METHOD FOR PREPARING HIGH-PERFORMANCE MELAMINE FOAM

Abstract

The present disclosure relates to a method for preparing high-performance melamine foam, comprising the following steps: preparing a primary polymer of waterborne melamine formaldehyde resin; uniformly mixing the primary polymer of the waterborne melamine formaldehyde resin, the polar solvent, the surfactant and the additive to obtain a mixture A; uniformly mixing the mixture A with the solid methylol melamine to obtain a mixture B; uniformly mixing the mixture B with the foaming agent to obtain a mixture C; uniformly mixing the mixture C with the curing agent to obtain a mixture D; and carrying out microwave radiation, foaming, curing, drying and quenching on the mixture D in a microwave foaming device to obtain the high-density melamine foam. The melamine foam described in the present invention has high density and high strength performance.

Claims

1. A method for preparing high-performance melamine foam, characterized by comprising the following steps: a. preparing a primary polymer of waterborne melamine formaldehyde resin; b. uniformly mixing the primary polymer of the waterborne melamine formaldehyde resin, a polar solvent, a surfactant and an additive in a thermostatic mixing tank proportionally to obtain a mixture A; c. uniformly mixing the mixture A with solid methylol melamine in a thermostatic single screw extruder or twin-screw extruder proportionally to obtain a mixture B; d. uniformly mixing the mixture B with a foaming agent in the twin-screw extruder proportionally to obtain a mixture C; e. uniformly mixing the mixture C with a curing agent in a thermostatic high-speed mixer proportionally to obtain a mixture D; and f. carrying out microwave radiation, foaming, curing, drying and quenching on the mixture D in a microwave foaming device to obtain the high-performance melamine foam.

2. The method for preparing the high-performance melamine according to claim 1, characterized in that a solid content of the mixture B in step c is 70% to 99%.

3. The method for preparing the high-performance melamine foam according to claim 1, characterized in that a mixing rotating speed of step b, step c and step d is 100 r/min to 500 r/min, and a mixing rotating speed of step e is 500 r/min to 3000 r/min; a material temperature of the mixture A, the mixture B and the mixture C is 26° C. to 40° C., and a material temperature of the mixture D is 10° C. to 30° C.; and microwave radiation power in step f is 1 kW/kg to 10 kW/kg, radiation foaming time is 1 min to 20 min, a drying temperature is 150° C. to 250 ° C. and drying time is 10 min to 60 min.

Description

DETAILED DESCRIPTION OF EMBODIMENTS

[0022] The parts by weight of the components in the high-density melamine foam of the present invention are changed greatly, and the specific parameters in a preparing process can also be changed, therefore, many embodiments of the present invention are presented, and cannot be exhaustive at all; and the present invention is further described below in combination with three specific embodiments, but undoubtedly, the three embodiments do not limit the technical solution of the present invention.

Embodiment 1

[0023] The high-density melamine foam is prepared according to the following steps: [0024] (1) Preparing 3200 g of primary polymer of waterborne melamine formaldehyde resin according to a conventional method, wherein the solid content of the waterborne melamine formaldehyde resin is 75%, and the molar ratio of formaldehyde to melamine in raw materials for preparing the waterborne melamine formaldehyde resin is 3:1; [0025] (2) Uniformly mixing the primary polymer of the waterborne melamine formaldehyde resin with 80 g of alkylphenol ethoxylates (OP-10 for short) and 8 g of dicyandiamide in a thermostatic mixing tank to obtain a mixture A, wherein the stirring rotating speed 250 r/min, and the temperature of the mixture A is 30° C.; [0026] (3) Transferring the mixture A and 800 g of tetramethylol melamine to a thermostatic twin-screw extruder through a metering transfer pump and a metering feeder respectively to uniformly mix to obtain a mixture B, wherein the mixing rotating speed is 150 r/min, and the temperature of the mixture B is 30° C.; [0027] (4) After extruding the mixture B from the twin-screw extruder, sending the same to another twin-screw extruder to uniformly mix with 400 g of trichlorotrifluoroethane sent to the twin-screw extruder through a metering pump to obtain a mixture C, wherein the mixing rotating speed is 180 r/min and the temperature of the mixture C is 25° C.; [0028] (5) After extruding the mixture C from the twin-screw extruder, sending the same to a high-speed mixer to uniformly mix with 120 g of benzoic acid sent to the high-speed mixer through the metering pump at a constant temperature obtain a mixture D, wherein the r fixing rotating speed is 2000 r/min, and the temperature of the mixture 0 is 20° C.; [0029] (6) Carrying out microwave radiation, curing, drying and quenching on the mixture D in a microwave foaming device to obtain the high-density melamine foam, wherein the microwave radiation power for the mixture 0 is 6.3 kW/kg, the radiation time is 3 min, the drying temperature is 220° C., and the drying time is 20 min,

[0030] The density of the high-density melamine foam prepared with the above method is 14.3 kg/m3, the tensile strength is 170.0 kpa and the elongation at break is

Embodiment 2

[0031] The high-density melamine foam is prepared according to the following steps: [0032] (1) Preparing 2000 g of primary polymer of waterborne melamine formaldehyde resin according to a conventional method, wherein the solid content of the waterborne melamine formaldehyde resin is 78%, and the molar ratio of formaldehyde to melamine in raw materials for preparing the waterborne melamine formaldehyde resin is 3:1; [0033] (2) Uniformly mixing the primary polymer of the waterborne melamine formaldehyde resin with 188 g of desalted water, 120 g of sodium lauryl polyoxyethylene ether sulfate (AES for short) and 20 g of talcum powder in a thermostatic mixing tank to obtain a mixture A, wherein the stirring rotating speed is 250 r/min, and the temperature of the mixture A is 30° C.; [0034] (3) Transferring the mixture A and 2000 g of tetramethylol melamine to a thermostatic twin-screw extruder through a metering transfer pump and a metering feeder respectively to uniformly mix to obtain a mixture B, wherein the mixing rotating speed is 150 r/min, and the temperature of the mixture B is 28° C., [0035] (4) After extruding the mixture B from the twin-screw extruder, sending the same to another twin-screw extruder to uniformly mix with 480 g of cyclopentane sent to the twin-screw extruder through a metering pump to obtain a mixture C, wherein the mixing rotating speed is 180 r/min, and the temperature of the mixture C is 24° C.; (5) After extruding the mixture C from the twin-screw extruder, sending the same to a high-speed mixer to uniformly mix with 140 g of oxalic acid sent to the high-speed mixer through the metering pump at a constant temperature to obtain a mixture D, wherein the mixing rotating speed is 1500 r/min, and the temperature of the mixture 0 is 21° C.; [0036] (6) Carrying out microwave radiation, curing, drying and quenching on the mixture D in a microwave foaming device to obtain the high-density melamine foam, wherein the microwave radiation power for the mixture D is 3.6 kW/kg, the radiation time is 8 min, the drying temperature is 180° C., and the drying time is 40 min

[0037] The density of the high-density melamine foam prepared with the above method is 22.0 kg/m3, the tensile strength is 180.9 kpa, and the elongation at break is 13.6%.

Embodiment 3

[0038] The high-density melamine foam is prepared according to the following steps: [0039] (1) Preparing 2000 g of primary polymer of waterborne melamine formaldehyde resin according to a conventional method, wherein the solid content of the waterborne melamine formaldehyde resin is 73%, and the molar ratio of formaldehyde to melamine in raw materials for preparing the waterborne melamine formaldehyde resin is 2:1; [0040] (2) Uniformly mixing the primary polymer of the waterborne melamine formaldehyde resin with 68 g of ethyl alcohol, 80 g of sodium dodecyl sulfate, 40 g of dodecyl polyethenoxy ether, 8 g of dicyandiamide and 20 g of talcum powder in a thermostatic mixing tank to obtain a mixture A, wherein the stirring rotating speed is 250 r/min, and the temperature of the mixture A is 33° C.; [0041] (3) Transferring the mixture A with 1000 g of tetramethylol melamine and 1000 g of hexamethylol melamine which are pre-mixed to a thermostatic twin-screw extruder through a metering transfer pump and a metering feeder respectively to uniformly mix to obtain a mixture B, wherein the mixing rotating speed is 150 r/min, and the temperature of the mixture B is 28° C.; (4) After extruding the mixture B from the twin-screw extruder, sending the same to another twin-screw extruder to uniformly mix with 400 g of petroleum ether sent to the twin-screw extruder through a metering pump to obtain a mixture C, wherein the mixing rotating speed is 160 r/min, and the temperature of the mixture C is 26° C.; [0042] (5) After extruding the mixture C from the twin-screw extruder, sending the same to a high-speed mixer to uniformly mix with 200 g of benzoic acid sent to the high-speed mixer through the metering pump at a constant temperature to obtain a mixture D, wherein the mixing rotating speed is 1800 r/mm, and the temperature of the mixture 0 is 23° C.; [0043] (6) Carrying out microwave radiation, curing, drying and quenching on the mixture D in a microwave foaming device to obtain the high-density melamine foam, wherein the microwave radiation power for the mixture D is 4.5 kW/kg, the radiation time is 5 min, the drying temperature is 200° C., and the drying time is 30 min.

[0044] The density of the high-density melamine foam prepared with the above method is 18.1 kg/m3, the tensile strength is 166.0 kpa and the elongation at break is 17.3%.

[0045] The above embodiments are just the preferred embodiments of the present invention, not limitation to the technical solution of the present invention. Technical solutions which can be achieved on the basis of the above embodiments without creative labor shall be considered to fall into the protection scope of claims of the patent of the present invention.