Air-permeable sponge composition and method for preparing air-permeable sponge by using the same
An air-permeable sponge composition and a method for preparing an air-permeable sponge by using the same belong to the field of articles for daily use. An air-permeable sponge composition includes a sponge body and an air-permeable coating, and an outer surface layer of the sponge body being coated with the air-permeable coating. A method for making the air-permeable sponge utilizes the composition of the air-permeable sponge, wherein the air-permeable sponge is made from the air-permeable sponge composition under specific process parameters. The sponge body and air-permeable coating have the same or similar contents of isocyanate, polyether polyol and polymeric polyol and a similar porous structure.
1. An air-permeable sponge composition, comprising a sponge body and an air-permeable coating, wherein the outer surface layer of the sponge body is coated with the air-permeable coating; and components of the sponge body are, based on parts by weight, as follows:
isocyanate
10-50
a phase change material
0-40
polyether polyol
20-100
polymeric polyol
10-100
water
0.5-5
an amine-based catalyst
0.1-1
a tin-based catalyst
0.09-1
a silicone oil
0.3-3
cell-opener
0.01-5
a flame retardant
0.01-15
a cross-linking agent
0.01-3
components of the air-permeable coating are, based on parts by weight, as follows:
isocyanate
30-60
a phase change material
10-40
polyether polyol
30-90
polymeric polyol
10-80
water
0.01-1
an amine-based catalyst
0.3-0.4
a tin-based catalyst
0.2-0.25
a silicone oil
1-3;
the phase change material comprises paraffin, non-paraffin wax, crystalline hydrated salt or eutectic salt; contents of the isocyanate, polyether polyol and polymeric polyol of the sponge body and those of the air-permeable coating are the same; the density of the sponge body is 10-60 kg/m 3 ; the density of the air-permeable coating is 30-100 kg/m 3 .
2. The air-permeable sponge composition as claimed in claim 1 , wherein contents of components of the sponge body are, base on parts by weight, as follows:
isocyanate
32-50
a phase change material
0-25
polyether polyol
20-85
polymeric polyol
15-80
water
0.5-5
an amine-based catalyst
0.1-1
a tin-based catalyst
0.09-1
a silicone oil
0.3-3
cell-opener
0.1-5
a flame retardant
0.1-10
a cross-linking agent
0.05-1
components of the air-permeable coating are, based on parts by weight, as follows:
isocyanate
30-60
a phase change material
15-30
polyether polyol
30-90
polymeric polyol
10-80
water
1
an amine-based catalyst
0.3-0.4
a tin-based catalyst
0.2-0.25
a silicone oil
1.
3. The air-permeable sponge composition as claimed in claim 1 , wherein the air-permeable coating has a thickness of 0.1-0.3 mm.
4. The air-permeable sponge composition as claimed in claim 2 , wherein the air-permeable coating has a thickness of 0.1-0.3 mm.
5. The air-permeable sponge composition as claimed in claim 1 , wherein the air-permeable coating has a thickness of 0.2 mm.
6. The air-permeable sponge composition as claimed in claim 2 , wherein the air-permeable coating has a thickness of 0.2 mm.
7. The air-permeable sponge composition as claimed in claim 1 , wherein the crystalline hydrated salt comprises one or more of sodium sulfate decahydrate, magnesium chloride hexahydrate, calcium chloride hexahydrate, sodium acetate trihydrate or disodium phosphate dodecahydrate; the eutectic salt comprises one or more of polyoxyethylene ether, polyoxyethylene, polyoxypropylene-ethylene oxide copolyether, lithium sulphate, pentaerythritol, neopentyl glycol or dihydroxymethylpropanediol.
8. The air-permeable sponge composition as claimed in claim 2 , wherein the crystalline hydrated salt comprises one or more of sodium sulfate decahydrate, magnesium chloride hexahydrate, calcium chloride hexahydrate, sodium acetate trihydrate or disodium phosphate dodecahydrate; the eutectic salt comprises one or more of polyoxyethylene ether, polyoxyethylene, polyoxypropylene-ethylene oxide copolyether, lithium sulphate, pentaerythritol, neopentyl glycol or dihydroxymethylpropanediol.
9. The air-permeable sponge composition as claimed in claim 1 , wherein the isocyanate comprises one or more of TDI, MDI, PAPI, HDI or IPDI, and the NCO % content of the used isocyanate is 3-50%.
10. The air-permeable sponge composition as claimed in claim 2 , wherein the isocyanate comprises one or more of TDI, MDI, PAPI, HDI or IPDI, and the NCO % content of the used isocyanate is 3-50%.
11. The air-permeable sponge composition as claimed in claim 1 , wherein the polyether polyol comprises one or more of polyether polyols having a hydroxy value of 20-350 mgKOH/g; the polymeric polyol comprises one or more of polymeric polyols having a hydroxy value of 10-50 mgKOH/g.
12. The air-permeable sponge composition as claimed in claim 2 , wherein the polyether polyol comprises one or more of polyether polyols having a hydroxy value of 20-350 mgKOH/g; the polymeric polyol comprises one or more of polymeric polyols having a hydroxy value of 10-50 mgKOH/g.
13. The air-permeable sponge composition as claimed in claim 1 , wherein the amine-based catalyst comprises one or more amine-based or tertiary amine-based catalysts of triethylenediamine and (dimethylaminoethyl) ether, the tin-based catalyst comprises one or more tin-based catalysts of stannous octoate or dibutyltin dilaurate.
14. The air-permeable sponge composition as claimed in claim 2 , wherein the amine-based catalyst comprises one or more amine-based or tertiary amine-based catalysts of triethylenediamine and (dimethylaminoethyl) ether; the tin-based catalyst comprises one or more tin-based catalysts of stannous octoate or dibutyltin dilaurate.
15. The air-permeable sponge composition as claimed in claim 1 , wherein the silicone oil comprises a silicone oil of polyether-modified organosiloxane; the flame retardant comprises one or more of melamine tricresyl phosphate, triphenyl phosphite, dimethylmethylphosphonate, a composite phosphor-based flame retardant or a halogenated bisphosphonate compound reactive flame retardant; the cell-opener comprises one or more of liquid paraffin, polybutadiene, dimethylpolysiloxane, a paraffin dispersion, polyoxyethylene or polyoxyalkylene-polysiloxane copolymer; and the crosslinking agent comprises one or more of glycerol, diethanolamine or triethanolamine.
16. The air-permeable sponge composition as claimed in claim 2 , wherein the silicone oil comprises a silicone oil of polyether-modified organosiloxane; the flame retardant comprises one or more of melamine tricresyl phosphate, triphenyl phosphite, dimethylmethylphosphonate, a composite phosphor-based flame retardant or a halogenated bisphosphonate compound reactive flame retardant; the cell-opener comprises one or more of liquid paraffin, polybutadiene, dimethylpolysiloxane, a paraffin dispersion, polyoxyethylene or polyoxyalkylene-polysiloxane copolymer; and the crosslinking agent comprises one or more of glycerol, diethanolamine or triethanolamine.
17. A method for preparing an air-permeable sponge by using the air-permeable sponge composition as claimed in claim 1 , wherein the method comprises the steps of:
step 1), placing components of the sponge body into a reaction kettle according to the above-described parts by weight, mixing, stirring, foaming and curing; wherein a stirring speed is 3000-5000 r/min and a temperature is 18-25° C., a pressure is 0.1-0.3 MPa; an injected gas flow rate is 0.1-3 L/min, a foaming speed is 2-5 m/min, a foaming height is 30-110 cm; a curing temperature is 20-30° C., and a curing time is 50-80 h;
step 2), performing a stripping process on the cured sponge to obtain a first sponge body, which then is cut and processed as needed;
step 3), mixing and stirring uniformly components of the air-permeable coating according to the above-described parts by weight using a high-speed shear stirring process to obtain a first mixture, wherein a stirring speed is 1000 to 4000 r/min;
step 4), coating the first mixture obtained in step 3 on the first sponge body obtained in step 2 in 1-3 times and controlling a coating thickness to 0.03-0.3 mm; and drying the coating at a temperature of 30-90° C. for 1-10 min and then placing at room temperature to subsequently cure for 5-7 h, thereby obtaining an air-permeable sponge.