Polyurethane antibacterial breathable memory foam as well as preparation method and application thereof

Abstract

The invention relates to polyurethane antibacterial breathable memory foam as well as a preparation method and application thereof, and mainly solves the problems that in the prior art, polyurethane memory foam is poor in breathability, easy to breed bacteria and relatively low in tearing performance after being washed with water. According to the novel polyurethane antibacterial breathable memory foam and the preparation method thereof, the novel polyurethane antibacterial breathable memory foam is prepared from the following components in parts by weight: 30 to 60 parts of polyether polyol A, 25 to 50 parts of polyether polyol B, 5 to 15 parts of polyether polyol C, 5 to 10 parts of polymer polyol D, 5 to 10 parts of antibacterial polyether polyol E, 1.5 to 3.5 parts of water, 0 to 10 parts of a physical foaming agent, 0.3 to 1.5 parts of a polyurethane catalyst, 1 to 2.5 parts of a foam stabilizer and 0 to 1 part of color paste, according to the technical scheme, the problems are well solved, and the composite material can be applied to household fields such as pillows and mattresses and filtering systems for sewage purification treatment and the like.

Description

Technical Field

[0001] This invention relates to a polyurethane antibacterial and breathable memory foam, its preparation method, and its application. Background Technology

[0002] Memory foam, also known as slow rebound foam, is a type of polyurethane foam material with a special viscoelasticity. It was originally developed by NASA as a high-tech material to alleviate the immense pressure astronauts experience during launch and reentry. Due to its unique slow rebound properties and excellent comfort, memory foam is widely used in mattresses, pillows, seat cushions, and other home furnishings, as well as in cushioning and support components in the medical and automotive industries.

[0003] However, traditional polyurethane memory foam materials have some shortcomings in use. Firstly, memory foam is prone to the growth of bacteria, mold, and other microorganisms, especially in humid environments. This microbial growth can cause odors, affect material performance and lifespan, and potentially threaten the user's health. Secondly, existing memory foam generally has poor breathability, making it difficult for heat and moisture to dissipate, reducing comfort. For example, users may feel stuffy and damp when using memory foam mattresses or pillows. Finally, existing MDI memory foams have strong moisture absorption and are easily swollen by water, leading to a decrease in tear resistance.

[0004] Therefore, developing a polyurethane memory foam with antibacterial and breathable properties as well as good tear resistance is of great practical significance.

[0005] Chinese patent CN110577625A discloses a breathable slow-rebound polyurethane foam, its preparation method, and its application. It mainly solves the problems of low air permeability or poor slow-rebound effect of existing slow-rebound polyurethane foam. Although the high-pore structure makes it difficult for bacteria to grow, the memory foam prepared by this invention does not have a certain antibacterial property. Moreover, the polyether used in the memory foam of this invention is trifunctional, and its tear performance is relatively poor after swelling in water.

[0006] Chinese patent CN117820588A discloses an antibacterial memory foam and its preparation method, comprising the following components: polyether polyol-1: 65-75 parts, polyether polyol-2: 15-25 parts, polyether polyol-3: 5-15 parts, diphenylmethane diisocyanate: 45-55 parts, organosilicon surfactant: 1-2 parts, amine composite catalyst: 0.2-0.3 parts, tin composite catalyst: 0.2-0.3 parts, bamboo fiber powder: 5-6 parts, and antibacterial agent: 5-10 parts. The sponge prepared by this invention does not mention breathability, and the antibacterial properties of the sponge are improved by combining bamboo fiber powder and antibacterial agent in this formulation system. Antibacterial agents are currently mainly divided into organic, inorganic, and natural antibacterial agents, but all are additives and will migrate over time, eventually leading to a decrease in antibacterial rate. Summary of the Invention

[0007] One of the technical problems to be solved by the present invention is that the existing polyurethane antibacterial memory foam has poor air permeability, is prone to bacterial growth, and has low tear resistance after washing. The present invention provides a new polyurethane antibacterial breathable memory foam with the advantages of good air permeability, high and long-lasting antibacterial rate and excellent tear resistance.

[0008] The second technical problem to be solved by the present invention is to provide a method for preparing polyurethane antibacterial and breathable memory foam, which corresponds to the solution of the first technical problem.

[0009] The third technical problem to be solved by this invention is to provide an application of polyurethane antibacterial and breathable memory foam, which corresponds to solving one of the technical problems.

[0010] To solve one of the above-mentioned technical problems, the present invention adopts the following technical solution: a polyurethane antibacterial and breathable memory foam, comprising the following components by weight: polyether polyol A: 30-60 parts, polyether polyol B: 25-50 parts, polyether polyol C: 5-15 parts, polymer polyol D: 5-10 parts, antibacterial polyether polyol E: 5-10 parts, water: 1.5-3.5 parts, physical foaming agent: 0-10 parts, polyurethane catalyst: 0.3-1.5 parts, foam stabilizer: 1-2.5 parts, color paste: 0-1 part, isocyanate: 35-65 parts; wherein, the hydroxyl value of polyether polyol A is 100-200 mgKOH / g, the degree of unsaturation is 0.01-0.2 mmol / g, the functionality is 2-4, and the weight percentage of ethylene oxide in the molecular weight of polyether polyol A is... The content of polyether polyol A is 50%–80%; the hydroxyl value of polyether polyol B is 25–50 mgKOH / g, the degree of unsaturation is 0.01–0.2 mmol / g, the functionality is 2–4, and the weight percentage of ethylene oxide in the molecular weight of polyether polyol A is 50%–75%; the hydroxyl value of polyether polyol C is 150–400 mgKOH / g, the degree of unsaturation is 0.01–0.2 mmol / g, the functionality is 2–4, and it is formed by ring-opening polymerization of propylene oxide and an initiator; the hydroxyl value of polymer polyol D is 26–30 mgKOH / g, the water content is ≤0.05%, the pH value is 5–8, the viscosity is ≤6000 mPa·s, and the solid content is 40–45%; the molecular weight of antibacterial polyether polyol E is 200–500, the viscosity is 2000–4000 mPa·s, and the functionality is 2–4;

[0011] The preparation method of the antibacterial polyether polyol E includes the following steps:

[0012] (1) After adding the ionic liquid cation as an initiator and catalyst to the reactor for dehydration for 1 to 2 hours, add epoxide alkane to react. Control the temperature inside the reactor to 90 to 120°C, the reaction pressure to ≤0.45 MPa, and the internal pressure time to 1 to 4 hours. After the pressure inside the reactor decreases and stabilizes, polyether polyol I is obtained.

[0013] (2) In polyether polyol I, add 6-10% water and 1-5% adsorbent based on the mass percentage of polyether polyol I, stir for 1-5 hours, then dehydrate under vacuum for 2-8 hours, and filter to obtain polyether polyol II.

[0014] (3) After mixing haloalkanes with polyether polyol II in a molar ratio of 1 to 3:1, the reaction temperature is controlled at 80 to 130°C and the reaction is carried out for 3 to 15 hours to obtain ionic liquid modified polyether polyol III.

[0015] (4) After mixing the ionic liquid modified polyether polyol III with the metal halide at a molar ratio of 1 to 3:1, the reaction temperature is controlled at 80 to 130°C and the reaction is carried out for 4 to 15 hours to obtain antibacterial polyether polyol E.

[0016] In the above technical solution, preferably, the hydroxyl value of polyether polyol A is 140-160 mgKOH / g, and the weight percentage of ethylene oxide in the molecular weight of polyether polyol A is 60%-75%; the hydroxyl value of polyether polyol B is 30-40 mgKOH / g, and the weight percentage of ethylene oxide in the molecular weight of polyether polyol A is 55%-75%; the hydroxyl value of polyether polyol C is 180-240 mgKOH / g; the polymer polyol D is CHP-2045; and the molecular weight of antibacterial polyether polyol E is 300-450.

[0017] In the above technical solution, preferably, the physical foaming agent is at least one of dichloromethane or 1,1-dichloro-1-fluoroethane (HCFC-141B); the polyurethane catalyst is at least one of tertiary amine type or metal catalyst; the foam stabilizer is a polysiloxane-oxidized olefin block or graft copolymer; and the isocyanate is selected from BASF T80, Covestro 3133 or CNI-1100.

[0018] To solve the second technical problem mentioned above, the present invention adopts the following technical solution: a method for preparing polyurethane antibacterial and breathable memory foam, comprising the following steps:

[0019] (1) In container A, add the following components by weight: polyether polyol A: 30-60 parts, polyether polyol B: 25-50 parts, polyether polyol C: 5-15 parts, polymer polyol D: 5-10 parts, antibacterial polyether polyol E: 5-10 parts, water: 1.5-3.5 parts, physical foaming agent: 0-10 parts, polyurethane catalyst: 0.3-1.5 parts, foam stabilizer: 1-2.5 parts, color paste: 0-1 parts. Stir evenly at a speed of 2000-3000 rpm and control the material temperature at 20-30℃ to obtain material I.

[0020] (2) Add 35 to 65 parts by weight of isocyanate to container A and stir quickly and evenly for 4 to 6 seconds to obtain mixture II. The stirring speed is 2000 to 5000 rpm.

[0021] (3) Quickly inject the mixture II into the mold. It will naturally form in about 5 minutes. After curing at room temperature for 48 hours, polyurethane antibacterial and breathable memory foam is obtained.

[0022] To solve the third technical problem mentioned above, the present invention adopts the following technical solution: the application of a polyurethane antibacterial and breathable memory foam in pillows, mattresses, home furnishings, and sewage purification and filtration systems.

[0023] This invention provides a novel polyurethane antibacterial and breathable memory foam. It is produced by foaming a combination of five polyols: polyether polyol A, polyether polyol B, polyether polyol C, polymer polyol D, and antibacterial polyether polyol E. This results in a polyurethane antibacterial and breathable memory foam with high breathability, high antibacterial rate, and high tear strength. By selecting an appropriate percentage of ethylene oxide in the polyether structure and adjusting the functionality of polyether polyol B, the tensile and tear properties of the memory foam after water absorption and swelling are significantly improved. Furthermore, by introducing reactive antibacterial polyether polyol, the antibacterial structure is integrated into the macromolecular chain, ensuring long-lasting antibacterial effectiveness. Finally, through a reasonable combination of amine-tin catalyst and foam stabilizer, the foam is able to form properly and achieve a good open-cell structure and a comfortable slow rebound effect, resulting in excellent technical performance. Attached Figure Description

[0024] Figure 1 This is a comparison chart of the antibacterial effects against Escherichia coli in the first test of Comparative Example 1 and Example 1.

[0025] Figure 2 This is a comparison chart of the antibacterial effects against Staphylococcus aureus in the first test of Comparative Example 1 and Example 1.

[0026] Figure 3 This is a comparison chart showing the antibacterial effects of Comparative Example 1 and Example 1 on Escherichia coli after 60 days of storage.

[0027] Figure 4 This is a comparison chart showing the antibacterial effects of Comparative Example 1 and Example 1 on Staphylococcus aureus after 60 days of storage. Detailed Implementation

[0028] The present invention will be further described below with reference to specific embodiments. The described embodiments are only some, not all, of the embodiments of the present invention.

[0029] Table 1 Raw Material List

[0030]

[0031]

[0032] The antibacterial polyether polyol E used in the examples was prepared by the following method:

[0033] (1) After adding the ionic liquid cation as an initiator and catalyst to the reactor for dehydration for 1 to 2 hours, add epoxide alkane to react. Control the temperature inside the reactor to 90 to 120°C, the reaction pressure to ≤0.45 MPa, and the internal pressure time to 1 to 4 hours. After the pressure inside the reactor decreases and stabilizes, polyether polyol I is obtained.

[0034] (2) In polyether polyol I, add 6-10% water and 1-5% adsorbent based on the mass percentage of polyether polyol I, stir for 1-5 hours, then dehydrate under vacuum for 2-8 hours, and filter to obtain polyether polyol II.

[0035] (3) After mixing haloalkanes with polyether polyol II in a molar ratio of 1 to 3:1, the reaction temperature is controlled at 80 to 130°C and the reaction is carried out for 3 to 15 hours to obtain ionic liquid modified polyether polyol III.

[0036] (4) After mixing the ionic liquid modified polyether polyol III with the metal halide at a molar ratio of 1 to 3:1, the reaction temperature is controlled at 80 to 130°C and the reaction is carried out for 4 to 15 hours to obtain antibacterial polyether polyol E.

[0037] Example 1

[0038] (1) In container A, add the following components by weight: polyether polyol A: 30 parts, polyether polyol B: 45 parts, polyether polyol C: 5 parts, polymer polyol D: 10 parts, antibacterial polyether polyol E: 10 parts, water: 2.4 parts, physical foaming agent (dichloromethane): 2 parts, polyurethane catalyst A33: 0.3 parts, ZF-10: 0.1 parts, T9: 0.03 parts, foam stabilizer L-595: 1.5 parts, color paste: 0.2 parts. Stir evenly at a speed of 2000-3000 rpm and control the material temperature at 20-30℃ to obtain material I.

[0039] (2) Add 55 parts by weight of isocyanate to container A and stir quickly and evenly for 4 to 6 seconds to obtain mixture II. The stirring speed is 2000 to 5000 rpm.

[0040] (3) Quickly inject the mixture II into the mold. It will naturally form in about 5 minutes. After curing at room temperature for 48 hours, polyurethane antibacterial and breathable memory foam is obtained.

[0041] Examples 2-8

[0042] Examples 2 to 8 were carried out according to the steps of Example 1, with the only difference being the different proportions of raw materials such as reaction raw materials and catalysts, as shown in Table 2. The performance test data of the prepared polyurethane antibacterial and breathable memory foam are shown in Tables 3 and 4.

[0043] Comparative Examples 1-3

[0044] Comparative Examples 1 to 3 were carried out according to the steps of Example 1, with the only difference being the different proportions of raw materials such as reaction raw materials and catalysts, as shown in Table 3. The conventional physical property test data of the prepared polyurethane antibacterial and breathable memory foam are shown in Tables 3 and 4.

[0045] Table 2 shows the raw material weight parts of each component in the polyurethane antibacterial and breathable memory foam in Examples 1-8.

[0046]

[0047] Table 3 shows the raw material weight parts of each component in the polyurethane antibacterial and breathable memory foam in Comparative Examples 1-3.

[0048]

[0049]

[0050] Table 4. Physical property test data of polyurethane antibacterial and breathable memory foam prepared in Examples 1-8 and Comparative Examples 1-3.

[0051]

[0052]

[0053] Table 5. Test data on the antibacterial, antifungal, and antimite properties of polyurethane antibacterial and breathable memory foam prepared in Examples 1-8 and Comparative Examples 1-3.

[0054]

[0055] Comparative Example 1 is Example 6 in patent CN110577625B; Comparative Example 2 is based on Comparative Example 1, but the foam density is adjusted to be consistent with that of Examples 1-8 by increasing the amount of water, thereby improving comparability; Comparative Example 3 is based on Comparative Example 1, but the density is kept consistent with that of Examples 1-8, and the TDI system is replaced with the MDI system, thereby further improving comparability.

[0056] As can be seen from Examples 1-8, the tensile strength of the polyurethane antibacterial and breathable memory foam of the present invention can reach 365 kPa, and the tear strength can reach 7.11 N / cm. After absorbing water, the tensile strength and tear strength can still maintain a relatively high level of 240 kPa and 4.83 N / cm, respectively. Furthermore, even in the MDI system, compared with Comparative Example 1, its tensile strength is increased by 20% to 30%, and its tear performance is increased by 80% to 90%.

[0057] In terms of antibacterial, antifungal, and mite-repellent properties, there is a significant improvement compared to the comparative example. (See attached...) Figures 1-4It can be seen that, whether it is Escherichia coli or Staphylococcus aureus, compared with Comparative Example 1, the number of colonies in the petri dishes of Example 1 is visible to the naked eye and shows an exponential decrease. After testing with professional testing instruments, its antibacterial rate reaches 99% or above.

[0058] The above content provides a detailed description of the preparation method of polyurethane antibacterial and breathable memory foam provided by the present invention. The embodiments in this document illustrate the principles and implementation methods of the present invention. The description of the above embodiments is only for understanding the core idea of ​​the present invention, but the scope of protection of the present invention is not limited thereto. Any modifications to the present invention made by those skilled in the art without departing from the principles of the present invention should fall within the scope of protection of the claims.

Claims

1. A polyurethane antibacterial and breathable memory foam, comprising, by weight, the following components: polyether polyol A: 30-60 parts, polyether polyol B: 25-50 parts, polyether polyol C: 5-15 parts, polymer polyol D: 5-10 parts, antibacterial polyether polyol E: 5-10 parts, water: 1.5-3.5 parts, physical foaming agent: 0-10 parts, polyurethane catalyst: 0.3-1.5 parts, foam stabilizer: 1-2.5 parts, colorant: 0-1 part, isocyanate: 35-65 parts; wherein, Polyether polyol A has a hydroxyl value of 100–200 mg KOH / g, an unsaturation degree of 0.01–0.2 mmol / g, a functionality degree of 2–4, and ethylene oxide accounts for 50%–80% of the molecular weight of polyether polyol A; polyether polyol B has a hydroxyl value of 25–50 mg KOH / g, an unsaturation degree of 0.01–0.2 mmol / g, a functionality degree of 2–4, and ethylene oxide accounts for 50%–75% of the molecular weight of polyether polyol A; polyether polyol C… The hydroxyl value is 150–400 mg KOH / g, the degree of unsaturation is 0.01–0.2 mmol / g, and the functionality is 2–4. It is formed by ring-opening polymerization of propylene oxide and an initiator. The polymer polyol D has a hydroxyl value of 26–30 mg KOH / g, a water content ≤0.05%, a pH value of 5–8, a viscosity ≤6000 mPa·s, and a solid content of 40–45%. The antibacterial polyether polyol E has a molecular weight of 200–500, a viscosity of 2000–4000 mPa·s, and a functionality of 2–4.

2. The polyurethane antibacterial and breathable memory foam according to claim 1, characterized in that, The polyether polyol A has a hydroxyl value of 140–160 mg KOH / g, and ethylene oxide accounts for 60%–75% of the molecular weight of polyether polyol A by weight; the polyether polyol B has a hydroxyl value of 30–40 mg KOH / g, and ethylene oxide accounts for 55%–75% of the molecular weight of polyether polyol A by weight; the polyether polyol C has a hydroxyl value of 180–240 mg KOH / g; the polymer polyol D is CHP-2045; and the antibacterial polyether polyol E has a molecular weight of 300–450.

3. The polyurethane antibacterial and breathable memory foam according to claim 1, characterized in that, The physical blowing agent is at least one of dichloromethane or 1,1-dichloro-1-fluoroethane (HCFC-141B); the polyurethane catalyst is at least one of tertiary amine type or metal catalyst; the foam stabilizer is a polysiloxane-oxidized olefin block or graft copolymer; and the isocyanate is selected from BASF T80, Covestro 3133 or CNI-1100.

4. The polyurethane antibacterial and breathable memory foam according to claim 1, characterized in that, Its preparation method includes the following steps: (1) In container A, by weight, the following components are added: polyether polyol A: 30-60 parts, polyether polyol B: 25-50 parts, polyether polyol C: 5-15 parts, polymer polyol D: 5-10 parts, antibacterial polyether polyol E: 5-10 parts, water: 1.5-3.5 parts, physical foaming agent: 0-10 parts, polyurethane catalyst: 0.3-1.5 parts, foam stabilizer: 1-2.5 parts, color paste: 0-1 parts. The mixture is stirred evenly at a speed of 2000-3000 rpm and the material temperature is controlled at 20-30℃ to obtain material I. (2) Add 35 to 65 parts by weight of isocyanate to container A and stir quickly and evenly for 4 to 6 seconds to obtain mixture II. The stirring speed is 2000 to 5000 rpm. (3) Quickly inject the mixture II into the mold. It will naturally form in about 5 minutes. After curing at room temperature for 48 hours, polyurethane antibacterial and breathable memory foam is obtained.

5. The method for preparing polyurethane antibacterial and breathable memory foam according to claim 4, characterized in that, The density of the polyurethane antibacterial and breathable memory foam is 30-50 kg / m³. 3 It has an antibacterial rate of 99% and a tear strength of 4.8–8.0 N / cm.

6. The application of memory foam prepared from the polyurethane antibacterial and breathable memory foam according to claim 1 in the fields of pillows, mattresses, and wastewater purification and filtration systems.

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