Composition for producing polyurethane foam, polyurethane foam, and vehicle interior material using polyurethane foam

Abstract

To provide a technology capable of producing high-quality polyurethane foam while contributing to environmental preservation.SOLUTION: In this technology, provided is a composition for producing polyurethane foam that contains a polyol, with 50 pts.mass or more of plant-derived polyol contained in 100 pts.mass of the polyol. The polyol includes a polyether polyol having a hydroxyl value of 100 mgKOH / g or less and a polyether polyol having a hydroxyl value of 200 mgKOH / g or more and 700 mgKOH / g or less.SELECTED DRAWING: None

Description

[Technical field]

[0001] The present technology relates to a composition for producing a polyurethane foam. More specifically, the present technology relates to a composition for producing a polyurethane foam, a polyurethane foam formed using the composition for producing a polyurethane foam, and a vehicle interior material using the polyurethane foam. [Background technology]

[0002] Polyurethane foams are widely used in a variety of fields, from furniture such as sofas and chairs, bedding such as mattresses and pillows, clothing such as underwear, daily necessities such as dish sponges and cleaning sponges, interior products for vehicles and aircraft such as car seats, electronic devices such as mobile phones, cameras, televisions, electrical appliances such as home appliances, toys, and miscellaneous goods. Various developments are being carried out to improve quality and add new functions according to each field and purpose.

[0003] In recent years, in order to contribute to environmental consideration and the formation of a sustainable society, a technology for producing polyurethane foam using plant resources has also been proposed. For example, Patent Document 1 discloses a technology for producing a polyurethane foam by combining a plant-derived polyol and a low monol polyol, which contributes to reducing the environmental load and provides a plant-derived polyurethane foam that achieves a good balance of appropriate hardness, impact resilience, and excellent durability. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] International Publication No. 2007 / 020904 Summary of the Invention [Problem to be solved by the invention]

[0005] As mentioned above, various developments are being made to contribute to environmental consideration and the formation of a sustainable society, but there is still a long way to go. For example, if a large amount of plant-derived polyol is used to produce a polyurethane foam with a high biomass content, there is a problem that the foaming property during production and the physical properties of the produced polyurethane foam are reduced. Thus, it is difficult to produce a high-quality polyurethane foam while contributing to reducing the environmental load.

[0006] Therefore, the main objective of this technology is to provide a technology capable of producing high-quality polyurethane foam while contributing to environmental conservation. [Means for solving the problem]

[0007] In the present technology, first, a composition for producing a polyurethane foam containing a polyol is provided, The polyol contains 50 parts by mass or more of a plant-derived polyol per 100 parts by mass of the polyol, The polyol may include A polyether polyol having a hydroxyl value of 100 mgKOH / g or less; The present invention provides a composition for producing polyurethane foam, which contains a polyether polyol having a hydroxyl value of 200 mgKOH / g or more and 700 mgKOH / g or less. The polyether polyol having a hydroxyl value of 100 mgKOH / g or less used in the composition for producing polyurethane foam according to the present technology includes: A polyether polyol having an ethylene oxide addition rate of 50% or more; It may contain a polyether polyol having an ethylene oxide addition rate of less than 50%.

[0008] Next, the present technology provides a polyurethane foam formed using the composition for producing a polyurethane foam according to the present technology. In addition, this technology requires a biomass content of 20% or more. Provided is a polyurethane foam having a wet heat compression set of 10.0% or less, measured in accordance with JIS K6400-4.

[0009] The present technology also provides a vehicle interior material using the polyurethane foam according to the present technology. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] A preferred embodiment for carrying out the present technology will be described below. The embodiments described below are representative examples of the present technology, and any of the embodiments can be combined. In addition, the scope of the present technology is not narrowly interpreted by these.

[0011] 1. Composition for producing polyurethane foam The polyurethane foam production composition according to the present technology contains a plant-derived polyol, a polyether polyol having a hydroxyl value of 100 mgKOH / g or less, and a polyether polyol having a hydroxyl value of 200 mgKOH / g or more and 700 mgKOH / g or less. The polyurethane foam production composition according to the present technology may also contain other polyols, isocyanates, catalysts, blowing agents, foam stabilizers, etc., as necessary. Each component will be described in detail below.

[0012] (1) Polyol The composition for producing polyurethane foam according to the present technology contains a plant-derived polyol, a polyether polyol having a hydroxyl value of 100 mgKOH / g or less, and a polyether polyol having a hydroxyl value of 200 mgKOH / g to 700 mgKOH / g. The composition for producing polyurethane foam according to the present technology may also contain other polyols as necessary.

[0013] (1-1) Plant-derived polyol The composition for producing polyurethane foam according to the present technology is characterized in that a plant-derived polyol is used as the polyol. The plant-derived polyol that can be used in the present technology can be one or more freely selected plant-derived polyols that can be used in the production of polyurethane foam, as long as the action and effect of the present technology are not impaired.

[0014] Examples of plant-derived polyols that can be used in the present technology include polyols derived from natural fats and oils. Natural fat-derived polyols are natural fats and oils such as castor oil, soybean oil, rapeseed oil, and coconut oil, or derivatives thereof (modified natural fat and oil polyols, unmodified natural fat and oil polyols, etc.), which contain hydroxyl groups on the hydrocarbon chain and have two or more hydroxyl groups in one molecule. In the present technology, two or more of these may be used in combination. Examples of other plant-derived polyols include polyols derived from cashew nut shell liquid. In addition, commercially available plant-derived polyols may be used.

[0015] Among these, in the present technology, it is preferable to use castor oil. "Castor oil" includes any 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 glycerin. Unmodified castor oil contains ricinoleic acid as a main component, and other components include unsaturated fatty acids such as oleic acid, linoleic acid, and linolenic acid, and saturated fatty acids such as palmitic acid and stearic acid.

[0016] In the present technology, it is preferable to use an unmodified natural fat polyol or a modified natural fat polyol as the plant-derived polyol, and it is more preferable to use them in combination. It is more preferable to use unmodified castor oil as the unmodified natural fat polyol, and it is more preferable to use modified castor oil as the modified natural fat polyol.

[0017] When using an unmodified natural fat polyol, its hydroxyl value is not particularly limited as long as it does not impair the action or effect of the present technology. The lower limit of the hydroxyl value of the unmodified natural fat polyol is, for example, 130 mg KOH / g or more, preferably 140 mg KOH / g or more, more preferably 145 mg KOH / g or more. The upper limit of the hydroxyl value of the unmodified natural fat polyol is, for example, 185 mg KOH / g or less, preferably 180 mg KOH / g or less, more preferably 175 mg KOH / g or less.

[0018] When using a modified natural fat polyol, its hydroxyl value is not particularly limited as long as it does not impair the action or effect of the present technology. The lower limit of the hydroxyl value of the modified natural fat polyol is, for example, 30 mgKOH / g or more, preferably 40 mgKOH / g or more, more preferably 50 mgKOH / g or more. The upper limit of the hydroxyl value of the modified natural fat polyol is, for example, 140 mgKOH / g or less, preferably 130 mgKOH / g or less, more preferably 120 mgKOH / g or less.

[0019] When using unmodified natural fat polyol, its functional number is not particularly limited as long as it does not impair the action or effect of the present technology.The lower limit of the functional number of unmodified natural fat polyol is, for example, 2.0 or more, preferably 2.4 or more, more preferably 2.5 or more.The upper limit of the functional number of unmodified natural fat polyol is, for example, 3.5 or less, preferably 3.0 or less, more preferably 2.9 or less.

[0020] When using modified natural fat polyol, its number of functional groups is not particularly limited as long as it does not impair the action and effect of the present technology. The lower limit of the number of functional groups of modified natural fat polyol is, for example, 2.5 or more, preferably 3.0 or more, more preferably 3.2 or more. The upper limit of the number of functional groups of modified natural fat polyol is, for example, 4.5 or less, preferably 4.0 or less, more preferably 3.8 or less.

[0021] In the composition for producing a polyurethane foam according to the present technology, the content of the plant-derived polyol per 100 parts by mass of the polyol is 50 parts by mass or more, preferably 55 parts by mass or more, more preferably 60 parts by mass or more, and even more preferably 65 parts by mass or more. By setting the content of the plant-derived polyol per 100 parts by mass of the polyol within this range, the effect of reducing the environmental load can be improved.

[0022] In the polyurethane foam producing composition according to the present technology, the upper limit of the content of the plant-derived polyol relative to 100 parts by mass of polyol is not particularly limited as long as it does not impair the action and effect of the present technology, but it can be adjusted according to the required amount of other polyols described later. The upper limit of the content of the plant-derived polyol relative to 100 parts by mass of polyol can be set to, for example, 90 parts by mass or less, 85 parts by mass or less, 80 parts by mass or less, 75 parts by mass or less, 70 parts by mass or less, etc.

[0023] When using unmodified natural fat polyol, the content of unmodified natural fat polyol relative to 100 parts by mass of polyol is not particularly limited as long as it does not impair the action or effect of the present technology.The lower limit of the content of unmodified natural fat polyol relative to 100 parts by mass of polyol is, for example, 20 parts by mass or more, preferably 30 parts by mass or more, more preferably 35 parts by mass or more.The upper limit of the content of unmodified natural fat polyol relative to 100 parts by mass of polyol is, for example, 60 parts by mass or less, preferably 55 parts by mass or less, more preferably 50 parts by mass or less.

[0024] When using modified natural fat polyol, the content of modified natural fat polyol relative to 100 parts by mass of polyol is not particularly limited as long as it does not impair the action or effect of the present technology. The lower limit of the content of modified natural fat polyol relative to 100 parts by mass of polyol is, for example, 5.0 parts by mass or more, preferably 10 parts by mass or more, more preferably 15 parts by mass or more. The upper limit of the content of modified natural fat polyol relative to 100 parts by mass of polyol is, for example, 40 parts by mass or less, preferably 35 parts by mass or less, more preferably 30 parts by mass or less.

[0025] (1-2) Polyether polyol The polyether polyol used in the present technology includes, for example, polyethylene glycol, polypropylene glycol, polytetramethylene ether glycol, etc., which are obtained by polymerizing cyclic ethers such as ethylene oxide and propylene oxide, respectively, and their copolyethers. In addition, it is also possible to obtain the above-mentioned cyclic ethers by polymerizing polyhydric alcohols such as glycerin and trimethylolethane. In addition, commercially available polyether polyols may be used.

[0026] Also, as the polyether polyol, a polymer polyol can be used. The polymer polyol is obtained by polymerizing an ethylenically unsaturated monomer in a polyether polyol, or by emulsifying and dispersing a polymer of an ethylenically unsaturated monomer in a polyether polyol. Specifically, for example, a polyether polyol is graft-polymerized with acrylonitrile, styrene, or the like, or a polyether polyol is dispersed with polystyrene or polyacrylonitrile, or the like.

[0027] [Hydroxyl value] The composition for producing polyurethane foam according to the present technology is characterized by containing polyether polyol A having a hydroxyl value of 100 mgKOH / g or less and polyether polyol B having a hydroxyl value of 200 mgKOH / g or more and 700 mgKOH / g or less. By using these polyether polyols A and B having different hydroxyl values ​​in combination, even when a plant-derived polyol is used, it is possible to suppress a decrease in foamability during production, and to improve the quality of the polyurethane foam produced. Specifically, by improving the foamability during production, it is possible to improve the appearance of the polyurethane foam produced and optimize the gas-filling property, while maintaining a quality equal to or higher than that of a general polyurethane foam. In particular, the present technology can reduce the moist heat compression set of the polyurethane foam produced.

[0028] The hydroxyl value of polyether polyol A is not limited as long as it is 100 mgKOH / g or less, as long as it does not impair the action and effect of the present technology, but is preferably 60 mgKOH / g or less, more preferably 50 mgKOH / g or less, and even more preferably 45 mgKOH / g or less. The lower limit of the hydroxyl value of polyether polyol A is not limited as long as it does not impair the action and effect of the present technology, but is, for example, 5.0 mgKOH / g or more, preferably 10 mgKOH / g or more, and more preferably 15 mgKOH / g or more. By setting the hydroxyl value of polyether polyol A in this range, it is possible to further suppress the decrease in foamability during production, and to further improve the quality of the polyurethane foam produced.

[0029] The lower limit of the hydroxyl value of polyether polyol B is not limited as long as it is 200 mgKOH / g or more and does not impair the action and effect of the present technology, but is preferably 250 mgKOH / g or more, and more preferably 300 mgKOH / g or more. The upper limit of the hydroxyl value of polyether polyol B is not limited as long as it is 700 mgKOH / g or less and does not impair the action and effect of the present technology, but is preferably 650 mgKOH / g or less, and more preferably 600 mgKOH / g or less. By setting the hydroxyl value of polyether polyol B in this range, it is possible to further suppress the decrease in foamability during production, and to further improve the quality of the polyurethane foam produced.

[0030] In the polyurethane foam producing composition according to the present technology, the content of polyether polyol A relative to 100 parts by mass of polyol is not particularly limited as long as it does not impair the action or effect of the present technology. The lower limit of the content of polyether polyol A relative to 100 parts by mass of polyol is, for example, 10 parts by mass or more, preferably 15 parts by mass or more, more preferably 20 parts by mass or more, and even more preferably 25 parts by mass or more. The upper limit of the content of polyether polyol A relative to 100 parts by mass of polyol is, for example, 55 parts by mass or less, preferably 50 parts by mass or less, more preferably 45 parts by mass or less, and even more preferably 35 parts by mass or less.

[0031] In the polyurethane foam producing composition according to the present technology, the content of polyether polyol B relative to 100 parts by mass of polyol is not particularly limited as long as it does not impair the action or effect of the present technology. The lower limit of the content of polyether polyol B relative to 100 parts by mass of polyol is, for example, 1 part by mass or more, preferably 2 parts by mass or more, more preferably 2.5 parts by mass or more. The upper limit of the content of polyether polyol B relative to 100 parts by mass of polyol is, for example, 15 parts by mass or less, preferably 10 parts by mass or less, more preferably 7.0 parts by mass or less, and even more preferably 6.0 parts by mass or less.

[0032] [Ethylene oxide addition rate (EO rate)] The ethylene oxide addition ratio (hereinafter also referred to as "EO ratio") refers to the weight ratio of ethylene oxide (EO) to the total amount of alkylene oxide (AO) such as ethylene oxide (EO) and propylene oxide (PO) which are monomers in the production of polyether polyol. That is, the EO ratio can be calculated based on the following formula (1). EO rate (%) = EO weight x 100 / AO total weight (EO weight + PO weight, etc.)...(1)

[0033] The EO ratio of the polyether polyol used in the present technology is not particularly limited as long as it does not impair the function and effect of the present technology.The lower limit of the EO ratio of the polyether polyol is, for example, 5.0% or more, preferably 10% or more, more preferably 12% or more.The upper limit of the EO ratio of the polyether polyol is, for example, 95% or less, preferably 90% or less, more preferably 85% or less.

[0034] In the present technology, the polyether polyol A having a hydroxyl value of 100 mgKOH / g or less preferably contains a polyether polyol having an EO ratio of 50% or more (hereinafter also referred to as "high EO ratio polyether polyol A") and a polyether polyol having an EO ratio of less than 50% (hereinafter also referred to as "low EO ratio polyether polyol A"). By using a high EO ratio polyether polyol A having a hydroxyl value of 100 mgKOH / g or less and an EO ratio of 50% or more in combination with a low EO ratio polyether polyol A having a hydroxyl value of 100 mgKOH / g or less and an EO ratio of less than 50%, the decrease in foamability during production can be further suppressed, and the quality of the polyurethane foam produced can be further improved.

[0035] The lower limit of the EO ratio of the high EO ratio polyether polyol A is preferably 50% or more, more preferably 55% or more, even more preferably 60% or more, and particularly preferably 65% ​​or more. The upper limit of the EO ratio of the high EO ratio polyether polyol A is not particularly limited as long as it does not impair the action or effect of the present technology, and can be set to, for example, 95% or less, 90% or less, 85% or less, etc.

[0036] The upper limit of the EO ratio of the low EO ratio polyether polyol A is preferably less than 50%, more preferably 45% or less, even more preferably 40% or less, even more preferably 35% or less, and particularly preferably 30% or less. The lower limit of the EO ratio of the low EO ratio polyether polyol A is not particularly limited as long as it does not impair the action or effect of the present technology, and can be set to, for example, 5.0% or more, 8.0% or more, 10% or more, etc.

[0037] In the polyurethane foam producing composition according to the present technology, the content of the high EO polyether polyol A relative to 100 parts by mass of polyol is not particularly limited as long as it does not impair the action or effect of the present technology. The lower limit of the content of the high EO polyether polyol A relative to 100 parts by mass of polyol is, for example, 10 parts by mass or more, preferably 15 parts by mass or more, more preferably 20 parts by mass or more, and even more preferably 25 parts by mass or more. The upper limit of the content of the high EO polyether polyol A relative to 100 parts by mass of polyol is, for example, 50 parts by mass or less, preferably 45 parts by mass or less, more preferably 40 parts by mass or less, and even more preferably 35 parts by mass or less.

[0038] In the polyurethane foam producing composition according to the present technology, the content of the low EO ratio polyether polyol A relative to 100 parts by mass of polyol is not particularly limited as long as it does not impair the action or effect of the present technology. The lower limit of the content of the low EO ratio polyether polyol A relative to 100 parts by mass of polyol is, for example, 0.5 parts by mass or more, preferably 1.0 parts by mass or more, more preferably 1.5 parts by mass or more. The upper limit of the content of the low EO ratio polyether polyol A relative to 100 parts by mass of polyol is, for example, 10 parts by mass or less, preferably 7.0 parts by mass or less, more preferably 6.0 parts by mass or less, and even more preferably 5.0 parts by mass or less.

[0039] The EO ratio of polyether polyol B is not particularly limited as long as it does not impair the function and effect of the present technology. The lower limit of the EO ratio of polyether polyol B is, for example, 5% or more, preferably 10% or more, and more preferably 15% or more. The upper limit of the EO ratio of polyether polyol B is, for example, 70% or less, preferably 60% or less, and more preferably 55% or less.

[0040] [Number of functional groups] The number of functional groups of the polyether polyol used in the present technology is not particularly limited as long as it does not impair the action and effect of the present technology.The lower limit of the number of functional groups of the polyether polyol is, for example, 1.5 or more, preferably 2.0 or more, more preferably 2.5 or more.The upper limit of the number of functional groups of the polyether polyol is, for example, 8.0 or less, preferably 7.0 or less, more preferably 6.0 or less.

[0041] In the present technology, it is preferable to use in combination a polyether polyol having a functionality of 2 to 4 and a polyether polyol having a functionality of 4.5 to 6.0, and it is more preferable to use in combination a polyether polyol having a functionality of 2.5 to 3.5 and a polyether polyol having a functionality of 5.0 to 6.0. By using polyether polyols having different functionality in combination, it is possible to further suppress the decrease in foamability during production, and to further improve the quality of the polyurethane foam produced.

[0042] The number of functional groups of the high EO polyether polyol A used in the present technology is not particularly limited as long as it does not impair the action and effect of the present technology. The lower limit of the number of functional groups of the high EO polyether polyol A is, for example, 1.5 or more, preferably 2.0 or more, more preferably 2.5 or more. The upper limit of the number of functional groups of the high EO polyether polyol A is, for example, 5.0 or less, preferably 4.0 or less, more preferably 3.5 or less.

[0043] The number of functional groups of the low EO ratio polyether polyol A used in the present technology is not particularly limited as long as it does not impair the action and effect of the present technology. The lower limit of the number of functional groups of the low EO ratio polyether polyol A is, for example, 1.5 or more, preferably 2.0 or more, more preferably 2.5 or more. The upper limit of the number of functional groups of the low EO ratio polyether polyol A is, for example, 5.0 or less, preferably 4.0 or less, more preferably 3.5 or less.

[0044] The number of functional groups of the polyether polyol B used in the present technology is not particularly limited as long as it does not impair the action or effect of the present technology. The lower limit of the number of functional groups of the polyether polyol B is, for example, 3.0 or more, preferably 4.0 or more, more preferably 5.0 or more. The upper limit of the number of functional groups of the polyether polyol B is, for example, 8.0 or less, preferably 7.0 or less, more preferably 6.0 or less.

[0045] [Number average molecular weight] The number average molecular weight of the polyether polyol used in the present technology is not particularly limited as long as it does not impair the function and effect of the present technology.The lower limit of the number average molecular weight of the polyether polyol is, for example, 100 or more, preferably 200 or more, more preferably 300 or more.The upper limit of the number average molecular weight of the polyether polyol is, for example, 10000 or less, preferably 9000 or less, more preferably 8000 or less.

[0046] In the present technology, it is preferable to use in combination a polyether polyol having a number average molecular weight of 2000 or more and a polyether polyol having a number average molecular weight of less than 2000, and it is more preferable to use in combination a polyether polyol having a number average molecular weight of 3000 or more and a polyether polyol having a number average molecular weight of 1000 or less. By using polyether polyols having different number average molecular weights in combination, it is possible to further suppress the decrease in foamability during production, and to further improve the quality of the polyurethane foam produced.

[0047] The number average molecular weight of the high EO polyether polyol A used in the present technology is not particularly limited as long as it does not impair the function and effect of the present technology. The lower limit of the number average molecular weight of the high EO polyether polyol A is, for example, 2000 or more, preferably 2500 or more, more preferably 3000 or more. The upper limit of the number average molecular weight of the high EO polyether polyol A is, for example, 8000 or less, preferably 7000 or less, more preferably 6000 or less.

[0048] The number average molecular weight of the low EO ratio polyether polyol A used in the present technology is not particularly limited as long as it does not impair the function and effect of the present technology. The lower limit of the number average molecular weight of the low EO ratio polyether polyol A is, for example, 1000 or more, preferably 2000 or more, more preferably 3000 or more. The upper limit of the number average molecular weight of the low EO ratio polyether polyol A is, for example, 10000 or less, preferably 9000 or less, more preferably 8000 or less.

[0049] The number average molecular weight of the polyether polyol B used in the present technology is not particularly limited as long as it does not impair the function and effect of the present technology. The lower limit of the number average molecular weight of the polyether polyol B is, for example, 100 or more, preferably 200 or more, more preferably 300 or more. The upper limit of the number average molecular weight of the polyether polyol B is, for example, less than 2000, preferably 1500 or less, more preferably 1000 or less.

[0050] (1-3) Other polyols In the present invention, one or more polyols other than plant-derived polyols and polyether polyols that can be used in the production of polyurethane foams can be freely selected and used in combination. Examples of other polyols include polyester polyols, polycarbonate polyols, and polyester ether polyols.

[0051] Examples of polyester polyols include aliphatic dicarboxylic acids such as succinic acid, adipic acid, sebacic acid, and azelaic acid; aliphatic carboxylic acids such as ricinoleic acid; aromatic dicarboxylic acids such as phthalic acid, terephthalic acid, isophthalic acid, and naphthalenedicarboxylic acid; alicyclic dicarboxylic acids such as hexahydrophthalic acid, hexahydroterephthalic acid, and hexahydroisophthalic acid; and acid esters or acid anhydrides of these, and ethylene glycol, 1,3-propylene glycol, 1,2-propylene glycol. , 1,3-butanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 3-methyl-1,5-pentanediol, neopentyl glycol, 1,8-octanediol, 1,9-nonanediol, or a mixture thereof; polylactone polyols and polycaprolactone polyols obtained by ring-opening polymerization of lactone monomers such as ε-caprolactone and methylvalerolactone. In addition to these, examples of polyester polyols include polyols having naturally occurring ester groups.

[0052] Examples of polycarbonate polyols include those obtained by reacting at least one of polyhydric alcohols such as ethylene glycol, 1,2-propylene glycol, 1,3-propylene glycol, 1,3-butanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 3-methyl-1,5-pentanediol, neopentyl glycol, 1,8-octanediol, 1,9-nonanediol, and diethylene glycol with diethylene carbonate, dimethyl carbonate, diethyl carbonate, and the like.

[0053] Examples of polyester ether polyols include those obtained by a dehydration condensation reaction of an aliphatic dicarboxylic acid such as succinic acid, adipic acid, sebacic acid, or azelaic acid; an aromatic dicarboxylic acid such as phthalic acid, terephthalic acid, isophthalic acid, or naphthalenedicarboxylic acid; an alicyclic dicarboxylic acid such as hexahydrophthalic acid, hexahydroterephthalic acid, or hexahydroisophthalic acid; or an acid ester or anhydride of these and a glycol such as diethylene glycol or a propylene oxide adduct, or a mixture thereof.

[0054] In this technology, biodegradable polyols can also be used in consideration of the environment. As the biodegradable polyols that can be used in this technology, one or more biodegradable polyols that can be used in the production of polyurethane foam can be freely selected and used as long as they do not impair the purpose and effect of this technology. For example, polyglycolic acid (PGA), polylactic acid (PLA), polybutylene succinate (PBS), polybutylene succinate adipate (PBSA), polybutylene adipate terephthalate (PBAT), polycaprolactone (PCL), polyethylene glycol (PEG), polyvinyl alcohol (PVA), polyhydroxyalkanoic acid (PHA), etc. can be mentioned.

[0055] (2) Isocyanate The isocyanate that can be used in the present technology can be freely selected from one or more isocyanates that can be used in the production of polyurethane foam, as long as the purpose and effect of the present technology are not impaired. For example, aromatic isocyanates such as toluene diisocyanate (TDI), diphenylmethane diisocyanate (MDI), naphthalene diisocyanate, xylylene diisocyanate, and polymeric polyisocyanate; aliphatic isocyanates such as hexamethylene diisocyanate, isophorone diisocyanate, and dicyclohexamethane diisocyanate; modified polyisocyanates obtained by modifying these, and the like can be mentioned. Among these, in the present technology, it is preferable to use aromatic isocyanates, and it is more preferable to use toluene diisocyanate (TDI) and / or polymeric MDI (crude MDI).

[0056] In addition, the isocyanate index of the polyurethane foam is not particularly limited as long as it does not impair the action and effect of the present technology. In the present technology, the lower limit of the isocyanate index is, for example, 80 or more, preferably 85 or more, more preferably 90 or more, and even more preferably 92 or more. By setting the lower limit of the isocyanate index within this range, the mechanical strength (tensile strength / elongation) and hardness of the polyurethane foam can be improved.

[0057] The upper limit of the isocyanate index is, for example, not more than 120, preferably not more than 110, more preferably not more than 105, and even more preferably not more than 100. By setting the upper limit of the isocyanate index within this range, the mechanical strength (tensile strength / elongation) and hardness of the polyurethane foam can be prevented from becoming too high, and the flexibility can be improved.

[0058] In the present technology, the isocyanate index is a value calculated by [(isocyanate equivalent in the composition for producing polyurethane foam / active hydrogen equivalent in the composition for producing polyurethane foam)×100].

[0059] (3) Catalyst A catalyst can be used in the production of polyurethane foam according to the present technology. As the catalyst that can be used in the present technology, one or more catalysts that can be used in the production of polyurethane foam can be freely selected and used as long as the action and effect of the present technology are not impaired.

[0060] Examples of the catalyst include triethylamine, triethylenediamine (TEDA), tetramethylguanidine, diethanolamine, bis(2-dimethylaminoethyl)ether, N,N,N',N",N"-pentamethyldiethylenetriamine, imidazole compounds, dimethylpiperazine, N-methyl-N'-(2-dimethylamino)ethylpiperazine, N-methyl-N'-(2-hydroxyethyl) Piperazine-based amines such as piperazine, morpholine-based amines such as N-methylmorpholine and N-ethylmorpholine, and DBU congeners such as 1,8-diazabicyclo-[5,4,0]-undecene-7 (DBU), 1,5-diazabicyclo-[4,3,0]-nonene-5 (DBN), 1,8-diazabicyclo-[5,3,0]-decene-7 (DBD), and 1,4-diazabicyclo-[3,3,0]octene-4 (DBO) Examples of suitable catalysts include amine-based catalysts such as amines referred to as "catalysts" and metal-based catalysts (organometallic catalysts) such as organic iron compounds (iron acetylacetonate, etc.), organic nickel compounds (nickel acetylacetonate, nickel octylate, nickel naphthenate, etc.), organic tin compounds (tin (II) octylate (tin 2-ethylhexanoate, stannous octoate, etc.), organic bismuth compounds (bismuth octylate, bismuth naphthenate, etc.), organic lead compounds (lead octoate, lead naphthenate, etc.), organic cobalt compounds (cobalt acetylacetonate, cobalt octylate, cobalt naphthenate, etc.), organic zirconium compounds (zirconium acetylacetonate, etc.), and organic zinc compounds. Among these, in the present technology, it is preferable to use an amine-based catalyst, and it is more preferable to use triethylenediamine (TEDA) or an imidazole-based compound.

[0061] The amount of catalyst in the composition used for producing the polyurethane foam according to the present technology can be freely set as long as it does not impair the action and effect of the present technology. In the present technology, the lower limit of the catalyst content in the composition is, for example, 0.1 parts by mass or more, preferably 0.5 parts by mass or more, more preferably 1.0 parts by mass or more, relative to 100 parts by mass of polyol. By setting the lower limit of the catalyst content in the composition within this range, various reactions during production can be controlled, and as a result, a polyurethane foam with excellent mechanical properties and appearance can be obtained.

[0062] In this technology, the upper limit of the catalyst content in the composition is, for example, 5.0 parts by mass or less, preferably 3.0 parts by mass or less, more preferably 2.0 parts by mass or less, relative to 100 parts by mass of polyol. By setting the upper limit of the catalyst content in the composition within this range, it is possible to prevent instability of various reactions during production. As a result, it is possible to obtain a polyurethane foam with excellent mechanical properties and appearance.

[0063] (4) Foaming agent A blowing agent can be used in the composition for producing polyurethane foam according to the present technology. As the blowing agent that can be used in the present technology, one or more blowing agents that can be used in the production of polyurethane foam can be freely selected and used as long as the purpose and effect of the present technology are not impaired.

[0064] Examples of the foaming agent include water, hydrocarbons, and halogen-based compounds. Examples of the hydrocarbons include cyclopentane, isopentane, and normal pentane. Examples of the halogen-based compounds include methylene chloride, trichlorofluoromethane, dichlorodifluoromethane, nonafluorobutyl methyl ether, nonafluorobutyl ethyl ether, pentafluoroethyl methyl ether, and heptafluoroisopropyl methyl ether. In the present technology, it is preferable to use water as the foaming agent among these. The water may be any of ion-exchanged water, tap water, and distilled water.

[0065] The amount of the blowing agent used in the polyurethane foam producing composition according to the present technology can be freely set as long as it does not impair the action and effect of the present technology. In the present technology, the lower limit of the blowing agent content in the polyurethane foam producing composition is, for example, 0.5 parts by mass or more, preferably 1.0 parts by mass or more, and more preferably 2.0 parts by mass or more, relative to 100 parts by mass of polyol. By setting the lower limit of the blowing agent content in the polyurethane foam producing composition within this range, it is possible to improve the foamability, and as a result, it is possible to obtain a polyurethane foam having excellent mechanical properties and appearance.

[0066] In the present technology, the upper limit of the content of the blowing agent in the composition for producing polyurethane foam is, for example, 10 parts by mass or less, preferably 5.0 parts by mass or less, more preferably 4.0 parts by mass or less, and even more preferably 3.0 parts by mass or less, relative to 100 parts by mass of polyol. By setting the upper limit of the content of the blowing agent in the composition for producing polyurethane foam within this range, formation defects due to excessive foaming can be suppressed, and also contribute to cost reduction.

[0067] (5) Foam stabilizer A foam stabilizer can be used in the composition for producing polyurethane foam according to the present technology. As the foam stabilizer that can be used in the present technology, one or more foam stabilizers that can be used in the production of polyurethane foam can be freely selected and used as long as they do not impair the purpose and effect of the present technology.

[0068] Examples of foam stabilizers that can be used in the present technology include silicone-based foam stabilizers, fluorine-containing compound-based foam stabilizers, surfactants, etc. Among these, it is preferable to use a silicone-based foam stabilizer in the present technology. Examples of silicone-based foam stabilizers include those that are mainly composed of siloxane chains, those that have a linear structure of siloxane chains and polyether chains, those that are branched and branched, and those in which polyether chains are modified to be pendant to siloxane chains.

[0069] The amount of the foam stabilizer used in the polyurethane foam producing composition according to the present technology can be freely set as long as it does not impair the action and effect of the present technology. In the present technology, the lower limit of the foam stabilizer content in the polyurethane foam producing composition is, for example, 0.1 parts by mass or more, preferably 0.2 parts by mass or more, more preferably 0.3 parts by mass or more, relative to 100 parts by mass of polyol. By setting the lower limit of the foam stabilizer content in the polyurethane foam producing composition within this range, the foaming reaction can be stabilized, and as a result, a polyurethane foam with excellent mechanical properties and appearance can be obtained.

[0070] In the present technology, the upper limit of the foam stabilizer content in the composition for producing polyurethane foam is, for example, 5.0 parts by mass or less, preferably 3.0 parts by mass or less, more preferably 2.0 parts by mass or less, and even more preferably 1.5 parts by mass or less, relative to 100 parts by mass of polyol. Setting the upper limit of the foam stabilizer content in the composition for producing polyurethane foam within this range can improve the moldability of the polyurethane foam and contribute to cost reduction.

[0071] (6)Other In the composition for producing polyurethane foam according to the present technology, one or more of various components that can be used in compositions for producing polyurethane foam can be freely selected and used as other components depending on the purpose, as long as the action and effect of the present technology is not impaired.

[0072] Examples of components that can be used in the composition for producing polyurethane foam according to the present technology include flame retardants, stabilizers, plasticizers, colorants, pigments, antioxidants, crosslinking agents, antibacterial agents, dispersants, and ultraviolet absorbers.

[0073] 2.Polyurethane foam The polyurethane foam according to the present technology can be produced by using the composition for producing a polyurethane foam according to the present technology. The polyurethane foam according to the present technology may be any of a flexible polyurethane foam, a rigid polyurethane foam, and a semi-rigid polyurethane foam. The physical properties of the polyurethane foam according to the present technology will be described below.

[0074] (1) Biomass ratio The biomass degree of the polyurethane foam according to the present technology can be freely set as long as it does not impair the action and effect of the present technology. The lower limit of the biomass degree of the polyurethane foam according to the present technology is, for example, 20% or more, preferably 30% or more, more preferably 35% or more, and even more preferably 40% or more. The higher the biomass degree of the polyurethane foam according to the present technology, the more it contributes to the environment, so there is no upper limit on the biomass degree.

[0075] In this technology, the "biomass degree" is a value calculated using the following formula. Biomass ratio (%) = {(Weight of biomass material × Biomass ratio of biomass material / 100) / Total weight of raw materials} × 100

[0076] (2) Humid heat compression set As demonstrated in the examples described below, the polyurethane foam according to the present technology is characterized by having a low wet heat compression set compared to conventional polyurethane foams, despite its high biomass content. Specifically, the wet heat compression set of the polyurethane foam according to the present technology is preferably 20.0% or less, more preferably 10.0% or less.

[0077] In the present technology, the "humid heat compression set" is a value measured in accordance with JIS K6400-4.

[0078] (3) Core density The core density of the polyurethane foam according to the present invention can be freely set as long as it does not impair the function and effect of the present invention. The lower limit of the core density of the polyurethane foam according to the present invention is, for example, 30 kg / m 3 More than 35kg / m 3 More preferably, 40 kg / m 3 More preferably, 45 kg / m 3 The upper limit of the core density of the polyurethane foam according to the present technology is, for example, 80 kg / m 3 Less than 75kg / m 3 Less than or equal to 70 kg / m 3 More preferably, 65 kg / m 3 The following is the result.

[0079] In this technology, the "density" is a value measured in accordance with a method based on JIS K7222:2005.

[0080] 3. Uses of polyurethane foam The polyurethane foam according to the present technology can be used for various purposes in various fields by taking advantage of its high quality. For example, it can be suitably used for vehicle and aircraft interior materials such as vehicle seat components, furniture such as sofas and chairs, bedding such as mattresses and pillows, clothing such as underwear, daily necessities such as dish sponges and cleaning sponges, building joint materials, building cushioning materials, building sealing materials, home appliance sealing materials, sound absorbing materials, soundproofing materials, packaging materials, vehicle insulation materials, condensation prevention materials, interior materials, home appliance insulation materials, pipe insulation materials, various covers, cushioning materials, toys, miscellaneous goods, etc.

[0081] The polyurethane foam according to the present technology can be suitably used for vehicle and aircraft interior materials such as vehicle seat components.

[0082] 4. Manufacturing method of polyurethane foam The polyurethane foam according to the present technology can be produced by mixing the components of the composition for producing polyurethane foam according to the present technology described above to prepare a composition, and foaming the composition. As for the foaming method, any general method can be freely combined and used as long as it does not impair the action and effect of the present technology.

[0083] In the polyurethane foam manufacturing method according to the present technology, either mold foaming or slab foaming can be used for foaming. Mold foaming is a method in which a polyurethane foam manufacturing composition (raw material for polyurethane foam) is mixed and injected into a cavity of a mold (metal mold) to foam into the shape of the cavity. On the other hand, slab foaming is a method in which a polyurethane foam manufacturing composition (raw material for polyurethane foam) is mixed and discharged into a foaming box to foam at atmospheric pressure and room temperature.

[0084] Generally, polyurethane foams with a high biomass ratio that use a large amount of plant-derived polyols tend to have poor foaming during production, making it difficult to perform mold foaming. However, this technology uses a large amount of plant-derived polyols, and despite the high biomass ratio, it has good foaming properties, so mold foaming can be suitably adopted. EXAMPLES

[0085] The present technology will be described in more detail below based on examples. Note that the examples described below are representative examples of the present technology, and the scope of the present technology is not to be interpreted narrowly by these examples.

[0086] (1) Manufacture of polyurethane foam Each component of the polyurethane production composition shown in Table 1 below was mixed by stirring to prepare a mixture, and then the prepared mixture was foamed under atmospheric pressure in a mold of 400 mm x 400 mm x 70 mm thick to produce each polyurethane foam.

[0087] (2) Foamability evaluation The foaming properties of the produced polyurethane foams were evaluated by the following method. [Molding possible] The case where the appearance was good was rated as ◯, and the case where the appearance was poor was rated as ×. [Gas ingress] The polyurethane foams of Examples 1 to 3 and Comparative Examples 1 to 6 that were moldable were evaluated by hand to see if they had good gas inclusion, and if they had poor gas inclusion, they were rated as "◯" or "X."

[0088] (3) Physical property measurements For the polyurethane foams of Examples 1 to 3, all of which were good in the foaming property evaluation, the physical properties shown in Table 1 were measured.

[0089] (4) Results The results are shown in Table 1 below. [Table 1]

[0090] (5) Discussion As shown in Table 1, the polyurethane foams of Examples 1 to 3, which used a polyether polyol having a hydroxyl value of 100 mgKOH / g or less and a polyether polyol having a hydroxyl value of 200 mgKOH / g to 700 mgKOH / g in combination as the polyol, contained 50 parts by mass or more of plant-derived polyol in 100 parts by mass of polyol, and had a biomass degree of 20% or more, but had good moldability and excellent gas-filling properties, and showed physical properties equal to or better than those of general polyurethane foams. In particular, while the wet heat compression set of general polyurethane foams is often about 20 to 40%, the wet heat compression set of the polyurethane foams of Examples 1 to 3 was 10.0% or less, which was very excellent.

[0091] On the other hand, among Comparative Examples 1 to 10 in which neither a polyether polyol with a hydroxyl value of 100 mgKOH / g or less nor a polyether polyol with a hydroxyl value of 200 mgKOH / g or more and 700 mgKOH / g or less was used in combination, Comparative Examples 7 to 10 were unable to be molded, and Comparative Examples 1 to 6 were able to be molded, but there was too much gas in the foam, resulting in poor gas penetration.

Claims

1. A composition for producing a polyurethane foam, comprising a polyol, The polyol contains 50 parts by mass or more of a plant-derived polyol per 100 parts by mass of the polyol, The polyol may include A polyether polyol having a hydroxyl value of 100 mgKOH / g or less; A composition for producing polyurethane foam, comprising: a polyether polyol having a hydroxyl value of 200 mgKOH / g or more and 700 mgKOH / g or less.

2. The polyether polyol with a hydroxyl value of 100 mgKOH / g or less includes A polyether polyol having an ethylene oxide addition rate of 50% or more; The composition for producing a polyurethane foam according to claim 1 , further comprising a polyether polyol having an ethylene oxide addition rate of less than 50%.

3. A polyurethane foam formed using the composition for producing a polyurethane foam according to claim 1.

4. Biomass content is 20% or more, A polyurethane foam having a wet heat compression set of 10.0% or less as measured in accordance with JIS K6400-4.

5. 5. A vehicle interior material comprising the polyurethane foam according to claim 3 or 4.

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