Method of manufacturing polyurethane filter foam

Patent metadata

Field	Value
Publication number	US-11970566-B2
Application number	US-202217936849-A
Country	US
Kind code	B2
Filing date	Sep 30, 2022
Priority date	Oct 1, 2021
Publication date	Apr 30, 2024
Grant date	Apr 30, 2024

Abstract

Disclosed is a method of manufacturing a polyurethane filter foam having excellent air permeability, elasticity, and restoring force. In the method of manufacturing the polyurethane filter foam, the cell size of the filter foam is made regular by controlling the pressure by adjusting the diameter of the foaming head of a foaming machine, rather than adding a cell opener, cell irregularity caused by poor dispersion of the cell opener is alleviated, and air permeability, porosity, and compression set are excellent.

First claim

What is claimed is:

1. A method of manufacturing a polyurethane filter foam, comprising:
preparing a foam composition comprising a polyol component and an isocyanate;
stirring the foam composition;
discharging stirred foam composition through a foaming head of a foaming machine to obtain an intermediate;
foaming the intermediate to obtain a foam; and
forming the polyurethane filter foam with the foam,
wherein a diameter of the foaming head is about 30 mm to 45 mm; and
wherein the polyol component comprises:
a first polyol having a weight average molecular weight of about 2,000 g/mol to 3,000 g/mol and having 3 to 4 first functional groups;
a second polyol having a weight average molecular weight of 9,000 g/mol to 11,000 g/mol and having 5 to 7 second functional groups; and
a third polyol having a weight average molecular weight of 50 g/mol to 1,000 g/mol and having 1 to 2 third functional groups.

2. The method of claim 1 , wherein each of the first functional groups, the second functional groups and the third functional groups comprises a hydroxyl group or an amine group.

3. The method of claim 1 , wherein the polyol component comprises an amount of about 40% to 65% by weight of the first polyol, an amount of about 25% to 50% by weight of the second polyol, and an amount of about 5% to 15% by weight of the third polyol, based on a total amount of the polyol component.

4. The method of claim 1 , wherein the foam composition comprises an amount of 20 to 30 parts by weight of the isocyanate based on 100 parts by weight of the polyol component.

5. The method of claim 1 , wherein the foam composition further comprises an additive, and the additive comprises at least one of a chain extender, a crosslinking agent, a foam stabilizer, a foaming agent, a catalyst, a heat stabilizer or any combination thereof.

6. The method of claim 5 , wherein the foam composition comprises an amount of 1 to 3 parts by weight of the additive based on 100 parts by weight of the polyol component.

7. The method of claim 1 , wherein a discharge pressure of the foaming head is about 4 bar to 8 bar.

8. A foam composition for manufacturing a polyurethane filter foam through a foaming head of a foaming machine, comprising:
a polyol component and an isocyanate;
wherein a diameter of the foaming head is about 30 mm to 45 mm,
wherein the polyol component comprises:
a first polyol having a weight average molecular weight of about 2,000 g/mol to 3,000 g/mol and having 3 to 4 first functional groups;
a second polyol having a weight average molecular weight of 9,000 g/mol to 11,000 g/mol and having 5 to 7 second functional groups; and
a third polyol having a weight average molecular weight of 50 g/mol to 1,000 g/mol and having 1 to 2 third functional groups,
wherein the polyol component comprises an amount of about 40% to 65% by weight of the first polyol, an amount of about 25% to 50% by weight of the second polyol, and an amount of about 5% to 15% by weight of the third polyol, based on a total amount of the polyol.

Assignees

• Hyundai Transys Inc
• Chin Yang Co Ltd

Inventors

• Ko Jae Yong
• Woo Seung Keon
• Cho Young Tae
• Choi Won Sug
• Lee Sung Yoon
• Lee Jae Kwang
• Song Jun Ho

Classifications

• C08G18/4804 Primary

  Two or more polyethers of different physical or chemical nature · CPC title

• C08G18/7621

  being toluene diisocyanate including isomer mixtures · CPC title

• C08K11/00

  Use of ingredients of unknown constitution, e.g. undefined reaction products · CPC title

• C08G18/4833 Primary

  Polyethers containing oxyethylene units · CPC title

• B29C44/35 Primary

  Component parts; Details or accessories · CPC title