof.
[0005] In one aspect, the present application provides a foamed sponge, which is prepared from the following components by weight:
[0006] 30-60 parts of polyol;
[0007] 20-40 parts of isocyanate;
[0008] 8-12 parts of modified attapulgite;
[0009] 1-5 parts water;
[0010] 0.5-3 parts of catalyst;
[0011] 0.5-3 parts of surfactant;
[0012] 0-5 parts of foaming agent;
[0013] 5-12 parts of flame retardant;
[0014] The preparation method of the modified attapulgite is as follows: the attapulgite powder is firstly subjected to an acid washing treatment, then subjected to an alkali washing treatment, washed with deionized water until neutral, and then subjected to filtering and drying processes.
[0015] Optionally, the pickling treatment is: adding attapulgite powder into an inorganic acid solution, heating to 25-50° C., and stirring for 2-5 minutes.
[0016] Optionally, the alkaline washing treatment is: adding the attapulgite powder after the acid washing treatment into an alkaline solution, heating it to 25 to 50° C., and stirring it for 2 to 5 minutes.
[0017] Optionally, the weight ratio of the isocyanate to the modified attapulgite is 3.5 to 3.9:1.
[0018] Optionally, the modified attapulgite has a particle size of 0.1 to 20 μm.
[0019] Optionally, the polyol is PPG;
[0020] And / or, the isocyanate is TDI or MDI;
[0021] And / or, the catalyst is an amine catalyst;
[0022] And / or, the surfactant is sodium dodecylbenzene sulfonate;
[0023] And / or, the foaming agent is HFOs;
[0024] And / or, the flame retardant is melamine and its derivatives.
[0025] In a second aspect, the present application provides a method for preparing the above-mentioned foamed sponge, comprising mixing polyol, isocyanate, modified attapulgite, water, a catalyst, a surfactant, a foaming agent, and a flame retardant, and stirring at high speed; injecting into a mold, heating and maintaining pressure; and demolding after cooling to obtain a foamed sponge.
[0026] Optionally, the stirring speed is 800-1200 rpm.
[0027] Optionally, the heating temperature is 25-40° C. and the pressure is 2-5 bar.
[0028] In a third aspect, the present application provides the application of the above-mentioned foam sponge in the field of automobile interior decoration.
[0029] In summary, the present invention adds modified attapulgite and grafts hydroxyl groups in the porous structure inside the attapulgite, so that when the polyol reacts with the isocyanate, part of them can react with the hydroxyl groups in the attapulgite, so that foaming is continuously carried out with the attapulgite particles as the center, and a plurality of attapulgite centers are formed in the foamed sponge, thereby improving the uniformity of foaming, thereby reducing the overall density of the foamed sponge, and being able to improve the internal strength of the foamed sponge, and improving the tensile strength and 40% compression hardness of the foamed sponge. DETAILED DESCRIPTION
[0030] The present application is further described in detail below in conjunction with embodiments.
[0031] In the following examples of the present application, the main components involved, unless otherwise specified, were purchased from commercially available products.
[0032] The modified attapulgite is prepared by the following preparation method: attapulgite powder with a particle size of 0.1 to 20 μm is first added to a hydrochloric acid solution, heated to 25° C., and stirred for 3 minutes; then added to a sodium hydroxide solution, heated to 25° C., and stirred for 3 minutes; washed with deionized water until neutral, and then filtered and dried;
[0033] The polyol is exemplified by PPG;
[0034] Isocyanate is exemplarily TDI or MDI;
[0035] The catalyst is exemplarily an amine catalyst;
[0036] The surfactant is exemplified by sodium dodecylbenzene sulfonate;
[0037] The blowing agent is exemplarily HFOs;
[0038] Melamine is exemplified as the flame retardant. Specific embodiments
[0040] Example 1
[0041] 30 parts by weight of polyol, 20 parts by weight of isocyanate, 8 parts by weight of modified attapulgite, 1 part by weight of water, 0.5 parts by weight of catalyst, 3 parts by weight of surfactant, 5 parts by weight of foaming agent and 5 parts by weight of flame retardant were mixed and stirred at 1000 rpm; injected into a mold, heated to 30°C and maintained at a pressure of 3 bar; after molding and cooling, demolded to obtain a foamed sponge.
[0042] Example 2
[0043] 40 parts by weight of polyol, 25 parts by weight of isocyanate, 10 parts by weight of modified attapulgite, 2 parts by weight of water, 1 part by weight of catalyst, 2 parts by weight of surfactant, 3 parts by weight of foaming agent and 8 parts by weight of flame retardant were mixed and stirred at 1000 rpm; injected into a mold, heated to 30°C and maintained at a pressure of 3 bar; after molding and cooling, demolded to obtain a foamed sponge.
[0044] Example 3
[0045] 45 parts by weight of polyol, 30 parts by weight of isocyanate, 12 parts by weight of modified attapulgite, 3 parts by weight of water, 2 parts by weight of catalyst, 2 parts by weight of surfactant, 3 parts by weight of foaming agent and 10 parts by weight of flame retardant were mixed and stirred at 1000 rpm; injected into a mold, heated to 30°C and maintained at a pressure of 3 bar; after molding and cooling, demolded to obtain a foamed sponge.
[0046] Example 4
[0047] 50 parts by weight of polyol, 35 parts by weight of isocyanate, 10 parts by weight of modified attapulgite, 4 parts by weight of water, 2 parts by weight of catalyst, 1 part by weight of surfactant and 12 parts by weight of flame retardant were mixed and stirred at 1000 rpm; injected into a mold, heated to 30°C and maintained at a pressure of 3 bar; after molding and cooling, demolded to obtain a foamed sponge.
[0048] Example 5
[0049] 60 parts by weight of polyol, 40 parts by weight of isocyanate, 8 parts by weight of modified attapulgite, 5 parts by weight of water, 3 parts by weight of catalyst, 0.5 parts by weight of surfactant and 10 parts by weight of flame retardant were mixed and stirred at 1000 rpm; injected into a mold, heated to 30°C and maintained at a pressure of 3 bar; after molding and cooling, demolded to obtain a foamed sponge.
[0050] Comparative Example 1
[0051] The difference between this comparative example and Example 1 is that attapulgite is not added in this comparative example; the details are as follows.
[0052] 30 parts by weight of polyol, 20 parts by weight of isocyanate, 1 part by weight of water, 0.5 parts by weight of catalyst, 3 parts by weight of surfactant, 5 parts by weight of foaming agent and 5 parts by weight of flame retardant were mixed and stirred at 1000 rpm; injected into a mold, heated to 30°C and maintained at a pressure of 3 bar; after molding and cooling, demolded to obtain a foamed sponge.
[0053] The performance of the foamed sponges prepared in Examples 1 to 5 was tested according to GBT 24451-2020 Slow Resilience Soft Polyurethane Foam Plastics. The results are shown in Table 1, where N is the weight ratio of isocyanate to attapulgite.
[0054] Table 1
[0055] Foam sponge N <![CDATA[Density / kg*m -3 > Tensile strength / KPa 40% indentation hardness / N Example 1 2.5 22.5 135 256 Example 2 2.5 21.9 141 275 Example 3 2.5 22.1 139 281 Example 4 3.5 19.7 154 311 Example 5 5.0 20.8 146 289 Comparative Example 1 / 25.6 105 93
[0056] It can be seen from Examples 1 to 5, Comparative Example 1 and Table 1 that the density of the foamed sponge prepared in the present application is small, less than 23 kg / m 3 , significantly decreased compared to comparative example 1, and the tensile strength and 40% indentation hardness were significantly improved, the tensile strength could reach above 135MPa, which was about 30% higher than that in comparative example 1, and the 40% indentation hardness reached above 250N, which was more than 175% higher than that in comparative example 1.
[0057] Further analysis of Table 1 shows that the performance of Example 4 is significantly improved compared with other examples. The density of the foamed sponge prepared in Example 4 is lower than 20 kg / m 3, tensile strength is higher than 150MPa, and 40% indentation hardness reaches more than 300N.
[0058] The inventors prepared the following Examples 6 to 9, only changing the amount of attapulgite added. The details are as follows.
[0059] Example 6
[0060] 50 parts by weight of polyol, 35 parts by weight of isocyanate, 8 parts by weight of modified attapulgite, 4 parts by weight of water, 2 parts by weight of catalyst, 1 part by weight of surfactant and 12 parts by weight of flame retardant were mixed and stirred at 1000 rpm; injected into a mold, heated to 30°C and maintained at a pressure of 3 bar; after molding and cooling, demolded to obtain a foamed sponge.
[0061] Example 7
[0062] 50 parts by weight of polyol, 35 parts by weight of isocyanate, 9 parts by weight of modified attapulgite, 4 parts by weight of water, 2 parts by weight of catalyst, 1 part by weight of surfactant and 12 parts by weight of flame retardant were mixed and stirred at 1000 rpm; injected into a mold, heated to 30°C and maintained at a pressure of 3 bar; after molding and cooling, demolded to obtain a foamed sponge.
[0063] Example 8
[0064] 50 parts by weight of polyol, 35 parts by weight of isocyanate, 11 parts by weight of modified attapulgite, 4 parts by weight of water, 2 parts by weight of catalyst, 1 part by weight of surfactant and 12 parts by weight of flame retardant were mixed and stirred at 1000 rpm; injected into a mold, heated to 30°C and maintained at a pressure of 3 bar; after molding and cooling, demolded to obtain a foamed sponge.
[0065] Example 9
[0066] 50 parts by weight of polyol, 35 parts by weight of isocyanate, 12 parts by weight of modified attapulgite, 4 parts by weight of water, 2 parts by weight of catalyst, 1 part by weight of surfactant and 12 parts by weight of flame retardant were mixed and stirred at 1000 rpm; injected into a mold, heated to 30°C and maintained at a pressure of 3 bar; after molding and cooling, demolded to obtain a foamed sponge.
[0067] The performance of the foamed sponges prepared in Examples 6 to 9 was tested. The results are shown in Table 2, where N is the weight ratio of isocyanate to attapulgite.
[0068] Table 2
[0069] Foam sponge N <![CDATA[Density / kg*m -3 > Tensile strength / KPa 40% indentation hardness / N Example 6 4.4 20.5 144 279 Example 7 3.9 19.5 156 309 Example 4 3.5 19.7 154 311 Example 8 3.2 21.7 143 286 Example 9 2.9 22.3 139 291
[0070] It can be seen from Examples 6 to 9, Example 4 and Table 2 that compared with Examples 6 and Examples 8 to 9, Examples 4 and Example 7 have lower density, higher tensile strength and 40% indentation hardness; the density is less than 20 kg / m3 , tensile strength is higher than 150MPa, and 40% indentation hardness reaches more than 300N.
[0071] Therefore, it can be seen that in the technical solution of the present application, when the weight ratio of isocyanate to modified attapulgite is 3.5 to 3.9:1, the density of the foamed sponge can be further reduced, and the tensile strength and 40% indentation hardness can be improved; the performance is more excellent.
[0072] The above are all preferred embodiments of the present application, and the protection scope of the present application is not limited thereto. Therefore, any equivalent changes made according to the structure, shape, and principle of the present application should be included in the protection scope of the present application.
Claims
1. A foam sponge, characterized in that: Prepared from the following components by weight: 30-60 parts of polyol; 20-40 parts of isocyanate; 8-12 parts of modified attapulgite; 1-5 parts water; 0.5-3 parts of catalyst; 0.5-3 parts of surfactant; 0-5 parts of foaming agent; 5-12 parts of flame retardant; The preparation method of the modified attapulgite is as follows: the attapulgite powder is firstly subjected to an acid washing treatment, then subjected to an alkali washing treatment, washed with deionized water until neutral, and then subjected to filtering and drying processes.
2. The foam sponge according to claim 1, characterized in that: The acid washing treatment is as follows: adding attapulgite powder into an inorganic acid solution, heating to 25-50° C., and stirring for 2-5 minutes.
3. The foam sponge according to claim 1, characterized in that: The alkaline washing treatment is as follows: adding the acid-washed attapulgite powder into an alkaline solution, heating the solution to 25-50° C., and stirring the solution for 2-5 minutes.
4. The foam sponge according to claim 1, characterized in that: The weight ratio of the isocyanate to the modified attapulgite is 3.5 to 3.9:
1.
5. The foam sponge according to claim 1, characterized in that: The modified attapulgite particle size is 0.1 to 20 μm.
6. The foam sponge according to claim 1, characterized in that: The polyol is PPG; And / or, the isocyanate is TDI or MDI; And / or, the catalyst is an amine catalyst; And / or, the surfactant is sodium dodecylbenzene sulfonate; And / or, the foaming agent is HFOs; And / or, the flame retardant is melamine and its derivatives.
7. A method for preparing the foamed sponge according to claim 1, characterized in that: The polyol, isocyanate, modified attapulgite, water, catalyst, surfactant, foaming agent and flame retardant are mixed and stirred at high speed; injected into a mold, heated and pressure maintained; and demolded after cooling to obtain a foamed sponge.
8. The preparation method according to claim 7, characterized in that: The stirring speed is 800-1200 rpm.
9. The preparation method according to claim 7, characterized in that: The heating temperature is 25-40°C and the pressure is 2-5 bar.
10. Use of the foamed sponge according to claim 1 in the field of automobile interior decoration.