Composition for manufacturing furan resin foam

Abstract

To provide a composition for manufacturing furan resin foam that can produce a furan resin foam with excellent mechanical properties and has an improved curing reaction rate. [Solution] A composition for manufacturing furan resin foam, containing 2,5-bis(hydroxymethyl)furan (component A).

Description

Technical Field

[0001] The present invention relates to a composition for producing a furan resin foam.

Background Art

[0002] Foams made of furan resins, etc. are used as heat insulating materials in the construction industry and other industrial fields because they are excellent in heat insulation, flame retardancy, fire resistance, etc. (for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0008] <Composition for manufacturing furan resin foam> The furan resin foam manufacturing composition of this embodiment contains 2,5-bis(hydroxymethyl)furan (component A). The furan resin foam manufacturing composition of this embodiment can produce a furan resin foam with excellent mechanical properties and excellent curing reaction rate.

[0009] The content of component A in the furan resin foam manufacturing composition is preferably 1% by mass or more, more preferably 5% by mass or more, even more preferably 10% by mass or more, and even more preferably 15% by mass or more, from the viewpoint of improving the curing reaction rate and improving mechanical properties. The content of component A in the furan resin foam manufacturing composition is preferably less than 100% by mass, more preferably 80% by mass or less, even more preferably 60% by mass or less, even more preferably 40% by mass or less, and even more preferably 30% by mass or less, from the viewpoint of improving mechanical properties.

[0010] The furan resin foam manufacturing composition of this embodiment may contain furfuryl alcohol (component B) from the viewpoint of improving curing stability.

[0011] The content of component B in the furan resin foam manufacturing composition is preferably more than 0% by mass, more preferably 10% by mass or more, even more preferably 30% by mass or more, even more preferably 40% by mass or more, and even more preferably 50% by mass or more, from the viewpoint of improving curing stability. The content of component B in the furan resin foam manufacturing composition is preferably 90% by mass or less, more preferably 85% by mass or less, and even more preferably 80% by mass or less, from the viewpoint of improving curing reaction rate and improving mechanical properties.

[0012] The mass ratio of component A to component B (component A / component B) in the furan resin foam manufacturing composition is preferably 5 / 95 or higher, more preferably 10 / 90 or higher, and even more preferably 15 / 85 or higher, from the viewpoint of improving the curing reaction rate and improving mechanical properties. The mass ratio of component A to component B (component A / component B) in the furan resin foam manufacturing composition is preferably less than 100 / 0, more preferably 80 / 20 or lower, even more preferably 60 / 40 or lower, even more preferably 50 / 50 or lower, and even more preferably 40 / 60 or lower, from the viewpoint of improving curing stability.

[0013] The furan resin foam manufacturing composition may contain a resin (component C) having constituent units derived from phenol or furfuryl alcohol. Component C can be one of conventionally known components, such as one selected from the group consisting of condensates of phenol and aldehydes, condensates of furfuryl alcohol and aldehydes, condensates of furfuryl alcohol, melamine and aldehydes, and condensates of furfuryl alcohol, urea and aldehydes, or a mixture of two or more components selected from these groups. Furthermore, a mixture of two or more co-condensates selected from these groups is also a possible example.

[0014] From the viewpoint of improving the curing reaction rate, the content of component C in the furan resin foam manufacturing composition is preferably 50% by mass or less, more preferably 30% by mass or less, and even more preferably 20% by mass or less.

[0015] The furan resin foam manufacturing composition preferably contains a curing agent. The curing agent is not particularly limited as long as it can be a curing agent capable of curing component A, a curing agent capable of curing component A and component B if the furan resin foam manufacturing composition contains component B, or a curing agent capable of curing component A, component B, and furan resins other than component B if the furan resin foam manufacturing composition contains component B and furan resins other than component B. Examples of the curing agent include acid-based curing agents, such as inorganic acids like sulfuric acid, phosphoric acid, and hydrochloric acid; sulfonic acids like benzenesulfonic acid, ethylbenzenesulfonic acid, toluenesulfonic acid (especially p-toluenesulfonic acid), xylenesulfonic acid (especially m-xylenesulfonic acid), naphthalenesulfonic acid, naphtholsulfonic acid, and phenolsulfonic acid; carboxylic acids like acetic acid, formic acid, and propionic acid; and organic acids like phenylphosphonic acid and alkylphosphonic acid. These may be used alone or in combination of two or more. Furthermore, the furan resin foam manufacturing composition may contain resorcinol, cresol, or the like as a curing aid.

[0016] When the furan resin foam manufacturing composition contains the curing agent, the amount of the curing agent in the furan resin foam manufacturing composition can be set as appropriate, but from the viewpoint of improving the curing reaction rate and improving mechanical properties, the amount of the curing agent is preferably 0.1 parts by mass or more, more preferably 1 part by mass or more, even more preferably 3 parts by mass or more, even more preferably 5 parts by mass or more, and also preferably 15 parts by mass or less, more preferably 12 parts by mass or less, and even more preferably 10 parts by mass or less, based on 100 parts by mass of the total amount of component A and component B.

[0017] The aforementioned furan resin foam production composition preferably contains a foaming agent. The foaming agent may be a chemical foaming agent or a physical foaming agent.

[0018] Examples of the chemical foaming agent include those that decompose upon heating to generate gas and those that react with the curing agent to generate gas. Examples of such agents include one or more selected from the group consisting of inorganic compounds such as sodium bicarbonate, sodium carbonate, calcium carbonate, and magnesium carbonate; azo compounds such as azodicarbonamide, azobisisobutyronitrile, and barium azodicarbonate; nitroso compounds such as N,N'-dinitrosopentamethylenetetramine; sulfohydrazide compounds such as P,P'-oxybisbenzenesulfonylhydrazide; and trihydrazinotriazine.

[0019] Examples of the physical foaming agent include hydrocarbons, hydrofluorocarbons, chlorinated hydrofluoroolefins, non-chlorinated hydrofluoroolefins, and chlorinated hydrocarbons.

[0020] Preferably, the hydrocarbon is a cyclic or linear alkane, alkene, or alkyne having 3 to 7 carbon atoms. Specific examples include one or more selected from the group consisting of normal butane, isobutane, cyclobutane, normal pentane, isopentane, cyclopentane, neopentane, normal hexane, isohexane, 2,2-dimethylbutane, 2,3-dimethylbutane, and cyclohexane.

[0021] Examples of the hydrofluorocarbon include one or more selected from the group consisting of hydrofluoropropene, hydrochlorofluoropropene, hydrobromofluoropropene, hydrofluorobutene, hydrochlorofluorobutene, hydrobromofluorobutene, hydrofluoroethane, hydrochlorofluoromethane, and hydrobromofluoromethane.

[0022] Examples of the chlorinated hydrofluoroolefin include 1-chloro-3,3,3-trifluoropropene.

[0023] Examples of non-chlorinated hydrofluoroolefins include one or more selected from the group consisting of 1,3,3,3-tetrafluoro-1-propene, 2,3,3,3-tetrafluoro-1-propene, and 1,1,1,4,4,4-hexafluoro-2-butene.

[0024] Examples of the chlorinated hydrocarbon include one or more selected from the group consisting of dichloroethane, propyl chloride, isopropyl chloride, butyl chloride, isobutyl chloride, pentyl chloride, and isopentyl chloride.

[0025] The foaming agent may be used alone or in combination of two or more.

[0026] When the composition for producing the furan resin foam contains the foaming agent, the content of the foaming agent in the composition for producing the furan resin foam can be appropriately set depending on foaming conditions, curing conditions, etc. For example, based on 100 parts by mass of the total content of Component A and Component B, it is preferably 0.1 part by mass or more, more preferably 0.5 part by mass or more, still more preferably 1 part by mass or more, and is preferably 10 parts by mass or less, more preferably 8 parts by mass or less, still more preferably 6 parts by mass or less.

[0027] The composition for producing the furan resin foam may contain a filler, a plasticizer, a foam stabilizer, etc. within a range not impairing the effects of the present invention.

[0028] The composition for producing the furan resin foam can be obtained by adding and mixing each component by a conventional method.

[0029] <Method for Producing Furan Resin Foam> The method for producing the furan resin foam of the present embodiment has a foaming step of foaming the composition for producing the furan resin foam.

[0030] The foaming step may involve heating the furan resin foam manufacturing composition to cause foaming, or foaming the furan resin foam manufacturing composition containing the foaming agent by a known method corresponding to the foaming agent, or heating the furan resin foam manufacturing composition containing the foaming agent to cause foaming. A furan resin foam can be manufactured by foaming and curing the furan resin foam manufacturing composition containing the foaming agent and the curing agent by a known method (e.g., heating) corresponding to the foaming agent and the curing agent. The furan resin foam manufacturing composition may also be filled into a mold such as a mold or wooden mold before foaming and curing.

[0031] From the viewpoint of ensuring mechanical strength, the density of the furan resin foam produced by the method for producing furan resin foam of this embodiment is preferably 10 kg / m³. 3 Therefore, from the viewpoint of ensuring thermal insulation performance, 60 kg / m² is preferred. 3 The following applies: The density of the furan resin foam can be adjusted by changing the amount of the foaming agent and curing agent, the reaction temperature and stirring conditions of the furan resin foam production composition, etc.

[0032] The closed-cell ratio of the furan resin foam is 20% or more, from the viewpoint of ensuring thermal insulation performance. The closed-cell ratio of the furan resin foam can be adjusted by changing the type and amount of the foaming agent and curing agent, the reaction temperature and stirring conditions of the composition for producing the furan resin foam, etc.

[0033] The average bubble diameter of the furan resin foam is preferably 50 μm or more from the viewpoint of ensuring thermal insulation performance, and 5000 μm or less from the same viewpoint. The average bubble diameter of the furan resin foam can be adjusted by changing the type and amount of the foaming agent and curing agent, the reaction temperature and stirring conditions of the composition for producing the furan resin foam, etc.

[0034] The aforementioned furan resin foam can be suitably used as an insulating material in the construction industry and other industrial fields. [Examples]

[0035] <Example 1 and Comparative Example 1> [Manufacturing of furan resin foam] In a polypropylene cup with an inner diameter of 70 mm, the proportions of 2,5-bis(hydroxymethyl)furan (manufactured by Fujifilm Wako Pure Chemical Industries, Ltd.), furfuryl alcohol (manufactured by Fujifilm Wako Pure Chemical Industries, Ltd.), and sodium bicarbonate (manufactured by Fujifilm Wako Pure Chemical Industries, Ltd.) listed in Table 1 were mixed. Then, a 70% p-toluenesulfonic acid aqueous solution (manufactured by Fujifilm Wako Pure Chemical Industries, Ltd.) was added to obtain the furan resin foam production compositions according to Example 1 and Comparative Example 1. These compositions were then mixed in a mixer (MT31, manufactured by Yamato Scientific Co., Ltd.) for 10 seconds immediately after the addition of the 70% p-toluenesulfonic acid. After mixing, the mixtures were allowed to stand until the curing reaction was complete and there were no changes in fluidity or appearance due to foaming, thereby obtaining the furan resin foams according to Example 1 and Comparative Example 1, respectively.

[0036] <Example 2> [Manufacturing of furan resin foam] In a polypropylene cup with an inner diameter of 70 mm, the following ingredients were mixed: 2,5-bis(hydroxymethyl)furan (manufactured by Fujifilm Wako Pure Chemical Industries, Ltd.), furfuryl alcohol (manufactured by Fujifilm Wako Pure Chemical Industries, Ltd.), and sodium bicarbonate (manufactured by Fujifilm Wako Pure Chemical Industries, Ltd.) in the amounts listed in Table 2. Then, a 70% p-toluenesulfonic acid aqueous solution (manufactured by Fujifilm Wako Pure Chemical Industries, Ltd.) was added to obtain the furan resin foam production composition according to Example 2. The mixture was then mixed in a mixer (MT31, manufactured by Yamato Scientific Co., Ltd.) for 10 seconds immediately after the addition of the 70% p-toluenesulfonic acid. After that, it was allowed to stand until the curing reaction was complete and there was no change in fluidity or appearance due to foaming, and the mixture was obtained to the same density (38 kg / m³) as the furan resin foam according to Comparative Example 1. 3 A furan resin foam according to Example 2 of the same method was obtained.

[0037] <Evaluation Method> [Measurement of the time until the foaming and hardening reaction is complete] The foam curing reaction was defined as the point at which the fluidity and appearance of the furan resin foam manufacturing composition ceased to change due to foaming. The time from immediately after mixing with 70% p-toluenesulfonic acid to the end of the foam curing reaction was measured for the furan resin foam manufacturing compositions of Example 1 and Comparative Example 1. The evaluation results are shown in Table 1.

[0038] [Measurement of compressive strength of furan resin foam] The furan resin foams according to Example 2 and Comparative Example 1 were evaluated using a compression strength evaluation tester ("SDW-020F," Imada Manufacturing Co., Ltd.) at a speed of 5 mm / min, and their compressive strength was measured. The evaluation results are shown in Table 2.

[0039] [Table 1]

[0040] [Table 2]

Claims

1. A composition for producing furan resin foam, containing 2,5-bis(hydroxymethyl)furan (component A).

2. A composition for producing furan resin foam according to claim 1, comprising furfuryl alcohol (component B).

3. The composition for producing furan resin foam according to claim 2, wherein the mass ratio of component A to component B (component A / component B) is 10 / 90 or more and less than 100 / 0.

4. A composition for producing furan resin foam according to claim 1, comprising a curing agent.

5. A composition for producing furan resin foam according to claim 1, comprising a foaming agent.

6. A method for producing a furan resin foam, comprising a foaming step of foaming a furan resin foam composition according to any one of claims 1 to 5.

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