阅读说明：本技术 作为吸音材料的低密度聚氨酯泡沫组合物，制造聚氨酯泡沫的方法和由其制造的聚氨酯泡沫 (Low density polyurethane foam composition as sound absorbing material, method of making polyurethane foam and polyurethane foam made therefrom ) 是由 李廷勖 金世勋 金智婉 李晋馨 金成制 金大镛 柳钟铉 李明植 禹旼序 于 2020-08-27 设计创作，主要内容包括：本申请公开了作为吸音材料的低密度聚氨酯泡沫组合物、制造聚氨酯泡沫的方法和由其制造的聚氨酯泡沫。具体地,公开了一种包含包括多元醇和添加剂的多元醇混合物以及异氰酸酯的组合物,和用于吸音材料的低密度聚氨酯泡沫的制造,该吸音材料通过控制组合物的含量和用于发泡组合物的条件而被赋予了改进的外观可成形性、降低的气味和增强的吸音性能。(Disclosed herein are low density polyurethane foam compositions as sound absorbing materials, methods of making polyurethane foams, and polyurethane foams made therefrom. Specifically, disclosed is a composition comprising a polyol mixture including a polyol and an additive, and an isocyanate, and the manufacture of a low-density polyurethane foam for a sound-absorbing material, which is imparted with improved appearance formability, reduced odor, and enhanced sound-absorbing performance by controlling the content of the composition and conditions for foaming the composition.)

1. A low density polyurethane foam composition for sound absorbing materials comprising:

a polyol mixture comprising a polyol and at least one additive selected from the group consisting of catalysts, cell openers, chain extenders, cross-linkers, blowing agents, surfactants, reducing agents, and combinations thereof; and

an isocyanate compound selected from the group consisting of,

wherein the catalyst comprises a gelling catalyst and a blowing catalyst.

2. The low density polyurethane foam composition of claim 1, wherein the polyol comprises:

a first polyol having a molecular weight of 5,500 to 6,500 and a hydroxyl number of 26 to 30 and containing 14 to 16% ethylene oxide; and

a second polyol having a molecular weight of 500 to 1,500 and a hydroxyl number of 110 to 114.

3. The low-density polyurethane foam composition of claim 1, wherein the catalyst comprises a gelling catalyst comprising at least one of a primary or secondary alcohol; and

a blowing catalyst comprising at least one of a primary or secondary alcohol.

4. The low density polyurethane foam composition of claim 1, wherein

The gelling catalyst comprises at least one of 1, 4-diazabicyclo [2,2,2] octane-2-methanol, N- (3-dimethylaminopropyl) -N, N-diisopropanolamine or N, N-bis (3-dimethylaminopropyl) -N-isopropanolamine, and

the blowing catalyst includes at least one of N, N, N '-trimethyl-N' -hydroxyethyl-bis (aminoethyl) ether or N, N-dimethylethanolamine.

5. The low density polyurethane foam composition of claim 1 wherein the cell opener has a molecular weight of 3,800 to 4,600 and a hydroxyl number of 37 to 43 and comprises 65 to 75 wt% ethylene oxide.

6. The low-density polyurethane foam composition of claim 1, wherein the cell opener comprises at least one of propoxylated glycerin, ethoxylated glycerin, or propoxylated-ethoxylated glycerin copolymer.

7. A low density polyurethane foam composition as set forth in claim 1 wherein said chain extender has a molecular weight of from 350 to 450 and a hydroxyl number of from 270 to 290.

8. The low density polyurethane foam composition of claim 1 wherein the crosslinker has a molecular weight of 100 to 110 and a hydroxyl number of 1,600 to 1,650.

9. The low-density polyurethane foam composition of claim 1, wherein the blowing agent has a molecular weight of 10 to 30 and a hydroxyl number of 6,230 to 6,235.

10. The low density polyurethane foam composition of claim 1 wherein the polyol mixture comprises 19.8 to 24.0 parts by weight of the additive based on 100 parts by weight of the polyol.

11. The low density polyurethane foam composition of claim 1 wherein the polyol mixture comprises, based on 100 parts by weight of the polyol:

4.4 to 6.4 parts by weight of the cell opener;

3.3 to 4.3 parts by weight of the catalyst;

1.0 to 1.4 parts by weight of the chain extender;

0.55 to 0.65 parts by weight of the crosslinking agent;

4.85 to 4.95 parts by weight of the blowing agent;

3.4 to 4.4 parts by weight of the surfactant; and

2.3 to 2.5 parts by weight of the reducing agent.

12. The low-density polyurethane foam composition according to claim 1, wherein the polyol mixture comprises 3.0 to 3.8 parts by weight of the gelling catalyst and 0.3 to 0.5 parts by weight of the blowing catalyst, based on 100 parts by weight of the polyol.

13. The low density polyurethane foam composition of claim 2, wherein the polyol comprises from 92 to 94 wt% of the first polyol and from 6 to 8 wt% of the second polyol.

14. A low density polyurethane foam composition as set forth in claim 1 wherein said polyurethane foam composition comprises said isocyanate in an amount of from 40 to 60 parts by weight based on 100 parts by weight of said polyol mixture.

15. A method of making a low density polyurethane foam for sound absorbing materials comprising:

adding an additive to a polyol to produce a polyol mixture;

adding an isocyanate to the polyol mixture to produce a polyurethane foam composition; and

foaming the polyurethane foam composition, and then,

wherein the catalyst comprises a gelling catalyst and a blowing catalyst.

16. The method of claim 15, wherein after the additive is added to the polyol, the polyol mixture is stirred at 1,500 to 1,800rpm for 30 to 60 minutes, and

after the isocyanate is added to the polyol mixture, the polyurethane foam composition is stirred at 6,000 to 8,000 rpm.

17. The method of claim 15, wherein the polyurethane foam composition is foamed in a mold,

the foaming pressure is from 120 to 160bar,

the polyurethane foam composition has a temperature of 18 to 28 ℃, and

the temperature of the mold is 50 to 70 ℃.

18. A low density polyurethane foam for sound absorbing material made by the process of claim 15, having less than 75kg/m³The density of (c).

Technical Field

The present disclosure relates to a polyurethane foam composition for a sound-absorbing material, a method of manufacturing a polyurethane foam, and a polyurethane foam manufactured using the method. More particularly, the present disclosure relates to a composition comprising a polyol mixture containing a polyol and an additive, and an isocyanate, and the manufacture of a low-density polyurethane foam for a sound-absorbing material, which imparts improved appearance formability, reduced odor, and enhanced sound-absorbing performance by controlling the content of the composition and the foaming conditions of the composition.

Background

The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

In order to reduce the weight of the automobile, the physical properties of the lightweight alternative material should be comparable to or superior to conventional materials.

In particular, physical fluidity related to the viscosity of the raw material (crude) solution and chemical fluidity related to foaming reaction behavior are very important for the molding of instrument panel insulation (iso) pads, since these factors may cause defects in the unformed end part during foam molding. When the molding problem is solved by increasing the feed weight, the weight of the product increases, whereby it is difficult to achieve weight reduction.

In general, the cell structure of the polyurethane foam constituting for increased sound absorption should be designed such that more open cells (continuous foam) are present than closed cells (single foam), and a higher density is advantageous.

Meanwhile, automotive interior materials are advantageous when they are light in the range of maintaining performance. As the weight of interior materials, including instrument panel spacers, increases, the weight of the vehicle body also increases, which adversely affects fuel economy. Therefore, there is still a need to develop a high-foaming polyurethane foam satisfying formability in spite of an increase in manufacturing cost due to its weight.

For this reason, a method of reducing the weight of the interior material has been studied, but for polyurethane foam for instrument panel insulation, simply increasing the content of the blowing agent to reduce the density may reduce the formability and fail to satisfy the appearance, and result in reduced sound absorption properties and physical properties such as tensile strength and tear strength.

Meanwhile, in order to improve sound absorption properties, fillers such as carbon nanotubes, calcium carbonate, graphite and magnesium hydroxide are generally used in polyurethane foam compositions, but such fillers may cause problems such as formation of precipitates or layer separation in polyurethane foam compositions.

The above information disclosed in this background section is only for enhancement of understanding of the background of the disclosure and therefore may contain information that does not form the prior art that is already known to a person of ordinary skill in this country.

Disclosure of Invention

The present disclosure is directed to solving the above-mentioned problems associated with the prior art.

The present disclosure provides a polyurethane foam having a low density, satisfactory mold formability, and improved sound absorption properties as compared to conventional polyurethane foams.

The present disclosure provides a method for improving sound absorption without using fillers such as carbon nanotubes, calcium carbonate, graphite, and magnesium hydroxide, which are generally used to improve sound absorption properties.

The present disclosure provides polyurethane foams having reduced odor.

The present disclosure is not limited to those described above. The present disclosure will be clearly understood from the following description, and may be embodied by the means defined in the present invention and combinations thereof.

In one aspect, the present disclosure provides a low density polyurethane foam composition for sound absorbing materials comprising a polyol mixture comprising a polyol and at least one additive selected from the group consisting of a catalyst, a cell opener, a chain extender, a crosslinker, a blowing agent, a surfactant, a reducing agent, and combinations thereof, and an isocyanate, wherein the catalyst comprises a gelling catalyst and a blowing catalyst.

The polyols may include a first polyol having a molecular weight of 5,500 to 6,500 and a hydroxyl (OH) value of 26 to 30 and containing 14 to 16% Ethylene Oxide (EO), and a second polyol having a molecular weight of 500 to 1,500 and a hydroxyl value of 110 to 114.

The catalyst may include a gelling catalyst comprising at least one of a primary alcohol and a secondary alcohol and a blowing catalyst comprising at least one of a primary alcohol and a secondary alcohol.

The gelling catalyst may include at least one of 1, 4-diazabicyclo [2,2,2] octane-2-methanol, N- (3-dimethylaminopropyl) -N, N-diisopropanolamine or N, N-bis (3-dimethylaminopropyl) -N-isopropanolamine, and the blowing catalyst may include at least one of N, N '-trimethyl-N' -hydroxyethyl-bis (aminoethyl) ether or N, N-dimethylethanolamine.

The cell opener can have a molecular weight of 3,800 to 4,600 and a hydroxyl number of 37 to 43, and comprise 65 to 75 weight percent Ethylene Oxide (EO).

The cell opener can include at least one of propoxylated glycerin, ethoxylated glycerin, or propoxylated-ethoxylated glycerin copolymer.

The chain extender may have a molecular weight of 350 to 450 and a hydroxyl number of 270 to 290.

The crosslinker may have a molecular weight of 100 to 110 and a hydroxyl number of 1,600 to 1,650.

The blowing agent can have a molecular weight of 10 to 30 and a hydroxyl number of 6,230 to 6,235.

The polyol mixture may include 19.8 to 24.0 parts by weight of the additive based on 100 parts by weight of the polyol.

The polyol mixture may include 4.4 to 6.4 parts by weight of a cell opener, 3.3 to 4.3 parts by weight of a catalyst, 1.0 to 1.4 parts by weight of a chain extender, 0.55 to 0.65 parts by weight of a cross-linking agent, 4.85 to 4.95 parts by weight of a blowing agent, 3.4 to 4.4 parts by weight of a surfactant, and 2.3 to 2.5 parts by weight of a reducing agent, based on 100 parts by weight of the polyol.

The polyol mixture may include 3.0 to 3.8 parts by weight of a gelling catalyst and 0.3 to 0.5 parts by weight of a blowing catalyst, based on 100 parts by weight of the polyol.

The polyols may include 92 to 94 wt% of the first polyol and 6 to 8 wt% of the second polyol.

The polyurethane foam composition may include 40 to 60 parts by weight of isocyanate based on 100 parts by weight of the polyol mixture.

In another aspect, the present disclosure also provides a method of manufacturing a low density polyurethane foam for a sound absorbing material, the method comprising adding an additive to a polyol to prepare a polyol mixture, adding an isocyanate to the polyol mixture to prepare a polyurethane foam composition, and foaming the polyurethane foam composition, wherein the catalyst comprises a gelling catalyst and a foaming catalyst.

After the additives are added to the polyol, the polyol mixture may be stirred at 1,500 to 1,800rpm for 30 to 60 minutes, and after the isocyanate is added to the polyol mixture, the polyurethane foam composition may be stirred at 6,000 to 8,000 rpm.

The polyurethane foam composition may be foamed in a mold, the foaming pressure may be 120 to 160bar, the temperature of the polyurethane foam composition may be 18 to 28 ℃, and the temperature of the mold may be 50 to 70 ℃.

In another aspect, the present invention provides a low density polyurethane foam for sound absorbing material manufactured by the method, having less than 75kg/m³The density of (c).

Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

Drawings

In order that the disclosure may be fully understood, various forms thereof will now be described by way of example and with reference to the accompanying drawings, in which:

FIG. 1 shows the appearance and cross-sectional view of polyurethane foams produced using the polyurethane foam compositions of example 1 and comparative examples 1 to 4;

FIG. 2 shows the appearance of a polyurethane foam produced in the form of an instrument panel insulation pad using the polyurethane foam composition of comparative example 1; and

fig. 3 shows the appearance of a polyurethane foam manufactured in the form of an instrument panel insulation pad using the polyurethane foam composition of example 2.

The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

Detailed Description

The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. In the drawings, the size of structures may be exaggerated for clarity. It will be understood that, although the terms "first," "second," etc. may be used herein to describe various elements, these elements should not be construed as limited by these terms, which are used merely to distinguish one element from another. For example, a "first" element may be termed a "second" element, and, similarly, a "second" element may be termed a "first" element, within the scope of the present disclosure. The singular is intended to include the plural unless the context clearly dictates otherwise.

It will be further understood that the terms "comprises" and/or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, components, or groups thereof, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, or groups thereof. In addition, it will be understood that when an element such as a layer, film, region or substrate is referred to as being "on" another element, it can be directly on the other element or intervening elements may also be present. It will also be understood that when an element such as a layer, film, region or substrate is referred to as being "under" another element, it can be directly under the other element or intervening elements may also be present.

Unless the context clearly dictates otherwise, all numbers, figures and/or expressions which represent ingredients, reaction conditions, polymer compositions and amounts of mixtures in this specification are approximations and others which reflect the various measurement uncertainties inherent in obtaining such figures. For this reason, it should be understood that in all instances, the term "about" should be interpreted as modifying all numbers, figures, and/or expressions. Further, when numerical ranges are disclosed in the specification, unless otherwise defined, the ranges are continuous and include all numbers from minimum to maximum, including the maximum value within each range. Further, when a range is an integer, unless otherwise defined, it includes all integers from the minimum to the maximum, including the maximum within the range.

It should be understood that in this specification, when reference is made to a range for a parameter, the parameter encompasses all numbers including endpoints disclosed within the range. For example, a range of "5 to 10" includes numbers from 5, 6, 7, 8, 9, and 10, as well as any subrange, such as the range of 6 to 10, 7 to 10, 6 to 9, 7 to 9, and any number between suitable integers within the range, such as 5.5, 6.5, 7.5, 5.5 to 8.5, and 6.5 to 9. Further, for example, a range of "10% to 30%" encompasses all integers, including numbers such as 10%, 11%, 12%, and 13% and 30%, and any subrange from 10% to 15%, 12% to 18%, or 20% to 30%, and any number between suitable integers within that range, such as 10.5%, 15.5%, and 25.5%.

The present disclosure relates to a low-density polyurethane foam composition for a sound-absorbing material having excellent appearance formability, reduced odor, and enhanced sound-absorbing performance, a method for manufacturing a polyurethane foam, and a polyurethane foam manufactured by the method.

The low density polyurethane foam composition according to the present invention includes a polyol mixture including a polyol and at least one additive selected from the group consisting of a catalyst, a cell opener, a chain extender, a cross-linker, a blowing agent, a surfactant, a reducing agent, and combinations thereof, and an isocyanate.

The polyol of the present disclosure is an organic compound having two or more hydroxyl groups (-OH) at its terminal, and is a main component for achieving the properties of the polyurethane foam of the present disclosure.

The polyols include a first polyol having a molecular weight of 5,500 to 6,500 and a hydroxyl (OH) value of 26 to 30 and containing 14 to 16% Ethylene Oxide (EO) and a second polyol having a molecular weight of 500 to 1,500 and a hydroxyl value of 110 to 114.

The first polyol preferably has trifunctional groups and the second polyol preferably has difunctional groups.

The polyols of the present disclosure include 92 to 94 wt% of a first polyol and 6 to 8 wt% of a second polyol.

Catalysts of the present disclosure include gelling catalysts and blowing catalysts.

The gelling catalyst includes at least one of a primary or secondary alcohol, and the blowing catalyst includes at least one of a primary or secondary alcohol.

More specifically, the gelling catalyst is a catalyst for promoting the reaction between the polyol and the isocyanate (gelling reaction), and preferably includes at least one of 1, 4-diazabicyclo [2,2,2] octane-2-methanol, N- (3-dimethylaminopropyl) -N, N-diisopropanolamine or N, N-bis (3-dimethylaminopropyl) -N-isopropanolamine.

The blowing catalyst is a catalyst for promoting the reaction (saturation reaction) of isocyanate with water, and preferably includes at least one of N, N '-trimethyl-N' -hydroxyethyl-bis (aminoethyl) ether or N, N-dimethylethanolamine.

In the present disclosure, the gelling catalyst is present in an amount of 3.0 to 3.8 parts by weight, preferably 3.0 to 3.5 parts by weight, and more preferably 3.0 to 3.2 parts by weight, based on 100 parts by weight of the polyol of the present disclosure. When the content of the gelling catalyst is less than 3.0 parts by weight, there is a problem of curability due to insufficient gelling reaction of the polyurethane foam of the present disclosure, and when the content of the gelling catalyst is more than 3.8 parts by weight, the gelling reaction is promoted, flowability is deteriorated, density is increased, and the odor-reducing effect and economic efficiency of the catalyst are thereby deteriorated.

The blowing catalyst is present in an amount of 0.3 to 0.5 parts by weight based on 100 parts by weight of the polyol. When the content of the foaming catalyst is less than 0.3 parts by weight, foaming efficiency is reduced due to delayed saturation reactivity of the polyurethane foam, and collapse of the interior of the foam due to insufficient partial curing may result in defects during molding, such as poor appearance or failure in molding due to cell aggregation and cracking of interfered portions. When the foaming catalyst is present in an amount of more than 0.5 parts by weight, the shape of cells is elongated in the foaming direction due to excessive saturation (gelation) of the polyurethane foam, thereby increasing the generation of cells (voids) and accelerating the internal reaction of the polyurethane foam to increase the number of closed cells. This may cause deterioration of sound absorption performance due to shrinkage and reduction in openness.

The cell opener of the present disclosure functions to partially finely open cells formed inside the foam, and has a molecular weight of 3,800 to 4,600, a trifunctional group, and a hydroxyl value of 37 to 43, and contains Ethylene Oxide (EO) in an amount of 65 to 75 wt%.

For example, the cell opener of the present disclosure may include at least one of propoxylated glycerin, ethoxylated glycerin, or propoxylated-ethoxylated glycerin copolymer, and preferably includes propoxylated-ethoxylated glycerin copolymer.

The cell opener is present in an amount of 4.4 to 6.4 parts by weight based on 100 parts by weight of the polyol of the present disclosure. When the cell opener is present in an amount of less than 4.4 parts by weight, the polyurethane foam shrinks due to an increase in the number of closed cells, whereas when the content of the blowing agent of the present invention satisfies 4.85 parts by weight or more based on 100 parts by weight of the polyol, the polyurethane foam cannot withstand an excessive amount of gas (CO) during foaming₂) And the interior thereof collapses and 5% or more of the polyurethane foam is settled after foaming, resulting in deterioration of the overall foaming efficiency, increase of the foam density and reduction of the sound absorption performance. In addition, when the cell opener exceeds 6.4 parts by weight based on 100 parts by weight of the polyol and the content of the blowing agent satisfies 4.85 parts by weight or more, the number of irregular open cells increases as the content of the cell opener increases, and the cell size increases due to the generation of a large amount of gas during the foaming reaction, resulting in the formation of more voids, the sedimentation ratio after foaming is 5% or more due to excessive open cells, and the foaming efficiency is lowered. Therefore, the sound absorbing path may be relatively short and the sound absorbing performance may be reduced as compared to the fine and uniform cell opening state.

Chain extenders are substances that extend the polymer backbone and are used in the present disclosure to impart chemical flow and cell stability. The chain extenders of the present disclosure preferably have a molecular weight of 350 to 450, difunctional and hydroxyl number of 270 to 290.

The chain extender is present in the polyol mixture of the present disclosure in an amount of 0.5 to 1 weight percent.

The chain extender of the present disclosure may be used in the technical field of polyurethane foam, and may be used without particular limitation as long as the conditions of the chain extender are satisfied.

A cross-linking agent is a substance used to form polymer chains in the form of branched or network (mesh) structures. In the present disclosure, a crosslinker is used to impart firmness and cell stability to a polyurethane foam. The crosslinking agents of the present disclosure preferably have a molecular weight of 100 to 110, a trifunctional group, and a hydroxyl number of 1,600 to 1,605.

In the polyol mixtures of the present disclosure, the crosslinking agent is present in an amount of 0.5 to 1 wt%.

The crosslinking agent of the present disclosure may be used in the field of polyurethane foam without particular limitation as long as the crosslinking agent condition is satisfied.

The blowing agent of the present disclosure is a material used to make a foam having a molecular weight of 10 to 30, a difunctional group, and a hydroxyl number of 6,230 to 6,235.

The blowing agent is present in the polyol mixture of the present disclosure in an amount of 2 to 5 weight percent.

The blowing agent of the present disclosure can be used in the field of polyurethane foam without particular limitation as long as the blowing agent conditions are satisfied.

The surfactant of the present invention affects the cell structure in the foam due to the surface active effect, and affects the mixing property, stability, foam generation, foam stability, etc. of raw materials.

The surfactant is a silicone-based stabilizer, and serves to suppress collapse of cells, increase structural stability and impart elasticity, and also serves to provide opening of cells, and to make cells dense and uniform, thereby imparting stability to the cells.

The surfactant of the present disclosure is sufficient to be a silicone surfactant commonly used in the art of polyurethane foam technology. For example, it is sufficient to include at least one of organopolysiloxane or organomodified polysiloxane, and there is no particular limitation in the present disclosure.

The surfactant of the present invention can be used in the field of polyurethane foam technology, and can be used without particular limitation as long as the surfactant conditions are satisfied.

The base surfactant is present in an amount of 3.4 to 4.4 parts by weight based on 100 parts by weight of the polyol of the present disclosure.

The reducing agent of the present disclosure is an adsorbent for removing formaldehyde (HCHO) generated during polyurethane foaming, and has a moisture content of 25 to 30%. Carbon having a partial negative charge and oxygen having a partial positive charge in carbonyl groups contained in aldehydes such as formaldehyde come into contact with hydroxyl (-OH) groups of the reducing agent by electrostatic attraction and form hydrogen bonds, resulting in chemisorption through formal conversion and recombination. Thus, there are no secondary problems such as desorption or re-decomposition.

The reducing agent is present in an amount of 2.3 to 2.5 parts by weight, based on 100 parts by weight of the polyol of the present disclosure. Any reducing agent may be used without particular limitation so long as it can be used in the technical field of polyurethane foam and satisfies the condition of the reducing agent.

The isocyanates of the present disclosure have an NCO content of 34.5 to 35.5% and an NCO index of 0.5 to 0.9.

The isocyanate is present in an amount of 40 to 60 parts by weight based on 100 parts by weight of the polyol mixture in the polyurethane foam composition of the present disclosure.

The polyol mixture of the present disclosure includes 4.4 to 6.4 parts by weight of a cell opener, 3.3 to 4.3 parts by weight of a catalyst, 1.0 to 1.4 parts by weight of a chain extender, 0.55 to 0.65 parts by weight of a cross-linking agent, 4.85 to 4.95 parts by weight of a blowing agent, 3.4 to 4.4 parts by weight of a surfactant, and 2.3 to 2.5 parts by weight of a reducing agent, based on 100 parts by weight of the polyol mixture including the first polyol and the second polyol, and the polyurethane foam composition of the present disclosure includes an isocyanate in an amount of 40 to 60 parts by weight, based on 100 parts by weight of the polyol mixture.

The polyurethane foam manufacturing method according to the present disclosure includes: the method includes the steps of adding an additive to a polyol to produce a polyol mixture, adding an isocyanate to the polyol mixture to produce a polyurethane foam composition, and foaming the polyurethane foam composition.

In the step of adding the additive to the polyol, the polyol mixture is preferably stirred at 1,500 to 1,800rpm for 30 to 60 minutes.

In the step of adding the isocyanate, the polyurethane foam composition is preferably stirred at 6,000 to 8,000 rpm.

In the step of foaming the polyurethane foam composition, the polyurethane foam composition may be foamed in a mold, the foaming pressure is preferably 120 to 160bar, the temperature of the polyurethane foam composition is preferably 18 to 28 ℃, and the temperature of the mold is preferably 50 to 70 ℃.

According to the present disclosure, low density polyurethane foams may be produced as sound absorbing materials using the aforementioned production methods. In this case, under the condition that the foam thickness is 10 to 50mm, the sound absorption rate (vertical sound absorption rate in a frequency band of 0.4 to 5 kHz) is 0.70 or more, and the density is less than 75kg/m³. Preferably, the polyurethane foam for the automobile instrument panel insulating mat is manufactured by the above-described manufacturing method.

Hereinafter, the present disclosure will be described in more detail with reference to specific embodiments. However, the following examples are provided only for better understanding of the present disclosure, and should not be construed as limiting the scope of the present disclosure.

Example 1

A polyol was prepared comprising 93 wt% of a first polyol comprising a polypropylene glycol having a molecular weight of 6,000, a hydroxyl number of 28 and an ethylene oxide content of 15%, and 7% of a second polyol comprising a polypropylene glycol having a molecular weight of 1,000 and a hydroxyl number of 112, and an additive comprising 3.1 parts by weight of a gelling catalyst comprising 1, 4-diazabicyclo [2,2,2] octane-2-methanol, 0.6 parts by weight of a cross-linking agent comprising diethanolamine having a molecular weight of 105, 1.2 parts by weight of a chain extender comprising ethylene glycol having a molecular weight of 400, 4.9 parts by weight of a blowing agent comprising water, 3.4 parts by weight of a surfactant comprising L-3002(Momentive Corp.) and 2.4 parts by weight of a reducing agent (nvts-s) was prepared based on 100 parts by weight of the polyols. An opening agent (propoxylated-ethoxylated glycerin copolymer) having a molecular weight of 42,00, a hydroxyl number of 40 and an EO content of 60% and a blowing catalyst comprising N, N, N '-trimethyl-N' -hydroxyethyl-bis (aminoethyl) ether were prepared in 5.4 parts by weight and 0.4 part by weight, respectively, based on 100 parts by weight of polyol, and further added to the additive to prepare a polyol mixture, the polyol mixture was stirred at 1,600rpm for 30 minutes, and then 47 parts by weight of an isocyanate (NCO content: about 35%, NCO index: 0.78) was mixed with 100 parts by weight of the polyol mixture, then stirred at 6,000rpm to prepare a polyurethane foam composition, and the polyurethane foam composition was maintained at a temperature of 20 ℃, and foamed in a mold at a temperature of 55 ℃ under a pressure of 130bar to produce a polyurethane foam (200 mm. times.200 mm. times.20 mm).

Examples 2 to 7

A polyurethane foam was produced in the same manner as in example 1, except that the content of the cell opener was adjusted as shown in Table 1 (based on 100 parts by weight of the polyol).

TABLE 1

Comparative examples 1 and 2

A polyurethane foam was prepared in the same manner as in example 1, except that the contents of the cell opener were adjusted to 4 parts by weight and 7 parts by weight, respectively, based on 100 parts by weight of the polyol.

Comparative examples 3 and 4

A polyurethane foam was prepared in the same manner as in example 1, except that the contents of the foaming catalyst were adjusted to 0.2 parts by weight and 0.6 parts by weight, respectively, based on 100 parts by weight of the polyol.

Comparative example 5

A polyurethane foam was prepared in the same manner as in example 1, except that the content of the cell opener was adjusted to 3.0 parts by weight, the content of the blowing catalyst was adjusted to 0.1 part by weight, and the content of the blowing agent was adjusted to 4.0 parts by weight, based on 100 parts by weight of the polyol.

Comparative examples 6 and 7

A polyurethane foam was prepared in the same manner as in example 1, except that the contents of the foaming catalyst were adjusted to 2.8 parts by weight and 4.0 parts by weight, respectively, based on 100 parts by weight of the polyol.

Experimental example 1

The polyurethane foam compositions prepared in example 1 and comparative examples 1 to 4 were maintained at a temperature of 20 ℃ and then foamed in a cup-shaped molding die under a pressure of 130bar to produce polyurethane foams. A section of the produced polyurethane foam was cut to check the internal state of the polyurethane foam (fig. 1A ═ example 1, fig. 1B ═ comparative example 1, fig. 1C ═ comparative example 2, fig. 1D ═ comparative example 3, and fig. 1E ═ comparative example 4).

As can be seen from fig. 1A, the foam has a good appearance and the inner cells are uniformly formed, and as can be seen from fig. 1B, as a whole, the foam shrinks and has an inner structure including a large and round cavity due to the restriction of the generated gas and the breakage of the cells. As can be seen from FIG. 1C, the overall appearance was good, but the foam shrunk irregularly. As can be seen from fig. 1D, the polyurethane foam is not foamed completely and cured sufficiently, resulting in collapse of the internal structure and frequent aggregation and breakage of cells. As can be seen from fig. 1E, the polyurethane foam was over-foamed, creating more internal voids.

Experimental example 2

The density, tensile strength, elongation, tear strength and normal incidence sound absorption coefficient of the polyurethane foams prepared in examples 1 to 7 were measured and are shown in table 2 below. At this time, tensile strength, elongation and tear strength were measured using dumbbell No. 1 according to the MS341-18 standard, and sound absorption performance was evaluated as the arithmetic average of the measurements in the 0.4-5KHz frequency band by the impedance tube method (29 Ψ).

TABLE 2

As can be seen from the results in Table 2, all of the polyurethane foams had a weight of 76kg/m³Or lower, and thus has low density characteristics and excellent sound absorption properties, and both satisfy the evaluation criteria of tensile strength and tear strength.

Experimental example 3

A polyurethane foam was prepared from the polyurethane foam composition produced in example 1 under the conditions of the following table 3 (mold temperature, polyurethane foam composition temperature (═ mother liquor temperature) and foaming pressure) and the absorption coefficient of the polyurethane foam (Alpha Cabin (ISO 345)) was evaluated (B was the same as the polyurethane foam of example 1).

TABLE 3

As can be seen from Table 3 above, when the mold temperature was raised and the foaming pressure was increased (dope temperature: 20 ℃, mold temperature: 65 ℃, foaming pressure: 150bar), cell coalescence was minimized, resulting in superior sound absorption properties, as compared to the conventional manufacturing conditions of example 1 (dope temperature: 20 ℃, mold temperature: 55 ℃, foaming pressure: 130 bar).

Experimental example 4

The sound absorption properties of the polyurethane foams of examples 1 and 4 and comparative example 5 were measured and are shown in table 4 below. Here, the frequency band is 0.4-10 kHz.

TABLE 4

As can be seen from the results of table 4, the polyurethane foams produced in examples 1 and 4 exhibited almost the same sound absorption performance as comparative example 5, while the foam density was reduced by about 11%.

Experimental example 5

Polyurethane foams in the form of instrument panel spacers were produced using the polyurethane foam compositions of comparative example 5 and example 2 to evaluate the appearance formability quality of parts of the polyurethane foams, and the results are shown in fig. 1 (comparative example 5) and fig. 2 (example 1). Consider comparative example 5 having 85kg/m³And 1500g/m²Density characteristic ofExample 2 has a density of 72kg/m³And 1270g/m²The density characteristics of (a) can be seen as different densities of the foams, but the appearance is the same.

Experimental example 6

In order to evaluate the odor of the polyurethane foams, the polyurethane foams of examples 1 and 4 and comparative examples 5 to 7 were subjected to sensory evaluation by five evaluators, and the results are shown in the following table 5. The dimensions, according to the evaluation criteria MS300-34, are 40mm by 50mm by 20 mm.

TABLE 5

As can be seen from Table 5, the polyurethane foams of examples 1 and 4 have higher odor evaluation levels than comparative examples 5 to 7.

Experimental example 7

The polyurethane foams of examples 1 and 4 and comparative example 5 were used to measure volatile organic materials of the polyurethane foam. The polyurethane foam was cut into a size of 100mm × 100mm, sealed in a Tedlar bag, and heated in a dry box set to 65 ℃ for 2 hours in the presence of 3L of high-purity nitrogen gas, and then adsorbed on a DNPH box and extracted. The results of HPLC equipment analysis of formaldehyde emissions are shown in table 6 below.

TABLE 6

Comparative example 5	Example 1	Example 4
			141μg/m3	97μg/m3	102μg/m3

As shown in Table 6, unlike comparative example 5, less formaldehyde was released from the polyurethane foams produced using the polyurethane foam compositions of examples 1 and 4.

As is apparent from the above, according to the present disclosure, a polyurethane foam having a low density, satisfactory mold formability, and improved sound absorption can be provided as compared with the prior art.

According to the present disclosure, deterioration in quality uniformity of a polyurethane foam composition due to the phenomenon of layer separation and formation of precipitates of fillers such as carbon nanotubes, calcium carbonate, graphite, and magnesium hydroxide can be suppressed.

According to the present disclosure, polyurethane foams having reduced odor may be provided.

The effects of the present disclosure are not limited to those described above. It should be understood that the effects of the present disclosure include all effects that can be inferred from the description of the present disclosure.

The present disclosure has been described in detail with reference to variations thereof. It would be appreciated by those skilled in the art that changes may be made in these forms without departing from the principles and spirit of the disclosure, the scope of which is defined in the claims and their equivalents.