Melamine formaldehyde foam with reduced formaldehyde emission

Abstract

Method for lowering the formaldehyde emissions of melamine/formaldehyde polymer moldings, films or fibers by impregnating the melamine/formaldehyde polymer moldings, films or fibers with an aqueous solution of at least one formaldehyde scavenger.

Claims

1. A method for lowering the formaldehyde emissions of melamine/formaldehyde polymer moldings made from melamine/formaldehyde foams by impregnating the melamine/formaldehyde polymer moldings made from melamine/formaldehyde foams with an aqueous solution a formaldehyde scavenger comprising ethylenediamine bis-acetoacetamide.

2. A method for preparing melamine/formaldehyde polymer moldings made from melamine/formaldehyde foams with low formaldehyde emissions, by first preparing a molding made from melamine/formaldehyde foams of a melamine/formaldehyde polymer and subsequently impregnating the surface of the melamine/formaldehyde polymer molding made from melamine/formaldehyde foams with an aqueous solution a formaldehyde scavenger comprising ethylenediamine bis-acetoacetamide.

Description

EXAMPLES

(1) A melamine/formaldehyde foam (Basotect) was prepared according to Example 2 of US 2015/0210814 A1. The foam had a density of 8 to 10 g/l. A molding in the form of a foam sheet was cut from the melamine/formaldehyde foam.

(2) A impregnating solution was prepared by dissolving 1 to 25 wt % of ethylenediamine-N,N-bis(acetoacetamide) or of acetoacetamide in water. The impregnated active amount refers to the impregnated active without water, based on the dry foam.

(3) The following results for the formaldehyde (FA) emission from the melamine/formaldehyde foam molding (Basotect) were obtained:

(4) TABLE-US-00001 Impregnated active [wt %, based on foam molding] 0.1 0.2 0.5 mg FA/kg Basotect (acetoacetamide)* 3 2 0 mg FA/kg Basotect 1 1 0 (ethylenediamine-N,N-bis(acetoacetamide))* *Basotect reference without impregnation: 22

(5) TABLE-US-00002 Impregnated active [%] 50 25 12 mg FA/kg Basotect (acetoacetamide)* 0 0 0 mg FA/kg Basotect 0 0 (ethylenediamine-N,N-bis(acetoacetamide))* *Basotect reference with water impregnation: 162-171
Result of AgBB Test:
Emissions after 28 Days:

(6) TABLE-US-00003 Basotect X1 Basotect X2 maximum (0.1% EA) (1% EA) Basotect G+ (AgBB) TVOC <0.005 mg/m.sup.3 <0.005 mg/m.sup.3 <0.005 mg/m.sup.3 1 mg/m.sup.3 TSVOC <0.005 mg/m.sup.3 <0.005 mg/m.sup.3 <0.005 mg/m.sup.3 0.1 mg/m.sup.3 Total carcinogens <0.001 mg/m.sup.3 <0.001 mg/m.sup.3 <0.001 mg/m.sup.3 0.001 mg/m.sup.3 Formaldehyde <0.003 mg/m.sup.3 <0.003 mg/m.sup.3 0.0055 mg/m.sup.3 0.1 mg/m.sup.3 EA: Ethylenediamine-N,N-bis(acetoacetamide), amount in wt % based on the foam molding Basotect G+: Melamine/formaldehyde foam molding without impregnation Maximum (AgBB): The maximum values allowed by the AgBB test, the AgBB test was performed according to the art TVOC: Total volatile organic compounds TSVOC: Total semi-volatile organic compounds