Polyurethane foam and sponge material using the same

Abstract

To provide a technology that enables production of a polyurethane foam with high quality while contributing to preservation of the environment.SOLUTION: The present technology is directed to a polyurethane foam obtained from a composition comprising a polyol and an isocyanate, wherein the polyol contains a biomass-derived polyol, and the biomass-derived polyol includes a biomass-derived polyester polyol produced by condensing a dibasic acid with a polyol having a primary hydroxyl group.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present technology relates to polyurethane foams, and more particularly to polyurethane foams and sponge materials using the polyurethane foams. [Background technology]

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

[0003] Furthermore, in recent years, technology that utilizes biomass raw materials in polyurethane foam as a so-called carbon-neutral renewable resource has been attracting attention in order to contribute to the formation of a sustainable society.

[0004] For example, Patent Document 1 discloses a technology for obtaining a polyurethane foam for frame lamination that has a sufficiently high plant-based content and exhibits good frame lamination properties by using at least one polyol selected from the group consisting of phthalic acid-based polyester polyols, dimer acid-based polyols, and adipate-based polyols together with a plant-derived polyol. Patent Document 2 also discloses a technology for producing a polyurethane foam that dries well after washing by increasing the biomass content of the polyurethane foam to 24% or more as measured by accelerator mass spectrometry (AMS). [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Publication No. 2011-202026 [Patent Document 2] Japanese Patent Publication No. 2023-80375 Summary of the Invention [Problem to be solved by the invention]

[0006] As mentioned above, various developments are being made to contribute to environmental considerations and the creation of a sustainable society, but there is still much work to be done. For example, when biomass-derived polyols are used to produce polyurethane foams with a high biomass content, there are problems with the foaming properties during production and the physical properties of the produced polyurethane foam. In particular, it is difficult to produce polyurethane foams with excellent rebound resilience, tensile strength, elongation, etc., which are necessary for sponge materials, using biomass-derived polyols.

[0007] Therefore, the main objective of this technology is to provide a technology that can produce high-quality polyurethane foam while contributing to environmental conservation. [Means for solving the problem]

[0008] In the present technology, first, a polyurethane foam obtained from a composition containing a polyol and an isocyanate, The polyol contains a biomass-derived polyol, The polyurethane foam is provided in which the biomass-derived polyol contains a biomass-derived polyester polyol obtained by condensing a dibasic acid with a polyol containing a primary hydroxyl group. In the polyurethane foam according to the present technology, 1,3-propanediol can be used as the polyol containing a primary hydroxyl group. In the polyurethane foam according to the present technology, the content of the biomass-derived polyester polyol in 100 parts by weight of the polyol in the raw material can be 10 parts by weight or more and 80 parts by weight or less. The polyurethane foam according to the present technology can be used as a sponge material. DETAILED DESCRIPTION OF THE INVENTION

[0009] Preferred embodiments for implementing the present technology will be described below. The embodiments described below are examples of typical embodiments of the present technology, and any of the embodiments can be combined. Furthermore, the scope of the present technology is not to be interpreted narrowly by these embodiments.

[0010] 1. Composition for producing polyurethane foam The polyurethane foam according to the present technology is produced using a composition containing a polyol and an isocyanate. The composition used for producing the polyurethane foam according to the present technology may also contain a blowing agent, a catalyst, a foam stabilizer, etc., as necessary. Each component will be described in detail below.

[0011] (1) Polyol The polyurethane foam according to the present invention is characterized by containing a biomass-derived polyol as a polyol component. Furthermore, depending on the properties and application of the polyurethane foam to be produced, one or more polyols used in general polyurethane foams can be freely selected and used.

[0012] (1-1) Biomass-derived polyol The biomass-derived polyol used in this technology is characterized by containing a biomass-derived polyester polyol obtained by condensing a dibasic acid with a polyol containing a primary hydroxyl group. Conventionally, the use of a biomass-derived polyol has generally resulted in poor foamability during polyurethane foam production. However, this technology uses a biomass-derived polyester polyol obtained by condensing a dibasic acid with a polyol containing a primary hydroxyl group. This technology achieves good foamability during production, even when using a biomass-derived polyol, and allows the production of polyurethane foams with physical properties equivalent to or better than those produced without using a biomass-derived polyol, i.e., using only a petroleum-derived polyol.

[0013] As the dibasic acid constituting the biomass-derived polyol used in the present technology, one or more common dibasic acids can be freely selected and used as long as the action and effect of the present technology are not impaired. Examples of dibasic acids include sebacic acid, succinic acid, azelaic acid, dimer acid, adipic acid, phthalic acid, isophthalic acid, terephthalic acid, hexahydrophthalic acid, hexahydroterephthalic acid, hexahydroisophthalic acid, maleic acid, fumaric acid, oxalic acid, malonic acid, glutaric acid, pimelic acid, suberic acid, tartaric acid, malic acid, and itaconic acid. Among these, in the present technology, biomass-derived dibasic acids are preferred. Examples of biomass-derived dibasic acids include sebacic acid, succinic acid, azelaic acid, and dimer acid. Among these, sebacic acid is particularly preferred. In addition, if the polyol containing a primary hydroxyl group described later is derived from biomass, the dibasic acid may not be derived from biomass, i.e., may be derived from petroleum. Therefore, even when using sebacic acid, succinic acid, azelaic acid, dimer acid, etc., these are not limited to those derived from biomass, and petroleum-derived sebacic acid, petroleum-derived succinic acid, petroleum-derived azelaic acid, petroleum-derived dimer acid, etc. may also be used.

[0014] The primary hydroxyl group-containing polyol constituting the biomass-derived polyol used in the present invention can be freely selected from one or more general primary hydroxyl group-containing polyols, as long as it does not impair the effects of the present invention. Examples of primary hydroxyl group-containing polyols include 1,3-propanediol, 1,2-ethanediol, 1,4-butanediol, 1,5-pentenediol, 1,5-pentanediol, 3-methyl-1,5-pentanediol, 1,6-hexanediol, 1,7-heptanediol, 1,8-octanediol, 1,9-nonanediol, 1,10-decanediol, and dimer diol. These primary hydroxyl group-containing polyols are preferably derived from biomass. However, when a biomass-derived dibasic acid is used as the dibasic acid, a petroleum-derived polyol containing primary hydroxyl groups may also be used. In the present technology, it is preferable to use biomass-derived 1,3-propanediol as the polyol containing a primary hydroxyl group.

[0015] The content of biomass-derived polyester polyol (hereinafter also referred to as "biomass-derived polyester polyol") obtained by condensing a dibasic acid with a polyol containing a primary hydroxyl group in a composition for producing polyurethane foam can be freely set as long as it does not impair the functions and effects of the present technology. The lower limit of the content of the biomass-derived polyester polyol per 100 parts by weight of the polyol in the raw material is, for example, 5 parts by weight or more, preferably 10 parts by weight or more, more preferably 15 parts by weight or more, and even more preferably 20 parts by weight or more. Setting the content of biomass-derived polyol in the polyol within this range improves the biomass content of the polyurethane foam produced, further reducing the environmental load and further contributing to the creation of a sustainable society. In addition, the impact resilience of the polyurethane foam produced can be improved.

[0016] The upper limit of the content of the biomass-derived polyester polyol per 100 parts by weight of the polyol in the raw material is, for example, 100 parts by weight or less, preferably 90 parts by weight or less, and more preferably 80 parts by weight or less. By setting the content of the biomass-derived polyol in the polyol within this range, it is possible to prevent a decrease in the physical properties of the polyurethane foam to be produced, and a higher quality polyurethane foam can be produced.

[0017] The biomass degree of the biomass-derived polyester polyol used in the present technology can be freely set as long as it does not impair the functions and effects of the present technology. The lower limit of the biomass degree of the biomass-derived polyester polyol is, for example, 50% or more, preferably 60% or more, more preferably 70% or more, even more preferably 80% or more, and even more preferably 90% or more. By setting the biomass degree of the biomass-derived polyester polyol used in the present technology within this range, the biomass degree of the polyurethane foam produced can be improved, the environmental load can be further reduced, and a sustainable society can be further contributed to.

[0018] The upper limit of the biomass content of the biomass-derived polyester polyol is not particularly limited, and can be set to 100%.

[0019] The biomass-derived polyol used in this technology can be a biomass-derived polyol other than a biomass-derived polyester polyol obtained by condensing a dibasic acid with a polyol containing a primary hydroxyl group, as long as the function and effect of the technology are not impaired. Examples of biomass-derived polyols other than the biomass-derived polyester polyol include 1,2,3-propanetriol (glycerin) derived from animals and plants, condensates thereof, castor oil, soybean oil, palm oil, palm kernel oil, coconut oil, cashew nut shell liquid (CNSL), cashew nut oil, olive oil, cottonseed oil, safflower oil, sesame oil, sunflower oil, and linseed oil, and derivatives thereof (e.g., modified natural oil polyol, unmodified natural oil polyol, etc.).

[0020] (1-2) Polyols other than biomass-derived polyols In the present technology, polyols other than biomass-derived polyols can also be used in combination. Examples of polyols other than biomass-derived polyols include polyester polyols, polyether polyols, polyester ether polyols, polycarbonate polyols, and polymer polyols. Among these, in the present technology, it is preferable to use polyester polyols as the polyols other than biomass-derived polyols.

[0021] 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 esters or acid anhydrides of these with diethylene glycol, trimethylolpropane, ethylene glycol, 1,3-propylene glycol, 1, Examples include polyester polyols obtained by a dehydration condensation reaction with 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 the like, or a mixture thereof; and polylactone polyols and polycaprolactone polyols obtained by ring-opening polymerization of lactone monomers such as ε-caprolactone and methylvalerolactone.

[0022] When a polyester polyol is used as a polyol other than the biomass-derived polyol, its content can be freely set as long as it does not impair the action and effect of the present technology. The lower limit of the content of the polyester polyol per 100 parts by mass of the polyol component used in the present technology is, for example, 3 parts by mass or more, preferably 5 parts by mass or more, and more preferably 10 parts by mass or more. In the present technology, by setting the content of the polyester polyol in the polyol component within this range, it is possible to improve the reactivity during polyurethane foam production and further improve the physical properties of the polyurethane foam produced.

[0023] The upper limit of the content of polyester polyol in 100 parts by mass of the polyol component used in this technology is, for example, 95 parts by mass or less, preferably 90 parts by mass or less, more preferably 85 parts by mass or less, and even more preferably 80 parts by mass or less. In this technology, by setting the content of polyester polyol in the polyol component within this range, the biomass content of the polyurethane foam produced can be improved, the environmental load can be reduced, and this can further contribute to the creation of a sustainable society.

[0024] (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 it does not impair the purpose and effects of the present technology. Examples include aliphatic isocyanates such as hexamethylene diisocyanate, isophorone diisocyanate, and dicyclohexylmethane diisocyanate; aromatic isocyanates such as toluene diisocyanate (TDI), diphenylmethane diisocyanate (MDI), naphthalene diisocyanate, xylylene diisocyanate, and polymethylene polyphenyl polyisocyanate (polymeric MDI); and modified polyisocyanates obtained by modifying these. Among these, in the present technology, aromatic isocyanates are preferably used as the isocyanate, and toluene diisocyanate (TDI) is more preferably used.

[0025] The isocyanate index of the polyurethane foam is not particularly limited as long as it does not impair the functions and effects 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, and more preferably 90 parts by mass or more. By setting the lower limit of the isocyanate index within this range, the strength of the polyurethane foam produced can be improved.

[0026] The upper limit of the isocyanate index is, for example, not more than 120, preferably not more than 115, and more preferably not more than 110. By setting the upper limit of the isocyanate index within this range, it is possible to prevent the polyurethane foam from becoming too hard and brittle, which would result in a loss of flexibility, and to improve the elasticity of the polyurethane foam.

[0027] 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].

[0028] (3) Foaming agent A blowing agent can be used in the production of 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 effects of the present technology are not impaired.

[0029] Examples of the blowing agent include water, hydrocarbons, and halogenated compounds. Examples of hydrocarbons include cyclopentane, isopentane, and normal pentane. Examples of the halogenated 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 blowing agent. The water may be ion-exchanged water, tap water, distilled water, or the like.

[0030] The amount of blowing agent used in producing the polyurethane foam of the present technology can be freely set as long as it does not impair the function and effect of the present technology. In the present technology, the lower limit of the content of the blowing agent in the composition is, for example, 0.1 parts by mass or more, preferably 0.5 parts by mass or more, and more preferably 1 part by mass or more, per 100 parts by mass of polyol. By setting the lower limit of the content of the blowing agent in the composition within this range, foamability can be improved, and as a result, polyurethane foam with excellent mechanical properties and appearance can be obtained.

[0031] In this technology, the upper limit of the content of the blowing agent in the composition is, for example, 20 parts by mass or less, preferably 15 parts by mass or less, and more preferably 10 parts by mass or less, relative to 100 parts by mass of the polyol. By setting the upper limit of the content of the blowing agent in the composition within this range, it is possible to prevent formation defects due to excessive foaming and also contribute to cost reduction.

[0032] (4) 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.

[0033] Examples of the catalyst include metal 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 octylate, tin 2-ethylhexanoate, 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; triethylamine, triethylenediamine (TEDA), tetramethylguanidine, diethanolamine, bis(2-dimethylaminoethyl) ether, N ,N,N',N",N"-pentamethyldiethylenetriamine, imidazole compounds, piperazine amines such as N,N'-dimethylpiperazine, N,N',N'-trimethylaminoethylpiperazine, N-methyl-N'-(2-dimethylamino)ethylpiperazine, and N-methyl-N'-(2-hydroxyethyl)piperazine, morpholine amines such as N-methylmorpholine and N-ethylmorpholine, and amine catalysts such as amines known as DBU homologues, 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). Among these, in the present technology, it is preferable to use one or more catalysts selected from organotin compounds, piperazine-based amines, and morpholine-based amines, and it is more preferable to use one or more catalysts selected from tin octoate, N,N'-dimethylpiperazine, N,N',N'-trimethylaminoethylpiperazine, and N-ethylmorpholine.

[0034] The amount of catalyst in the composition used to produce the polyurethane foam of the present technology can be freely set as long as it does not impair the function 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, and more preferably 1.0 parts by mass or more, per 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, polyurethane foam with excellent mechanical properties and appearance can be obtained.

[0035] In this technology, the upper limit of the catalyst content in the composition is, for example, 10 parts by mass or less, preferably 5 parts by mass or less, and more preferably 3 parts by mass or less, per 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 destabilization of various reactions during production. As a result, a polyurethane foam with excellent mechanical properties and appearance can be obtained.

[0036] (5) Foam stabilizer A foam stabilizer can be used in the production of polyurethane foam according to the present technology. By using a foam stabilizer, a better quality polyurethane foam can be produced.

[0037] 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 the action and effect of the present technology are not impaired. Examples include silicone-based foam stabilizers, fluorine-containing compound-based foam stabilizers, surfactants, etc. Silicone-based foam stabilizers include those mainly composed of siloxane chains, those in which the siloxane chain and polyether chain have a linear structure, those that are branched, and those in which the polyether chain is modified to be pendant to the siloxane chain.

[0038] The amount of foam stabilizer in the composition used to produce the polyurethane foam according to the present technology can be freely set as long as it does not impair the function and effect of the present technology. The lower limit of the content of the foam stabilizer in the composition is, for example, 0.1 parts by mass or more, preferably 0.5 parts by mass or more, and more preferably 1 part by mass or more, per 100 parts by mass of polyol. The upper limit of the content of the foam stabilizer in the composition is, for example, 10 parts by mass or less, preferably 5 parts by mass or less, and more preferably 3 parts by mass or less, per 100 parts by mass of polyol.

[0039] (6) Other In the production of polyurethane foam according to the present technology, one or more of the various components that can be used in the production of 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 are not impaired.

[0040] Examples of components that can be used in the production of polyurethane foams according to the present technology include flame retardants, pigments, stabilizers, plasticizers, colorants, crosslinking agents, antibacterial agents, dispersants, fillers, antioxidants, and ultraviolet absorbers.

[0041] 2. Polyurethane foam The polyurethane foam according to the present technology can be produced using the above-described composition. The physical properties of the polyurethane foam according to the present technology will be described in detail below.

[0042] (1) Apparent density The apparent 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 apparent density of the polyurethane foam according to the present invention is, for example, 20 kg / m 3 or more, preferably 25 kg / m 3 More preferably, 30 kg / m 3 More preferably, 35 kg / m 3 The upper limit of the apparent density of the polyurethane foam according to the present technology is, for example, 60 kg / m 3 Less than or equal to 55 kg / m 3Less than or equal to 50 kg / m 3 or less, more preferably 45 kg / m 3 By setting the apparent density of the polyurethane foam within this range, it is possible to impart cushioning properties without impairing the flexibility of the polyurethane foam (preventing it from becoming hard).

[0043] In the present technology, the apparent density is a value measured by the method described in the examples below.

[0044] (2) 25% CLD hardness The 25% CLD hardness of the polyurethane foam according to the present technology can be freely set as long as it does not impair the function and effect of the present technology. The lower limit of the 25% CLD hardness of the polyurethane foam according to the present technology is, for example, 2.0 kPa or more, preferably 2.5 kPa or more, and more preferably 3.0 kPa or more. The upper limit of the 25% CLD hardness of the polyurethane foam according to the present technology is not particularly limited, and is, for example, 10 kPa or less, 7.0 kPa or less.

[0045] In the present technology, the 25% CLD hardness is a value measured by the method described in the examples below.

[0046] (3) Rebound elasticity The resilience of the polyurethane foam according to the present technology can be freely set as long as it does not impair the function and effect of the present technology. The lower limit of the resilience of the polyurethane foam according to the present technology is, for example, 20% or more, preferably 23% or more, and more preferably 25% or more. The upper limit of the resilience of the polyurethane foam according to the present technology is, for example, 40% or less, preferably 35% or less, and more preferably 33% or less.

[0047] In the present technology, the impact resilience is a value measured by the method described in the examples below.

[0048] (4) Tensile strength The tensile strength of the polyurethane foam according to the present technology can be freely set as long as it does not impair the function and effect of the present technology. The lower limit of the tensile strength of the polyurethane foam according to the present technology is, for example, 110 kPa or more, preferably 130 kPa or more, and more preferably 150 kPa or more. The upper limit of the tensile strength of the polyurethane foam according to the present technology is not particularly limited, and is, for example, 200 kPa or less.

[0049] In the present technology, the tensile strength is a value measured by the method described in the examples below.

[0050] (5) Growth rate The elongation percentage of the polyurethane foam according to the present technology can be freely set as long as it does not impair the functions and effects of the present technology. The lower limit of the elongation percentage of the polyurethane foam according to the present technology is, for example, 180% or more, preferably 200% or more, and more preferably 220% or more. The upper limit of the elongation percentage of the polyurethane foam according to the present technology is, for example, 300% or less, preferably 290% or less, and more preferably 280% or less.

[0051] In the present technology, the elongation percentage is a value measured by the method described in the examples below.

[0052] (6) Number of cells The cell number of the polyurethane foam according to the present technology can be freely set as long as it does not impair the function and effect of the present technology. The lower limit of the cell number of the polyurethane foam according to the present technology is, for example, 10 cells / 25 mm or more, preferably 13 cells / 25 mm or more, and more preferably 15 cells / 25 mm or more. The upper limit of the cell number of the polyurethane foam according to the present technology is, for example, 60 cells / 25 mm or less, preferably 55 cells / 25 mm or less, and more preferably 50 cells / 25 mm or less.

[0053] In the present technology, the number of cells is a value measured by the method described in the examples below.

[0054] (7) Compression set The compression set of the polyurethane foam according to the present technology can be freely set as long as it does not impair the function and effect of the present technology. The upper limit of the compression set of the polyurethane foam according to the present technology is, for example, 10.0% or less, preferably 9.8% or less, and more preferably 9.6% or less. The lower limit of the compression set of the polyurethane foam according to the present technology is not particularly limited, and is, for example, 1.0% or more.

[0055] In the present technology, the compression set is a value measured by the method described in the examples below.

[0056] (8) Breathability The breathability of the polyurethane foam according to the present technology can be freely set as long as it does not impair the function and effect of the present technology. The lower limit of the breathability of the polyurethane foam according to the present technology is, for example, 10 L / min or more, preferably 11 L / min or more, and more preferably 15 L / min or more. The upper limit of the breathability of the polyurethane foam according to the present technology is, for example, 35 L / min or less, preferably 30 L / min or less, and more preferably 25 L / min or less.

[0057] In the present technology, the breathability is a value measured by the method described in the examples below.

[0058] (9) Moisture and heat resistance The moist heat resistance of the polyurethane foam according to the present technology can be freely set as long as it does not impair the function and effect of the present technology. The lower limit of the moist heat resistance of the polyurethane foam according to the present technology is, for example, 60% or more, preferably 65% ​​or more, and more preferably 70% or more. The upper limit of the moist heat resistance of the polyurethane foam according to the present technology is not particularly limited, and is, for example, 100% or less.

[0059] In the present technology, the moist heat resistance is a value measured by the method described in the examples below.

[0060] (10) Biomass ratio As demonstrated in the Examples below, this technology allows the production of high-quality polyurethane foams even using biomass-derived polyols, thereby improving the biomass ratio of the produced polyurethane foam and contributing to environmental conservation and the creation of a sustainable society. The biomass ratio of the polyurethane foam according to this technology can be, for example, 5% or more, preferably 8% or more, more preferably 10% or more, and even more preferably 15% or more.

[0061] In the present technology, the biomass degree is a value calculated using a mathematical formula described in the examples below.

[0062] (11)Applications Taking advantage of its high quality, the polyurethane foam according to the present technology can be used for a wide variety of purposes in a wide range of fields. For example, it can be used for furniture such as sofas and chairs, bedding such as mattresses and pillows, clothing such as underwear, daily necessities such as tableware and cleaning sponges, vehicle and aircraft interior products such as car seats, building joint materials, building cushioning materials, building sealants, home appliance sealants, electrical equipment cushioning materials, electronic equipment cushioning materials, electrical equipment sealants, electronic equipment sealants, various battery sealants, soundproofing materials, packaging materials, vehicle insulation materials, vehicle battery sealants, vehicle electronic control unit sealants, anti-condensation materials, interior materials, home appliance insulation materials, pipe insulation materials, various covers, cushioning materials, toys, miscellaneous goods, etc. Among these, the polyurethane foam according to the present technology can be particularly suitably used as a sponge material.

[0063] 3. Polyurethane foam manufacturing method The polyurethane foam according to the present technology can be produced by mixing the components of the composition for producing the polyurethane foam described above to prepare a composition, and then carrying out a resinification reaction and a foaming reaction. As the methods for the resinification reaction and the foaming reaction, any general method can be freely combined and used as long as the action and effect of the present technology are not impaired.

[0064] The foaming method for producing polyurethane foam according to the present technology can employ any of slab foaming, batch foaming, and mold foaming. Slab foaming is a method in which a polyurethane foam production composition (a raw material for polyurethane foam) is mixed and cast onto a moving conveyor, and foamed at atmospheric pressure and room temperature. Batch foaming is a method in which the mixture is discharged into a foaming box and foamed at atmospheric pressure and room temperature. On the other hand, mold foaming is a method in which a polyurethane foam production composition (a raw material for polyurethane foam) is mixed and injected into the cavity of a mold (forming die), and foamed to the shape of the cavity.

[0065] The present technology can be configured as follows. [1] A polyurethane foam obtained from a composition containing a polyol and an isocyanate, The polyol contains a biomass-derived polyol, The polyurethane foam, wherein the biomass-derived polyol comprises a biomass-derived polyester polyol obtained by condensing a dibasic acid with a polyol containing a primary hydroxyl group. [2] The polyurethane foam according to [1], wherein the polyol containing a primary hydroxyl group is 1,3-propanediol. [3] The polyurethane foam according to [1] or [2], wherein the content of the biomass-derived polyester polyol in 100 parts by weight of the polyol in the raw material is 10 parts by weight or more and 80 parts by weight or less. [4] A sponge material using the polyurethane foam according to any one of [1] to [3]. [Example]

[0066] The present technology will be described in more detail below based on examples. Note that the examples described below are examples of typical examples of the present technology, and the scope of the present technology should not be construed as being narrow.

[0067] (1) Raw materials The raw materials used in this example are as follows: Polyol 1: Adipic acid / trimethylolpropane / diethylene glycol condensate, Functionality: 2.4, Hydroxyl value: 51 mg KOH / g, Molecular weight: 2600, Biomass content: 0% Polyol 2: Sebacic acid / 1,3-propanediol condensate, Functionality: 2, Hydroxyl value: 56 mg KOH / g, Molecular weight: 2000, Biomass content: 100% Polyol 3: Castor oil (ricinoleic acid / glycerin condensate), Functionality: 2.7, Hydroxyl value: 160 mg KOH / g, Molecular weight: 947, Biomass content: 100% Polyol 4: Modified castor oil (condensation product of sebacic acid and castor oil), functionality: 3.5, hydroxyl value: 90 mg KOH / g, molecular weight: 2182, biomass content: 100% Polyol 5: Cashew nut shell-derived polyester diol, functionality: 2, hydroxyl value: 64 mg KOH / g, molecular weight: 1753, biomass content: 87% Polyol 6: Polylactic acid diol, Functionality: 2, Hydroxyl value: 224 mg KOH / g, Molecular weight: 501, Biomass ratio: 80% or more Polyol 7: Polylactic acid diol, Functionality: 2, Hydroxyl value: 112 mg KOH / g, Molecular weight: 1002, Biomass ratio: 80% or more Foaming agent; water Amine catalyst 1: N,N'-dimethylpiperazine Amine catalyst 2; N,N',N'-trimethylaminoethylpiperazine Amine catalyst 3; N-ethylmorpholine Metal catalyst 1: stannous octoate Foam stabilizer 1: Silicone foam stabilizer, NIAX SILICONE SE-232, manufactured by Momentive Performance Materials Japan, LLC Foam stabilizer 2: Non-silicone foam stabilizer, BJ-100, manufactured by Kao Corporation Foam stabilizer 3: Non-silicone foam stabilizer, AX-31, manufactured by Sanyo Chemical Industries, Ltd. Antibacterial agent 1; Ag-based antibacterial agent Plasticizer 1; Dioctyl adipate Antioxidant 1; Phenolic antioxidant Isocyanate; Toluene diisocyanate

[0068] (2) Polyurethane foam manufacturing The components other than the isocyanate shown in Table 1 below were mixed in the formulation shown in Table 1 below, and then the isocyanate was added and mixed. The reaction time (cream time / rise time) and foaming state (visually checked for the presence or absence of health bubbles) were confirmed, and the mixture was aged in a heating furnace at 70°C and then at room temperature to produce a polyurethane foam.

[0069] (3) Measurement and evaluation of physical properties [Foaming] [Appearance] The foaming and appearance of the produced polyurethane foam were visually inspected.

[0070] [Apparent density] The density of the produced polyurethane foam was measured by a method in accordance with JIS K7222.

[0071] [25% CLD hardness] The 25% CLD hardness of the produced polyurethane foam was measured by a method in accordance with ASTM D 3574-11.

[0072] [Rebound resilience] The impact resilience of the produced polyurethane foam was measured by a method in accordance with JIS K 6400-3.

[0073] [Tensile strength] The tensile strength of the produced polyurethane foam was measured by a method in accordance with JIS K6400-5 No. 5.2 type.

[0074] [Elongation rate] The elongation of the produced polyurethane foam was measured by a method in accordance with JIS K 6400-5.

[0075] Number of Cells The cell number of the produced polyurethane foam was measured by a method in accordance with JIS K·BR>U400-1.

[0076] [Compression set] The compression set of the produced polyurethane foam was measured according to JIS 6400-4 4.5.2 Method A.

[0077] [Breathability] The air permeability of the produced polyurethane foam was measured by a method in accordance with ASTM D 3574.

[0078] [Moisture and heat resistance] The polyurethane foam manufactured using a method conforming to JIS K6400-5 No. 5.2 type was exposed to conditions of a temperature of 80°C and humidity of 95% for 14 days, and the strength retention rate (%) after humid heating relative to the initial tensile strength was calculated.

[0079] [Biomass ratio] The biomass ratio was calculated using the following formula. Biomass ratio (%) = {(number of biomass-derived polyols added × biomass ratio) / (total number of added parts − gas loss)} × 100 The gas loss was calculated by the formula: Gas loss = (parts of water added / 18) x 44.

[0080] (4) Results The results are shown in Table 1 below. [Table 1]

[0081] (5) Discussion As shown in Table 1, Comparative Examples 1 to 6, which used a biomass-derived polyol, had poor foaming properties, but Examples 1 to 4, which used a biomass-derived polyester polyol obtained by condensing a dibasic acid with a polyol containing a primary hydroxyl group as the biomass-derived polyol, had good foaming properties and physical properties equal to or better than those of the Reference Example, which did not use a biomass-derived polyol.

[0082] Comparing the Examples, Example 4, which used 100 parts by weight of a biomass-derived polyester polyol obtained by condensing a dibasic acid with a polyol containing a primary hydroxyl group as the polyol, tended to have slightly inferior physical properties compared to Examples 1 to 3, in which the amount of biomass-derived polyester polyol used was 80 parts by weight or less. These results demonstrate that the content of the biomass-derived polyester polyol obtained by condensing a dibasic acid with a polyol containing a primary hydroxyl group in the polyol is preferably 80 parts by weight or less.

Claims

1. A polyurethane foam obtained from a composition containing a polyol and an isocyanate, The polyol contains a biomass-derived polyol, The polyurethane foam, wherein the biomass-derived polyol comprises a biomass-derived polyester polyol obtained by condensing a dibasic acid with a polyol containing a primary hydroxyl group.

2. 2. The polyurethane foam according to claim 1, wherein the polyol containing primary hydroxyl groups is 1,3-propanediol.

3. The polyurethane foam according to claim 1, wherein the content of the biomass-derived polyester polyol in 100 parts by weight of the polyol in the raw material is 10 parts by weight or more and 80 parts by weight or less.

4. A sponge material using the polyurethane foam according to any one of claims 1 to 3.

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