High-toughness sponge, preparation method therefor, and use thereof
By adding a tensile agent to form a cross-linked structure in the sponge raw material, the problem of sponge being easily damaged is solved, resulting in sponge products with high toughness and long lifespan, suitable for mattresses and other applications.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- SLEEMON HEALTHY SLEEP TECHNOLOGY CO LTD
- Filing Date
- 2025-10-13
- Publication Date
- 2026-06-25
Smart Images
Figure PCTCN2025127270-APPB-I100001
Abstract
Description
A tough sponge, its preparation method and application Technical Field
[0001] This invention belongs to the field of mattress materials, and specifically relates to a high-toughness sponge, its preparation method, and its application. Background Technology
[0002] Existing sponges have good elasticity and shock resistance. However, due to the soft material properties of ordinary sponges, they are more prone to collapse, resulting in a relatively short lifespan. The elongation at break of conventional sponges ranges from 140 to 230 mm. They are easily damaged and broken during use, and their lifespan is correspondingly shorter when used as mattresses. Summary of the Invention
[0003] To address the problem that existing sponges are prone to damage and breakage, resulting in a short service life, this invention provides a sponge with high toughness, its preparation method, and its application. By adding a tensile agent, a sponge with good toughness and meeting the requirements for use is prepared.
[0004] The technical solution adopted in this invention is as follows: a high-toughness sponge, the raw materials comprising, by mass, the following: polyol, 100 parts; isocyanate, index 0.85-1.05; amine catalyst, 0.2-0.5 parts; metal catalyst, 0.05-0.3 parts; organosilicon foam stabilizer, 0.3-1.5 parts; water, 1.2-4.5 parts; tensile agent, 0.8-3 parts; wherein, the hydroxyl value of the polyol is 20-80.
[0005] Tensile agents can form cross-linked structures between the raw materials used to prepare sponges, significantly enhancing the tensile and tear strength of the sponges, thereby helping to extend the service life of sponge products and reduce replacement frequency and costs.
[0006] Furthermore, the raw materials of the tensile agent are, by weight, 900-1200 parts of polyether polyol, 50-70 parts of crosslinking agent, 300-350 parts of isocyanate, and 5-10 parts of alkaline additive. The tensile agent used in this application is a liquid organic substance, which can be fully mixed with other raw materials, ensuring the uniform performance of the strong and resilient sponge of this application.
[0007] Furthermore, the polyol includes one or more of high-activity polyether polyols, ordinary polyether polyols, and grafted polyether polyols. High-activity polyether polyols (HAPP) are polyols measured by their epoxy value. Compared to polyester polyols, they exhibit high reactivity, good toughness, good processability, and lower cost. Their molecules contain multiple hydroxyl groups, which give them high reactivity, allowing them to undergo various chemical reactions with other compounds. Ordinary polyether polyols offer advantages such as abundant raw materials, good processability, excellent physical properties, high chemical stability, environmental friendliness, wide application range, and cost-effectiveness.
[0008] Furthermore, the isocyanate is at least one of industrial-grade TDI-80 and MDI.
[0009] Furthermore, the silicone foam stabilizer is one or more of BF2370, B8295, and C8139. The silicone foam stabilizer can significantly reduce the surface tension of the foaming liquid, thereby generating a large number of fine and uniformly distributed bubbles. These bubbles, under the action of the stabilizer, can maintain stability for a longer period of time and are not easily broken or collapsed. Simultaneously, it can automatically repair weak points in the cell walls, further enhancing the stability and durability of the foam. During the foaming process, the silicone foam stabilizer can emulsify and solubilize various raw materials, making the chemical reactions between them more uniform and effective. This helps to generate foam plastics with excellent cell structure, mechanical strength, air permeability, and thermal conductivity. In addition, it can improve the elasticity and tensile strength of the foam, giving it better physical properties and service life. Using silicone foam stabilizers can significantly improve production efficiency. Because it can stabilize the foam structure and improve foaming quality, it can reduce the scrap rate and rework rate during the production process. At the same time, it can also improve equipment utilization and automation, reducing production costs and energy consumption.
[0010] Furthermore, the elongation at break of the highly resilient foam is 300-360 mm. Good breaking and tensile properties mean a more robust structure, less prone to cracking or tearing with prolonged use, significantly extending the mattress's lifespan. Strong structural stability means the foam is not easily torn or broken under external forces, ensuring the mattress maintains a stable structure under various usage conditions and preventing destructive changes within the mattress. Excellent tensile properties allow it to maintain its shape and function under high loads and frequent use, preventing collapse or deformation over time. It quickly returns to its original shape after being compressed or stretched, ensuring consistent support and comfort with every use.
[0011] This application also proposes a highly resilient sponge and a method for preparing the same, comprising the following steps:
[0012] Step 1, Preparation of tensile agent: Stir the tensile agent raw materials according to the mass parts to allow them to react fully, and then obtain a liquid tensile agent, which is then sealed for later use;
[0013] Step 2, Mix and stir: Mix and stir the raw materials according to the above-mentioned raw material components of the tough sponge;
[0014] Step 3, foaming: The mixture is poured into the mold, foaming is completed, and after maturation, a high-toughness sponge is obtained.
[0015] Liquid tensile agents can fully contact and react with the raw materials of the sponge, giving the product ideal toughness and strength to meet usage requirements.
[0016] This application also protects the use of a resilient sponge in mattresses.
[0017] The beneficial effects of this invention are as follows: This application relates to a highly resilient sponge, its preparation method, and its application. The resulting sponge has good breaking and tensile properties, is not easily broken or torn due to long-term use, has strong structural stability, is not prone to destructive changes internally, and has excellent tensile properties. It can maintain its shape and function under high load and frequent use, and will not collapse or deform due to long-term use. In addition, the sponge of this application has an ideal service life when used as a mattress. Embodiments of the present invention
[0018] The technical solutions of the embodiments of the present invention will be explained and described below with reference to the accompanying drawings. 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.
[0019] Example 1:
[0020] A high-toughness sponge, comprising the following raw materials by weight: 60 parts of highly active polyether polyol; 20 parts of grafted polyether polyol; 20 parts of ordinary polyether polyol; TDI-80 index of isocyanate, 100; 0.35 parts of amine catalyst; 0.1 parts of metal catalyst; 0.8 parts of silicone foam stabilizer BF2370; 0.5 parts of silicone foam stabilizer B8295; 2.9 parts of water; and 0.8 parts of tensile agent. The highly active polyether polyol has a hydroxyl value of 40-45, the grafted polyether polyol has a hydroxyl value of 26-30, and the ordinary polyether polyol has a hydroxyl value of 52-58.
[0021] The preparation method is as follows:
[0022] Step 1, Preparation of tensile agent: The raw materials of the tensile agent are as follows by weight: 1000 parts of polyether polyol, 50 parts of triethanolamine, 300 parts of isocyanate (TDI-80), and 5 parts of NaOH; stir thoroughly and react to obtain a liquid tensile agent, which is then sealed and stored for later use.
[0023] Step 2, Mix and stir: Mix and stir the raw materials according to the above-mentioned mass proportions;
[0024] Step 3, foaming: The mixture is poured into the mold, foaming is completed, and after maturation, a high-toughness sponge is obtained.
[0025] Example 2:
[0026] A high-toughness sponge, comprising the following raw materials by weight: 60 parts of highly active polyether polyol; 20 parts of grafted polyether polyol; 20 parts of ordinary polyether polyol; TDI-80 index of isocyanate, 100; 0.35 parts of amine catalyst; 0.1 parts of metal catalyst; 0.8 parts of silicone foam stabilizer BF2370; 0.5 parts of silicone foam stabilizer B8295; 2.9 parts of water; and 1 part of tensile agent. The highly active polyether polyol has a hydroxyl value of 40-45, the grafted polyether polyol has a hydroxyl value of 26-30, and the ordinary polyether polyol has a hydroxyl value of 52-58.
[0027] Except for the different raw material components, the rest of the preparation process is the same as in Example 1.
[0028] Example 3:
[0029] A high-toughness sponge, comprising the following raw materials by weight: 60 parts of highly active polyether polyol; 20 parts of grafted polyether polyol; 20 parts of ordinary polyether polyol; TDI-80 index of isocyanate, 100; 0.35 parts of amine catalyst; 0.1 parts of metal catalyst; 0.8 parts of silicone foam stabilizer BF2370; 0.5 parts of silicone foam stabilizer B8295; 2.9 parts of water; and 2 parts of tensile agent. The highly active polyether polyol has a hydroxyl value of 40-45, the grafted polyether polyol has a hydroxyl value of 26-30, and the ordinary polyether polyol has a hydroxyl value of 52-58.
[0030] Except for the different raw material components, the rest of the preparation process is the same as in Example 1.
[0031] Example 4:
[0032] A high-toughness sponge, comprising the following raw materials by weight: 60 parts of highly active polyol; 20 parts of grafted polyether polyol; 20 parts of ordinary polyether polyol; TDI-80 index of isocyanate, 100; 0.35 parts of amine catalyst; 0.1 parts of metal catalyst; 0.8 parts of silicone foam stabilizer BF2370; 0.5 parts of silicone foam stabilizer B8295; 2.9 parts of water; and 3 parts of tensile agent. The highly active polyether polyol has a hydroxyl value of 40-45, the grafted polyether polyol has a hydroxyl value of 26-30, and the ordinary polyether polyol has a hydroxyl value of 52-58.
[0033] Except for the different raw material components, the rest of the preparation process is the same as in Example 1.
[0034] Example 5:
[0035] A high-toughness sponge, comprising the following raw materials by weight: 60 parts of highly active polyol; 20 parts of grafted polyether polyol; 20 parts of ordinary polyether polyol; TDI-80 index of isocyanate, 105; 0.3 parts of amine catalyst; 0.05 parts of metal catalyst; 0.8 parts of silicone foam stabilizer BF2370; 0.5 parts of silicone foam stabilizer B8295; 2.9 parts of water; and 1.5 parts of tensile agent. The highly active polyether polyol has a hydroxyl value of 40-45, the grafted polyether polyol has a hydroxyl value of 26-30, and the ordinary polyether polyol has a hydroxyl value of 52-58.
[0036] Except for the different raw material components, the rest of the preparation process is the same as in Example 1.
[0037] Example 6:
[0038] A high-strength sponge, comprising the following raw materials by weight: 60 parts of highly active polyol; 20 parts of grafted polyether polyol; 20 parts of ordinary polyether polyol; MDI index of isocyanate, 85; 0.3 parts of amine catalyst; 0.05 parts of metal catalyst; 0.8 parts of silicone foam stabilizer BF2370; 0.5 parts of silicone foam stabilizer B8295; 2.9 parts of water; and 1.5 parts of tensile agent. The highly active polyether polyol has a hydroxyl value of 40-45, the grafted polyether polyol has a hydroxyl value of 26-30, and the ordinary polyether polyol has a hydroxyl value of 52-58.
[0039] Except for the different raw material components, the rest of the preparation process is the same as in Example 1.
[0040] Example 7:
[0041] A high-strength sponge, comprising the following raw materials by weight: 60 parts of highly active polyol; 20 parts of grafted polyether polyol; 20 parts of ordinary polyether polyol; TDI-80 index of isocyanate, 105; 0.4 parts of amine catalyst; 0.2 parts of metal catalyst; 1.0 part of silicone foam stabilizer C8139; 3.0 parts of water; and 2 parts of tensile agent. The highly active polyether polyol has a hydroxyl value of 40-45, the grafted polyether polyol has a hydroxyl value of 26-30, and the ordinary polyether polyol has a hydroxyl value of 52-58.
[0042] Except for the different raw material components, the rest of the preparation process is the same as in Example 1.
[0043] Example 8:
[0044] A high-strength sponge, comprising the following raw materials by weight: 60 parts of highly active polyol; 20 parts of grafted polyether polyol; 20 parts of ordinary polyether polyol; TDI-80 index of isocyanate, 85; 0.5 parts of amine catalyst; 0.05 parts of metal catalyst; 0.3 parts of silicone foam stabilizer C8139; 1.2 parts of water; and 1.0 part of tensile agent. The highly active polyether polyol has a hydroxyl value of 40-45, the grafted polyether polyol has a hydroxyl value of 26-30, and the ordinary polyether polyol has a hydroxyl value of 52-58.
[0045] The preparation method is as follows:
[0046] Step 1, Preparation of tensile agent: The raw materials of the tensile agent are as follows by weight: 1200 parts of polyether polyol, 50 parts of triethanolamine, 350 parts of isocyanate (TDI-80), and 10 parts of NaOH; stir thoroughly and react to obtain a liquid tensile agent, which is then sealed and stored for later use.
[0047] Step 2, Mix and stir: Mix and stir the raw materials according to the above-mentioned mass proportions;
[0048] Step 3, foaming: The mixture is poured into the mold, foaming is completed, and after maturation, a high-toughness sponge is obtained.
[0049] Example 9:
[0050] A high-strength sponge, comprising the following raw materials by weight: 60 parts of highly active polyol; 20 parts of grafted polyether polyol; 20 parts of ordinary polyether polyol; TDI-80 index of isocyanate, 105; 0.2 parts of amine catalyst; 0.3 parts of metal catalyst; 1.5 parts of silicone foam stabilizer C8139; 4.5 parts of water; and 3.0 parts of tensile agent. The highly active polyether polyol has a hydroxyl value of 40-45, the grafted polyether polyol has a hydroxyl value of 26-30, and the ordinary polyether polyol has a hydroxyl value of 52-58.
[0051] The preparation method is as follows:
[0052] Step 1, Preparation of tensile agent: The raw materials of the tensile agent are as follows by weight: 1000 parts of polyether polyol, 70 parts of triethanolamine, 350 parts of isocyanate (TDI-80), and 10 parts of NaOH; stir thoroughly and react to obtain a liquid tensile agent, which is then sealed and stored for later use.
[0053] Step 2, Mix and stir: Mix and stir the raw materials according to the above-mentioned mass proportions;
[0054] Step 3, foaming: The mixture is poured into the mold, foaming is completed, and after maturation, a high-toughness sponge is obtained.
[0055] Comparative Example 1:
[0056] The raw materials in this embodiment, by weight, include: 60 parts of highly active polyether polyol; 20 parts of grafted polyether polyol; 20 parts of ordinary polyether polyol; TDI-80 index of isocyanate, 100; 0.3 parts of amine catalyst; 0.15 parts of metal catalyst; 0.8 parts of silicone foam stabilizer BF2370; 0.5 parts of silicone foam stabilizer B8295; 2.9 parts of water; and 0 parts of tensile agent. The highly active polyether polyol has a hydroxyl value of 40-45, the grafted polyether polyol has a hydroxyl value of 26-30, and the ordinary polyether polyol has a hydroxyl value of 52-58.
[0057] Except for the absence of a tensile agent, the preparation process is the same as in Example 1.
[0058] [According to Rule 26, amended 24.10.2025] The performance of the products of Examples 1 to 6 was tested using the standard GB / T10802-2023 for general flexible polyurethane foams, and the results are shown in the table.
[0059] [Revised according to Rule 26, dated October 2025]
[0060] As can be seen from the table:
[0061] 1. By comparing Comparative Example 1 with Example 1, it can be seen that by adding a tensile agent, the tensile strength and elongation at break of the sponge can be significantly improved. Specifically, the tensile strength is increased from 95 kPa to 108 kPa, and the elongation at break is increased from 180% to 316%.
[0062] 2. To further verify the physical properties of the tensile agent at different dosages, Examples 2, 3, and 4 were conducted. Analysis of the test data showed that as the amount of tensile agent increased, the tensile strength increased from 110 kPa to 128 kPa, and the elongation at break increased from 319% to 333%, with all data increasing synchronously.
[0063] 3. To further verify the effect of using different indexes of TDI and MDI on tensile strength in the formulation, Examples 5 and 6 were conducted. Analysis of the test data showed that the tensile strength of the sponge in the MDI system was lower than that in the TDI system, but the elongation at break of both exceeded 300%.
[0064] 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 contents described in the accompanying drawings and the specific embodiments above. 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 highly resilient sponge, characterized in that, Raw materials, by mass parts, include: Polyols, 100 parts; Isocyanates, index 0.85-1.05; Amine catalyst, 0.2-0.5 parts; Metal catalyst, 0.05-0.3 parts; Organosilicon foam stabilizer, 0.3-1.5 parts; Water, 1.2-4.5 parts; Tensioning agent, 0.8-3 parts; The hydroxyl value of the polyol is 20 to 80.
2. The high-toughness sponge according to claim 1, characterized in that, The raw materials of the tensile agent are as follows by weight: 900-1200 parts of polyether polyol, 50-70 parts of crosslinking agent, 300-350 parts of isocyanate, and 5-10 parts of alkaline additive.
3. The high-toughness sponge according to claim 1 or 2, characterized in that, The polyols include one or more of highly active polyether polyols, ordinary polyether polyols, and grafted polyether polyols.
4. The high-toughness sponge according to claim 1 or 2, characterized in that, The isocyanate is at least one of industrial-grade TDI-80 and MDI.
5. The high-toughness sponge according to claim 1 or 2, characterized in that, The silicone foam stabilizer is one or more of BF2370, B8295, and C8139.
6. The high-toughness sponge according to claim 1 or 2, characterized in that, The elongation at break of the highly resilient sponge is 300-360.
7. A method for preparing the tough sponge according to any one of claims 1 to 6, characterized in that, Includes the following steps: Step 1, Preparation of tensile agent: Stir the tensile agent raw materials according to the mass parts to allow them to react fully, and then obtain a liquid tensile agent, which is then sealed for later use; Step 2, Mix and stir: Mix and stir the raw materials according to the components of a tough sponge; Step 3, foaming: The mixture is poured into the mold, foaming is completed, and after maturation, a high-toughness sponge is obtained.
8. The application of the resilient sponge according to any one of claims 1 to 6 in mattresses.