Sponge with high comfort factor and high tensile strength as well as preparation method and application thereof

Abstract

The invention relates to a sponge with a high comfort factor and high tensile strength and a preparation method and application thereof, belongs to the field of sponge materials, and provides the sponge with the high comfort factor and the high tensile strength aiming at the problem that an existing mattress is poor in supporting comfort and tensile strength. Comprising 70 parts of high molecular weight polyether polyol, 10 parts of common polyether polyol, 10 parts of polymer polyol, 10 parts of low molecular weight polyol, 56 parts of modified MDI, 1.0 part of a silicone oil surfactant, 0.21 part of an amine catalyst, 0.09 part of a tin catalyst, 0.5 part of a non-tin metal catalyst, 0.3 part of a cross-linking agent and 2.8 parts of water. The sponge product with high comfort factor and high tensile strength can be obtained by using the non-tin metal catalyst as the raw material and matching the non-tin metal catalyst with high molecular weight polyether polyol, common polyether polyol, polymer polyol, low molecular weight polyol and other raw materials.

Description

Technical Field

[0001] This application relates to the field of sponge materials, and in particular to a sponge with high comfort factor and high tensile strength, its preparation method and application. Background Technology

[0002] In the modern furniture industry, foam, as a key filling material, has a decisive impact on furniture quality and user experience. Users generally desire superior comfort. Traditional latex offers excellent comfort, but its production is complex, it has a strong odor, is prone to causing allergies, easily powders over time, and has poor tensile strength. The comfort factor of polyurethane foam is a crucial factor affecting its comfort. The comfort factor is the result of dividing 65% of the indentation hardness by 25% of the crease hardness. Existing foam products possess high comfort factors, but these high-comfort-factor foams often lack high tensile strength (strength below 50 kPa), thus often resulting in insufficient durability and inability to meet normal usage requirements. Summary of the Invention

[0003] To address the issue that traditional sponges cannot simultaneously achieve both high comfort factor and high tensile strength, this application provides a sponge with both high comfort factor and high tensile strength, as well as its preparation method and application. The obtained polyurethane sponge has good comfort properties and simultaneously meets the usage requirements of softness, sufficient elasticity, and good tensile strength.

[0004] This invention provides a sponge with high comfort factor and high tensile strength, the raw materials of which, calculated by weight, include:

[0005] 60-80 parts high molecular weight polyether polyol;

[0006] 5-15 parts of common polyether polyol;

[0007] 5-15 parts polymer polyether polyol;

[0008] 5-15 parts low molecular weight polyols;

[0009] 0.5-1.5 parts silicone oil surfactant;

[0010] 0.15-0.3 parts amine catalyst;

[0011] 0.072-0.108 parts of tin-based catalysts;

[0012] 0.5-1.5 parts of non-tin metal catalyst;

[0013] 0.15-0.45 parts crosslinking agent;

[0014] 2.5-3.5 parts water;

[0015] 48.1-59.7 parts modified MDI;

[0016] Comfort factor > 2.8 (according to ASTM D3574-17 standard), tensile strength > 80 kPa.

[0017] This application utilizes a combination of high molecular weight polyether polyols, ordinary polyether polyols, polymeric polyether polyols, and low molecular weight polyols. Using high molecular weight polyether polyols alone cannot yield sponges with good tensile strength, while using ordinary polyether polyols alone results in sponges with insufficient comfort. Polyurethane materials prepared from ordinary polyether polyols typically possess a certain degree of resilience. Combining them with high molecular weight polyether polyols further enhances the elasticity of the sponge product. Therefore, this mixed use can yield a stable sponge product with a high comfort factor. Furthermore, the use of non-tin metal catalysts makes it less susceptible to environmental influences and ensures stable performance. When used in combination with raw materials such as high molecular weight polyether polyols, polymeric polyether polyols, and ordinary polyether polyols, it can produce sponges with both high comfort factor and high tensile strength. While ensuring high comfort, its tensile strength also meets usage requirements, and it also maintains softness and good elasticity.

[0018] Preferably, the sponge with high comfort factor and high tensile strength comprises, by weight parts:

[0019] 62-78 parts high molecular weight polyether polyol, 5-15 parts ordinary polyether polyol, 5-15 parts polymer polyether polyol, 5-15 parts low molecular weight polyol, 50-60 parts modified MDI, 0.8-1.2 parts silicone oil surfactant, 0.15-0.25 parts amine catalyst, 0.072-0.108 parts tin catalyst, 0.25-1.5 parts non-tin metal catalyst, 0.24-0.36 parts crosslinking agent, and 2.24-3.36 parts water.

[0020] Furthermore, the high molecular weight polyether polyol has a functionality of 3-6 and a molecular weight of 4000-12000mw.

[0021] Furthermore, the functionality of the common polyether polyol is 2-3, and the molecular weight is 1000-3500mw.

[0022] Furthermore, the polymer polyether polyol is a styrene-acrylonitrile grafted polymer polyol based on polyether polyol, and its styrene-acrylonitrile polymer microparticle solid content is 40%-50%.

[0023] Furthermore, the low molecular weight polyol has a functionality of 2 and a molecular weight of 200-800 mw.

[0024] Furthermore, the modified MDI is a liquid isocyanate formed by mixing diphenylmethane diisocyanate and polyisocyanate, or a liquid isocyanate formed by reacting diphenylmethane diisocyanate, polyisocyanate, and polyether or polyester polyol, with an NCO content of 25%-33%. Modified MDI is a commonly used isocyanate in polyurethane flexible foam foaming, and its curing speed is faster than that of TDI.

[0025] Furthermore, the silicone oil surfactant is a medium-to-low activity silicone oil surfactant. Medium-to-low activity silicone oil surfactants have lower reactivity than highly active silicone oil surfactants. When participating in the reaction, they can both protect the growth of small gas nuclei, maintain foam stability, and preserve a relatively high open-cell ratio. Therefore, limiting the silicone oil surfactant is necessary.

[0026] Furthermore, the amine catalyst is one or more mixed tertiary amine catalysts, which can be reactive or non-reactive catalysts.

[0027] Furthermore, the tin catalyst is a stannous octoate catalyst or a stannous neodecanoate catalyst.

[0028] Furthermore, the non-tin metal catalyst is at least one of bismuth-based, cobalt-based, and zinc-based metal catalysts. Non-tin metal catalysts typically exhibit relatively mild catalytic activity, making the reaction process easier to control. This is beneficial for improving product quality and stability, reducing the defect rate, and providing better resistance to hydrolysis and thermal stability, making them less prone to losing activity due to hydrolysis or thermal decomposition.

[0029] Furthermore, the crosslinking agent is at least one or more of glycerol, trihydroxypropane, diethanolamine, and triethanolamine.

[0030] The preparation method of the above-mentioned sponge with high comfort factor and high tensile strength includes the following steps:

[0031] Step 1: Prepare the raw materials according to the above mass proportions, and then mix the high molecular weight polyether polyol, ordinary polyether polyol, polymer polyol, silicone oil surfactant, amine catalyst, tin catalyst, non-tin metal catalyst, crosslinking agent and water to form a mixture.

[0032] Step 2: The obtained mixture is mixed with modified MDI, and foamed and cured at room temperature to form a sponge with high comfort factor and high tensile strength.

[0033] This application also protects the application of the aforementioned high-comfort and high-tensile-strength foam in home furnishings, particularly in mattresses.

[0034] The beneficial effects of this application are as follows: This application relates to a sponge with high comfort factor and high tensile strength, its preparation method and application, which, in conjunction with high molecular weight polyether polyol, ordinary polyether polyol, polymer polyol, low molecular weight polyol and non-tin metal catalyst, obtains a sponge product with high comfort factor and high tensile strength; in addition, the obtained sponge with high comfort factor and high tensile strength can also maintain good performance. Detailed Implementation

[0035] The technical solutions of the embodiments of the present invention will be explained and described below. However, the following embodiments are only preferred embodiments of the present invention and not all of them. Other embodiments obtained by those skilled in the art based on the embodiments in the implementation methods without creative effort are all within the protection scope of the present invention.

[0036] The raw materials used are shown in Table 1.

[0037] Table 1

[0038]

[0039] Example 1

[0040] The sponge with high comfort factor and high tensile strength in this embodiment comprises the following components by weight:

[0041] 70 parts high molecular weight polyether polyol, 10 parts ordinary polyether polyol, 10 parts polymer polyol, 10 parts low molecular weight polyol, 56.5 parts modified MDI, 1.0 part silicone oil surfactant, 0.21 parts amine catalyst, 0.09 parts tin catalyst, 0.5 parts non-tin metal catalyst, 0.3 parts crosslinking agent and 2.8 parts water.

[0042] Among them, the high molecular weight polyether polyol has a functionality of 3 and a molecular weight of 6000mw; the ordinary polyether polyol has a functionality of 2 and a molecular weight of 2000mw; the polymer polyol has a solid content of 45%; the low molecular weight polyol has a functionality of 2 and a molecular weight of 400mw; the modified MDI has an NCO content of 29.5%; the silicone oil surfactant is BL8333; the amine catalyst is a reactive catalyst; the tin catalyst is T9; the non-tin metal catalyst is a bismuth-zinc metal catalyst; and the crosslinking agent is diethanolamine.

[0043] The above-mentioned sponge with high comfort factor and high tensile strength is prepared by the following steps:

[0044] Step 1: Prepare the raw materials according to the above mass proportions, and then mix the high molecular weight polyether polyol, ordinary polyether polyol, polymer polyol, low molecular weight polyol, silicone oil surfactant, amine catalyst, tin catalyst, non-tin metal catalyst, crosslinking agent and water to form a mixture.

[0045] Step 2: Mix the obtained mixture with modified MDI, and foam and cure at room temperature to form a high comfort factor sponge.

[0046] Example 2

[0047] The sponge with high comfort factor and high tensile strength in this embodiment comprises the following components by weight:

[0048] 70 parts high molecular weight polyether polyol, 10 parts ordinary polyether polyol, 10 parts polymer polyol, 10 parts low molecular weight polyol, 56.5 parts modified MDI, 1.0 part silicone oil surfactant, 0.21 parts amine catalyst, 0.09 parts tin catalyst, 0.5 parts non-tin metal catalyst, 0.3 parts crosslinking agent and 2.8 parts water.

[0049] Among them, the high molecular weight polyether polyol has a functionality of 6 and a molecular weight of 12,000 mw; the ordinary polyether polyol has a functionality of 2 and a molecular weight of 2,000 mw; the solid content of the polymer polyol is 45%; the low molecular weight polyol has a functionality of 2 and a molecular weight of 400 mw; the NCO content of the modified MDI is 29.5%; the silicone oil surfactant is BL8333; the amine catalyst is a reactive catalyst; the tin catalyst is Evonik T900 (tin neodecanoate catalyst); the non-tin metal catalyst is a bismuth-zinc metal catalyst; and the crosslinking agent is diethanolamine.

[0050] The preparation method in this embodiment is the same as that in Example 1.

[0051] Example 3

[0052] The sponge with high comfort factor and high tensile strength in this embodiment comprises the following components by weight:

[0053] 70 parts high molecular weight polyether polyol, 10 parts ordinary polyether polyol, 10 parts polymer polyol, 10 parts low molecular weight polyol, 56.5 parts modified MDI, 1.0 part silicone oil surfactant, 0.21 parts amine catalyst, 0.09 parts tin catalyst, 0.5 parts non-tin metal catalyst, 0.3 parts crosslinking agent and 2.8 parts water.

[0054] Among them, the high molecular weight polyether polyol has a functionality of 3 and a molecular weight of 6000mw; the ordinary polyether polyol has a functionality of 2 and a molecular weight of 2000mw; the solid content of the polymer polyol is 45%; the low molecular weight polyol has a functionality of 2 and a molecular weight of 400mw; the NCO content of the modified MDI is 29.5%; the silicone oil surfactant is BL8333; the amine catalyst is a non-reactive catalyst; the tin catalyst is T9; the non-tin metal catalyst is a bismuth-zinc metal catalyst; and the crosslinking agent is diethanolamine.

[0055] Example 4

[0056] The sponge with high comfort factor and high tensile strength in this embodiment comprises the following components by weight:

[0057] 60 parts high molecular weight polyether polyol, 15 parts ordinary polyether polyol, 15 parts polymer polyol, 10 parts low molecular weight polyol, 56.8 parts modified MDI, 1.0 part silicone oil surfactant, 0.21 parts amine catalyst, 0.09 parts tin catalyst, 0.5 parts non-tin metal catalyst, 0.3 parts crosslinking agent and 2.8 parts water.

[0058] Among them, the high molecular weight polyether polyol has a functionality of 3 and a molecular weight of 6000mw; the ordinary polyether polyol has a functionality of 2 and a molecular weight of 2000mw; the solid content of the polymer polyol is 45%; the low molecular weight polyol has a functionality of 2 and a molecular weight of 400mw; the NCO content of the modified MDI is 29.5%; the silicone oil surfactant is BL8333; the amine catalyst is a non-reactive catalyst; the tin catalyst is T9; the non-tin metal catalyst is a bismuth-zinc metal catalyst; and the crosslinking agent is diethanolamine.

[0059] Example 5

[0060] The sponge with high comfort factor and high tensile strength in this embodiment comprises the following components by weight:

[0061] 80 parts high molecular weight polyether polyol, 5 parts ordinary polyether polyol, 5 parts polymer polyol, 15 parts low molecular weight polyol, 59.7 parts modified MDI, 1.0 part silicone oil surfactant, 0.21 parts amine catalyst, 0.09 parts tin catalyst, 0.5 parts non-tin metal catalyst, 0.3 parts crosslinking agent and 2.8 parts water.

[0062] Among them, the high molecular weight polyether polyol has a functionality of 3 and a molecular weight of 6000mw; the ordinary polyether polyol has a functionality of 2 and a molecular weight of 2000mw; the solid content of the polymer polyol is 45%; the low molecular weight polyol has a functionality of 2 and a molecular weight of 400mw; the NCO content of the modified MDI is 29.5%; the silicone oil surfactant is BL8333; the amine catalyst is a non-reactive catalyst; the tin catalyst is T9; the non-tin metal catalyst is a bismuth-zinc metal catalyst; and the crosslinking agent is diethanolamine.

[0063] Example 6

[0064] The sponge with high comfort factor and high tensile strength in this embodiment comprises the following components by weight:

[0065] 75 parts high molecular weight polyether polyol, 10 parts ordinary polyether polyol, 10 parts polymer polyol, 5 parts low molecular weight polyol, 48.1 parts modified MDI, 1.0 part silicone oil surfactant, 0.21 parts amine catalyst, 0.09 parts tin catalyst, 0.5 parts non-tin metal catalyst, 0.3 parts crosslinking agent and 2.8 parts water.

[0066] Among them, the high molecular weight polyether polyol has a functionality of 3 and a molecular weight of 6000mw; the ordinary polyether polyol has a functionality of 2 and a molecular weight of 2000mw; the solid content of the polymer polyol is 45%; the low molecular weight polyol has a functionality of 2 and a molecular weight of 400mw; the NCO content of the modified MDI is 32.8%; the silicone oil surfactant is BL8333; the amine catalyst is a non-reactive catalyst; the tin catalyst is T9; the non-tin metal catalyst is a bismuth-zinc metal catalyst; and the crosslinking agent is diethanolamine.

[0067] The preparation method in this embodiment is the same as that in Example 1.

[0068] Example 7

[0069] The sponge with high comfort factor and high tensile strength in this embodiment comprises the following components by weight:

[0070] 70 parts high molecular weight polyether polyol, 10 parts ordinary polyether polyol, 10 parts polymer polyol, 10 parts low molecular weight polyol, 52 parts modified MDI, 1.0 part silicone oil surfactant, 0.21 parts amine catalyst, 0.09 parts tin catalyst, 0.5 parts non-tin metal catalyst, 0.3 parts crosslinking agent and 2.5 parts water.

[0071] Among them, the high molecular weight polyether polyol has a functionality of 3 and a molecular weight of 6000mw; the ordinary polyether polyol has a functionality of 2 and a molecular weight of 2000mw; the polymer polyol has a solid content of 45%; the low molecular weight polyol has a functionality of 2 and a molecular weight of 400mw; the modified MDI has an NCO content of 29.5%; the silicone oil surfactant is BL8333; the amine catalyst is a reactive catalyst; the tin catalyst is T9; the non-tin metal catalyst is a bismuth-zinc metal catalyst; and the crosslinking agent is diethanolamine.

[0072] The preparation method in this embodiment is the same as that in Example 1.

[0073] Example 8

[0074] The sponge with high comfort factor and high tensile strength in this embodiment comprises the following components by weight:

[0075] 70 parts high molecular weight polyether polyol, 10 parts ordinary polyether polyol, 10 parts polymer polyol, 10 parts low molecular weight polyol, 67.1 parts modified MDI, 1.0 part silicone oil surfactant, 0.21 parts amine catalyst, 0.09 parts tin catalyst, 0.5 parts non-tin metal catalyst, 0.3 parts crosslinking agent and 3.5 parts water.

[0076] Among them, the high molecular weight polyether polyol has a functionality of 3 and a molecular weight of 6000mw; the ordinary polyether polyol has a functionality of 2 and a molecular weight of 2000mw; the polymer polyol has a solid content of 45%; the low molecular weight polyol has a functionality of 2 and a molecular weight of 400mw; the modified MDI has an NCO content of 29.5%; the silicone oil surfactant is BL8333; the amine catalyst is a reactive catalyst; the tin catalyst is T9; the non-tin metal catalyst is a bismuth-zinc metal catalyst; and the crosslinking agent is diethanolamine.

[0077] The preparation method in this embodiment is the same as that in Example 1.

[0078] Example 9

[0079] The sponge with high comfort factor and high tensile strength in this embodiment comprises the following components by weight:

[0080] 70 parts high molecular weight polyether polyol, 10 parts ordinary polyether polyol, 10 parts polymer polyol, 10 parts low molecular weight polyol, 56 parts modified MDI, 1.5 parts silicone oil surfactant, 0.21 parts amine catalyst, 0.09 parts tin catalyst, 0.5 parts non-tin metal catalyst, 0.15 parts crosslinking agent and 2.8 parts water.

[0081] Among them, the high molecular weight polyether polyol has a functionality of 3 and a molecular weight of 6000mw; the ordinary polyether polyol has a functionality of 2 and a molecular weight of 2000mw; the polymer polyol has a solid content of 45%; the low molecular weight polyol has a functionality of 2 and a molecular weight of 400mw; the modified MDI has an NCO content of 29.5%; the silicone oil surfactant is BL8333; the amine catalyst is a reactive catalyst; the tin catalyst is T9; the non-tin metal catalyst is a bismuth-zinc metal catalyst; and the crosslinking agent is diethanolamine.

[0082] The preparation method in this embodiment is the same as that in Example 1.

[0083] Example 10

[0084] The sponge with high comfort factor and high tensile strength in this embodiment comprises the following components by weight:

[0085] 70 parts high molecular weight polyether polyol, 10 parts ordinary polyether polyol, 10 parts polymer polyol, 10 parts low molecular weight polyol, 57.1 parts modified MDI, 0.5 parts silicone oil surfactant, 0.21 parts amine catalyst, 0.09 parts tin catalyst, 0.5 parts non-tin metal catalyst, 0.45 parts crosslinking agent and 2.8 parts water.

[0086] Among them, the high molecular weight polyether polyol has a functionality of 3 and a molecular weight of 6000mw; the ordinary polyether polyol has a functionality of 2 and a molecular weight of 2000mw; the polymer polyol has a solid content of 45%; the low molecular weight polyol has a functionality of 2 and a molecular weight of 400mw; the modified MDI has an NCO content of 29.5%; the silicone oil surfactant is BL8333; the amine catalyst is a reactive catalyst; the tin catalyst is T9; the non-tin metal catalyst is a bismuth-zinc metal catalyst; and the crosslinking agent is diethanolamine.

[0087] The preparation method in this embodiment is the same as that in Example 1.

[0088] Example 11

[0089] The sponge with high comfort factor and high tensile strength in this embodiment comprises the following components by weight:

[0090] 70 parts high molecular weight polyether polyol, 10 parts ordinary polyether polyol, 10 parts polymer polyol, 10 parts low molecular weight polyol, 56.5 parts modified MDI, 1.0 part silicone oil surfactant, 0.3 parts amine catalyst, 0.072 parts tin catalyst, 1.5 parts non-tin metal catalyst, 0.3 parts crosslinking agent and 2.8 parts water.

[0091] Among them, the high molecular weight polyether polyol has a functionality of 3 and a molecular weight of 6000mw; the ordinary polyether polyol has a functionality of 2 and a molecular weight of 2000mw; the polymer polyol has a solid content of 45%; the low molecular weight polyol has a functionality of 2 and a molecular weight of 400mw; the modified MDI has an NCO content of 29.5%; the silicone oil surfactant is BL8333; the amine catalyst is a reactive catalyst; the tin catalyst is T9; the non-tin metal catalyst is a bismuth-zinc metal catalyst; and the crosslinking agent is diethanolamine.

[0092] The preparation method in this embodiment is the same as that in Example 1.

[0093] Example 12

[0094] The sponge with high comfort factor and high tensile strength in this embodiment comprises the following components by weight:

[0095] 70 parts high molecular weight polyether polyol, 10 parts ordinary polyether polyol, 10 parts polymer polyol, 10 parts low molecular weight polyol, 56.5 parts modified MDI, 1.0 part silicone oil surfactant, 0.15 parts amine catalyst, 0.108 parts tin catalyst, 0.5 parts non-tin metal catalyst, 0.3 parts crosslinking agent and 2.8 parts water.

[0096] Among them, the high molecular weight polyether polyol has a functionality of 3 and a molecular weight of 6000mw; the ordinary polyether polyol has a functionality of 2 and a molecular weight of 2000mw; the polymer polyol has a solid content of 45%; the low molecular weight polyol has a functionality of 2 and a molecular weight of 400mw; the modified MDI has an NCO content of 29.5%; the silicone oil surfactant is BL8333; the amine catalyst is a reactive catalyst; the tin catalyst is T9; the non-tin metal catalyst is a bismuth-zinc metal catalyst; and the crosslinking agent is diethanolamine.

[0097] The preparation method in this embodiment is the same as that in Example 1.

[0098] Comparative Example 1

[0099] A sponge, which differs from Example 1 in that it does not contain ordinary polyether polyol.

[0100] Calculated by parts by mass, it includes the following components:

[0101] 80 parts high molecular weight polyether polyol, 10 parts polymer polyol, 10 parts low molecular weight polyol, 55.9 parts modified MDI, 1.0 part silicone oil surfactant, 0.21 parts amine catalyst, 0.09 parts tin catalyst, 0.5 parts non-tin metal catalyst, 0.3 parts crosslinking agent and 2.8 parts water.

[0102] Among them, the high molecular weight polyether polyol has a functionality of 3 and a molecular weight of 6000mw; the polymer polyol has a solid content of 45%; the low molecular weight polyol has a functionality of 2 and a molecular weight of 400mw; the modified MDI has an NCO content of 29.5%; the silicone oil surfactant is BL8333; the amine catalyst is a reactive catalyst; the tin catalyst is T9; the non-tin metal catalyst is a bismuth-zinc metal catalyst; and the crosslinking agent is diethanolamine.

[0103] The preparation method for this comparative example is the same as that for Example 1.

[0104] Comparative Example 2

[0105] A sponge, which differs from Example 1 in that it does not contain polymer polyether polyol.

[0106] Calculated by parts by mass, it includes the following components:

[0107] 80 parts high molecular weight polyether polyol, 10 parts ordinary polyether polyol, 10 parts low molecular weight polyol, 56.7 parts modified MDI, 1.0 part silicone oil surfactant, 0.21 parts amine catalyst, 0.09 parts tin catalyst, 0.5 parts non-tin metal catalyst, 0.3 parts crosslinking agent and 2.8 parts water.

[0108] Among them, the high molecular weight polyether polyol has a functionality of 3 and a molecular weight of 6000mw; the ordinary polyether polyol has a functionality of 2 and a molecular weight of 2000mw; the low molecular weight polyol has a functionality of 2 and a molecular weight of 400mw; the NCO content of the modified MDI is 29.5%; the silicone oil surfactant is BL8333; the amine catalyst is a reactive catalyst; the tin catalyst is T9; the non-tin metal catalyst is a bismuth-zinc metal catalyst; and the crosslinking agent is diethanolamine.

[0109] The preparation method for this comparative example is the same as that for Example 1.

[0110] Comparative Example 3

[0111] A sponge, which differs from Example 1 in that it does not contain low molecular weight polyols.

[0112] Calculated by parts by mass, it includes the following components:

[0113] 80 parts high molecular weight polyether polyol, 10 parts ordinary polyether polyol, 10 parts polymer polyol, 50.5 parts modified MDI, 1.0 part silicone oil surfactant, 0.21 parts amine catalyst, 0.09 parts tin catalyst, 0.5 parts non-tin metal catalyst, 0.3 parts crosslinking agent and 2.8 parts water.

[0114] Among them, the high molecular weight polyether polyol has a functionality of 3 and a molecular weight of 6000mw; the ordinary polyether polyol has a functionality of 2 and a molecular weight of 2000mw; the solid content of the polymer polyol is 45%; the NCO content of the modified MDI is 29.5%; the silicone oil surfactant is BL8333; the amine catalyst is a reactive catalyst; the tin catalyst is T9; the non-tin metal catalyst is a bismuth-zinc metal catalyst; and the crosslinking agent is diethanolamine.

[0115] The preparation method for this comparative example is the same as that for Example 1.

[0116] Comparative Example 4

[0117] A sponge, which differs from Example 1 in that it does not contain a crosslinking agent.

[0118] Calculated by parts by mass, it includes the following components:

[0119] 70 parts high molecular weight polyether polyol, 10 parts ordinary polyether polyol, 10 parts polymer polyol, 10 parts low molecular weight polyol, 55.4 parts modified MDI, 1.0 part silicone oil surfactant, 0.21 parts amine catalyst, 0.09 parts tin catalyst, 0.5 parts non-tin metal catalyst and 2.8 parts water.

[0120] Among them, the high molecular weight polyether polyol has a functionality of 3 and a molecular weight of 6000mw; the ordinary polyether polyol has a functionality of 2 and a molecular weight of 2000mw; the polymer polyol has a solid content of 45%; the low molecular weight polyol has a functionality of 2 and a molecular weight of 400mw; the modified MDI has an NCO content of 29.5%; the silicone oil surfactant is BL8333; the amine catalyst is a reactive catalyst; the tin catalyst is T9; and the non-tin metal catalyst is a bismuth-zinc metal catalyst.

[0121] The preparation method for this comparative example is the same as that for Example 1.

[0122] Comparative Example 5

[0123] A sponge, differing from Example 1 in that it is made with ordinary silicone oil.

[0124] Calculated by parts by mass, it includes the following components:

[0125] 70 parts high molecular weight polyether polyol, 10 parts ordinary polyether polyol, 10 parts polymer polyol, 10 parts low molecular weight polyol, 56.5 parts modified MDI, 1.0 part silicone oil surfactant, 0.21 parts amine catalyst, 0.09 parts tin catalyst, 0.5 parts non-tin metal catalyst, 0.3 parts crosslinking agent and 2.8 parts water.

[0126] Among them, the high molecular weight polyether polyol has a functionality of 3 and a molecular weight of 6000mw; the ordinary polyether polyol has a functionality of 2 and a molecular weight of 2000mw; the polymer polyol has a solid content of 45%; the low molecular weight polyol has a functionality of 2 and a molecular weight of 400mw; the modified MDI has an NCO content of 29.5%; the silicone oil surfactant is L580; the amine catalyst is a reactive catalyst; the tin catalyst is T9; the non-tin metal catalyst is a bismuth-zinc metal catalyst; and the crosslinking agent is diethanolamine.

[0127] The preparation method for this comparative example is the same as that for Example 1.

[0128] Comparative Example 6

[0129] A sponge, which differs from Example 1 in that it does not contain a tin-based catalyst.

[0130] Calculated by parts by mass, it includes the following components:

[0131] 70 parts high molecular weight polyether polyol, 10 parts ordinary polyether polyol, 10 parts polymer polyol, 10 parts low molecular weight polyol, 56.5 parts modified MDI, 1.0 part silicone oil surfactant, 0.21 parts amine catalyst, 0.5 parts non-tin metal catalyst, 0.3 parts crosslinking agent and 2.8 parts water.

[0132] Among them, the high molecular weight polyether polyol has a functionality of 3 and a molecular weight of 6000mw; the ordinary polyether polyol has a functionality of 2 and a molecular weight of 2000mw; the polymer polyol has a solid content of 45%; the low molecular weight polyol has a functionality of 2 and a molecular weight of 400mw; the modified MDI has an NCO content of 29.5%; the silicone oil surfactant is BL8333; the amine catalyst is a reactive catalyst; the non-tin metal catalyst is a bismuth-zinc metal catalyst; and the crosslinking agent is diethanolamine.

[0133] The preparation method for this comparative example is the same as that for Example 1.

[0134] Comparative Example 7

[0135] A sponge, which differs from Example 1 in that it does not contain a non-tin metal catalyst.

[0136] Calculated by parts by mass, it includes the following components:

[0137] 70 parts high molecular weight polyether polyol, 10 parts ordinary polyether polyol, 10 parts polymer polyol, 10 parts low molecular weight polyol, 56.5 parts modified MDI, 1.0 part silicone oil surfactant, 0.21 parts amine catalyst, 0.09 parts tin catalyst, 0.3 parts crosslinking agent and 2.8 parts water.

[0138] Among them, the high molecular weight polyether polyol has a functionality of 3 and a molecular weight of 6000mw; the ordinary polyether polyol has a functionality of 2 and a molecular weight of 2000mw; the polymer polyol has a solid content of 45%; the low molecular weight polyol has a functionality of 2 and a molecular weight of 400mw; the modified MDI has an NCO content of 29.5%; the silicone oil surfactant is BL8333; the amine catalyst is a reactive catalyst; the tin catalyst is T9; and the crosslinking agent is diethanolamine.

[0139] The preparation method for this comparative example is the same as that for Example 1.

[0140] To more clearly illustrate the present invention, the foaming conditions and performance of the sponges prepared in the examples and comparative examples were tested and compared. The tensile strength and elongation at break were tested according to the method of GB / T 6344, the tear strength according to the method of GB / T 10808, the resilience according to the method of GB / T 6670, and the 40% indentation hardness according to the method of GB / T10807. The foaming conditions and sponge physical property test results are shown in Table 2.

[0141] The formula for calculating the comfort factor is as follows:

[0142]

[0143] Table 2

[0144]

[0145] In the table above, the higher the indentation ratio, the higher the comfort factor of the prepared sponge; the higher the tensile strength value, the less likely the prepared sponge is to break; the higher the elongation at break value, the better the elasticity of the prepared sponge; the higher the tear strength value, the less likely the prepared sponge is to tear; and the higher the resilience value, the better the elasticity of the prepared sponge.

[0146] As can be seen from the table above, Examples 1-12 all have high comfort factors, high tensile strength, and their tear strength, resilience, hardness, and density all meet the requirements. The tensile strength of Comparative Example 1 is lower than that of Example 1 because it did not use ordinary polyether. The indentation ratio and tensile strength of Comparative Example 2 are lower than those of Example 1 because it did not use polymer polyether polyol. The indentation ratio of Comparative Example 3 is lower than that of Example 1 because it did not use low molecular weight polyol. The collapse of Comparative Example 4 is the result of not adding a crosslinking agent. The closed-cell shrinkage of Comparative Example 5 is the result of using ordinary silicone oil. The collapse of Comparative Example 6 is the result of not adding a tin catalyst. The sinking of Comparative Example 7 is the result of not adding a non-tin metal catalyst.

[0147] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Those skilled in the art should understand that the present invention includes, but is not limited to, the content described in the above specific embodiments. Any modifications that do not depart from the functional and structural principles of the present invention will be included within the scope of the claims.

Claims

1. A sponge with high comfort factor and high tensile strength, characterized in that, Its raw materials, calculated by mass parts, include: 60-80 parts high molecular weight polyether polyol; 5-15 parts of common polyether polyol; 5-15 parts polymer polyether polyol; 5-15 parts low molecular weight polyols; 0.5-1.5 parts silicone oil surfactant; 0.15-0.3 parts amine catalyst; 0.072-0.108 parts of tin-based catalysts; 0.5-1.5 parts of non-tin metal catalyst; 0.15-0.45 parts crosslinking agent; 2.5-3.5 parts water; 48.1-59.7 parts modified MDI; Comfort factor > 2.8, tensile strength > 80 kPa.

2. The sponge with high comfort factor and high tensile strength according to claim 1, characterized in that, Its raw materials, calculated by mass parts, include: 62-78 parts high molecular weight polyether polyol, 5-15 parts ordinary polyether polyol, 5-15 parts polymer polyether polyol, 5-15 parts low molecular weight polyol, 50-60 parts modified MDI, 0.8-1.2 parts silicone oil surfactant, 0.15-0.25 parts amine catalyst, 0.072-0.108 parts tin catalyst, 0.25-1.5 parts non-tin metal catalyst, 0.24-0.36 parts crosslinking agent, and 2.24-3.36 parts water.

3. The sponge with high comfort factor and high tensile strength according to claim 1 or 2, characterized in that... The high molecular weight polyether polyol has a functionality of 3-6 and a molecular weight of 4000-12000mw.

4. The sponge with high comfort factor and high tensile strength according to claim 1 or 2, characterized in that... The common polyether polyol has a functionality of 2-3 and a molecular weight of 1000-3500mw.

5. The sponge with high comfort factor and high tensile strength according to claim 1 or 2, characterized in that... The polymer polyether polyol is a styrene-acrylonitrile grafted polyether polyol based on polyether triol, and the styrene and acrylonitrile copolymer microparticles have a solid content of 40%-50%.

6. The sponge with high comfort factor and high tensile strength according to claim 1 or 2, characterized in that, The low molecular weight polyol has a functionality of 2 and a molecular weight of 200-800 mw.

7. The sponge with high comfort factor and high tensile strength according to claim 1 or 2, characterized in that, The silicone oil surfactant is a medium-to-low activity silicone oil surfactant.

8. The sponge with high comfort factor and high tensile strength according to claim 1 or 2, characterized in that, The non-tin metal catalyst is at least one of bismuth metal catalysts, cobalt metal catalysts, and zinc metal catalysts.

9. A method for preparing a sponge with high comfort factor and high tensile strength according to any one of claims 1 to 8, characterized in that, Includes the following steps: Step 1: Prepare the raw materials of the sponge with high comfort factor and high tensile strength as described in any one of claims 1 to 8 according to the mass proportions, and then mix high molecular weight polyether polyol, ordinary polyether polyol, polymer polyether polyol, low molecular weight polyol, silicone oil surfactant, amine catalyst, tin catalyst, non-tin metal catalyst, crosslinking agent and water to obtain a mixture. Step 2: The obtained mixture is mixed with modified MDI, and foamed and cured at room temperature to form a sponge with high comfort factor and high tensile strength.

10. The application of a sponge with high comfort factor and high tensile strength according to any one of claims 1 to 8 in household products.

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