Melamine foam-polyurethane composite material and method for manufacturing the same

Abstract

Disclosed are a melamine foam composite polyurethane material and a manufacturing method thereof, comprising: a polyurethane layer formed by mixing a polyol having an OH value of 50 mg KOH / g to 300 mg KOH / g and an isocyanate having an NCO value of 6% to 30% at a temperature range of 20°C to 60°C and heating at a temperature range of 80°C to 130°C; and a melamine foam layer directly attached to the polyurethane layer in an adhesive-free manner, and the attached polyurethane layer and the melamine foam layer are formed into a hot melt bond by heating at a temperature range of 80°C to 130°C.

Description

Technical Field

[0001] This invention relates to a melamine foam material, and more particularly to a melamine foam composite polyurethane material and its manufacturing method. Background Technology

[0002] Melamine foam is a lightweight, flame-retardant material with good sound absorption, heat insulation, and strong cleaning ability. It is widely used in sound-absorbing materials, heat insulation and cold insulation materials, and cleaning and wiping materials. However, its mechanical strength, such as tear strength, is significantly inferior to that of traditional PU polyurethane foam, which is especially inconvenient in the field of cleaning and wiping.

[0003] Methods for improving the mechanical strength of melamine foam include: patent document TWM538454U using polyester film lamination; TWM283607U using polyester / nylon composite yarn lamination; US20240391210A1 using aerogel reinforcement; and US20240181744A1 using non-woven double-sided lamination for reinforcement. However, these methods have drawbacks such as difficulty in manufacturing or solvent residue. Summary of the Invention

[0004] Therefore, based on the above problems, the present invention provides a melamine foam composite polyurethane material and its manufacturing method to solve the problems of the prior art.

[0005] The present invention addresses the problems of the prior art by providing a melamine foam composite polyurethane material, comprising: a polyurethane layer formed by mixing a polyol with an OH value of 50 mg KOH / g to 300 mg KOH / g and an isocyanate with an NCO value of 6% to 30% at a temperature range of 20°C to 60°C and heating at a temperature range of 80°C to 130°C; and a melamine foam layer directly bonded to the polyurethane layer without adhesive, wherein the bonded polyurethane layer and the melamine foam layer are thermally fused together by heating at a temperature range of 80°C to 130°C.

[0006] In one embodiment of the present invention, a melamine foam composite polyurethane material is provided, wherein the polyol is a mixture of polyether polyols and the isocyanate is a mixture of aromatic isocyanates or a mixture of aliphatic isocyanates.

[0007] Furthermore, another technical means adopted by the present invention to solve the problems of the prior art is to provide a method for manufacturing melamine foam composite polyurethane material, which sequentially includes: a mixing step, in which a polyol with an OH value of 50 mg KOH / g to 300 mg KOH / g and an isocyanate with an NCO value of 6% to 30% are mixed in a temperature range of 20°C to 60°C to form a polyurethane raw material; a coating step, in which the polyurethane raw material is coated in a layered manner to form a coating layer; a baking step, in which the coating layer is heated in a temperature range of 80°C to 130°C to form a polyurethane film; a laminating step, in which the melamine foam film is directly laminating to the polyurethane film without adhesive; and a bonding step, in which the laminated polyurethane film and the melamine foam film are heated in a temperature range of 80°C to 130°C to form a thermal fusion bond between the laminated polyurethane film and the melamine foam film, thereby obtaining the melamine foam composite polyurethane material.

[0008] In one embodiment of the present invention, a method for manufacturing a melamine foam composite polyurethane material is provided, wherein in the mixing step, the polyol is a mixture of polyether polyols, and the isocyanate is a mixture of aromatic isocyanates or a mixture of aliphatic isocyanates.

[0009] Through the technical means employed in this invention, the melamine foam composite polyurethane material of this invention features a melamine foam layer directly bonded to a polyurethane layer without adhesive. Heating causes the bonded polyurethane layer and melamine foam layer to form a thermally fused bond, thereby enhancing the overall mechanical strength without the use of adhesives. This method combines the advantages of no organic solvent residue and good mechanical strength. Furthermore, the manufacturing method of the melamine foam composite polyurethane material of this invention enables the production of a melamine foam composite polyurethane material with both the advantages of no organic solvent residue and good mechanical strength without the use of adhesives. Attached Figure Description

[0010] Figure 1 This is a perspective view of a melamine foam composite polyurethane material according to an embodiment of the present invention.

[0011] Figure 2 This is a side view of a melamine foam composite polyurethane material according to an embodiment of the present invention.

[0012] Figure 3 This is a flowchart illustrating a method for manufacturing a melamine foam composite polyurethane material according to an embodiment of the present invention.

[0013] Figure 4 This is a schematic diagram illustrating an example of a method for manufacturing melamine foam composite polyurethane material according to an embodiment of the present invention.

[0014] Figure 5 This is a schematic diagram of an example of the equipment used in the manufacturing method of melamine foam composite polyurethane material according to an embodiment of the present invention.

[0015] Explanation of reference numerals in the attached diagram:

[0016] 100 melamine foam composite polyurethane material

[0017] Polyurethane layer 10

[0018] 10' polyurethane membrane

[0019] Coating layer 11

[0020] melamine foam layer 20

[0021] 20' melamine foam film

[0022] Release paper 30

[0023] Mixer 210

[0024] Coating device 220

[0025] Thickness control mechanism 230

[0026] 240 rollers

[0027] Oven 250 Detailed Implementation

[0028] The following is based on Figures 1 to 5 This description illustrates one embodiment of the present invention. This description is not intended to limit the embodiments of the present invention, but rather to illustrate one example of the present invention.

[0029] Figure 1 This is a perspective view of a melamine foam composite polyurethane (MPU) material according to an embodiment of the present invention. Figure 2 This is a side view of a melamine foam composite polyurethane (MPU) material according to an embodiment of the present invention.

[0030] like Figures 1 to 3 As shown, the melamine foam composite polyurethane material 100 of the present invention includes a polyurethane layer 10 and a melamine foam layer 20.

[0031] In this embodiment, the polyurethane layer 10 is formed by mixing a polyol with an OH value of 50 mg KOH / g to 300 mg KOH / g and an isocyanate with an NCO value of 6% to 30% in a temperature range of 20°C to 60°C, and heating it in a temperature range of 80°C to 130°C.

[0032] Furthermore, the polyol is preferably a mixture of polyether polyols, and the isocyanate is preferably a mixture of aromatic isocyanates or a mixture of aliphatic isocyanates.

[0033] Polyols are essential raw materials for polyurethane synthesis. Containing hydroxyl groups (-OH), they can undergo addition reactions with isocyanates (-NCO) to form polyurethane chains. Hydroxyl value (HV) is a crucial indicator of polyol reactivity, representing the amount of hydroxyl groups per gram of polyol that can react with isocyanates. OH value can be determined using methods such as acetic anhydride esterification titration or the pyridine hydrochloride method. Specifically, the basic principle of OH value determination is as follows: the -OH functional groups in the sample react with acetic anhydride to form acetate; an equivalent amount of acetic acid is released during the reaction; the released acetic acid is titrated with potassium hydroxide (KOH) solution, allowing the calculation of the number of hydroxyl groups in the sample. A higher OH value indicates a higher hydroxyl content within the polyol molecule, which affects its reactivity with isocyanates and the hardness and mechanical properties of the final product.

[0034] Furthermore, isocyanate is a key raw material in the synthesis of polyurethane, and the NCO value (NCO Content, the content of isocyanate functional groups) is an important indicator of isocyanate activity. The NCO value represents the mass percentage of isocyanate functional groups (-NCO) in an isocyanate compound, expressed as a percentage (%). The NCO value affects the reactivity of the isocyanate. A higher NCO value indicates a higher concentration of isocyanate functional groups, resulting in a higher rate and degree of cross-linking when reacting with polyols. This directly impacts the physical properties of polyurethane foams, coatings, elastomers, and other materials.

[0035] In this embodiment, the melamine foam layer 20 is directly bonded to the polyurethane layer 10 without adhesive, and the bonded polyurethane layer 10 and the melamine foam layer 20 are thermally fused together by heating in a temperature range of 80°C to 130°C.

[0036] Melamine foam (scientific name: melamine-formaldehyde resin foam, abbreviated as MF) is a soft elastomer made by polymerizing and foaming melamine and formaldehyde. It possesses properties such as permanent flame retardancy, high temperature resistance, scratch and abrasion resistance, moisture and stain resistance, and good insulation, and is widely used in daily life and industrial fields. Furthermore, melamine foam is a porous, open-cell material, and due to its unique physical properties, it is widely used in cleaning, sound absorption, and heat insulation applications.

[0037] In a melamine foam composite polyurethane material 100 of an embodiment of the present invention, the melamine foam layer 20 is directly bonded to the polyurethane layer 10 without adhesive, and the bonded polyurethane layer 10 and the melamine foam layer 20 are thermally fused together by heating, thereby improving the mechanical strength of the melamine foam without the use of adhesive, and has the advantages of no organic solvent residue and good mechanical strength.

[0038] The following describes the manufacturing method of the melamine foam composite polyurethane (MPU) material of the present invention.

[0039] Figure 3 This is a flowchart illustrating a method for manufacturing a melamine foam composite polyurethane (MPU) material according to an embodiment of the present invention. Figure 4 This is a schematic diagram illustrating a method for manufacturing melamine foam composite polyurethane (MPU) according to an embodiment of the present invention. Figure 5 This is a schematic diagram of an example of the equipment used in a method for manufacturing melamine foam composite polyurethane (MPU) according to an embodiment of the present invention.

[0040] like Figure 3 As shown, the manufacturing method of melamine foam composite polyurethane material (MPU) according to an embodiment of the present invention includes, in sequence: mixing step S01, coating step S02, baking step S03, laminating step S04, and bonding step S05.

[0041] In mixing step S01, polyols with an OH value of 50 mg KOH / g to 300 mg KOH / g and isocyanates with an NCO value of 6% to 30% are mixed in a temperature range of 20°C to 60°C to form polyurethane raw materials.

[0042] Specifically, for example Figure 5As shown, polyols and isocyanates can be fed into mixer 210 via a metering pump (not shown), and the temperature of mixer 210 is controlled within a temperature range of 20°C to 60°C for mixing. Of course, the invention is not limited to this; as long as polyols and isocyanates can be mixed within a temperature range of 20°C to 60°C, any method can be used to mix polyols and isocyanates.

[0043] Furthermore, in the mixing step S01, the polyol may be a mixture of polyether polyols, and the isocyanate may be a mixture of aromatic isocyanates or a mixture of aliphatic isocyanates.

[0044] In the coating step S02, the polyurethane raw material is coated in a layered manner to form a coating layer 11.

[0045] Specifically, such as Figure 4 and Figure 5 As shown, the polyurethane raw material mixed by mixer 210 can be output and coated onto the surface of release paper 30 by coating device 220 to form coating layer 11. Of course, the present invention is not limited to coating polyurethane raw material onto release paper 30; any method can be used as long as the polyurethane raw material can be coated in a layered manner to form coating layer 11. Furthermore, the thickness of coating layer 11 can be controlled by controlling the coating amount through thickness control mechanism 230. Further, for example, the thickness control mechanism 230 can be a scraper, thereby allowing control of the thickness of coating layer 11 through scraping.

[0046] In baking step S03, the coating layer 11 is heated in a temperature range of 80°C to 130°C to form a polyurethane film 10'.

[0047] Specifically, such as Figure 4 and Figure 5 As shown, the coating layer 11, together with the release paper 30, can be fed into an oven 250 with a temperature range set to 80°C to 130°C for heating via rollers 240. Of course, the present invention is not limited to this; any heating method can be used as long as the coating layer 11 can be heated to form a polyurethane film 10'.

[0048] In the bonding step S04, the melamine foam film 20' is directly bonded to the polyurethane film 10' without adhesive.

[0049] Specifically, such as Figure 4 and Figure 5 As shown, the melamine foam film 20' can be output via the roller 240, and the melamine foam film 20' can be directly bonded to the polyurethane film 10' without adhesive.

[0050] In step S05, the laminated polyurethane film 10' and the melamine foam film 20' are heated in a temperature range of 80°C to 130°C, so that the laminated polyurethane film 10' and the melamine foam film 20' form a thermal fusion bond, thereby obtaining the melamine foam composite polyurethane material 100.

[0051] Specifically, such as Figure 4 and Figure 5 As shown, the laminated polyurethane film 10' and melamine foam film 20', along with the release paper 30, can be fed into an oven 250 with a temperature range set between 80°C and 130°C via rollers 240 for heating, causing the laminated polyurethane film 10' and melamine foam film 20' to form a thermally fused bond. Of course, the invention is not limited to this; any heating method can be used as long as the polyurethane film 10' and melamine foam film 20' can be heated to form a thermally fused bond. Afterwards, the release paper 30 is peeled off to obtain the melamine foam composite polyurethane material 100.

[0052] The method for manufacturing melamine foam composite polyurethane material according to an embodiment of the present invention provides a melamine foam composite polyurethane material 100 that combines the advantages of no organic solvent residue and good mechanical strength without the use of adhesives.

[0053] Furthermore, since the melamine foam composite polyurethane material 100 of the present invention has the advantages of no organic solvent residue and good mechanical strength, it can also be applied to cleaning and wiping products such as abrasive cleaning pads or makeup remover pads, warm shoe materials, thermal insulation covers, heat insulation pads and other fields.

[0054] Furthermore, the melamine foam composite polyurethane (MPU) material of the present invention is a recyclable material that can be physically crushed to replace rubber in building materials to reduce weight, for example, it can be applied to anti-slip mats and sound-absorbing mats.

[0055] Furthermore, the melamine foam composite polyurethane material (MPU) of the present invention can be modified by aerogel to form a special melamine foam recombined polyurethane material (special MPU), which is a material with extremely low thermal conductivity and can be applied to the field of electronic materials that require low weight and low thermal conductivity. Furthermore, it can also be applied to the core material of textiles for warmth and cold protection.

[0056] The above description and illustration are merely illustrative of preferred embodiments of the present invention. Those skilled in the art may make other modifications based on the defined claims and the above description, but these modifications should still be within the spirit of the invention and the scope of the invention.

Claims

1. A melamine foam composite polyurethane material, characterized in that, Include: A polyurethane layer, formed by mixing a polyol with an OH value of 50 mg KOH / g to 300 mg KOH / g and an isocyanate with an NCO value of 6% to 30% at a temperature range of 20°C to 60°C and heating at a temperature range of 80°C to 130°C; and The melamine foam layer is directly bonded to the polyurethane layer without adhesive, and the bonded polyurethane layer and the melamine foam layer are thermally fused together by heating in a temperature range of 80°C to 130°C.

2. The melamine foam composite polyurethane material as described in claim 1, characterized in that, The polyol is a mixture of polyether polyols, and the isocyanate is a mixture of aromatic isocyanates or a mixture of aliphatic isocyanates.

3. A method for manufacturing a melamine foam composite polyurethane material, characterized in that, In order, they include: In the mixing step, polyols with an OH value of 50 mg KOH / g to 300 mg KOH / g and isocyanates with an NCO value of 6% to 30% are mixed in a temperature range of 20°C to 60°C to form polyurethane raw materials; The coating step involves coating the polyurethane raw material in a layered coating manner to form a coating layer. The baking step involves heating the coating layer at a temperature range of 80°C to 130°C to form a polyurethane film. The bonding step involves directly bonding the melamine foam film onto the polyurethane film without adhesive; and In a combined step, the laminated polyurethane film and the melamine foam film are heated in a temperature range of 80°C to 130°C, so that the laminated polyurethane film and the melamine foam film form a thermal fusion bond, thereby obtaining the melamine foam composite polyurethane material.

4. The method for manufacturing the melamine foam composite polyurethane material as described in claim 3, characterized in that, In the mixing step, the polyol is a mixture of polyether polyols, and the isocyanate is a mixture of aromatic isocyanates or a mixture of aliphatic isocyanates.

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