Melamine foam composite polyurethane material and manufacturing method thereof

Abstract

A melamine foam composite polyurethane material comprises: 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 it 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.

Claims

1. 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 it 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.

2. The melamine foam composite polyurethane material as described in claim 1, wherein 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, comprising the following steps: a mixing step, 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 to form a polyurethane raw material; a coating step, coating the polyurethane raw material in a layered manner to form a coating layer; a baking step, heating the coating layer at a temperature range of 80°C to 130°C to form a polyurethane film; a laminating step, directly laminating the melamine foam film onto the polyurethane film without adhesive; and a bonding step, heating the laminated polyurethane film and the melamine foam film at 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.

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

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