Inert sponge and preparation method and application thereof

Abstract

The invention discloses inert sponge and a preparation method and application thereof. Relates to the technical field of functional sponges, in particular to an inert sponge which is prepared from the following components in parts by weight: 30-40 parts of bio-based polyol; 40 to 50 parts of polyether polyol; 10 to 20 parts of polymer polyol; 45 to 60 parts of isocyanate; 1-3 parts of silicon dioxide; 2-4 parts of a flame retardant; 0.5-1 part of an antibacterial agent; 3-8 parts of water; 0.1 to 0.3 part of a catalyst; and 0.2 to 0.5 part of a surfactant. The inert sponge is applied to the field of household bedding. According to the invention, the bio-based polyol, the polyether polyol and the polymer polyol are compounded, and other components and addition amounts are limited, so that the prepared inert sponge is low in density. The fatigue resistance is good, and the mechanical property is excellent. Relatively environment-friendly raw materials are adopted for preparation, VOC and formaldehyde are reduced, and the coating is more suitable for being used in household bedding; and low-temperature plasma treatment is adopted, the surface aperture ratio is optimized, and the air permeability is improved.

Description

Technical Field

[0001] This application relates to the technical field of functional sponges, and in particular to an inert sponge, its preparation method and application. Background Art

[0002] Inert sponges (also known as slow rebound sponges or memory sponges) are a type of polymer porous material based on polyurethane (PU) or polyether-polyester mixed systems. Their core characteristic is that they slowly recover deformation after being compressed (the rebound time is ≥ 3 seconds), and they can disperse pressure and absorb energy through deformation. In recent years, due to their unique properties, inert sponges have been widely used in fields such as medical protective equipment, household bedding, and sports protection.

[0003] When used in household bedding, such as bean bags, mattresses, pillows, etc., currently, inert sponges with low density generally have poor fatigue resistance and poor mechanical properties; while inert sponges with high density have increased costs and increased weight under the same application, affecting the use. Summary of the Invention

[0004] In order to solve at least one of the above technical problems and develop an inert sponge with low density, good fatigue resistance, and excellent mechanical properties, this application provides an inert sponge, its preparation method and application.

[0005] On the one hand, an inert sponge provided by this application is prepared from the following components in parts by weight:

[0006] 30 - 40 parts of bio-based polyol;

[0007] 40 - 50 parts of polyether polyol;

[0008] 10 - 20 parts of polymer polyol;

[0009] 45 - 60 parts of isocyanate;

[0010] 1 - 3 parts of silicon dioxide;

[0011] 2 - 4 parts of flame retardant;

[0012] 0.5 - 1 part of antibacterial agent;

[0013] 3 - 8 parts of water;

[0014] 0.1 - 0.3 part of catalyst;

[0015] 0.2 - 0.5 part of surfactant.

[0016] Optionally, the weight ratio of the bio-based polyol, polyether polyol, and polymer polyol is 32 - 35:4 - 48:12 - 15.

[0017] Optionally, the bio-based polyol is modified with castor oil and has a hydroxyl value of 160-190.

[0018] Optionally, the polyether polyol has a hydroxyl value of 220-240 and a functionality of 2-3.

[0019] Optionally, the polymer polyol has a solid content of 20% and a molecular weight of 6000-8000.

[0020] Optionally, the isocyanate is a combination of MDI-103C and hexamethylene diisocyanate.

[0021] Optionally, the silica has a particle size of 10-20 nm;

[0022] And / or, the flame retardant is a mixture of triphenyl phosphate and magnesium hydroxide in a weight ratio of 1:1;

[0023] And / or, the antibacterial agent is nano silver with a particle size of 10-50 nm;

[0024] And / or, the catalyst is tetramethylethylenediamine;

[0025] And / or, the surfactant is organosilicone oil.

[0026] In a second aspect, the present application provides a method for preparing the above-mentioned inert sponge, comprising the following steps:

[0027] S1. Mix the bio-based polyol, polyether polyol, and polymer polyol, then add silica, catalyst, and water and mix, and stir at room temperature to form a homogeneous white material;

[0028] S2. Add the isocyanate combination to the white material prepared in S1, stir and then inject into a mold to form a sponge blank;

[0029] S3. The sponge blank in S2 is cut after curing for 48 hours and subjected to surface treatment to obtain an inert sponge.

[0030] Optionally, in S1, the stirring speed is 4000±200 r / min and the stirring time is 30 seconds;

[0031] And / or, in S2, the stirring speed is 5000±500 r / min and the stirring time is 15 seconds;

[0032] And / or, in S2, after injecting into the mold, it is foamed with the assistance of nitrogen, the nitrogen purity is 99.99%, and the flow rate is 100±20 L / h;

[0033] And / or, in S3, the surface treatment is carried out by low-temperature plasma treatment, the power is 80-100 W, and the time is 5-10 minutes.

[0034] In a third aspect, the present application provides an application of the above-mentioned inert sponge in the field of household bedding.

[0035] In summary, the present invention includes at least one of the following beneficial technical effects:

[0036] 1. By using a composite of bio-based polyol, polyether polyol, and polymer polyol, and limiting other components and addition amounts, the prepared inert sponge has a low density, good anti-fatigue performance, and excellent mechanical properties;

[0037] 2. Prepared with relatively environmentally friendly raw materials, reducing VOC and formaldehyde, and being more suitable for use in household bedding;

[0038] 3. By using low-temperature plasma treatment, the surface pore opening rate is optimized, the air permeability is improved, and other properties are not reduced. Specific embodiments

[0039] The following further details the present application in conjunction with examples.

[0040] In the following examples of the present application, unless otherwise specified, the main components involved are all purchased from commercially available products.

[0041] Bio-based polyol: Exemplarily, the castor oil-modified bio-based polyol from BASF is used, with a hydroxyl value of 160-190.

[0042] Polyether polyol: The hydroxyl value is 220-240, and the functionality is 2-3.

[0043] Polymer polyol: The solid content is 20%, and the molecular weight is 6000-8000.

[0044] Isocyanate: Exemplarily, MDI-103C and hexamethylene diisocyanate are combined in a weight ratio of 2:1.

[0045] Silica: The particle size is 10-20 nm;

[0046] Flame retardant: Exemplarily, triphenyl phosphate and magnesium hydroxide are mixed in a weight ratio of 1:1;

[0047] Antibacterial agent: Exemplarily, nano-silver is used, with a particle size of 10-50 nm;

[0048] Catalyst: Exemplarily, tetramethylethylenediamine is used;

[0049] Surfactant: Exemplarily, organosilicon oil is used. Specific examples

[0051] Example 1

[0052] Mix 30 parts by weight of bio - based polyol, 50 parts by weight of polyether polyol, and 10 parts by weight of polymer polyol. Then add 2 parts by weight of silica, 2 parts by weight of flame retardant, 0.5 part by weight of antibacterial agent, 0.2 part by weight of catalyst, and 5 parts by weight of water and mix. Stir at a speed of 4000 ± 200 r / min for 30 seconds at room temperature to form a homogeneous white material; add 45 parts by weight of isocyanate and 0.2 part by weight of surfactant, stir at a speed of 5000 ± 500 r / min for 15 seconds at room temperature, inject into a mold, and foam with nitrogen assistance. The nitrogen purity is 99.99%, and the flow rate is 100 ± 20 L / h to form a sponge blank; after curing for 48 hours, cut it, and treat it with low - temperature plasma with a power of 80 - 100 W and a time of 5 - 10 minutes to obtain an inert sponge.

[0053] Example 2

[0054] Mix 32 parts by weight of bio - based polyol, 48 parts by weight of polyether polyol, and 12 parts by weight of polymer polyol. Then add 2 parts by weight of silica, 2 parts by weight of flame retardant, 0.5 part by weight of antibacterial agent, 0.2 part by weight of catalyst, and 5 parts by weight of water and mix. Stir at a speed of 4000 ± 200 r / min for 30 seconds at room temperature to form a homogeneous white material; add 50 parts by weight of isocyanate and 0.2 part by weight of surfactant, stir at a speed of 5000 ± 500 r / min for 15 seconds at room temperature, inject into a mold, and foam with nitrogen assistance. The nitrogen purity is 99.99%, and the flow rate is 100 ± 20 L / h to form a sponge blank; after curing for 48 hours, cut it, and treat it with low - temperature plasma with a power of 80 - 100 W and a time of 5 - 10 minutes to obtain an inert sponge.

[0055] Example 3

[0056] Mix 35 parts by weight of bio - based polyol, 45 parts by weight of polyether polyol, and 15 parts by weight of polymer polyol. Then add 2 parts by weight of silica, 2 parts by weight of flame retardant, 0.5 part by weight of antibacterial agent, 0.2 part by weight of catalyst, and 5 parts by weight of water and mix. Stir at a speed of 4000 ± 200 r / min for 30 seconds at room temperature to form a homogeneous white material; add 55 parts by weight of isocyanate and 0.2 part by weight of surfactant, stir at a speed of 5000 ± 500 r / min for 15 seconds at room temperature, inject into a mold, and foam with nitrogen assistance. The nitrogen purity is 99.99%, and the flow rate is 100 ± 20 L / h to form a sponge blank; after curing for 48 hours, cut it, and treat it with low - temperature plasma with a power of 80 - 100 W and a time of 5 - 10 minutes to obtain an inert sponge.

[0057] Example 4

[0058] Mix 38 parts by weight of bio - based polyol, 42 parts by weight of polyether polyol, and 18 parts by weight of polymer polyol. Then add 2 parts by weight of silica, 2 parts by weight of flame retardant, 0.5 part by weight of antibacterial agent, 0.2 part by weight of catalyst, and 5 parts by weight of water and mix. Stir at a speed of 4000 ± 200 r / min for 30 seconds at room temperature to form a homogeneous white material; add 60 parts by weight of isocyanate and 0.2 part by weight of surfactant, stir at a speed of 5000 ± 500 r / min for 15 seconds at room temperature, inject into a mold, and foam with nitrogen assistance. The nitrogen purity is 99.99%, and the flow rate is 100 ± 20 L / h to form a sponge blank; after curing for 48 hours, cut it, and treat it with low - temperature plasma. The power is 80 - 100 W, and the time is 5 - 10 minutes to obtain an inert sponge.

[0059] Example 5

[0060] Mix 40 parts by weight of bio - based polyol, 40 parts by weight of polyether polyol, and 20 parts by weight of polymer polyol. Then add 2 parts by weight of silica, 2 parts by weight of flame retardant, 0.5 part by weight of antibacterial agent, 0.2 part by weight of catalyst, and 5 parts by weight of water and mix. Stir at a speed of 4000 ± 200 r / min for 30 seconds at room temperature to form a homogeneous white material; add 50 parts by weight of isocyanate and 0.2 part by weight of surfactant, stir at a speed of 5000 ± 500 r / min for 15 seconds at room temperature, inject into a mold, and foam with nitrogen assistance. The nitrogen purity is 99.99%, and the flow rate is 100 ± 20 L / h to form a sponge blank; after curing for 48 hours, cut it, and treat it with low - temperature plasma. The power is 80 - 100 W, and the time is 5 - 10 minutes to obtain an inert sponge.

[0061] Perform performance tests on the sponges in Examples 1 - 5, and the results are shown in Table 1.

[0062] Table 1

[0063] Sponge <![CDATA[Density / g·m -3 > Rebound time / s Indentation ratio Folding times / times Example 1 38 4 4.8 ≥8000 Example 2 39 6 5.1 ≥9000 Example 3 39 7 5.2 ≥9000 Example 4 38 5 4.5 ≥8000 Example 5 37 4 4.6 ≥8000

[0064] From Examples 1 - 5 and Table 1, it can be seen that the density of the sponge prepared in this application is less than 40 g / m 3 , the rebound time is not less than four seconds, the indentation ratio is not less than 4.5, the folding times are not less than 8000 times, and the mechanical properties are excellent, making it more suitable for application in home bedding fields such as beanbag chairs, mattresses, and pillows.

[0065] It can be seen from Table 1 that compared with other examples, in Examples 2 - 3, except for an insignificant increase in density, their rebound time, indentation ratio, and folding times are significantly higher than those of other examples. Therefore, the inventor made the following Examples 6 - 11 for further verification. Specifically as follows.

[0066] Examples 6 to 8 are based on Example 2, with only the addition amount of isocyanate changed, as follows.

[0067] Example 6

[0068] Mix 32 parts by weight of bio-based polyol, 48 parts by weight of polyether polyol, and 12 parts by weight of polymer polyol, then add 2 parts by weight of silica, 2 parts by weight of flame retardant, 0.5 part by weight of antibacterial agent, 0.2 part by weight of catalyst, and 5 parts by weight of water and mix. Stir at a speed of 4000 ± 200 r / min for 30 seconds at room temperature to form a homogeneous white material; add 45 parts by weight of isocyanate and 0.2 part by weight of surfactant, stir at a speed of 5000 ± 500 r / min for 15 seconds at room temperature, inject into a mold, and foam with nitrogen assistance. The nitrogen purity is 99.99%, and the flow rate is 100 ± 20 L / h to form a sponge blank; after curing for 48 hours, cut and treat with low-temperature plasma. The power is 80 - 100 W, and the time is 5 - 10 minutes to obtain an inert sponge.

[0069] Example 7

[0070] Mix 32 parts by weight of bio-based polyol, 48 parts by weight of polyether polyol, and 12 parts by weight of polymer polyol, then add 2 parts by weight of silica, 2 parts by weight of flame retardant, 0.5 part by weight of antibacterial agent, 0.2 part by weight of catalyst, and 5 parts by weight of water and mix. Stir at a speed of 4000 ± 200 r / min for 30 seconds at room temperature to form a homogeneous white material; add 55 parts by weight of isocyanate and 0.2 part by weight of surfactant, stir at a speed of 5000 ± 500 r / min for 15 seconds at room temperature, inject into a mold, and foam with nitrogen assistance. The nitrogen purity is 99.99%, and the flow rate is 100 ± 20 L / h to form a sponge blank; after curing for 48 hours, cut and treat with low-temperature plasma. The power is 80 - 100 W, and the time is 5 - 10 minutes to obtain an inert sponge.

[0071] Example 8

[0072] Mix 32 parts by weight of bio - based polyol, 48 parts by weight of polyether polyol, and 12 parts by weight of polymer polyol. Then add 2 parts by weight of silica, 2 parts by weight of flame retardant, 0.5 part by weight of antibacterial agent, 0.2 part by weight of catalyst, and 5 parts by weight of water and mix. Stir at a speed of 4000 ± 200 r / min for 30 seconds at room temperature to form a homogeneous white material; add 60 parts by weight of isocyanate and 0.2 part by weight of surfactant, stir at a speed of 5000 ± 500 r / min for 15 seconds at room temperature, inject into a mold, and foam with the assistance of nitrogen. The nitrogen purity is 99.99%, and the flow rate is 100 ± 20 L / h to form a sponge blank; after curing for 48 hours, cut it and treat it with low - temperature plasma with a power of 80 - 100 W and a time of 5 - 10 minutes to obtain an inert sponge.

[0073] Examples 9 - 11 are based on Example 3, with only the addition amount of isocyanate changed, as follows.

[0074] Example 9

[0075] Mix 35 parts by weight of bio - based polyol, 45 parts by weight of polyether polyol, and 15 parts by weight of polymer polyol. Then add 2 parts by weight of silica, 2 parts by weight of flame retardant, 0.5 part by weight of antibacterial agent, 0.2 part by weight of catalyst, and 5 parts by weight of water and mix. Stir at a speed of 4000 ± 200 r / min for 30 seconds at room temperature to form a homogeneous white material; add 45 parts by weight of isocyanate and 0.2 part by weight of surfactant, stir at a speed of 5000 ± 500 r / min for 15 seconds at room temperature, inject into a mold, and foam with the assistance of nitrogen. The nitrogen purity is 99.99%, and the flow rate is 100 ± 20 L / h to form a sponge blank; after curing for 48 hours, cut it and treat it with low - temperature plasma with a power of 80 - 100 W and a time of 5 - 10 minutes to obtain an inert sponge.

[0076] Example 10

[0077] Mix 35 parts by weight of bio - based polyol, 45 parts by weight of polyether polyol, and 15 parts by weight of polymer polyol. Then add 2 parts by weight of silica, 2 parts by weight of flame retardant, 0.5 part by weight of antibacterial agent, 0.2 part by weight of catalyst, and 5 parts by weight of water and mix. Stir at a speed of 4000 ± 200 r / min for 30 seconds at room temperature to form a homogeneous white material; add 50 parts by weight of isocyanate and 0.2 part by weight of surfactant, stir at a speed of 5000 ± 500 r / min for 15 seconds at room temperature, inject into a mold, and foam with the assistance of nitrogen. The nitrogen purity is 99.99%, and the flow rate is 100 ± 20 L / h to form a sponge blank; after curing for 48 hours, cut it and treat it with low - temperature plasma with a power of 80 - 100 W and a time of 5 - 10 minutes to obtain an inert sponge.

[0078] Example 11

[0079] Mix 35 parts by weight of bio - based polyol, 45 parts by weight of polyether polyol, and 15 parts by weight of polymer polyol, then add 2 parts by weight of silica, 2 parts by weight of flame retardant, 0.5 part by weight of antibacterial agent, 0.2 part by weight of catalyst, and 5 parts by weight of water and mix. Stir at a speed of 4000 ± 200 r / min for 30 seconds at room temperature to form a homogeneous white material; add 60 parts by weight of isocyanate and 0.2 part by weight of surfactant, stir at a speed of 5000 ± 500 r / min for 15 seconds at room temperature, inject into a mold, and foam with the assistance of nitrogen. The purity of nitrogen is 99.99%, and the flow rate is 100 ± 20 L / h to form a sponge blank; after curing for 48 hours, cut it and treat it with low - temperature plasma with a power of 80 - 100 W and a time of 5 - 10 minutes to obtain an inert sponge.

[0080] The performance of the sponges in Examples 6 - 11 was tested, and the results are shown in Table 2.

[0081] Table 2

[0082]

[0083]

[0084] By comparing Example 2 with Examples 6 - 8, Example 3 with Examples 9 - 11, and Table 2, it can be seen that when the weight ratio of bio - based polyol, polyether polyol, and polymer polyol in the technical solution of this application is controlled to be 32 - 35:4 - 48:12 - 15, the rebound time of the prepared sponge is not less than 6 seconds, the indentation ratio is not less than 5.1, and the folding times are not less than 9000 times, and the mechanical properties are better.

[0085] The above are all preferred embodiments of this application. The protection scope of this application is not limited accordingly. Therefore, all equivalent changes made according to the structure, shape, and principle of this application should be covered within the protection scope of this application.

Claims

1. An inert sponge, characterized in that: The method is prepared by comprising the following components in parts by weight: 30-40 parts of bio-based polyol; 40-50 parts of polyether polyol; 10-20 parts of polymer polyol; 45-60 parts of isocyanate; 1-3 parts of silicon dioxide; 2 to 4 parts of flame retardant; 0.5-1 part of antibacterial agent; 3-8 parts water; Catalyst 0.1-0.3 parts; 0.2-0.5 parts of surfactant.

2. The inert sponge according to claim 1, characterized in that The weight ratio of the bio-based polyol, the polyether polyol and the polymer polyol is 32-35:4-48:12-15.

3. The inert sponge according to claim 1, characterized in that The bio-based polyol is modified with castor oil, and has a hydroxyl value of 160-190.

4. The inert sponge according to claim 1, characterized in that The polyether polyol has a hydroxyl value of 220-240 and a functionality of 2-3.

5. The inert sponge according to claim 1, characterized in that The polymer polyol has a solid content of 20% and a molecular weight of 6000-8000.

6. The inert sponge according to claim 1, characterized in that The isocyanate is a combination of MDI-103C and hexamethylene diisocyanate.

7. The inert sponge according to claim 1, characterized in that The particle size of the silicon dioxide is 10 to 20 nm; And / or, the flame retardant is a mixture of triphenyl phosphate and magnesium hydroxide in a weight ratio of 1:1; And / or, the antibacterial agent is nanosilver with a particle size of 10 to 50 nm; And / or, the catalyst is tetramethylethylenediamine; And / or, the surfactant is silicone oil.

8. A method for preparing the inert sponge according to claim 1, characterized in that: The following steps are involved: S1. Mix bio-based polyol, polyether polyol and polymer polyol, then add silica, catalyst and water, mix and stir at room temperature to form a homogeneous white material; S2, adding the isocyanate combination to the white material prepared in S1, stirring and injecting into a mold to form a sponge blank; The sponge blanks in S3 and S2 are cut after being ripened for 48 hours and subjected to surface treatment to obtain inert sponges.

9. The preparation method according to claim 8, characterized in that: In S1, the stirring speed is 4000±200 r / min, and the stirring time is 30 seconds; And / or, in S2, the stirring speed is 5000±500 r / min, and the stirring time is 15 seconds; And / or, in S2, after injection into the mold, nitrogen is used to assist foaming, the nitrogen purity is 99.99%, and the flow rate is 100±20L / h; And / or, in S3, the surface treatment adopts low-temperature plasma treatment with a power of 80 to 100 W and a time of 5 to 10 minutes.

10. Use of the inert sponge according to claim 1 in the field of household bedding.

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