Low-density high-flame-retardant low-VOC (volatile organic compound) polyurethane sound insulation material and preparation method thereof

Abstract

The invention relates to a low-density high-flame-retardant low-VOC (volatile organic compound) polyurethane sound insulation material and a preparation method thereof, and belongs to the technical field of polyurethane microporous elastomers. A polyurethane elastomer product which still has good flexibility under the conditions of low density and high strength is manufactured by adjusting the proportion of the raw materials in the component A and the proportion of the component A and the component B. The sound insulation material has the characteristics that the percentage of close area is 65% or above, the density is 120-320 kg / m < 3 >, the oxygen index is not lower than 30, the total volatile organic compound release limit content is not higher than 100 micrograms C / g, the compression strength is not lower than 20 KPa, and the sound insulation material has the good flexibility under the conditions of low density and high strength. The compressive deformation is not higher than 5%, the compression creep is not higher than 5%, and the sound insulation material can be used for sound insulation between floors and can also be used for manufacturing small sound insulation rooms, and sound can be effectively reduced by 60 dB or above.

Description

Technical Field

[0001] The invention relates to a low-density, high-flame-retardant, low-VOC polyurethane sound insulation material and a preparation method thereof, belonging to the technical field of polyurethane microporous elastomers. Background Art

[0002] Currently, floor insulation commonly uses materials like acoustic sponge, rubber, and polystyrene (XPS). While these materials offer some sound insulation, they lack strength and load-bearing properties, making them unsuitable for use between floors and only on walls. Rubber and XPS also have poor aging resistance. When used between floors, they are susceptible to creep under the combined effects of prolonged static pressure and floor heating, leading to rapid performance degradation. Furthermore, these materials lack flame retardancy and release volatile gases, posing a health risk.

[0003] Polyurethane microcellular elastomer is a new type of polyurethane material primarily used in applications such as damping and shock-absorbing pads, industrial seals, footwear, solid tires, and automobile bumpers. It boasts high impact resistance, excellent energy absorption and cushioning, superior wear resistance, and high strength. To achieve these properties, existing polyurethane elastomers generally have a high density, resulting in faster sound propagation speeds. Their high closed-cell ratio prevents the gradual attenuation of sound through their open-cell structure, thus failing to effectively block sound. Furthermore, these applications do not require flame retardancy or VOC emissions.

[0004] Therefore, although polyurethane microporous elastomer has many advantages, it cannot meet the index requirements of floor sound insulation and is not used in building floor sound insulation. Summary of the Invention

[0005] The purpose of the present invention is to solve the problems of poor sound insulation performance of floors under the existing technology and poor flame retardancy of existing materials, release of volatile gases such as formaldehyde, and short-term sound insulation performance. A low-density, high-flame retardant, low-VOC polyurethane sound insulation material and its preparation method are provided to solve the disadvantages of existing polyurethane elastomers such as high density, poor flame retardancy, no sound insulation effect, and high VOC content. The sound insulation material prepared by the present invention has a closed-pore rate of more than 65% and a density of 120kg / m 3 -320kg / m 3 , oxygen index is not less than 30, total volatile organic compound release limit content is not higher than 100μgC / g, compression strength is not less than 20KPa, compression deformation is not higher than 5% (23℃ / 50RH% / 4MPa / 24h), compression creep is not higher than 5% (40℃ / 50RH% / 4MPa / 168h). This sound insulation material can be used for floor sound insulation and for making small soundproof rooms, which can effectively reduce the sound by more than 60dB.

[0006] To achieve the above object, the present invention provides the following technical solutions: One of the purposes of the present invention is to provide a low-density, highly flame-retardant, low-VOC polyurethane sound insulation material, the raw materials of which include component A and component B, wherein the weight ratio of component A to component B is 100:80-130; The component A includes polyol, chain extender and cross-linking agent, flame retardant, catalyst, surfactant, foaming agent, antioxidant, wetting agent, formaldehyde scavenger, anti-settling agent, and suspending dispersant; The component B is a prepolymer formed by polymerization of polyol and isocyanate with isocyanate as the end-capping group, and the isocyanate content of the prepared prepolymer is 8%-23%.

[0007] Preferably, the weight proportions of the components in component A are as follows: 100 parts of polyol, 2.5-9 parts of chain extender and cross-linking agent, 10-20 parts of flame retardant, 0.5-3 parts of catalyst, 1-3 parts of surfactant, 0.5-2 parts of foaming agent, 0.1-0.8 parts of antioxidant, 0.1-0.5 parts of wetting agent, 0.1-1 parts of formaldehyde scavenger, 0.1-0.6 parts of anti-settling agent, and 3-15 parts of suspending dispersant.

[0008] Preferably, the polyol in component A includes long-chain polyol and short-chain polyol, wherein the long-chain polyol has a functionality of 2 or 3 and a molecular weight of 1000-12000, and the short-chain polyol has a functionality of not less than 3 and a molecular weight of less than 800.

[0009] Preferably, the long-chain polyol is any one or more combinations of the following: polytetramethylene ether polyol PTMG-1000, polytetramethylene ether polyol PTMG-2000, polyoxypropylene polyols 3128 and 3056, and polyether polyol CHE-628 of Changhua Company; the short-chain polyol is any one or more combinations of the following: glycerol and sucrose starting polyether polyols 635 and 8345, ethylenediamine starting polyether polyol 403, polyester polyol 2001 of Demei Science and Technology Company, and high flame retardant polyester polyol 2247 of Beijing Youbao Chemical.

[0010] Preferably, the chain extender and cross-linking agent are mainly used to further adjust the flexibility and hardness of the molecular chain. The chain extender is any one of 1,4-butanediol BDO, ethylene glycol EG, and diethylene glycol DEG. The cross-linking agent is any one of triethanolamine TEOA, trimethylolpropane TMP, and glycerol GL. Preferably, the flame retardant includes a liquid flame retardant and a solid flame retardant, the liquid flame retardant includes one or a combination of two of TEP, TCPP, and DMMP, preferably a combination of two, to reflect a synergistic effect and increase the flame retardant effect, and the solid flame retardant includes one or a combination of two of ammonium polyphosphate APP, aluminum hydroxide AL(OH)3, expanded graphite, and antimony trioxide, preferably a combination of two, to reflect a synergistic effect and increase the flame retardant effect; Preferably, the solid flame retardant uses Yunshan Technology's expanded graphite PUREGL modified graphite component, and the liquid flame retardant uses PUREGL liquid component. The PUREGL liquid component and the PUREGL modified graphite component are used together to enhance the flame retardant effect, and no melt is produced during combustion. Preferably, the catalyst includes a foaming catalyst and a gel catalyst, wherein the foaming catalyst adopts a low-odor reaction catalyst PC15 or DABCO T; the gel catalyst adopts A33 or environmentally friendly organic bismuth KOSMOS MB19; The surfactant includes dimethyl silicone oil and a pore opening agent. The silicone oil is one or more combinations of DC193, L580, and B8745LF2. When the dimethyl silicone oil itself cannot achieve the target porosity, the pore opening agent is compounded. The pore opening agent is one or a combination of two of DC500 and O-501. The foaming agent is a chemical foaming agent. In order to facilitate the control of the foaming ratio and product performance, water or an organic acid chemical foaming agent is used; The antioxidant is used to improve the anti-aging service life of the product, and ChicAY-01A from Shanghai Chic Fluorosilicone Materials Co., Ltd. is used; The wetting agent is used to ensure the wetting of the liquid component in component A and the solid flame retardant, and at the same time increases the adhesion between the product and the soundproof room frame during molding. YRFC-09 from Guangzhou Yourun Chemical is used; The formaldehyde remover is used to reduce harmful volatiles in the product, making the product more environmentally friendly, and uses Evonik ORTEGOL LA3; The anti-settling agent is used to prevent the powder in component A from settling, and comprises fumed silica, organic bentonite, and polyamide wax powder, and adopts fumed silica A200 of Evonik or THIXATROL P2100W of Hemmings. The suspending dispersant is used to suspend and disperse the powder in component A and is used in combination with an anti-settling agent to ensure that component A does not stratify for at least one month. The PUREGL liquid component of Yunshan Technology is used.

[0011] Preferably, the polyol in the component B is any one of polytetramethylene ether polyol PTMG-1000 and PTMG-2000, or a mixture of two of them; and the isocyanate is any one or more of MDI100, MDI100L, and TDI80 / 20.

[0012] A second object of the present invention is to provide a method for preparing a low-density, high-flame-retardant, low-VOC polyurethane sound insulation material, comprising the following steps: (1) First, the solid flame retardant and liquid flame retardant, anti-settling agent, suspending dispersant, wetting agent, antioxidant, and formaldehyde scavenger in component A are dispersed at high speed, and then the polyol, catalyst, surfactant, chain extender, cross-linking agent, foaming agent, etc. are added and stirred evenly to prepare component A; (2) The polyol in component B and the isocyanate are reacted with stirring at 60-80°C for 3-3.5 hours to prepare component B; (3) Component A and component B are weighed in a weight ratio of 100:80-130, and are uniformly mixed using a high-speed stirrer at 2000-3000 rpm. The mixed liquid is injected into a mold at 45°C-60°C, and the mixture is cured and molded by maintaining pressure for 10-30 minutes to produce the target product.

[0013] The beneficial effects achieved by the present invention are: (1) The PUREGL modified graphite component and the PUREGL liquid component have excellent flame retardant effects. When compounded with liquid flame retardants, they can significantly reduce the amount of flame retardant added, and combustion does not produce molten dripping. While ensuring excellent fire resistance, they reduce the risk of shrinkage and deformation of the product caused by excessive addition of a single flame retardant, thus ensuring product quality. (2) The density of water and organic acid foaming agents is more controllable than that of traditional chlorofluorocarbon or alkane foaming agents; (3) By matching the polyols with different chain lengths and functionalities and using chain extenders and cross-linkers, the strength and flexibility of the product can be effectively adjusted; (4) The addition of formaldehyde removers can effectively reduce volatile substances such as formaldehyde and acetaldehyde in the product, reduce the limit of indoor formaldehyde and total volatile organic compound release, and reduce harm to the human body; (5) The addition of anti-settling agent and suspending dispersant can keep component A stable and uniform; the addition of wetting agent ensures the wetting of the liquid component in component A and the solid flame retardant, while increasing the adhesion between the product and the soundproof room frame during molding; the addition of antioxidant improves the aging resistance of the product and increases the life of the product.

[0014] (6) Components A and B are molded to obtain a low-density, highly flame-retardant, low-VOC polyurethane sound insulation pad with an isocyanate index of 98%-120%. DETAILED DESCRIPTION

[0015] The following is a clear and complete description of the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts are within the scope of protection of the present invention.

[0016] Example 1 This embodiment provides a low-density, highly flame-retardant, low-VOC polyurethane sound insulation material for floor sound insulation. The weight proportions of component A are as follows: PTMG-2000 14.9 parts PTMG-1000 34.5 parts 3128 29.8 copies 8345 9.5 copies 2001 11.3 copies DEG 6.4 copies TEOA 2.2 parts B8745LF2 1.2 parts Chemical foaming agent H2O 0.5 parts DABCO T 0.63 parts KOSMOS MB19 0.012 copies ChicAY-01A 0.62 servings YRFC-09 0.25 copies 0.4 parts of ORTEGOL LA3 A200 0.23 parts 10 parts of PUREGL modified graphite component 4.2 parts of PUREGL liquid component TEP 6.6 parts The ingredients of material B are as follows: MDI100 50 parts PTMG1000 50 parts The present embodiment provides a method for preparing a low-density, highly flame-retardant, low-VOC polyurethane sound insulation material, comprising the following steps: (1) dispersing the PUREGL modified graphite component (PUREGL-1 (H component)), the PUREGL liquid component (PUREGL-1 (E component)), TEP, A200, ORTEGOL LA3, YRFC-09, and ChicAY-01A in the formulation of component A of the embodiment at high speed, then adding the other components and stirring evenly to prepare component A; (2) stirring PTMG1000 and MDI100 at 80°C for 3 hours to prepare a prepolymer component B, wherein the mass fraction of the isocyanate group is 12.6%; (3) stirring components A and B at a ratio of 1 to 1.1 (isocyanate index is 105%), injecting the mixture into a mold heated to 60°C, and maintaining the pressure for 15 minutes to prepare the target product.

[0017] The performance parameters of the sound insulation material in this embodiment are as follows: closed porosity of 67%, density of 227Kg / m 3 , oxygen index 30.5, total volatile organic compound emission limit content is 0.35 mg / (m 2 .h), compressive strength 23KPa, compression set 4.1% (23℃ / 50RH% / 4MPa / 24h), compression creep 3.5% (40℃ / 50RH% / 4MPa / 168h), weighted normalized impact sound level 58dB, meeting the requirements of GB / T 50118 "Code for Design of Sound Insulation of Civil Buildings" for ordinary residential buildings with a floor slab size of less than 75dB and for high-requirement residential buildings with a floor slab size of less than 65dB.

[0018] Example 2 This embodiment provides a low-density, highly flame-retardant, low-VOC polyurethane sound insulation material for use in the interlayer of a small soundproof room. The composition of component A is as follows: PTMG-2000 22.3 parts PTMG-1000 32.1 parts CHE628 21.7 servings 635 14.9 copies 2247 9 copies 3.2 parts of 1,4-butanediol 0.8 parts of TMP DC193 1 copy O-501 0.05 parts 1.51 parts of formic acid DABCO T 1.35 parts KOSMOS MB19 0.02 parts ChicAY-01A 0.4 serving YRFC-09 0.25 copies 0.4 parts of ORTEGOL LA3 A200 0.36 parts 8 parts of PUREGL modified graphite component 3.7 parts of PUREGL liquid component TCPP 7 copies The ingredients of material B are as follows: MDI100 35 parts TDI80 / 20 15 parts PTMG1000 50 parts The present embodiment provides a method for preparing a low-density, high-flame-retardant, low-VOC polyurethane sound insulation pad, comprising the following steps: (1) dispersing the PUREGL modified graphite component (PUREGL-1 (H component)), PUREGL liquid component (PUREGL-1 (E component)), TCPP, A200, ORTEGOL LA3, YRFC-09, and ChicAY-01A in the formula of component A of the embodiment at high speed, then adding the other components and stirring evenly to prepare component A; (2) stirring PTMG1000 with MDI100 and TDI80 / 20 at 60°C for 3.5h to prepare a prepolymer component B, whose mass fraction of isocyanate is 13.8%; (3) stirring components A and B at a ratio of 1 to 0.9 (isocyanate index is 98%), injecting the mixture into a small sound insulation chamber frame at 45°C, and maintaining the pressure for 20min to prepare the target product.

[0019] The performance parameters of this sound insulation pad are as follows: closed porosity of 70%, density of 180Kg / m 3 , oxygen index 30.1, total volatile organic compound emission limit content is 0.23 mg / (m 2 .h), compression strength 21.2KPa, compression deformation 4.6% (23℃ / 50RH% / 4MPa / 24h), compression creep 4.1% (40℃ / 50RH% / 4MPa / 168h), the soundproof room made of it can effectively reduce the sound by 63dB.

[0020] Table 1: Comparison of performance parameters of Example 1, Example 2, polystyrene XPS, and polyurethane microcellular elastomer for damping and vibration reduction

[0021]

[0022] By comparing the data in Table 1, we can see that: (1) Compared with Example 1 and Example 2, polystyrene XPS has insufficient flame retardancy due to its thermoplastic structure. In addition, molten droplets will appear during the combustion process, exacerbating the spread of fire. In addition, the internal hard body structure has lower density and higher compression strength, but poor compression set and compression creep performance. It cannot return to its original shape after being compressed, which seriously affects the appearance and quality.

[0023] (2) Compared with the polyurethane microporous elastomer for damping and shock absorption in Example 1, Example 2, the general density of the polyurethane elastomer decreases, resulting in a slowdown in the speed of sound propagation in the solid; as the closed-cell ratio decreases, the number of sound reflections in the pores increases, resulting in an increase in sound attenuation, thereby playing a good barrier role for sound and effectively reducing the sound index significantly. In addition, with the synergistic effect of different flame retardant systems such as modified graphite and liquid components in Example 1 and Example 2, the oxygen index can be increased from 19.7% to 30.5%, effectively increasing the flame retardancy and achieving a high flame retardant effect. The introduction of formaldehyde scavenger components in Examples 1 and 2 can effectively reduce volatile substances such as formaldehyde and acetaldehyde in the product, and reduce the indoor formaldehyde and total volatile organic compound emission limit content.

[0024] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A low-density, high-flame-retardant, low-VOC polyurethane sound insulation material, characterized in that The raw materials include component A and component B, and the weight ratio of component A to component B is 100:80-130; The component A includes polyol, chain extender and cross-linking agent, flame retardant, catalyst, surfactant, foaming agent, antioxidant, wetting agent, formaldehyde scavenger, anti-settling agent, and suspending dispersant; The component B is a prepolymer formed by polymerization of polyol and isocyanate with isocyanate as the end-capping group, and the isocyanate content of the prepared prepolymer is 8%-23%.

2. A low-density, high-flame-retardant, low-VOC polyurethane sound insulation material according to claim 1, characterized in that The weight proportions of the components in component A are as follows: 100 parts of polyol, 2.5-9 parts of chain extender and cross-linking agent, 10-20 parts of flame retardant, 0.5-3 parts of catalyst, 1-3 parts of surfactant, 0.5-2 parts of foaming agent, 0.1-0.8 parts of antioxidant, 0.1-0.5 parts of wetting agent, 0.1-1 parts of formaldehyde scavenger, 0.1-0.6 parts of anti-settling agent, and 3-15 parts of suspending dispersant.

3. A low-density, high-flame-retardant, low-VOC polyurethane sound insulation material according to claim 1, characterized in that The polyols in component A include long-chain polyols and short-chain polyols, wherein the long-chain polyols have a functionality of 2 or 3 and a molecular weight of 1000-12000, and the short-chain polyols have a functionality of not less than 3 and a molecular weight of less than 800.

4. A low-density, high-flame-retardant, low-VOC polyurethane sound insulation material according to claim 3, characterized in that The long-chain polyol is any one or more combinations of the following: polytetramethylene ether polyol PTMG-1000, polytetramethylene ether polyol PTMG-2000, polyoxypropylene polyols 3128 and 3056, and polyether polyol CHE-628 of Changhua Company; the short-chain polyol is any one or more combinations of the following: glycerol and sucrose started polyether polyols 635 and 8345, ethylenediamine started polyether polyol 403, polyester polyol 2001 of Demei Science and Technology Company, and high flame retardant polyester polyol 2247 of Beijing Youbao Chemical.

5. A low-density, high-flame-retardant, low-VOC polyurethane sound insulation material according to claim 1, characterized in that The chain extender is any one of 1,4-butanediol BDO, ethylene glycol EG, and diethylene glycol DEG; the crosslinking agent is any one of triethanolamine TEOA, trimethylolpropane TMP, and glycerol GL.

6. A low-density, high-flame-retardant, low-VOC polyurethane sound insulation material according to claim 1, characterized in that The flame retardant includes a liquid flame retardant and a solid flame retardant. The liquid flame retardant includes one or a combination of TEP, TCPP, and DMMP. The solid flame retardant includes one or a combination of ammonium polyphosphate APP, aluminum hydroxide AL(OH)3, expanded graphite, and antimony trioxide.

7. A low-density, high-flame-retardant, low-VOC polyurethane sound insulation material according to claim 6, characterized in that The solid flame retardant adopts Yunshan Technology's expanded graphite PUREGL modified graphite component, and the liquid flame retardant adopts PUREGL liquid component.

8. The low-density, high-flame-retardant, low-VOC polyurethane sound insulation material according to claim 1, characterized in that The catalyst includes a foaming catalyst and a gel catalyst. The foaming catalyst uses low-odor reaction catalyst PC15 and DABCOT; the gel catalyst uses A33 or environmentally friendly organic bismuth KOSMOS MB19. The surfactant includes dimethyl silicone oil and a pore opening agent. The silicone oil is one or more combinations of DC193, L580, and B8745LF2. The pore opening agent is one or two combinations of DC500 and O-501. The foaming agent is a chemical foaming agent, which is water or an organic acid chemical foaming agent; The antioxidant is ChicAY-01A produced by Shanghai Chic Fluorosilicone Materials Co., Ltd. The wetting agent used is YRFC-09 from Guangzhou Yourun Chemical; The formaldehyde remover is Evonik ORTEGOL LA3; The anti-settling agent comprises fumed silica, organic bentonite, and polyamide wax powder; The suspending dispersant adopts the PUREGL liquid component of Yunshan Technology.

9. The low-density, high-flame-retardant, low-VOC polyurethane sound insulation material according to claim 1, characterized in that The polyol in the component B is any one of polytetramethylene ether polyol PTMG-1000 and PTMG-2000 or a mixture of two thereof; the isocyanate is any one or more of MDI100, MDI100L and TDI80 / 20.

10. A method for producing a low-density, high-flame-retardant, low-VOC polyurethane sound insulation material according to any one of claims 1 to 9, characterized in that The following steps are involved: (1) First, the solid flame retardant and liquid flame retardant, anti-settling agent, suspending dispersant, wetting agent, antioxidant, and formaldehyde scavenger in component A are dispersed at high speed, and then the polyol, catalyst, surfactant, chain extender, cross-linking agent, and foaming agent are added and stirred evenly to prepare component A; (2) The polyol in component B and the isocyanate are reacted with stirring at 60-80°C for 3-3.5 hours to prepare component B; (3) Component A and component B are weighed in a weight ratio of 100:80-130, and are uniformly mixed using a high-speed stirrer at 2000-3000 rpm. The mixed liquid is injected into a mold at 45°C-60°C, and the mixture is cured and molded by maintaining pressure for 10-30 minutes to produce the target product.

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