Polyurethane foam and method for producing the same

Abstract

To provide a polyurethane foam having antimicrobial action and anti-viral action.SOLUTION: There is provided a polyurethane foam suitable for a mask 10 made of a polyurethane foam which covers a part of a face including a mouth and nostrils and has ear hanging parts 13 at both right and left end sides, which is formed from a polyurethane foam composition in which a polyol, a polyisocyanate, a foaming agent, a catalyst and an additive are blended, wherein an antimicrobial agent is blended as the additive, the antimicrobial agent is a porous silicate mineral synthesized from silica, alumina and a metal oxide which is an antiviral agent having antiviral property and the polyurethane foam has anti-viral action.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to polyurethane foams and methods for producing the same. [Background technology]

[0002] A mask that covers part of the face including the mouth and nostrils and is made of polyurethane foam has been proposed (Patent Document 1).

[0003] Furthermore, masks are not only required to be hygienic, but also to have a clean appearance in terms of color, etc. However, the polyurethane foam used in conventional masks does not take into consideration antibacterial or antiviral properties, and is prone to discoloration due to ultraviolet rays and other factors. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2016-137119 Summary of the Invention [Problem to be solved by the invention]

[0005] The present invention has been made in view of the above points, and an object of the present invention is to provide a polyurethane foam which has antibacterial and antiviral activities and is suitable for use in, for example, hygiene applications such as masks, clothing applications such as bra pads, and applications such as filters. [Means for solving the problem]

[0006] The first aspect is characterized in that, in a polyurethane foam formed from a polyurethane foam composition containing a polyol, a polyisocyanate, a blowing agent, a catalyst, and an additive, an antibacterial agent is blended as the additive, and the antibacterial agent is a porous silicate mineral synthesized from a metal oxide, silica, and alumina.

[0007] The second aspect is the first aspect, characterized in that the additive is any one of an antioxidant, an ultraviolet inhibitor, a photodiscoloration inhibitor, and an NOx discoloration inhibitor.

[0008] In a third aspect, in the first or second aspect, the yellowing is characterized in that the ΔYI value is 50 or less.

[0009] A fourth aspect is any one of the first to third aspects, characterized in that the peel strength is 4N or more.

[0010] A fifth aspect is any one of the first to fourth aspects, characterized in that the antibacterial agent is an antiviral agent having antiviral properties, and the polyurethane foam has antiviral activity.

[0011] A sixth aspect is a method for producing a polyurethane foam by foaming a polyurethane foam composition containing a polyol, a polyisocyanate, a blowing agent, a catalyst, and an additive, characterized in that an antibacterial agent is blended as the additive, and the antibacterial agent is a porous silicate mineral synthesized from a metal oxide, silica, and alumina.

[0012] The seventh aspect is the sixth aspect, characterized in that the additive is any one of an antioxidant, an ultraviolet inhibitor, a photodiscoloration inhibitor, and an NOx discoloration inhibitor.

[0013] An eighth aspect is the sixth or seventh aspect, characterized in that the antibacterial agent is an antiviral agent having antiviral properties, and the polyurethane foam has antiviral activity. [Effects of the Invention]

[0014] According to the present invention, a polyurethane foam having antibacterial and antiviral properties can be obtained from a single material. [Brief explanation of the drawings]

[0015] [Figure 1] FIG. 1 illustrates a mask according to an embodiment of the present invention. [Figure 2] 1 is a table showing the formulations and physical properties of each comparative example and each example. DETAILED DESCRIPTION OF THE INVENTION

[0016] Hereinafter, embodiments of the polyurethane foam of the present invention will be described. 1(1-A) shows a punched-out body 10A formed into a mask shape by punching out the polyurethane foam of the present invention. Reference numeral 13 denotes openings for ear hooks. The punched piece 10A is folded over at a central portion 15, which is the center of the face, and as shown in Figure 1 (1-B), the left and right sides are welded together at a predetermined width along the central portion 15 to form the mask 10. The shaded portion indicated by the reference numeral 16 is the welded portion. The welding range of the welded portion 16 of the central portion 15 is determined so that when the mask 10 is spread out to the left and right and used, the central portion 15 expands outward to form a three-dimensional shape that corresponds to the prominence of the nose. Note that the mask formed from the polyurethane foam of the present invention is not limited to the shape of the mask shown in Figure 1.

[0017] The polyurethane foam of the present invention is formed by foaming a polyurethane foam composition containing a polyol, a polyisocyanate, a blowing agent, a catalyst, and additives.

[0018] The polyol is a polyhydric alcohol or a polyol to which an alkylene oxide such as ethylene oxide (EO) or propylene oxide (PO) is added. Polyols for flexible polyurethane foams can be used, and for example, any of polyether polyols, polyester polyols, and polyether ester polyols may be used, and one or more of these may be used.

[0019] Examples of polyether polyols include polyether polyols obtained by adding alkylene oxides such as ethylene oxide (EO) and propylene oxide (PO) to polyhydric alcohols such as ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, butylene glycol, neopentyl glycol, glycerin, pentaerythritol, trimethylolpropane, sorbitol, and sucrose.

[0020] Examples of polyester polyols include polyester polyols obtained by polycondensation of an aliphatic carboxylic acid such as malonic acid, succinic acid, or adipic acid, or an aromatic carboxylic acid such as phthalic acid, and an aliphatic glycol such as ethylene glycol, diethylene glycol, or propylene glycol. Examples of polyetherester polyols include those obtained by reacting the above-mentioned polyether polyols with polybasic acids to form polyesters, and those having both polyether and polyester segments in one molecule.

[0021] The polyol preferably has a hydroxyl value (OHV) of 30 to 80 mg KOH / g, a functionality of 2 to 4, and a weight-average molecular weight of 1500 to 5000. In particular, when a polyester polyol or a polyol containing an ester component is used, adhesion by welding is high and peel strength can be increased. On the other hand, when a polyether polyol is used, resistance to moist heat aging is excellent, making it preferable for use in a mask that can be washed repeatedly.

[0022] The polyisocyanate may be an aliphatic or aromatic polyisocyanate having two or more isocyanate groups, a mixture thereof, or a modified polyisocyanate obtained by modifying the same. Examples of aliphatic polyisocyanates include hexamethylene diisocyanate, isophorone diisocyanate, and dicyclohexamethane diisocyanate. Examples of aromatic polyisocyanates include toluene diisocyanate (TDI), diphenylmethane diisocyanate (MDI), naphthalene diisocyanate, xylylene diisocyanate, and polymeric MDI (crude MDI). Other prepolymers may also be used.

[0023] The isocyanate index (INDEX) is preferably 100 or more, and more preferably 103 to 120. The isocyanate index is a value obtained by dividing the number of moles of isocyanate groups in the isocyanate by the total number of moles of active hydrogen groups such as hydroxyl groups in the polyol, and multiplying the result by 100, and is calculated as [NCO equivalent of isocyanate / active hydrogen equivalent × 100].

[0024] As the blowing agent, water, alternative chlorofluorocarbons, or hydrocarbons such as pentane can be used alone or in combination. In the case of water, carbon dioxide gas is generated during the reaction of polyol and polyisocyanate, and the carbon dioxide gas causes foaming. The amount of water used as the blowing agent is preferably 1.0 to 4.0 parts by weight per 100 parts by weight of polyol.

[0025] Known urethane catalysts can be used in combination as the catalyst. Examples include amine catalysts such as triethylamine, triethylenediamine, diethanolamine, dimethylaminomorpholine, N-ethylmorpholine, and tetramethylguanidine; tin catalysts such as stannous octoate and dibutyltin dilaurate; and metal catalysts (also called organometallic catalysts) such as phenylmercury propionate and lead octenate. Either the amine catalyst or the metal catalyst may be used alone, or both may be used in combination. The amount of the amine catalyst is preferably 0.1 to 3 parts by weight per 100 parts by weight of the polyol. The amount of the metal catalyst is preferably 0 to 0.1 parts by weight.

[0026] The additives include an antibacterial agent, and preferably further include any one of an antioxidant, an ultraviolet absorber, a photodiscoloration inhibitor, and an NOx discoloration inhibitor.

[0027] The antibacterial agent is an antiviral agent having antiviral activity, and a porous silicate mineral synthesized from a metal oxide, silica, and alumina is used. Examples of porous silicate minerals synthesized from a metal oxide, silica, and alumina include aluminum-containing metal silicate salts and their hydrates. Zinc oxide is preferred as the metal oxide. Porous silicate minerals (aluminum-containing metal silicate salts) synthesized from silica, alumina, and a metal oxide exhibit superior antibacterial and antiviral effects compared to silver-based antibacterial agents. In porous silicate minerals using zinc oxide as the metal oxide, the ratio of the three components is preferably SiO2: 5-80 mol%, ZnO: 5-65 mol%, and Al2O3: 1-60 mol%. An example of a suitable composition formula of silica, alumina, and zinc oxide in a porous silicate mineral is aSiO2·Al2O3·bZnO. In the composition formula, a preferably satisfies 7≦a≦10 and b preferably satisfies 3≦b≦7, and more preferably satisfies 8≦a≦9 and 4≦b≦6. The average particle size of the porous silicate mineral measured by the Coulter counter method is 1 to 10 μm, preferably 2 to 5 μm. The amount of the antibacterial agent (antiviral agent having antiviral activity) is preferably 0.1 to 3 parts by weight, more preferably 0.3 to 3 parts by weight, even more preferably 0.4 to 2.0 parts by weight, and particularly preferably 0.5 to 1.5 parts by weight, per 100 parts by weight of the polyol.

[0028] Examples of antioxidants include phenol-based antioxidants, amine-based antioxidants, particularly BHT (dibutyl cresol), hindered phenol-based antioxidants, etc. Adding an antioxidant to a polyurethane foam composition can prevent discoloration of the polyurethane foam. The amount of antioxidant is preferably 0.1 to 3 parts by weight, more preferably 0.5 to 1.0 part by weight, per 100 parts by weight of polyol.

[0029] Examples of the ultraviolet absorber include benzotriazole-based ultraviolet absorbers, benzophenone-based ultraviolet absorbers, benzoate-based ultraviolet absorbers, and cyanoacrylate-based ultraviolet absorbers.

[0030] Examples of benzotriazole-based ultraviolet absorbers include 2-(2H-benzotriazol-2-yl)-p-cresol, 2-(2'-hydroxy-3',5'-di-t-amylphenyl)benzotriazole, 2-(2-hydroxy-5-(1,1,3,3-tetraethylbutyl)phenyl)benzotriazole, 2,2'-methylenebis(6-(2H-benzotriazol-2-yl)-4-1,1,3,3-(tetramethylbutyl)phenol), 2-(2'-hydroxy-5'-methylphenyl)benzotriazole, and 2-[5-chloro(2H)-benzotriazol-2-yl]-4-methyl-6-(t-butyl)phenol.

[0031] Examples of benzophenone-based ultraviolet absorbers include 2-hydroxy-4-methoxybenzophenone, 5-benzoyl-4-hydroxy-2-methoxybenzenesulfonic acid 2-hydroxy-4-n-octyloxybenzophenone, and 2,4-dihydroxybenzophenone.

[0032] Benzoate-based ultraviolet absorbers include 2,4-t-butylphenyl-3,5-di-t-butyl-4-hydroxybenzoate.

[0033] Examples of the cyanoacrylate ultraviolet absorber include ethyl-2-cyano-3,3-diphenylacrylate and 2-ethylhexyl-2-cyano-3,3-diphenylacrylate.

[0034] The incorporation of an ultraviolet absorber can enhance the effect of suppressing discoloration of the polyurethane foam due to ultraviolet rays. The amount of the ultraviolet absorber is preferably 0.05 to 0.5 parts by weight, more preferably 0.1 to 0.3 parts by weight, per 100 parts by weight of the polyol.

[0035] Examples of photodiscoloration inhibitors (light stabilizers) include hindered amines. By incorporating photodiscoloration inhibitors, it is possible to enhance the effect of preventing discoloration of polyurethane foam caused by sunlight and ultraviolet rays.

[0036] Examples of hindered amine photodiscoloration inhibitors include bis(1,2,2,6,6-pentamethyl-4-piperidinyl)sebacate, methyl 1,2,2,6,6-pentamethyl-4-piperidyl sebacate, bis(2,2,6,6-tetramethyl-4-piperidinyl)sebacate, poly((6-((1,1,3,3-tetramethylbutyl)amino)-s-tetrazine-2,4-digly)(2,2,6,6-tetramethyl-4-piperidyl)imino)hexamethylene(2,2,6,6-tetramethyl-4-piperidyl)imino)), and bis(1,2,2,6,6-pentamethyl-4-piperidyl)[[3,5-bis(1,1-dimethylethyl)-4-hydroxyphenyl]methyl]butylmalonate. The amount of the photodiscoloration inhibitor is preferably 0.05 to 0.5 parts by weight, more preferably 0.05 to 0.3 parts by weight, based on 100 parts by weight of the polyol.

[0037] Examples of NOx discoloration inhibitors include phosphorus-based antioxidants and sulfur-based antioxidants. By incorporating NOx discoloration inhibitors, discoloration of polyurethane foam caused by NOx in the air can be suppressed. Examples of the phosphorus-based antioxidant include pentaerythritol diphosphate and diisodecylpentaerythritol diphosphite. Examples of sulfur-based antioxidants include bis{2-methyl-4-[3-n-alkyl(C12 or C14)thiopropionyloxy]-5-t-butylphenyl}sulfide. The amount of the NOx discoloration inhibitor is preferably 0.5 to 2 parts by weight, more preferably 0.7 to 1.5 parts by weight, based on 100 parts by weight of the polyol.

[0038] The polyurethane foam composition may contain other auxiliaries, such as a foam stabilizer and a colorant. As the foam stabilizer, any of those known for flexible polyurethane foams can be used, including, for example, silicone-based foam stabilizers, fluorine-containing compound-based foam stabilizers, and known surfactants. The coloring agent is appropriately blended to a color that suits the preference of the mask user.

[0039] The polyurethane foam composition is preferably foamed by slab foaming, which is a method in which a polyurethane foam composition is mixed, discharged onto a belt conveyor, and foamed at atmospheric pressure and room temperature. The mask 10 shown in FIG. 1 can be formed from the expanded polyurethane foam as follows. The polyurethane foam is thinned into a sheet, for example, about 2 mm thick, and the resulting sheet-like polyurethane foam is punched out using a punching die having a mask-shaped mold surface to form a punched body. The punched body is then folded over at the center, which corresponds to the left-right center of the face, and sandwiched between welding dies to weld a predetermined width along the center to form a mask. The welding can be performed, for example, by pressing the folded punched body at a temperature (die temperature) of 200 to 300°C for a predetermined time. [Example]

[0040] Polyurethane foam compositions were prepared from the following components according to the formulations shown in FIG. 2 for each of the comparative examples and examples, and the prepared polyurethane foam compositions were mixed and foamed to produce polyurethane foams.

[0041] Polyol: Polyester polyol, molecular weight: 2600, functionality: 2.4, hydroxyl value: 51 mg KOH / g, product name: N-101, manufactured by Nippon Polyurethane Industry Co., Ltd. Amine catalyst: N-ethylmorpholine, product name: Kao Raiser No. 22, manufactured by Kao Corporation Foam stabilizer: Silicone foam stabilizer, product name: SE232, manufactured by Momentive Foaming agent: water Antioxidant; hindered phenolic, benzenepropanoic acid, 3,5-bis(1,1-methyl-ethyl)-4 hydroxy-, C7-C9 side chain alkyl ester, product name: I-1135, manufactured by Ciba Specialty Chemicals UV absorber: Benzotriazole, product name: T-571, manufactured by BASF Photodiscoloration inhibitor; hindered amine type, product name: T-765, manufactured by BASF NOx discoloration inhibitor; phosphorus-based antioxidant, product name: CS-22LF, manufactured by Momentive Performance Materials Japan, LLC Antibacterial agent: Silver-based, Product name: Zeomic AW10N, manufactured by Sinanen Zeomic Co., Ltd. Antibacterial and antiviral agent: the antibacterial agent of the present invention (antiviral agent with antiviral properties), porous silicate mineral of zinc oxide / silicon dioxide / aluminum oxide, average particle size 2.5 to 4.5 μm, product name: Laonite SF, manufactured by Lion Specialty Chemicals, composition formula of silica, alumina and zinc oxide: 8.6SiO2·Al2O3·4.8ZnO Isocyanate: T-65, 2,4-TDI / 2,6-TDI=65 / 35

[0042] The foaming properties of the polyurethane foam were evaluated. The foaming properties were evaluated as "Good" if there were no punctures, down, or shrinkage and the foaming was good, and as "Poor" if the foaming was not good. The evaluation results are shown in Figure 2.

[0043] The physical properties of the polyurethane foams produced were measured, including density (JIS K6400), cell count (JIS K6400), tensile strength (JIS K6400-5), elongation (JIS K6400-5), and air permeability (JIS L 1096 Method A), and the properties of the polyurethane foams were evaluated based on the measurement results. Physical properties were evaluated as "Good" if they met current equivalent product standards, and "Poor" if they showed significant deterioration or degradation. The measurement results are shown in Figure 2.

[0044] The polyurethane foam was measured for its pollen collection, antibacterial and antiviral properties. Pollen collection was performed in accordance with the "Pollen Particle Collection (Filtration) Efficiency Test Method" of the Japan Sanitary Materials Industry Association and the National Mask Industry Association. Specifically, natural particles with a particle size of approximately 30 μm, the same as cedar pollen, were used as test particles, and these were uniformly dispersed and dropped at a constant flow rate onto a 2 mm thick sheet of polyurethane foam. The amount of a specified amount of test particles that passed through the polyurethane foam was measured, and the collection efficiency (%) was calculated. The measurement results are shown in Figure 2. A collection efficiency of 99% or higher is desirable.

[0045] The antibacterial activity values ​​for Staphylococcus aureus and Escherichia coli were measured based on JIS K6400-9:2019. The common logarithm of the viable cell count after 24 hours of shaking culture in the control group (air shaking) was 5.02. The measurement results are shown in Figure 2. For both Staphylococcus aureus and Escherichia coli, the antibacterial activity values ​​are preferably 2.0 or higher, more preferably 3.0 or higher, and particularly preferably 4.0 or higher.

[0046] The antiviral activity was measured for influenza A virus based on the JIS L 1922 plaque method, with host cells as influenza A. An activity value of 1 or more but less than 2 indicates a mortality rate of 90% or more, an activity value of 2 or more but less than 3 indicates a mortality rate of 99% or more, and an activity value of 3 or more indicates a mortality rate of 99.9% or more. The antiviral activity value is preferably 2.0 or more, more preferably 3.0 or more, and particularly preferably 4.0 or more.

[0047] The yellowing resistance of polyurethane foam was measured and evaluated. To measure the yellowing resistance, a polyurethane foam test piece (10 mm x 50 mm x 150 mm) was irradiated with a fade meter at 63°C for 10 hours, and the color difference ΔYI before and after irradiation was measured. The measurement results are shown in Figure 2. For yellowing resistance, a ΔYI value of less than 50 is preferred, and a value of less than 20 is more preferred.

[0048] A mask was prepared from the polyurethane foam as follows, and the peel strength was measured. The masks were produced by cutting and thinning polyurethane foam into a sheet of 2 mm thick x 200 mm x 150 mm, punching the resulting polyurethane foam sheet into a mask shape to form a punched body 10A as shown in Figure 1 (1-A). The punched body 10A was folded over at the center 15 and sandwiched between a welding mold, and pressed at a welding temperature (mold temperature) of 220°C for a press time of 1.5 seconds to weld along the center, producing the mask 10 as shown in Figure 1 (1-B).

[0049] To measure the peel strength, after preparing the mask 10, the mask 10 was left at room temperature for one day, and then a test piece was prepared by cutting the mask 10 to a width of 25 mm so that the central portion 15 of the mask 10 was in the center. The test piece was then set in the chuck of a Tensilon testing machine so that the welded portion was in the center, and the peel strength (unit: N) was measured by performing a 180-degree peel at a tensile speed of 200 mm / min with a 35 mm gap between the chucks. The measurement results are shown in Figure 2. The peel strength is preferably 4 N or more, and more preferably 6 N or more.

[0050] The results of each comparative example and each example are shown below. Comparison Example 1 Comparative Example 1 is an example in which the polyurethane foam composition consists of 100 parts by weight of polyol, 2.00 parts by weight of amine catalyst, 1.51 parts by weight of foam stabilizer, 1.40 parts by weight of blowing agent, 0.50 parts by weight of antioxidant, and isocyanate index 105.6, and does not contain any ultraviolet absorber, photodiscoloration inhibitor, NOx discoloration inhibitor, antibacterial agent, or antibacterial / viral agent (antibacterial agent of the present invention).

[0051] Comparative Example 1 has a density of 71.2 kg / m 3 , Cell count 70 / 25mm, Tensile strength 266kPa, Elongation 439%, Breathability 60.5ml / cm 2 / s, foaming property "Good", physical properties "Good". In addition, pollen collection was 99.6%, peel strength was 6.9N, antibacterial activity value was 0.0 against Staphylococcus aureus, 0.0 against Escherichia coli, antiviral activity value was 0.0, and yellowing resistance ΔYI was 50.1.

[0052] Comparison Example 2 Comparative Example 2 has the same formulation as Comparative Example 1, except that 0.20 parts by weight of a silver-based antibacterial agent was blended as the antibacterial agent in Comparative Example 1. Comparative Example 2 has a density of 73.6 kg / m 3 , Cell count 70 / 25mm, Tensile strength 348kPa, Elongation 491%, Breathability 69ml / cm 2 / s, foaming property "Good", physical properties "Good". In addition, pollen collection was 99.6%, peel strength was 10.0N, antibacterial activity value for Staphylococcus aureus was more than 4.0, antibacterial activity value for Escherichia coli was more than 7.3, antiviral activity value was 0.0, and yellowing resistance ΔYI was 59.2. In Comparative Example 2, a silver-based antibacterial agent was added as an antibacterial agent compared to Comparative Example 1, which improved the antibacterial properties, but did not provide any antiviral effect, and the yellowing resistance was worse than in Comparative Example 1.

[0053] Example 1 Example 1 has the same formulation as Comparative Example 2, except that 0.50 parts by weight of an antibacterial and antiviral agent (antibacterial agent of the present invention) made of a porous silicate mineral of zinc oxide / silicon dioxide / aluminum oxide was blended in place of 0.20 parts by weight of the silver-based antibacterial agent in Comparative Example 2. Example 1 has a density of 71.0 kg / m 3 , Cell count 76 / 25mm, Tensile strength 270kPa, Elongation 421%, Breathability 75ml / cm 2 / s, foaming property "Good", physical properties "Good". In addition, pollen collection was 99.1%, peel strength was 11.0N, antibacterial activity value against Staphylococcus aureus was more than 3.8, antibacterial activity value against Escherichia coli was 5.4, antiviral activity value was 4.0, and yellowing resistance ΔYI was 47.3. In Example 1, compared to Comparative Example 2, an antibacterial and antiviral agent (antibacterial agent of the present invention) made of a porous silicate mineral of zinc oxide / silicon dioxide / aluminum oxide was added instead of the silver-based antibacterial agent, and as a result, the antibacterial effect was improved, an antiviral effect was obtained, and yellowing resistance was improved.

[0054] Example 2 Example 2 has the same formulation as Example 1, except that 0.21 parts by weight of an ultraviolet absorber, 0.11 parts by weight of a photodiscoloration inhibitor, and 0.98 parts by weight of an NOx discoloration inhibitor are added to the formulation of Example 1. Example 2 has a density of 73.8 kg / m 3 , Cell count 78 / 25mm, Tensile strength 264kPa, Elongation 379%, Breathability 50ml / cm 2 / s, foaming property "Good", physical properties "Good". In addition, pollen collection rate was 99.5%, peel strength was 4.2N, antibacterial activity value against Staphylococcus aureus was 4.0, antibacterial activity value against Escherichia coli was 5.7, antiviral activity value was 4.0, and yellowing resistance ΔYI was 17.6. Example 2 has antibacterial and antiviral effects similar to Example 1. Furthermore, Example 2 has improved yellowing resistance compared to Example 1 due to the incorporation of an ultraviolet absorber, a photodiscoloration inhibitor, and a NOx discoloration inhibitor.

[0055] Example 3 Example 3 has the same formulation as Example 2, except that the amount of ultraviolet absorber in the formulation of Example 2 was reduced from 0.21 parts by weight to 0.16 parts by weight, the amount of photodiscoloration inhibitor was reduced from 0.11 parts by weight to 0.08 parts by weight, and the amount of NOx discoloration inhibitor was reduced from 0.98 parts by weight to 0.73 parts by weight. Example 3 has a density of 76.1 kg / m 3 , Cell count 70 / 25mm, Tensile strength 339kPa, Elongation 528%, Breathability 65ml / cm 2 / s, foaming property "Good", physical properties "Good". In addition, pollen collection was 99.1%, peel strength was 11.2N, antibacterial activity value against Staphylococcus aureus was 4.3, antibacterial activity value against Escherichia coli was 4.7, antiviral activity value was 4.0, and yellowing resistance ΔYI was 25.6. Example 3 has antibacterial and antiviral effects similar to Example 2. Furthermore, Example 3 has reduced amounts of the ultraviolet absorber, photodiscoloration inhibitor, and NOx discoloration inhibitor compared to Example 2, resulting in improved peel strength and slightly lower yellowing resistance than Example 2.

[0056] Example 4 Example 4 has the same formulation as Example 3, except that the amount of the antibacterial and antiviral agent (antibacterial agent of the present invention) in the formulation of Example 3 was increased from 0.50 parts by weight to 1.00 parts by weight. Example 4 has a density of 76.8 kg / m 3 , Cell count 70 / 25mm, Tensile strength 305kPa, Elongation 440%, Breathability 66ml / cm 2 / s, foaming property "Good", physical properties "Good". In addition, pollen collection was 99.5%, peel strength was 11.0N, antibacterial activity value against Staphylococcus aureus was greater than 3.8, antibacterial activity value against Escherichia coli was 6.4, antiviral activity value was 4.2, and yellowing resistance ΔYI was 25.6. In Example 4, the amount of the antibacterial and antiviral agent (the antibacterial agent of the present invention) was increased compared to Example 3, and as a result, the antibacterial and antiviral effects were improved.

[0057] As described above, the polyurethane foam of the present invention contains an antibacterial agent (antiviral agent having antiviral properties) made of a porous silicate mineral synthesized from metal oxide, silica, and alumina (a porous silicate mineral of zinc oxide / silicon dioxide / aluminum oxide), and therefore has antibacterial and antiviral effects, making it hygienic and suitable for, for example, hygiene applications such as masks that cover the mouth and nostrils of the face, clothing applications such as bra pads, and filters, etc. Furthermore, both antibacterial and antiviral effects can be obtained from a single material. [Explanation of symbols]

[0058] 10A punched body 10 Mask 13 Ear hook opening 15 The central part of the face 16 Welded area

Claims

1. A polyurethane foam formed from a polyurethane foam composition containing a polyol, a polyisocyanate, a blowing agent, a catalyst, and additives, An antibacterial agent is blended as the additive, A polyurethane foam characterized in that the antibacterial agent is a porous silicate mineral synthesized from a metal oxide, silica, and alumina.

2. 2. The polyurethane foam according to claim 1, wherein the additive is any one of an antioxidant, an ultraviolet inhibitor, a photodiscoloration inhibitor, and an NOx discoloration inhibitor.

3. 3. The polyurethane foam according to claim 1, wherein the yellowing is such that the ΔYI value is 50 or less.

4. 4. The polyurethane foam according to claim 1, wherein the peel strength is 4N or more.

5. 5. The polyurethane foam according to claim 1, wherein the antibacterial agent is an antiviral agent having antiviral properties, and the polyurethane foam has an antiviral effect.

6. A method for producing a polyurethane foam by foaming a polyurethane foam composition containing a polyol, a polyisocyanate, a blowing agent, a catalyst, and additives, comprising: The additives include an antioxidant and an antibacterial agent, A method for producing a polyurethane foam, wherein the antibacterial and antiviral agent is a porous silicate mineral synthesized from a metal oxide, silica, and alumina.

7. 7. The method for producing polyurethane foam according to claim 6, wherein the additives include an ultraviolet inhibitor, a photodiscoloration inhibitor, and a NOx discoloration inhibitor.

Images