Composition for producing polyurethane foam

Abstract

Provided is a technique that does not cause cell roughness and has excellent moldability even when a plant-derived raw material and / or a plant-derived polyol are used. In the present technology, provided is a composition for producing a polyurethane foam, which contains: a plant-derived raw material and / or a plant-derived polyol; a polymer polyol; and a polyether polyol having an EO of 10-70%. The composition for producing a polyurethane foam is used for integrally molding a skin. Also provided is a vehicle component in which a skin and a polyurethane foam formed using the composition for polyurethane foam production are integrally molded.

Description

Technical Field

[0001] The present invention relates to a composition for producing polyurethane foam. More specifically, it relates to an environmentally friendly composition for producing polyurethane foam and a vehicle component in which a polyurethane foam and a skin formed by using the composition are integrally molded. Background Art

[0002] Polyurethane foam is widely used in various fields, including furniture such as sofas and chairs, bedding such as mattresses and pillows, clothing such as underwear, daily necessities such as tableware sponges, cleaning sponges, and makeup sponges, products for vehicle and aircraft interior decoration such as seats, toys, and sundries. In addition, various developments are being carried out to improve quality or add new functions according to each field or purpose.

[0003] However, in the prior art, a large amount of petroleum-derived raw materials are used when producing polyurethane foams, so the amount of CO 2 emissions increases, which is not preferable from the viewpoint of achieving carbon neutrality.

[0004] In contrast, for example, Patent Document 1 discloses a vehicle interior material having a polyurethane foam layer formed using a plant-derived raw material. In addition, Patent Document 2 discloses a composition for producing a semi-rigid polyurethane foam, which is obtained by mixing a polyol component (A) containing a plant-derived polyester polyol, a polyol mixture (B) containing a catalyst and a foaming agent, and a polyisocyanate component (C).

[0005] Prior art literature

[0006] Patent Literature

[0007] Patent Document 1: Japanese Patent Application Publication No. 2011-765

[0008] Patent Document 2: Japanese Patent Application Publication No. 2011-208059 Summary of the invention

[0009] Here, when producing polyurethane foam, the use of plant-derived raw materials and / or plant-derived polyols certainly contributes to the achievement of carbon neutrality. On the other hand, the use of plant-derived raw materials and / or plant-derived polyols causes problems such as roughening of cells and reduced moldability.

[0010] Therefore, the main object of the present technology is to provide a technology that does not cause cell roughness and has excellent moldability even when using plant-derived raw materials and / or plant-derived polyols.

[0011] In the present technology, first, a composition for manufacturing polyurethane foam is provided, which contains: a plant-derived raw material and / or a plant-derived polyol; a polymer polyol; and a polyether polyol with 10% to 70% of EO, and the composition for manufacturing polyurethane foam is used for integral skin molding.

[0012] In the present technology, the polymer polyol may also be less than 30 parts by mass relative to 100 parts by mass of the polyol.

[0013] In the present technology, the polyether polyol may also be less than 30 parts by mass relative to 100 parts by mass of the polyol.

[0014] In the present technology, the biomass content may also be 15% or more.

[0015] In the present technology, in addition, a vehicle component is also provided, which is integrally molded with a polyurethane foam formed by using the composition for manufacturing polyurethane foam and a skin. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a substitute photograph of a drawing showing the cell situation in the cross-section of the polyurethane foam of Example 2.

[0017] Figure 2 It is a substitute photograph of a drawing showing the cell situation in the cross-section of the polyurethane foam of Comparative Example 6.

[0018] Figure 3 It is a substitute photograph of a drawing showing the moldability (no shrinkage) in the polyurethane foam of Example 2.

[0019] Figure 4 It is a substitute photograph of a drawing showing the moldability (with shrinkage) in the polyurethane foam of Comparative Example 3. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0020] Hereinafter, preferred modes for implementing the present technology will be described.

[0021] The embodiments described below show an example of a representative embodiment of the present technology, and any embodiments can be combined. In addition, the scope of the present technology will not be construed narrowly thereby.

[0022] 1. Composition for Manufacturing Polyurethane Foam

[0023] The composition for manufacturing polyurethane foam according to the present technology contains a plant-derived raw material and / or a plant-derived polyol, a polymer polyol, and a polyether polyol with 10% to 70% of EO, and the composition for manufacturing polyurethane foam is used for integral skin molding. In addition, as other components, isocyanate, foaming agent, catalyst, foam stabilizer, colorant, etc. may be contained.

[0024] By using the above components, the composition for manufacturing polyurethane foam according to the present technology can eliminate the problems of rough cell structure or poor molding caused when using plant-derived raw materials and / or plant-derived polyols, as shown in the following examples.

[0025] In addition, when used for integral skin molding, a decrease in adhesiveness to the skin material or the like also becomes a problem. However, in the present technology, since the rough cell structure is eliminated, a decrease in adhesiveness to the skin material or the like can also be avoided.

[0026] Hereinafter, each component will be described in detail.

[0027] (1) Plant-derived raw materials and / or plant-derived polyols

[0028] Examples of the plant-derived raw materials used in the present technology include natural oils. Examples of natural oils include castor oil, soybean oil, rapeseed oil, coconut oil and other natural oils or their derivatives (for example, modified natural oils, unmodified natural oils, etc.). In the present technology, two or more of them can also be used in combination.

[0029] Examples of the plant-derived polyols include polyols derived from the above natural oils. In addition, examples include polyols derived from cashew nut shell liquid. In the present technology, two or more of them can also be used in combination.

[0030] In the present technology, as the plant-derived raw material, castor oil and its derivatives are preferred. In addition, in this specification, "castor oil" includes any one of unmodified castor oil, modified castor oil, dehydrated castor oil, hydrogenated castor oil, etc. Here, unmodified castor oil is an ester of fatty acid and glycerol. Unmodified castor oil has ricinoleic acid as the main component, and as other components, it contains, for example, unsaturated fatty acids such as oleic acid, linoleic acid, and linolenic acid, and saturated fatty acids such as palmitic acid and stearic acid.

[0031] In addition, in the present technology, as the plant-derived polyol, a polyol derived from castor oil and its derivatives is preferred. As the polyol derived from a derivative of castor oil, a modified castor oil polyol such as an ester-modified castor oil polyol is preferred.

[0032] In the composition for manufacturing polyurethane foam according to the present technology, the biomass content is preferably 15% or more, more preferably 20% or more, further preferably 25% or more, and particularly preferably 30% or more. By making the biomass content within this range, the CO2 emissions can be reduced, which helps to achieve carbon neutrality. In addition, from the viewpoint of moldability, the biomass content is preferably 55% or less, more preferably 50% or less, further preferably 45% or less, and particularly preferably 40% or less.

[0033] In addition, the biomass ratio is the proportion of plant-derived raw materials such as natural oils in the total added parts. In this case, the calculation method can be carried out as shown in the following formula (1-1).

[0034] Biomass ratio = Plant-derived raw materials ÷ Total added parts × 100… (1-1)

[0035] In addition, in the case of plant-derived polyols rather than plant-derived raw materials themselves, the biomass ratio decreases according to the proportion. For example, in the case of a polyol with a plant-derived raw material ratio of 50%, the calculation method can be carried out as shown in the following formula (1-2).

[0036] (“50% polyol of plant-derived raw material ratio” 70 g) ÷ Total added parts 230 g × 100 = (70 × 1 / 2) ÷ 230 × 100 = 15.2%… (1-2)

[0037] In the polyurethane foam manufacturing composition according to the present technology, from the viewpoints of reducing CO2 emissions and contributing to carbon neutrality, the content of plant-derived raw materials and / or plant-derived polyols relative to 100 parts by mass of polyols is preferably 40 parts by mass or more, more preferably 50 parts by mass or more, further preferably 60 parts by mass or more, and particularly preferably 65 parts by mass or more. In addition, relative to 100 parts by mass of polyols, the plant-derived raw materials and / or plant-derived polyols are preferably 90 parts by mass or less, more preferably 80 parts by mass or less, and further preferably 75 parts by mass or less. By making the content of plant-derived raw materials and / or plant-derived polyols relative to 100 parts by mass of polyols within this range, it is possible to prevent the cell structure from being rough and to ensure the adhesiveness during skin integral molding.

[0038] In addition, in this specification, the polyols constituting 100 parts by mass of polyols are all main polyols that mainly undergo reactions, and do not include auxiliary polyols such as secondary polyols used as crosslinking agents or catalysts, foaming agents, etc. used for auxiliary purposes.

[0039] (2) Polymer polyol

[0040] Examples of the polymer polyol used in the present technology include: polymer polyols obtained by polymerizing ethylenically unsaturated monomers in polyols, or polymer polyols obtained by emulsifying and dispersing polymers of ethylenically unsaturated monomers in polyols. Specifically, examples include: polymer polyols obtained by graft polymerization of acrylonitrile, styrene, etc. in polyols, polymer polyols obtained by dispersing polystyrene or polyacrylonitrile in polyols, etc. In addition, as the polymer polyol, commercially available polymer polyols can also be used.

[0041] In the composition for producing polyurethane foam according to the present technology, the content of the polymer polyol relative to 100 parts by mass of the polyol is preferably less than 30 parts by mass, more preferably less than 25 parts by mass, and further preferably less than 20 parts by mass. By making the content of the polymer polyol relative to 100 parts by mass of the polyol within this range, shrinkage is prevented and the moldability becomes good. In addition, the content of the polymer polyol relative to 100 parts by mass of the polyol is preferably 5 parts by mass or more, more preferably 8 parts by mass or more, and further preferably 10 parts by mass or more. By making the content of the polymer polyol relative to 100 parts by mass of the polyol within this range, it is possible to reduce the occurrence of shrinkage while maintaining the fineness of the cell structure.

[0042] (3)Polyether polyol

[0043] In the polyether polyol used in the present technology, the addition rate of ethylene oxide (EO) is 10% to 70%. Examples of the polyether polyol used in the present technology include polyethylene glycol, polypropylene glycol, polytetramethylene ether glycol, etc. obtained by polymerizing cyclic ethers such as ethylene oxide and propylene oxide respectively, and their copolymers. In addition, polyols such as glycerol and trimethylolethane can be used to polymerize the cyclic ethers. In addition, commercially available polyether polyols can also be used as the polyether polyol.

[0044] The addition rate of EO ((wt)%) refers to the weight ratio of ethylene oxide (EO) relative to the total amount of alkylene oxides (AO) such as ethylene oxide (EO) or propylene oxide (PO) as monomers when producing the polyether polyol. That is, the addition rate of EO can be calculated based on the following formula (2).

[0045] Addition rate of EO (%) = EO weight × 100 / AO total amount (EO weight + PO weight, etc.) … (2)

[0046] In the composition for producing polyurethane foam according to the present technology, the addition rate of EO is 10% or more, preferably 11% or more, and more preferably 12% or more. By making the addition rate of EO within this range, the coarseness of the cell structure is prevented and the moldability becomes good. In addition, the rupture of the produced polyurethane foam and the generation of internal voids can also be prevented. In addition, the addition rate of EO is 70% or less, preferably 60% or less, more preferably 50% or less, further preferably 40% or less, still further preferably 30% or less, and particularly preferably 20% or less. By making the addition rate of EO within this range, the rupture of the produced polyurethane foam can be prevented.

[0047] In the composition for producing a polyurethane foam according to the present technology, the number of functional groups of the polyether polyol with 10% to 70% EO is preferably 1 to 4. In addition, in the composition for producing a polyurethane foam according to the present technology, the molecular weight (number average) of the polyether polyol with 10% to 70% EO is preferably 3000 to 8000.

[0048] In the composition for producing a polyurethane foam according to the present technology, as the content of the polyether polyol with 10% to 70% EO relative to 100 parts by mass of the polyol, it is preferably less than 30 parts by mass, more preferably less than 25 parts by mass, and further preferably less than 20 parts by mass. By making the content of the polyether polyol with 10% to 70% EO relative to 100 parts by mass of the polyol within this range, the fineness of the cell structure can be maintained. In addition, as the content of the polyether polyol with 10% to 70% EO relative to 100 parts by mass of the polyol, it is preferably 5 parts by mass or more, more preferably 8 parts by mass or more, and further preferably 10 parts by mass or more. By making the content of the polyether polyol with 10% to 70% EO relative to 100 parts by mass of the polyol within this range, generation of shrinkage can be reduced while maintaining the fineness of the cell structure.

[0049] (4) Other components

[0050] As other components, the composition for producing a polyurethane foam according to the present technology may include: other polyols, isocyanates, blowing agents, catalysts, foam stabilizers, colorants, flame retardants, antibacterial agents, stabilizers, plasticizers, dispersants, ultraviolet absorbers, etc.

[0051] (4-1) Other polyols

[0052] In the present technology, in addition to the above plant-derived polyols, polymer polyols, and polyether polyols with 10% to 70% EO, other polyols that can generally be used in the production of polyurethane foams can also be used within the range that does not impair the effects of the present technology. As other polyols, for example, one or more polyols that can generally be used in the production of polyurethane foams can be freely selected and used. Specifically, for example, polyester polyols, polycarbonate polyols, polyester ether polyols, etc. can be cited. In addition, as other polyols, commercially available polyols can also be used.

[0053] (4-2) Isocyanates

[0054] In the present technology, within the range that does not impair the effects of the present technology, one or more than two isocyanates that can generally be used in the production of polyurethane foam can be freely selected. For example, one or more selected from the group consisting of aromatic isocyanates, aliphatic isocyanates, alicyclic isocyanates, prepolymers formed by polymerizing MDI of these isocyanate groups with polyols, and polyisocyanates containing mixtures thereof can be used.

[0055] Examples of aromatic isocyanates include, for example: 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, m-phenylene diisocyanate, p-phenylene diisocyanate, diphenylmethane diisocyanate (MDI: 4,4'-diphenylmethane diisocyanate, 2,4'-diphenylmethane diisocyanate or 2,2'-diphenylmethane diisocyanate), xylylene diisocyanate, 3,3'-dimethyl-4,4'-biphenylene diisocyanate, 3,3'-dimethoxy-4,4'-biphenylene diisocyanate, and their derivatives, etc.

[0056] Examples of aliphatic isocyanates include, for example: trimethylene diisocyanate, 1,2-propylene diisocyanate, butylene diisocyanate (tetramethylene diisocyanate, 1,2-butylene diisocyanate, 2,3-butylene diisocyanate, 1,3-butylene diisocyanate), hexamethylene diisocyanate (HDI), pentamethylene diisocyanate, 2,2,4-trimethylhexamethylene diisocyanate, 2,4,4-trimethylhexamethylene diisocyanate, 2,6-diisocyanatomethylhexanoic acid ester, lysine diisocyanate, lysine ester triisocyanate, 1,6,11-undecane triisocyanate, 1,3,6-hexamethylene triisocyanate, trimethylhexamethylene diisocyanate, 1,5-pentamethylene diisocyanate (PDI), pentamethylene diisocyanate, and their derivatives, etc.

[0057] Examples of alicyclic isocyanates include, for example: 1,3-cyclopentane diisocyanate, 1,3-cyclopentene diisocyanate, cyclohexane diisocyanate (1,4-cyclohexane diisocyanate, 1,3-cyclohexane diisocyanate), 3-isocyanatomethyl-3,5,5-trimethylcyclohexyl isocyanate (isophorone diisocyanate), dimer acid diisocyanate, trans-cyclohexane 1,4-diisocyanate, hydrogenated toluene diisocyanate, hydrogenated tetramethylxylylene diisocyanate and other monocyclic alicyclic isocyanates; norbornene diisocyanate, norbornane diisocyanate methyl, bicycloheptane triisocyanate, isocyanatomethyl bicycloheptane, bis(diisocyanatomethyl) tricyclodecane and other crosslinked cyclic alicyclic isocyanates, and their derivatives, etc. In addition, as isocyanates, commercially available isocyanates can also be used.

[0058] In the present technology, the isocyanate index can be freely set within a range that does not impair the effects of the present technology. In the present technology, as the lower limit value of the isocyanate index, it can be, for example, 80 or more, preferably 90 or more, more preferably 95 or more. By setting the isocyanate index within this range, the strength of the produced polyurethane foam can be improved. In addition, as the upper limit value of the isocyanate index, it is, for example, 130 or less, preferably 120 or less, more preferably 110 or less. By setting the isocyanate index within this range, there is an advantage of cost reduction. In addition, it can prevent the hardness of the polyurethane foam from becoming too hard and impairing the softness, and can improve the elasticity of the polyurethane foam.

[0059] In addition, the isocyanate index can be calculated based on the following formula (3).

[0060] Isocyanate index = (isocyanate equivalent in the polyurethane foam production composition / equivalent of active hydrogen in the polyurethane foam production composition) × 100…(3)

[0061] (4 - 3) Blowing agent

[0062] In the present technology, within a range that does not impair the effects of the present technology, one or more blowing agents that can generally be used in the production of polyurethane foam can be freely selected and used.

[0063] Examples of the blowing agent include: water, hydrocarbon chains, halogen-based compounds, etc.

[0064] Examples of the hydrocarbon chain include: cyclopentane, isopentane, n-pentane, etc.

[0065] Examples of the halogen-based compound include: dichloromethane, trichlorofluoromethane, dichlorodifluoromethane, nonafluorobutyl methyl ether, nonafluorobutyl ethyl ether, pentafluoroethyl methyl ether, heptafluoroisopropyl methyl ether, etc. In addition, as the blowing agent, commercially available blowing agents can also be used.

[0066] In the present technology, among them, as the blowing agent, water is preferably used. In addition, in this specification, "water" includes any one of ion-exchanged water, tap water, distilled water, RO water, etc.

[0067] The content of the foaming agent used in the present technology can be freely set within the range that does not impair the effects of the present technology. In the composition for producing polyurethane foam according to the present technology, as the content of the foaming agent relative to 100 parts by mass of the polyol, it is preferably 0.1 part by mass or more, more preferably 0.5 part by mass or more, further preferably 1 part by mass or more, and particularly preferably 2 parts by mass or more. By making the content of the foaming agent relative to 100 parts by mass of the polyol within this range, the foaming property can be improved. As a result, polyurethane foam with excellent mechanical properties and appearance can be obtained. In addition, as the content of the foaming agent relative to 100 parts by mass of the polyol, it is preferably 10 parts by mass or less, more preferably 7 parts by mass or less, further preferably 5 parts by mass or less, and particularly preferably 4 parts by mass or less. By making the content of the foaming agent relative to 100 parts by mass of the polyol within this range, the formation defects caused by excessive foaming can be suppressed, and in addition, it can also contribute to cost reduction.

[0068] (4-4) Catalyst

[0069] In the present technology, within the range that does not impair the effects of the present technology, one or more catalysts that can generally be used in the production of polyurethane foam can be freely selected and used.

[0070] Examples of the catalyst include tin catalysts such as dibutyltin dilaurate and stannous octoate; metal catalysts (organometallic catalysts) such as phenylmercury propionate and lead octenoate.

[0071] In addition, examples of amine catalysts (including aliphatic amine catalysts) and quaternary ammonium salt catalysts include: bis(2-dimethylaminoethyl) ether, N,N-dimethyldodecylamine, N,N-dimethylaminohexanol, triethylenediamine, triethylamine, tripropylamine, triisopropanolamine, tributylamine, trioctylamine, cetyl dimethylamine, N-methylmorpholine, N-ethylmorpholine, N-octadecylmorpholine, monoethanolamine, diethanolamine, triethanolamine, N-methyldiethanolamine, N,N-dimethylethanolamine, N,N-dimethylaminoethoxyethoxyethanol, N,N-dimethylaminoethoxyethanol and other tertiary amine catalysts, formate salts and other salts of triethylenediamine, alkylene oxide adducts of the amino groups of primary and secondary amines, nitrogen heterocyclic compounds such as N-N-dialkylpiperazines, various N,N’,N’-trialkylaminoalkyl hexahydrotriazines, N,N,N’’,N’’-tetramethyldiethylenetriamine and other amine catalysts having an amino group as a functional group. In addition, as the catalyst, commercially available catalysts can also be used.

[0072] The content of the catalyst used in the present technology can be freely set within the range that does not impair the effects of the present technology. In the composition for producing polyurethane foam according to the present technology, as the content of the catalyst relative to 100 parts by mass of the polyol, it is preferably 0.1 part by mass or more, more preferably 0.5 part by mass or more, and still more preferably 1 part by mass or more. By making the content of the catalyst relative to 100 parts by mass of the polyol within this range, the resinification reaction or the foaming reaction can be promoted. As a result, polyurethane foam with excellent mechanical properties and appearance can be obtained. In addition, as the content of the catalyst relative to 100 parts by mass of the polyol, it is preferably 10 parts by mass or less, more preferably 8 parts by mass or less, and still more preferably 7 parts by mass or less. By making the content of the catalyst relative to 100 parts by mass of the polyol within this range, the destabilization of the resinification reaction or the foaming reaction can be prevented, and the balance between the resinification reaction and the foaming reaction can be maintained well. As a result, polyurethane foam with excellent mechanical properties and appearance can be obtained.

[0073] In addition, in the present specification, a "reactive" catalyst means that the catalyst is embedded in the polyurethane resin skeleton during the reaction. In the present technology, by using a reactive catalyst, it is effective in reducing volatile substances (VOC).

[0074] (4-5) Foam stabilizer

[0075] In the present technology, one or more foam stabilizers that can generally be used in the production of polyurethane foam can be freely selected and used within the range that does not impair the effects of the present technology.

[0076] Examples of the foam stabilizer include silicone-based foam stabilizers, fluorine compound-based foam stabilizers, surfactants, etc. Examples of the silicone-based foam stabilizers include foam stabilizers composed mainly of a siloxane chain, foam stabilizers in which the siloxane chain and the polyether chain have a linear structure, branched foam stabilizers, and foam stabilizers in which the polyether chain is modified in a pendant shape to be a siloxane chain. In addition, as the foam stabilizer, commercially available foam stabilizers can also be used.

[0077] The content of the foam stabilizer used in the present technology can be freely set within the range that does not impair the effects of the present technology. In the composition for producing polyurethane foam according to the present technology, the content of the foam stabilizer relative to 100 parts by mass of the polyol can be 0 part by mass, preferably 0.01 part by mass or more, more preferably 0.03 part by mass or more, and further preferably 0.05 part by mass or more. By making the content of the foam stabilizer relative to 100 parts by mass of the polyol within this range, the foaming reaction can be stabilized, and as a result, polyurethane foam with excellent mechanical properties and appearance can be obtained. In addition, as the content of the foam stabilizer relative to 100 parts by mass of the polyol, it is preferably 10 parts by mass or less, more preferably 5 parts by mass or less, further preferably 3 parts by mass or less, and particularly preferably 1 part by mass or less. By making the content of the foam stabilizer relative to 100 parts by mass of the polyol within this range, cost reduction can be facilitated.

[0078] (4-6)Colorant

[0079] In the present technology, within the range that does not impair the effects of the present technology, one or more colorants that can generally be used in the production of polyurethane foam can be freely selected and used.

[0080] Examples of the colorant include carbon pigments and the like. The content of the coloring material used in the present technology can be freely set according to the use and the like within the range that does not impair the effects of the present technology.

[0081] 2. Polyurethane Foam

[0082] The polyurethane foam is produced using the composition for producing polyurethane foam according to the present technology.

[0083] The polyurethane foam can be any one of flexible polyurethane foam, rigid polyurethane foam, and semi-rigid polyurethane foam, but flexible polyurethane foam is preferred.

[0084] [Core Density]

[0085] The core density of the polyurethane foam can be freely set within the range that does not impair the effects of the present technology. As the core density of the polyurethane foam, it is preferably 10 kg / m 3 or more, more preferably 15 kg / m 3 or more, further preferably 20 kg / m 3 or more, still further preferably 25 kg / m 3 or more, and particularly preferably 30 kg / m 3 or more. By making the core density of the polyurethane foam within this range, the range of applicable uses can be expanded. In addition, as the core density of the polyurethane foam, it is preferably 100 kg / m 3 or less, more preferably 80 kg / m3 Hereinafter, it is further preferably 60 kg / m 3 Hereinafter, it is particularly preferably 50 kg / m 3 Hereinafter. By making the core density of the polyurethane foam within this range, it is possible to impart cushioning properties without impairing the softness (preventing hardening) of the polyurethane foam and improve the touch feeling.

[0086] In addition, the core density of the polyurethane foam can be measured, for example, according to the method based on JIS K7222:2005.

[0087] [Hardness]

[0088] The hardness of the polyurethane foam can be freely set within the range that does not impair the effects of this technology. As the hardness of the polyurethane foam, it is preferably 1 kPa or more, more preferably 3 kPa or more, and further preferably 4 kPa or more. By making the hardness of the polyurethane foam within this range, it is possible to expand the range of applicable uses.

[0089] In addition, the hardness of the polyurethane foam can be measured, for example, by performing 25% compression after 75% preliminary compression.

[0090] [Rebound resilience]

[0091] The rebound resilience of the polyurethane foam can be freely set within the range that does not impair the effects of this technology. As the rebound resilience of the polyurethane foam, it is preferably 10% or more, more preferably 15% or more, and further preferably 20% or more. By making the rebound resilience of the polyurethane foam within this range, it is possible to improve the cushioning properties of the polyurethane foam. As the rebound resilience of the polyurethane foam related to this technology, it is preferably 50% or less, more preferably 40% or less, and further preferably 30% or less. By making the rebound resilience of the polyurethane foam within this range, it is possible to expand the range of applicable uses.

[0092] In addition, the rebound resilience of the polyurethane foam can be measured, for example, according to the method based on JIS K6400-3:2011.

[0093] [Tensile strength]

[0094] The tensile strength of the polyurethane foam can be freely set within the range that does not impair the effects of this technology. As the tensile strength of the polyurethane foam, it is preferably 100 kPa or more, more preferably 120 kPa or more, and further preferably 150 kPa or more. By making the tensile strength of the polyurethane foam within this range, it is possible to prevent the deformation of the polyurethane foam.

[0095] In addition, the tensile strength of the polyurethane foam can be measured, for example, according to the method based on JIS K6400-5:2012.

[0096] Tensile elongation

[0097] The tensile elongation of the polyurethane foam can be freely set within a range that does not impair the effects of the present technology. As the tensile elongation of the polyurethane foam, it is preferably 20% or more, more preferably 40% or more, and further preferably 50% or more. By making the tensile elongation of the polyurethane foam within this range, breakage during the use of the polyurethane foam can be prevented.

[0098] In addition, the tensile elongation of the polyurethane foam can be measured, for example, according to the method based on JIS K6400-5:2012.

[0099] [Tear strength]

[0100] The tear strength of the polyurethane foam can be freely set within a range that does not impair the effects of the present technology. As the tear strength of the polyurethane foam, it is preferably 1 N / cm or more, more preferably 3 N / cm or more, and further preferably 5 N / cm or more. By making the tear strength of the polyurethane foam within this range, breakage during the use of the polyurethane foam can be prevented.

[0101] In addition, the tear strength of the polyurethane foam can be measured, for example, according to the method based on JIS K6400-5:2012.

[0102] [25% dry heat compression deformation][50% dry heat compression deformation]

[0103] The 25% dry heat compression deformation of the polyurethane foam can be freely set within a range that does not impair the effects of the present technology. As the 25% dry heat compression deformation of the polyurethane foam, it is preferably 20% or less, more preferably 15% or less, further preferably 13% or less, and particularly preferably 11% or less. By making the dry heat compression deformation of the polyurethane foam within this range, low resilience is obtained. Therefore, the polyurethane foam according to the present technology can be suitably used, for example, for vehicle components such as headrests, armrests, and vehicle seat cushions.

[0104] In addition, the 25% dry heat compression deformation and 50% dry heat compression deformation of the polyurethane foam can be measured, for example, according to the method based on JIS K6400-4:2004.

[0105] [Reactivity (rise time)]

[0106] The reactivity (rise time) of the polyurethane foam can be freely set within the range that does not impair the effects of the present technology. As the reactivity (rise time) of the polyurethane foam, it is preferably 100 seconds or less, more preferably 75 seconds or less, further preferably 50 seconds or less, and particularly preferably 25 seconds or less. By making the reactivity (rise time) of the polyurethane foam within this range, for example, it is possible to eliminate the leakage of the polyurethane foam from the skin seam when manufacturing a product with integral skin molding.

[0107] 3. Uses of the polyurethane foam

[0108] The polyurethane foam manufactured using the composition for manufacturing polyurethane foam according to the present technology can be used for all applications in all fields due to its high quality. However, since it is an integral skin molding mold, it is particularly suitable for vehicle components such as headrests, armrests, vehicle seat cushions, footstools, etc.

[0109] 4. Manufacturing method of the polyurethane foam using the composition for manufacturing polyurethane foam according to the present technology

[0110] The polyurethane foam can be prepared by mixing the components of the composition for manufacturing polyurethane foam according to the present technology to obtain a mixed solution, and injecting the mixture into the skin material etc. preset in the molding mold to carry out the resinification reaction and the foaming reaction, thereby manufacturing an integral skin molding type polyurethane foam. Regarding the injection method into the skin material etc., and the methods of the resinification reaction and the foaming reaction, general methods can be freely combined within the range that does not impair the effects of the present technology. In addition, when manufacturing the polyurethane foam, a previously disclosed high-pressure foaming machine or low-pressure foaming machine etc. can also be used.

[0111] Specifically, the composition for manufacturing polyurethane foam according to the present technology is used for manufacturing vehicle components such as the above-mentioned headrest etc. For example, a mixed solution composed of the components of the polyurethane foam composition according to the present technology is sprayed into the skin material preset in the mold, and it is foamed, filled, and cured to obtain an integral skin molded article with the desired shape. As the material of the mold, for example, aluminum or iron materials are mostly used.

[0112] The skin material is not particularly limited, and examples include: cloth (fabric), a laminate of cloth (fabric) and plate-like foam (a two-layer structure of cloth and plate-like foam), a laminate of cloth (fabric), plate-like foam, and a film such as polyurethane (a three-layer structure of cloth, plate-like foam, and film), etc. In addition, in addition to cloth, artificial leather (PVC, polyurethane) or genuine leather etc. can also be used.

[0113] Examples

[0114] Hereinafter, the present technology will be described in more detail based on examples.

[0115] In addition, the embodiments described below show an example of a representative embodiment of the present technology, and the scope of the present technology should not be narrowly construed thereby.

[0116] (1) Components of the composition for producing polyurethane foam

[0117] ・Castor oil (manufactured by Ito Oil Co., Ltd., H-30)

[0118] ・Polyether polyol 1 (manufactured by Sanyo Chemical Industries, Ltd., PP4000)

[0119] ・Polyether polyol 2 (manufactured by Sanyo Chemical Industries, Ltd., GP3000)

[0120] ・Polyether polyol 3 (manufactured by Sanyo Chemical Industries, Ltd., GP3050NS)

[0121] ・Polyether polyol 4 (manufactured by Sanyo Chemical Industries, Ltd., T-5)

[0122] ・Polyether polyol 5 (manufactured by Dow Chemical Japan Co., Ltd., V4701)

[0123] ・Polyether polyol 6 (manufactured by AGC Inc., EX510)

[0124] ・Polyether polyol 7 (manufactured by Sanyo Chemical Industries, Ltd., 80-4000)

[0125] ・Polymer polyol (manufactured by Sanyo Chemical Industries, Ltd., FA728R)

[0126] ・Polyether polyol 8 (secondary polyol) (manufactured by AGC Inc., EL981)

[0127] ・Polyether polyol 9 (manufactured by Mitsui Chemicals, Inc., D-1000)

[0128] ・Polymer polyol (manufactured by Mitsui Chemicals, Inc., POP-93)

[0129] ・Modified castor oil (polyester polyol) (manufactured by Mitsui Chemicals, Inc., polyester polyol A)

[0130] ・Triethylenediamine (manufactured by Evonik Japan Co., Ltd., 33LSI)

[0131] ・Mixture of bis(2-dimethylaminoethyl) ether and dipropylene glycol (manufactured by Tosoh Corporation, TOYOCAT ET)

[0132] ・N,N-Dimethylethanolamine monomer grade (Dow Chemical Japan Co., Ltd., DMEA)

[0133] - Aliphatic amine composition (manufactured by Evonik Japan Co., Ltd., NE300)

[0134] - Diol solution of tertiary amine (Evonik Japan Co., Ltd., DABCO 3040A)

[0135] - Organically modified polysiloxane (manufactured by Evonik Japan Co., Ltd., B8738LF2)

[0136] - Silicone-based surfactant (manufactured by Momentive Performance Materials, L-580)

[0137] - Prepolymer formed by polymerizing MDI with diphenylmethane diisocyanate group and polyol (manufactured by SumikaCovestro Urethane Co., Ltd., M249)

[0138] - Mixture of 2,4-toluene diisocyanate and 2,6-toluene diisocyanate (Mitsui Chemicals, Inc., T-80)

[0139] - 1,2-Ethylene glycol (manufactured by Sankyo Chemical Co., Ltd., ethylene glycol)

[0140] - N,N-Dimethyldodecylamine (manufactured by Tosoh Corporation, TOYOCAT D60)

[0141] - Mixture of polyether polyol and diethanolamine (manufactured by Mitsui Chemicals, Inc., KL210)

[0142] - Bis(dodecylthio)dioctyltin (manufactured by Airproducts, T-9)

[0143] (2) Manufacture of polyurethane foam

[0144] After stirring and mixing each component of the polyurethane manufacturing composition shown in Table 1 and Table 2 below to prepare a mixture, the prepared mixture is foamed at atmospheric pressure at room temperature or in a mold at a temperature of 30 °C to 60 °C, thereby manufacturing each polyurethane foam.

[0145] (3) Evaluation

[0146] Regarding core density, hardness, resilience, tensile strength, tensile elongation, tear strength, 25% dry heat compression set, and 50% dry heat compression set, they were measured by the above method. In addition, regarding reactivity, it was evaluated using the rise time. Further, in Tables 1 and 2 below, for the parts marked with "※", since the moldability of the polyurethane foam was poor and the reliability of the data was very low, they could not be measured. In addition, in each evaluation item, for the parts marked with "-", it indicates that they were not measured.

[0147] In addition, for cell coarseness, moldability (shrinkage), and moldability (rupture), visual inspection was carried out. Regarding these evaluation criteria, they are as follows.

[0148] [Cell coarseness]

[0149] A: The cells are fine.

[0150] B: The cells are slightly coarse.

[0151] C: The cells are coarse.

[0152] D: The cells are very coarse.

[0153] In addition, Figure 1 is a substitute photograph of the drawing showing the cells in the cross-section of the polyurethane foam of Example 2, showing the state of A above. In addition, Figure 2 is a substitute photograph of the drawing showing the cells in the cross-section of the polyurethane foam of Comparative Example 6, showing the state of C above.

[0154] [Moldability (shrinkage)]

[0155] A: No shrinkage occurred.

[0156] B: Slight shrinkage occurred.

[0157] C: Shrinkage occurred.

[0158] D: Since rupture occurred, shrinkage could not be inspected.

[0159] In addition, Figure 3 is a substitute photograph of the drawing showing the moldability (no shrinkage) in the polyurethane foam of Example 2, showing the state of A above. In addition, Figure 4 is a substitute photograph of the drawing showing the moldability (with shrinkage) in the polyurethane foam of Comparative Example 3, showing the state of C above.

[0160] [Moldability (rupture)]

[0161] A: No rupture occurred.

[0162] B: Rupture occurred.

[0163] (4) Results

[0164] The results are shown in Table 1 and Table 2 below.

[0165] [Table 1]

[0166]

[0167] [Table 2]

[0168]

[0169] (5) Investigation

[0170] As shown in Table 1 and Table 2, compared with the control (Comparative Example 1) of polyurethane foam in Comparative Examples 2 to 7 that does not contain plant-derived raw materials and / or plant-derived polyols, the cell structure is rough, broken, and shrunk, resulting in poor moldability, and the rebound resilience, tensile strength, tensile elongation, tear strength, and 25% dry heat compression deformation cannot be measured (in addition, the core density and hardness cannot be measured in Comparative Examples 4 and 7). In contrast, the polyurethane foams of Examples 1 to 3 manufactured using the polyurethane foam manufacturing composition containing plant-derived raw materials and / or plant-derived polyols, polymer polyols, and polyether polyols with 10% to 70% EO do not have rough cell structures. Although slight shrinkage was confirmed in Example 1, the rebound resilience, tensile strength, tensile elongation, tear strength, and 25% dry heat compression deformation could not be measured, but the moldability was also generally good, and the physical properties equivalent to those of the control were maintained.

[0171] Regarding Examples 2 and 3, the rebound resilience was 23% and 24% respectively, indicating excellent low rebound resilience. As also recorded in Table 2, this is the same low rebound resilience as that of the conventional low-rebound product in Comparative Example 8. In addition, the 25% dry heat compression deformation was 9.7% and 10.7% respectively, indicating excellent durability. As also recorded in Table 2, this is the same durability as that of the conventional low-rebound product in Comparative Example 8. In addition, regarding the reactivity (rise time), Examples 2 and 3 were 25 seconds, which was 75 seconds faster than that in Comparative Example 9. Therefore, it can be expected that the polyurethane foam according to the present technology can prevent the polyurethane foam from leaking from the skin joint when manufacturing a product with an integrally formed skin.

[0172] From these results, it can be seen that when manufacturing polyurethane foam using plant-derived raw materials and / or plant-derived polyols, by using polymer polyols and polyether polyols with 10% to 70% EO together, a polyurethane foam with no rough cell structure and excellent moldability can be provided. In addition, the polyurethane foam manufacturing composition according to the present technology is used for integrally forming the skin, does not produce rough cell structures, and thus also has the excellent effect of adhesiveness to the skin.

Claims

1. A composition for manufacturing polyurethane foam, which contains: Plant-derived raw materials and / or plant-derived polyols; Polymer polyols; and Polyether polyols with 10% to 70% EO, The composition for manufacturing polyurethane foam is used for integral skin molding.

2. The composition for producing a polyurethane foam according to claim 1, wherein, The polymer polyols are less than 30 parts by mass relative to 100 parts by mass of polyols.

3. The composition for producing polyurethane foam according to claim 1, wherein, The polyether polyols are less than 30 parts by mass relative to 100 parts by mass of polyols.

4. The composition for producing polyurethane foam according to claim 1, wherein, The biomass degree is 15% or more.

5. A vehicle component, which is integrally molded with a polyurethane foam formed by using the composition for manufacturing polyurethane foam according to any one of claims 1 to 4 and a skin.

Images