Polyol-containing composition and polyurethane foam

Abstract

A new polyurethane foam is obtained. A polyol-containing composition for obtaining a polyurethane foam, comprising: A polyol-containing composition containing a polyol having all of the following properties (i) and (ii): (i) An alkylene oxide adduct of a novolac type phenolic resin. (ii) The number average molecular weight is 1,000 or more.

Description

[Technical Field]

[0001] The present disclosure relates to polyol-containing compositions and polyurethane foams. [Background technology]

[0002] Patent Documents 1 and 2 disclose polyurethane foams obtained by reacting a polyisocyanate component with an isocyanate-reactive component containing a polyether polyol. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] International Publication No. 2010 / 052860 [Patent Document 2] Special Publication No. 2017-532423 Summary of the Invention [Problem to be solved by the invention]

[0004] Some conventional polyurethane foams are not sufficient for practical use. The present disclosure aims to provide a novel polyurethane foam. The present disclosure can be realized in the following forms. [Means for solving the problem]

[0005] [1] A polyol-containing composition for obtaining a polyurethane foam, A polyol-containing composition containing a polyol having all of the following properties (i) and (ii): (i) An alkylene oxide adduct of a novolac type phenolic resin. (ii) The number average molecular weight is 1,000 or more. [Effects of the Invention]

[0006] In accordance with the present disclosure, novel polyurethane foams are provided. DETAILED DESCRIPTION OF THE INVENTION

[0007] Here, a preferred example of the present disclosure will be described. [2] The polyol-containing composition according to [1], wherein the polyol has the following property (iii): (iii) The number of functional groups is 4.0 or more.

[0008] [3] The polyol-containing composition according to [1] or [2], wherein the alkylene oxide adduct is an ethylene oxide adduct.

[0009] [4] The polyol-containing composition according to any one of [1] to [3], which is for application by a spray method.

[0010] [5] A polyurethane foam obtained from the polyol-containing composition according to any one of [1] to [4].

[0011] [6] A polyol-containing composition for obtaining a polyurethane foam, comprising: A polyol-containing composition containing a polyol that is an alkylene oxide adduct of a cardanol-derived novolac-type phenolic resin.

[0012] The present disclosure will be described in detail below. In this specification, when a numerical range is indicated using "-", it is intended to include both the lower limit and the upper limit unless otherwise specified. For example, the expression "10-20" includes both the lower limit "10" and the upper limit "20". In other words, "10-20" has the same meaning as "10 or more and 20 or less". In addition, in this specification, the upper limit and lower limit of each numerical range can be combined in any way.

[0013] 1. First embodiment 1-1. Polyol-containing composition The polyol-containing composition of the first embodiment is a composition for obtaining a polyurethane foam. The polyol-containing composition contains a polyol having both of the following properties (i) and (ii): (i) An alkylene oxide adduct of a novolac type phenolic resin. (ii) The number average molecular weight is 1,000 or more.

[0014] Polyurethane foams are obtained by reacting a polyol-containing composition with an isocyanate.

[0015] (1) Aromatic polyol In the present disclosure, a polyol having all of the above properties (i) and (ii) is also referred to as an "aromatic polyol." The aromatic polyol is an alkylene oxide adduct of a novolac phenolic resin. The novolac phenolic resin is a novolac synthetic resin obtained by an addition-condensation reaction between phenols and aldehydes. The phenol is preferably phenol. The aldehyde is preferably formaldehyde. The alkylene oxide adduct is preferably an ethylene oxide adduct.

[0016] The aromatic polyol is preferably a polyol derived from cashew nut shell liquid (CNSL). Cashew nut shell liquid is an oily liquid contained in the shells of cashew nuts (cashew nut shells) and is prepared from cashew nut shells by extraction or heating. Cashew nut shell liquid is a renewable resource material and is a plant-derived starting material that is not derived from petroleum. Cashew nut shell liquid mainly contains cardanol, anacardic acid, cardol, and methyl cardol.

[0017] The aromatic polyol is preferably represented by the following structural formula (1).

[0018] [ka]

[0019] [In formula (1), R 1 , R 2 are each independently a hydrogen atom or a saturated or unsaturated monovalent hydrocarbon group having from 1 to 8 carbon atoms, R 3 , R 4 , R 5 are saturated or unsaturated monovalent hydrocarbon groups each having 15 carbon atoms and are represented by any of the following structural formulas (2) to (6): n is between 0 and 10. In formulas (2) to (6), * indicates the bonding position. R 1 , R 2 is preferably a hydrogen atom.

[0020] R 3 =R 4 =R 5 An example of the synthesis scheme of the above formula (1) in the case of =R will be explained using the following structural formulas (7) to (9).

[0021] [ka]

[0022] [In formulas (7)-(9), R 1 , R 2 are each independently a hydrogen atom or a saturated or unsaturated monovalent hydrocarbon group having from 1 to 8 carbon atoms, R is a saturated or unsaturated monovalent hydrocarbon group having 15 carbon atoms; n is between 0 and 10.

[0023] Examples of the starting material cardanol (the above formula (7)) are shown in the following structural formulas (10)-(13). In addition to the following structural formulas (10)-(13), cardanol (the above formula (7)) may also include cardanol as shown in the following structural formula (14).

[0024] [ka]

[0025] The novolac phenolic resin represented by the formula (8) is obtained by an addition condensation reaction between the starting material, a phenol (cardanol) represented by the formula (7) and an aldehyde. The alkylene oxide adduct (aromatic polyol) represented by the formula (9) is obtained by adding an alkylene oxide to the novolac phenolic resin represented by the formula (8).

[0026] From the viewpoint of ensuring resin strength, the number average molecular weight of the aromatic polyol is 1000 or more, preferably 1200 or more, and more preferably 1300 or more. The upper limit of the number average molecular weight of the aromatic polyol is usually 4000 or less, 3000 or less, or 2000 or less. The number average molecular weight of the aromatic polyol is a value calculated by 56.1 × 1000 × (number of functional groups) / (hydroxyl value), where 56.1 is the molecular weight of potassium hydroxide (KOH).

[0027] The number of functional groups of the aromatic polyol is preferably 3.0 or more, more preferably 4.0 or more, even more preferably 4.2 or more, and particularly preferably 4.3 or more.

[0028] The hydroxyl value of the aromatic polyol is preferably 150 mgKOH / g or more and 200 mgKOH / g or less, more preferably 160 mgKOH / g or more and 190 mgKOH / g or less, and even more preferably 170 mgKOH / g or more and 180 mgKOH / g or less. The hydroxyl value of the aromatic polyol is a value measured in accordance with JIS K 0070.

[0029] The viscosity of the aromatic polyol at 25° C. is preferably 1000 cps or more and 3000 cps or less, more preferably 1200 cps or more and 2800 cps or less, and even more preferably 1500 cps or more and 2500 cps or less. The viscosity of the aromatic polyol is a value measured using an E-type viscometer.

[0030] From the viewpoint of improving flame retardancy, the aromatic concentration of the aromatic polyol is preferably 10% or more, more preferably 15% or more, and even more preferably 20% or more. From the viewpoint of suppressing an increase in viscosity, the aromatic concentration of the aromatic polyol is preferably 40% or less, more preferably 30% or less, and even more preferably 25% or less. From these viewpoints, the aromatic concentration of the aromatic polyol is preferably 10% to 40% or less, more preferably 15% to 30% or less, and even more preferably 20% to 25% or less. The aromatic concentration of the aromatic polyol is obtained based on the total mass% of carbon atoms and hydrogen atoms constituting the aromatic rings in the aromatic polyol. The aromatic concentration of the aromatic polyol can be calculated using the method disclosed in the non-patent document (Chemistry and Technology of Polyols for Polyurethanes, M. Ionescu, Rapra Technology, 2005).

[0031] From the viewpoint of improving flame retardancy, the content of the aromatic polyol is preferably 30 parts by mass or more, more preferably 35 parts by mass or more, and even more preferably 40 parts by mass or more, when the total amount of the polyols is 100 parts by mass. From the viewpoint of ensuring resin strength, the content of the aromatic polyol is preferably 60 parts by mass or less, more preferably 55 parts by mass or less, and even more preferably 50 parts by mass or less, when the total amount of the polyols is 100 parts by mass. From the above viewpoints, the content of the aromatic polyol is preferably 30 parts by mass or more and 60 parts by mass or less, more preferably 35 parts by mass or more and 55 parts by mass or less, and even more preferably 40 parts by mass or more and 50 parts by mass or less, when the total amount of the polyols is 100 parts by mass. Here, "polyol" includes aromatic polyols and all other polyols.

[0032] The biomass degree (biocontent) of the aromatic polyol is preferably 80% or more, more preferably 83% or more, and even more preferably 85% or more. The biomass degree of the aromatic polyol is the proportion of plant-derived materials in the aromatic polyol.

[0033] (2) Other polyols The polyol-containing composition preferably contains a polyol other than the aromatic polyol. The other polyol is preferably an ethylenediamine-based polyether polyol. The ethylenediamine-based polyether polyol is preferably obtained by addition polymerization of ethylenediamine with propylene oxide.

[0034] The hydroxyl value of the ethylenediamine-based polyether polyol is preferably 600 mgKOH / g or more and 900 mgKOH / g or less, more preferably 650 mgKOH / g or more and 850 mgKOH / g or less, and even more preferably 700 mgKOH / g or more and 800 mgKOH / g or less.

[0035] The viscosity of the ethylenediamine-based polyether polyol at 25°C is preferably 35,000 mPs·s or more and 60,000 mPs·s or less, more preferably 40,000 mPs·s or more and 55,000 mPs·s or less, and even more preferably 45,000 mPs·s or more and 50,000 mPs·s or less. The viscosity of the ethylenediamine-based polyether polyol is a value measured using an E-type viscometer.

[0036] The content of the ethylenediamine-based polyether polyol is preferably 40 parts by mass or more and 70 parts by mass or less, more preferably 45 parts by mass or more and 65 parts by mass or less, and even more preferably 50 parts by mass or more and 60 parts by mass or less, relative to 100 parts by mass of the total amount of polyols.

[0037] (3) Flame retardants The polyol-containing composition preferably contains a flame retardant, such as a phosphate ester compound (e.g., tris(β-chloropropyl)phosphate, triethylphosphate, or tricresylphosphate), a phosphorus compound (e.g., red phosphorus or ammonium polyphosphate), a melamine compound, a metal hydrate, or an antimony compound.

[0038] The content of the flame retardant is preferably 5 parts by mass or more and 40 parts by mass or less, more preferably 8 parts by mass or more and 35 parts by mass or less, and even more preferably 10 parts by mass or more and 30 parts by mass or less, when the total amount of the polyol is 100 parts by mass.

[0039] (4) Foam stabilizer The polyol-containing composition preferably contains a foam stabilizer, which may be any foam stabilizer commonly used as a raw material for urethane foam, such as a silicon compound or a nonionic surfactant.

[0040] The content of the foam stabilizer is preferably 1.0 parts by mass or more and 10.0 parts by mass or less, more preferably 2.0 parts by mass or more and 5.0 parts by mass or less, and even more preferably 2.5 parts by mass or more and 3.0 parts by mass or less, relative to 100 parts by mass of the total amount of polyol.

[0041] (5) Catalyst The polyol-containing composition preferably contains a catalyst. The catalyst is mainly used to promote the urethane reaction between the polyol and the isocyanate. Examples of the catalyst include amine catalysts such as tertiary amines, organometallic compounds, acetates, and alkali metal alcoholates. The catalyst preferably does not contain a trimerization catalyst.

[0042] The content of the tertiary amine is preferably 1.0 parts by mass or more and 10.0 parts by mass or less, more preferably 2.0 parts by mass or more and 7.0 parts by mass or less, and even more preferably 2.5 parts by mass or more and 5.0 parts by mass or less, relative to 100 parts by mass of the total amount of polyol.

[0043] Examples of the amine catalyst include N,N,N',N",N"-pentamethyldiethylenetriamine, bis(2-dimethylaminoethyl)ether, triethylamine, dimethylaminoethoxyethanol, and N,N,N'-trimethylaminoethyl-ethanolamine.

[0044] The content of the amine catalyst is preferably 0.5 parts by mass or more and 10.0 parts by mass or less, more preferably 1.0 parts by mass or more and 7.0 parts by mass or less, and even more preferably 1.5 parts by mass or more and 5.0 parts by mass or less, relative to 100 parts by mass of the total amount of polyol.

[0045] Examples of organometallic compounds include metal catalysts such as bismuth-based catalysts, tin-based catalysts, lead-based catalysts, etc. Examples of bismuth-based catalysts include bismuth 2-ethylhexanoate.

[0046] The content of the organometallic compound is preferably 0.8 parts by mass or more and 2.5 parts by mass or less, more preferably 1.0 parts by mass or more and 2.0 parts by mass or less, and even more preferably 1.3 parts by mass or more and 1.8 parts by mass or less, based on 100 parts by mass of the total amount of polyol.

[0047] (6) Foaming agent The polyol-containing composition preferably contains a blowing agent, such as water or a hydrohaloolefin. The water content is preferably 0.5 parts by mass or more and 10.0 parts by mass or less, more preferably 1.0 parts by mass or more and 5.0 parts by mass or less, and even more preferably 1.5 parts by mass or more and 3.0 parts by mass or less, based on 100 parts by mass of the total amount of polyol.

[0048] The hydrohaloolefin is preferably a hydrofluoroolefin (HFO) containing a fluorine atom. The hydrofluoroolefin (HFO) is preferably a hydrochlorofluoroolefin (HCFO). Examples of the hydrochlorofluoroolefin (HCFO) include 3-chloro-1,3,3-trifluoropropene (HCFO-1233ZE), 1-chloro-2,3,3-trifluoropropene (HCFO-1233yd), 2-chloro-1,1,3-trifluoropropene (HCFO-1233xc), 2-chloro-1,3,3-trifluoropropene (HCFO-1233xe), and 1-chloro-1,2,3 -Trifluoropropene (HCFO-1233yb), 1-chloro-1,3,3-trifluoropropene (HCFO-1233zb), 3-chloro-1,1,3-trifluoropropene (HCFO-1233zc), 1-chloro-3,3,3-trifluoropropene (HCFO-1233zd), 2,3,3-trichloro-3-fluoropropene (HCFO-1231xf), 2,3-dichloro-3,3-difluoropropene Fluoropropene (HCFO-1232xf), 2,3-dichloro-3,3-difluoropropene (HCFO-1232xf), 1,2-dichloro-3,3,3-trifluoropropene (HCFO-1223xd), 2-chloro-1,1,3,3-tetrafluoropropene (HCFO-1224xc), 1,1-dichloro-2-fluoroethylene (HCFO-1121a), 1,2-dichloro-1-fluoro Examples of suitable fluoroethylenes include 1-chloro-1-fluoroethylene (HCFO-1121), 1-chloro-1-fluoroethylene (HCFO-1131a), 1-chloro-2-fluoroethylene (HCFO-1131), 1-chloro-2,2-difluoroethylene (HCFO-1122), 1,1,2-trifluoro-2-chloroethylene (HCFO-1113), and 1-chloro-3,3,3-trifluoro-1-propyne (CF3-C≡CCl).

[0049] The content of the hydrohaloolefin is preferably 1 part by mass or more and 50 parts by mass or less, more preferably 10 parts by mass or more and 40 parts by mass or less, and even more preferably 15 parts by mass or more and 35 parts by mass or less, relative to 100 parts by mass of the total amount of polyol.

[0050] 1-2. Isocyanate The isocyanate that reacts with the polyol-containing composition to produce a polyurethane foam will now be described. As the isocyanate, any isocyanate commonly used in the production of polyurethane foams can be used. The isocyanate preferably contains one or more MDI-based compounds selected from the group consisting of diphenylmethane diisocyanate (MDI), modified MDI, and polymeric MDI.

[0051] Diphenylmethane diisocyanate includes, for example, 4,4'-diphenylmethane diisocyanate (4,4'-MDI), 2,2'-diphenylmethane diisocyanate (2,2'-MDI), 2,4'-diphenylmethane diisocyanate (2,4'-MDI), and mixtures of two or more of these.

[0052] The modified MDI is, for example, a carbodiimide-modified MDI, a urethane-modified MDI, a uretoimine-modified MDI, etc. The modified MDI preferably includes a carbodiimide-modified MDI.

[0053] Polymeric MDI is a polyphenylene polymethylene polyisocyanate, and is, for example, a mixture of dinuclear MDI and trinuclear or higher polynuclear MDI. The polymeric MDI may be untreated crude MDI obtained by an MDI synthesis reaction, or may be one whose composition has been adjusted by separating a desired amount of monomeric MDI from the crude MDI by vacuum distillation.

[0054] The isocyanate index (INDEX) is preferably 80 or more and 200 or less, preferably 90 or more and 150 or less, and more preferably 100 or more and 130 or less. 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 of the polyol and water as a blowing agent, and multiplying the result by 100, and is calculated as [NCO equivalent of isocyanate / active hydrogen equivalent × 100].

[0055] The isocyanate content is preferably 130 parts by mass or more and 300 parts by mass or less, more preferably 140 parts by mass or more and 250 parts by mass or less, and even more preferably 150 parts by mass or more and 200 parts by mass or less, relative to 100 parts by mass of the total amount of polyol.

[0056] 1-3. Uses of polyol-containing compositions The polyol-containing composition is preferably for application by a spray method, in which liquid A (polyol-containing composition) and liquid B (isocyanate) are mixed on-site and sprayed with a spray foaming machine to form a polyurethane foam (so-called foam-in-place polyurethane foam).

[0057] 1-4. Uses of polyurethane foam Polyurethane foams are preferably used for building components (walls, ceilings, roofs, floors, etc.), fixtures (windows, shoji screens, sliding doors, sliding screens, transoms, etc.), ships and storage tanks for transporting oil or gas, vehicles (engines, batteries, ceilings, floors, door panels, etc.), aircraft, transport aircraft, insulated bags for transporting pharmaceuticals, freezers and refrigerated rooms, plant facilities, electrical appliances such as refrigerators, insulation materials, heat materials, and cold resistance mitigation materials for retaining walls, underground filling reinforcement materials for land subsidence prevention work or road construction, injection repair materials for civil engineering applications such as tunnels, bridges, and floating piers, structural fillers for unnecessary basements, energy absorbers, waterproofing materials, water-stopping materials, buoyancy materials, etc. Polyurethane foams are preferably used for thermal insulation in wooden or reinforced concrete buildings, etc. Polyurethane foams are preferably used for sandwich panels (sandwiched between metal plates) used as insulation for factories and homes. The polyurethane foam is preferably used for an instrument panel or a headrest of a vehicle which is integrally molded with the surface skin.

[0058] 1-5. Physical properties of polyurethane foam [Biomass ratio] The biomass ratio based on the blending ratio of raw materials in a polyurethane foam is calculated using the following formula (15).

[0059]

number

[0060] In formula (15), "the number of parts of plant-derived polyol added" refers to the total number of parts of all plant-derived polyols added when multiple types of plant-derived polyols are used. The plant-derived polyol is, for example, the aromatic polyol described above. "The biomass content of the plant-derived polyol" refers to the proportion of plant-derived materials among the raw materials. "The number of parts of all raw materials added" refers to the total number of parts of all raw materials added to the polyurethane foam. "All raw materials" refers to plant-derived polyols, other polyols, flame retardants, foam stabilizers, catalysts, blowing agents, isocyanates, etc. "The number of parts of blowing agent added" refers to the total number of parts of all blowing agents added. "All blowing agents" refers to water, hydrohaloolefins, etc. The units of "the number of parts of plant-derived polyol added," "the number of parts of hydrohaloolefin added," and "the number of parts of all raw materials added" are parts by mass.

[0061] The biomass content based on the blending ratio of raw materials in the polyurethane foam is preferably 1% or more, more preferably 10% or more, and even more preferably 20% or more.

[0062] [Apparent density] The apparent density of polyurethane foam (JIS K 7222:2005) is 25 kg / m 3 More than 45kg / m 3 Less than 28 kg / m is preferable. 3 More than 42kg / m 3 Less than 30 kg / m is more preferable. 3 More than 40kg / m 3 The following is even more preferred:

[0063] [Burning distance and burning time] The burning distance (JIS A 9511) of the polyurethane foam is preferably 150 mm or less, more preferably 90 mm or less, and even more preferably 30 mm or less. There is no particular limitation on the lower limit of the burning distance of the polyurethane foam. The burning time (JIS A 9511) of the polyurethane foam is preferably 200 seconds or less, more preferably 120 seconds or less, and even more preferably 40 seconds or less.

[0064] [Adhesive strength] The adhesive strength (tensile strength, JIS A 9526 6.2.7) of the polyurethane foam is preferably 40 N or more, more preferably 100 N or more, and even more preferably 200 N or more. There is no particular upper limit to the adhesive strength of the polyurethane foam. The adhesive strength of the polyurethane foam can be measured using a sample prepared by spraying polyurethane foam onto a plate material.

[0065] [Compression strength] The compressive strength of the polyurethane foam is preferably 180 kPa or more, more preferably 200 kPa or more, and even more preferably 250 kPa or more. The upper limit of the compressive strength of the polyurethane foam is usually not particularly limited. The compressive strength of the polyurethane foam is measured by the method described in JIS K7220 "Rigid foam plastics - Determination of compression characteristics" based on the "Measurement of compressive strength" described in JIS A 9526 6.2.5.

[0066] [Moisture permeability] The moisture permeability (water vapor transmission coefficient) of polyurethane foam is preferably less than 9.00 ng / (m·s·Pa), more preferably 7.00 ng / (m·s·Pa) or less, and even more preferably 4.00 ng / (m·s·Pa) or less. The lower limit of the moisture permeability of polyurethane foam is usually not particularly limited. The moisture permeability of polyurethane foam is measured by the method described in JIS K7225 "Rigid foam plastics - Determination of water vapor permeability" based on the "Measurement of moisture permeability" described in JIS A 9526 6.2.8.

[0067] 1-6. Effects of the first embodiment The polyol-containing composition and polyurethane foam of the first embodiment can provide a novel polyurethane foam. Specifically, a polyurethane foam with improved flame retardancy can be produced. Furthermore, a polyurethane foam with improved adhesive strength and compressive strength can be produced. In particular, a polyurethane foam with excellent physical properties can be produced using raw materials derived from cashew nut shells.

[0068] 2. Polyol-containing composition and polyurethane foam of the second embodiment The polyol-containing composition of the second embodiment is a composition for obtaining a polyurethane foam. The polyol-containing composition contains a polyol that is an alkylene oxide adduct of a cardanol-derived novolac phenolic resin.

[0069] Polyurethane foams are obtained by reacting a polyol-containing composition with an isocyanate.

[0070] 2-1. Citation of the description of the polyol-containing composition and polyurethane foam of the first embodiment With regard to the polyol-containing composition, the explanations in the section "Polyol-containing composition and polyurethane foam of the first embodiment" regarding "other polyols," "flame retardants," "foam stabilizers," "catalysts," "blowing agents," "isocyanates," "uses of the polyol-containing composition," "uses of the polyurethane foam," and "physical properties of the polyurethane foam" apply as is, and the descriptions thereof are omitted. In other words, the explanations in the section "Polyol-containing composition and polyurethane foam of the first embodiment" regarding "other polyols," "flame retardants," "foam stabilizers," "catalysts," "blowing agents," "isocyanates," "uses of the polyol-containing composition," "uses of the polyurethane foam," and "physical properties of the polyurethane foam" apply as is.

[0071] (1) Aromatic polyol In the present disclosure, polyols that are alkylene oxide adducts of cardanol-derived novolac phenolic resins are also referred to as "aromatic polyols." Novolac phenolic resins are novolac synthetic resins obtained by an addition-condensation reaction between cardanol and aldehydes. The aldehyde is preferably formaldehyde. The alkylene oxide adduct is preferably an ethylene oxide adduct.

[0072] The aromatic polyol is preferably a polyol derived from cashew nut shell liquid (CNSL). Cashew nut shell liquid is an oily liquid contained in the shells of cashew nuts (cashew nut shells) and is prepared from cashew nut shells by extraction or heating. Cashew nut shell liquid is a renewable resource material and is a plant-derived starting material that is not derived from petroleum. Cashew nut shell liquid mainly contains cardanol, anacardic acid, cardol, and methyl cardol.

[0073] The aromatic polyol is preferably represented by the above structural formula (1). For the aromatic polyol, the descriptions of "synthesis scheme," "number of functional groups," "hydroxyl value," "viscosity," "aromatic concentration," "content in polyol," and "biomass degree" explained in the section "Polyol-containing composition and polyurethane foam of the first embodiment" apply as is.

[0074] From the viewpoint of ensuring resin strength, the number average molecular weight of the aromatic polyol is preferably 1000 or more, more preferably 1200 or more, and even more preferably 1400 or more. The upper limit of the number average molecular weight of the aromatic polyol is usually 2000 or less. The number average molecular weight of the aromatic polyol is a value calculated by 56.1 × 1000 × (number of functional groups) / (hydroxyl value), where 56.1 is the molecular weight of potassium hydroxide (KOH).

[0075] 2-2. Effects of the second embodiment The polyol-containing composition and polyurethane foam of the second embodiment can provide a novel polyurethane foam. Specifically, a polyurethane foam with improved flame retardancy can be produced. Furthermore, a polyurethane foam with improved adhesive strength and compressive strength can be produced. In particular, a polyurethane foam with excellent physical properties can be produced using raw materials derived from cashew nut shells. [Example]

[0076] The present invention will be explained in more detail below with reference to examples.

[0077] 1. Preparation of Polyurethane Foam Polyurethane foams of Examples 1-5 and Comparative Examples 1 and 2 were produced using the blending ratios shown in Table 1. In Examples 1-5, an aromatic polyol (a polyol represented by the above structural formula (1)) was used as a raw material. In Comparative Examples 1 and 2, an aromatic polyol (a polyol represented by the above structural formula (1)) was not used as a raw material. In Table 1, the blending ratios represent blending ratios (parts by mass) when the polyol is taken as 100 parts by mass.

[0078] [Table 1]

[0079] Details of the raw materials for polyurethane foam in Table 1 are shown below. (Polyol-containing composition: Solution A) Polyol 1...aromatic polyol derived from cashew nut shell liquid (polyol represented by the above structural formula (1)), product name: NX9001 (manufactured by Cardrite Co., Ltd.), biomass degree: 88%, hydroxyl value: 175 mg KOH / g, viscosity (25°C): 2000 cps, average number of functional groups: 4.3, number average molecular weight: 1378 (value calculated using the calculation method described in the above embodiment), aromatic concentration: 20.2% Polyol 2: Phthalic anhydride polyester polyol, product name: RDK133 (Kawasaki Chemical Industries, Ltd.), hydroxyl value: 315 mg KOH / g Polyol 3: Ethylenediamine-based polyether polyol (addition polymerization of ethylenediamine and propylene oxide), product name: Exenol 750ED (manufactured by AGC), hydroxyl value: 750 mg KOH / g Flame retardant: Tris(β-chloropropyl)phosphate, product name: TMCPP (manufactured by Daihachi Chemical Co., Ltd.) Foam stabilizer: Silicone compound, product name: L5420 (manufactured by Toray Dow Co., Ltd.) Catalyst 1: Tertiary amine, product name: TOYOCAT SX-60 (manufactured by Tosoh Corporation) Catalyst 2: Imidazole catalyst (N,N,N',N",N"-pentamethyldiethylenetriamine), product name: Kao Raiser No. 390 (manufactured by Kao Corporation) Foaming agent 1: Water Foaming agent 2: HFO, product name: LBA (1233ZE) (Honeywell) (Isocyanate: Liquid B) Isocyanate: Crude MDI, product name: Lupranate M20S (manufactured by BASF INOAC Polyurethanes)

[0080] 2. Evaluation Method (1) Combustion test The burning distance and burning time of polyurethane foam were measured using JIS A 9511. The polyurethane foam sample dimensions were 50 mm x 150 mm x 13 mm (thickness). The test results are shown in Table 1.

[0081] (2) Reactivity The reactivity (cream time, rise time) between the polyol-containing composition (liquid A) and the isocyanate (liquid B) was measured by the following method. The measurement results are shown in Table 1. Cream time: The time it took for a mixture of liquids A and B to become cloudy and creamy was measured as the cream time (seconds). Rise time: The time until the rise of the foam caused by foaming in the above mixed liquid stopped was measured as the rise time (seconds). In the above measurement, the time when mixing of the polyol-containing composition (liquid A) and the isocyanate (liquid B) was started was set as 0 seconds. The evaluation was performed visually.

[0082] (3) Evaluation of the physical properties of polyurethane foam (3-1) Density (Apparent Density) The density was measured according to JIS K7222:2005. The measurement results are shown in Table 1.

[0083] (3-2) Adhesive strength The adhesive strength (tensile strength) was measured according to JIS A 9526 6.2.7. Specifically, the temperature of liquids A and B was adjusted to 10°C and stirred in a 1000 mL disposable cup. The stirred liquid was foamed in a 200 mm × 200 mm × 300 mm foam bag with a wooden sample board at the bottom. The resulting sample with the board attached was cut into a 50 mm square with a foam thickness of 30 mm. The cut sample was attached to a 50 mm square metal jig on the bottom using urethane adhesive. The metal jig had a hook for attachment to the testing machine. The adhesive strength of the sample was then measured using the testing machine. The measurement results are shown in Table 1.

[0084] (3-3) Compressive strength Compressive strength was measured according to the method described in JIS K7220, "Rigid foam plastics - Determination of compression characteristics," based on the "Compressive strength measurement" described in JIS A 9526 6.2.5. Specifically, the temperature of liquids A and B was adjusted to 10°C, and they were stirred in a 1000 mL disposable cup and foamed in a 200 mm x 200 mm x 300 mm foam bag. The foam was cut into a square with a base of 100 mm on one side and a thickness of 30 mm. Five samples of the same size were prepared and measured. The measurement results are shown in Table 1.

[0085] (3-4) Moisture permeability The moisture permeability (water vapor transmission coefficient) was measured by the method described in "Rigid foam plastics - Determination of water vapor permeability" of JIS K7225, based on "Measurement of moisture permeability" described in JIS A 9526 6.2.8.

[0086] (4) Biomass content of polyurethane foam The biomass ratio of the polyurethane foam was calculated using the formula (15) shown in the above embodiment. The calculation results are shown in Table 1.

[0087] 3.Results As shown in Table 1, in Examples 1-5, the polyol-containing compositions contained Polyol 1 (aromatic polyol derived from cashew nut shell liquid, product name: NX9001, biomass degree: 88%), and the biomass degree was 9.54%-19.27%. On the other hand, in Comparative Examples 1 and 2, the polyol-containing compositions did not contain Polyol 1, and the biomass degree was 0.00%.

[0088] As shown in Table 1, Examples 1, 4, and 5 had shorter burning distances and better flame retardancy than Comparative Examples 1 and 2. Furthermore, Example 2 had a burning distance similar to that of Comparative Example 2, and Example 3 had better flame retardancy than Comparative Example 1. As shown in Table 1, the combustion time of Examples 1-5 was shorter than that of Comparative Examples 1 and 2, and the flame retardancy was excellent. As described above, in Examples 1 to 5, by using the aromatic polyol (polyol represented by the above structural formula (1)) of polyol 1, excellent flame retardancy equivalent to or better than that of a composition not using an aromatic polyol was exhibited. Such excellent flame retardancy is thought to be due to the presence of aromatic rings and alkyl chains (e.g., hydrocarbon chains represented by the above structural formulas (2) to (6)) in the aromatic polyol of polyol 1.

[0089] As shown in Table 1, Example 1 had a higher adhesive strength than Comparative Examples 1 and 2. Furthermore, Examples 2-5 also had adhesive strengths of 41N-164N, which were sufficient for practical use. Therefore, even in the case of a structure using an aromatic polyol (a polyol represented by the above structural formula (1)) as a raw material, adhesive strength sufficient for practical use was obtained. Such good adhesive strength is believed to be due to the high compatibility between the alkyl chain of the aromatic polyol in Polyol 1 and the sample board (wood).

[0090] As shown in Table 1, the moisture permeability of Example 1 was lower than that of Comparative Example 2. Such a good moisture permeability is thought to be due to the alkyl chain, which is a hydrophobic group in the aromatic polyol of Polyol 1, suppressing water permeation.

[0091] 4. Effects of the Example According to the above examples, polyurethane foams with improved flame retardancy were produced using aromatic polyols (polyols represented by the above structural formula (1)) as raw materials. Furthermore, polyurethane foams with improved adhesive strength and compressive strength were produced. In particular, polyurethane foams with excellent physical properties were produced using raw materials derived from cashew nut shells.

[0092] The present disclosure is not limited to the above-described embodiments, and various modifications and variations are possible.

Claims

1. 1. A polyol-containing composition for obtaining a polyurethane foam, comprising: A polyol-containing composition containing a polyol having all of the following properties (i) and (ii): (i) An alkylene oxide adduct of a novolac type phenolic resin. (ii) The number average molecular weight is 1,000 or more.

2. 2. The polyol-containing composition of claim 1, wherein the polyol has the following property (iii): (iii) The number of functional groups is 4.0 or more.

3. The polyol-containing composition according to claim 1 , wherein the alkylene oxide adduct is an ethylene oxide adduct.

4. The polyol-containing composition according to claim 1 , which is for application by spraying.

5. A polyurethane foam obtainable from the polyol-containing composition according to any one of claims 1 to 4.

6. 1. A polyol-containing composition for obtaining a polyurethane foam, comprising: A polyol-containing composition containing a polyol that is an alkylene oxide adduct of a cardanol-derived novolac-type phenolic resin.

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