Polyurethane foam manufacturing method and polyurethane foam

Abstract

To secure sufficient air permeability and good workability in a polyurethane foam blended with a polyolefin-based resin.SOLUTION: A polyurethane foam is obtained from a composition obtained by mixing polyol, polyisocyanate and polyolefin-based resin powder. The composition contains hydrocarbon having 5 to 50 carbon atoms.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present disclosure relates to polyurethane foams. [Background technology]

[0002] In the production of lightweight flexible polyurethane foams, it is necessary to increase the amount of water added as a blowing agent to increase the expansion ratio. However, increasing the amount of water added poses the problem of increasing the amount of heat generated by the reaction between water and isocyanate. To solve this problem, Patent Documents 1 and 2 disclose techniques that utilize polymers to absorb heat. For example, these documents suitably use polyolefin resin powders with melting points of 100°C to 150°C. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 06-199973 [Patent Document 2] Special Publication No. 2002-532596 [Patent Document 3] Japanese Patent Application Laid-Open No. 2011-037987 Summary of the Invention [Problem to be solved by the invention]

[0004] However, the addition of polyolefin resin powder inhibits the resinification reaction into polyurethane, so it is necessary to add a catalyst to accelerate the reaction, which can result in a decrease in the breathability of the polyurethane foam. Furthermore, polyolefin resin powders tend to generate static electricity, which can occur during processing of polyurethane foams, resulting in poor handling. Incidentally, a technique for adding cyclic siloxane to improve breathability is disclosed in Patent Document 3. However, this additive is subject to various regulations. The present disclosure aims to provide a polyurethane foam that ensures sufficient breathability and is highly processable. The present disclosure can be realized in the following aspects. [Means for solving the problem]

[0005] A polyol, Polyisocyanate, Polyolefin resin powder, A polyurethane foam obtained from a composition comprising: The polyurethane foam, wherein the composition contains a hydrocarbon having 5 to 50 carbon atoms. [Effects of the Invention]

[0006] According to the present disclosure, a polyurethane foam that ensures sufficient breathability and is highly processable can be provided. DETAILED DESCRIPTION OF THE INVENTION

[0007] Here, a preferred example of the present disclosure will be described. The polyurethane foam, wherein the hydrocarbon is at least one selected from the group consisting of n-nonane, n-decane, n-undecane, n-dodecane, n-tridecane, n-tetradecane, n-pentadecane, n-hexadecane, n-heptadecane, n-octadecane, n-nonadecane, and n-eicosane. The polyurethane foam, wherein the composition contains more than 0 parts by mass and 10 parts by mass or less of the hydrocarbon per 100 parts by mass of the polyol. - Polyurethane foam with an air permeability of 80L / min or more based on JIS K6400-7 A Method:2012. Polyolefin resin and a hydrocarbon having 5 to 50 carbon atoms; Contains polyurethane foam.

[0008] 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".

[0009] 1. Polyurethane foam (part 1) Polyurethane foam is obtained from a composition (hereinafter also referred to as "polyurethane resin composition") obtained by mixing polyol, polyisocyanate, and polyolefin resin powder. The composition contains hydrocarbons having 5 to 50 carbon atoms.

[0010] (1) Polyol The polyol is not particularly limited, and various polyols may be used alone or in combination of two or more kinds. Examples of polyols include polyether polyols, polyester polyols, polyether ester polyols, polycarbonate diols, and polyols having a carbon-carbon bond main chain. Examples of polyether polyols include polyoxypropylene-polyoxyethylene polyols, polymer polyols, and polyoxytetramethylene glycols. Examples of polyester polyols include aliphatic or aromatic polycondensation polyester polyols and polycaprolactone polyols. Examples of polyols having a carbon-carbon bond-based main chain include polyolefin polyols such as polybutadiene polyol and isoprene polyol, and acrylic polyols.

[0011] (1.1) Polyether polyol Examples of polyether polyols include polyether polyols obtained by adding one or more of ethylene oxide, propylene oxide, butylene oxide, tetrahydrofuran, epichlorohydrin, styrene oxide, etc. to one or more of the following initiators (compounds), or polytetramethylene ether glycol.

[0012] (1.1.1) Initiator (1.1.1.1) Polyhydric alcohols and alkylene oxide adducts of polyhydric alcohols Examples of polyhydric alcohols: [Difunctional alcohols] Ethylene glycol, propylene glycol, diethylene glycol, triethylene glycol, dipropylene glycol, trimethylene glycol [Trifunctional alcohol] Glycerin, trimethylolpropane [Tetrafunctional alcohol] Pentaerythritol [Hexafunctional alcohol] Sorbitol [Octafunctional alcohol] Sucrose (1.1.1.2) Alkylene oxide adducts of polyhydric phenols Examples of alkylene oxide adducts of polyhydric phenols: alkylene oxide adducts of bisphenol A (1.1.1.3) Polyhydroxy compounds Examples of polyhydroxy compounds: phosphoric acid, benzene phosphoric acid, polyphosphoric acid (e.g., tripolyphosphoric acid and tetrapolyphosphoric acid), etc. (1.1.1.4) Phenol-aniline-formaldehyde ternary condensation products (1.1.1.5) Aniline-formaldehyde condensation products (1.1.1.6) Polyamines Examples of polyamines: ethylenediamine, diethylenetriamine, triethylenetetramine, methylenebisorthochloroaniline, 4,4- and 2,4'-diphenylmethanediamine, 2,4-tolylenediamine, 2,6-tolylenediamine, etc. (1.1.1.7) Alkanolamines Examples of alkanolamines: triethanolamine, diethanolamine, etc.

[0013] (1.1.2) Polymer polyol The polymer polyol is a polyol obtained by graft polymerizing the above-mentioned polyether polyol with an ethylenically unsaturated compound such as acrylonitrile, styrene, or alkyl methacrylate.

[0014] (1.2) Polyester polyol The polyester polyol is a polyester polyol obtained by condensation of one or more compounds having at least two hydroxyl groups with one or more compounds having at least two carboxyl groups, or a ring-opening polymer of a cyclic ester such as caprolactone or methylvalerolactone.

[0015] (1.2.1) Examples of compounds having at least two hydroxy groups Ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, dipropylene glycol, trimethylene glycol, 1,3- and 1,4-butanediol, tetramethylene glycol, neopentyl glycol, methylpentanediol, butylethylpropanediol, hexamethylene glycol, decamethylene glycol, glycerin, trimethylolpropane, pentaerythritol, sorbitol

[0016] (1.2.2) Examples of compounds with at least two carboxyl groups Malonic acid, maleic acid, succinic acid, adipic acid, tartaric acid, pimelic acid, azelaic acid, sebacic acid, oxalic acid, phthalic acid, isophthalic acid, terephthalic acid, trimellitic acid, and hemellitic acid

[0017] (1.3) Polycarbonate diol Examples of polycarbonate polyols include those obtained by transesterification of a low molecular weight polyol such as butanediol or hexanediol with a low molecular weight carbonate such as propylene carbonate or diethyl carbonate.

[0018] (1.4) Polyolefin polyol Examples of polyolefin polyols include polybutadiene polyols, polyisoprene polyols, hydrogenated polybutadiene polyols, and hydrogenated polyisoprene polyols.

[0019] (1.5) Plant-derived polyols In addition to the above polyols, the polyol may also contain a plant-derived polyol. Examples of plant-derived polyols include castor oil-based polyols, soybean oil-based polyols, palm oil-based polyols, palm kernel oil-based polyols, coconut oil-based polyols, cashew oil-based polyols, olive oil-based polyols, cottonseed oil-based polyols, safflower oil-based polyols, sesame oil-based polyols, sunflower oil-based polyols, and linseed oil-based polyols. Plant-derived polyols typically have 2 to 3 functional hydroxyl groups per molecule. Examples of castor oil-based polyols include castor oil, reaction products of castor oil with polyols, esterification reaction products of castor oil fatty acids with polyols, etc. Examples of polyols to be reacted with castor oil or castor oil fatty acids include dihydric polyols such as ethylene glycol, diethylene glycol, and propylene glycol, and trihydric or higher polyols such as glycerin, trimethylolpropane, hexanetriol, and sorbitol. Examples of soybean oil-based polyols include polyols derived from soybean oil, such as a reaction product of soybean oil with a polyol and an esterification reaction product of soybean oil fatty acid with a polyol. The polyols to be reacted with soybean oil or soybean oil fatty acid can be the same as those used for castor oil. The same applies to palm oil-based polyols, cashew oil-based polyols, and the like. The various polyols exemplified as plant-derived polyols may be used alone or in combination of two or more.

[0020] (2) Catalyst The polyurethane resin composition may contain a catalyst. Any conventionally known catalyst may be used without particular limitation. Various catalysts may be used alone or in combination of two or more. As the catalyst, an amine catalyst or a quaternary ammonium salt catalyst can be used. Specific examples of these catalysts are shown below. Tertiary amine catalysts such as triethylenediamine, triethylamine, tripropylamine, triisopropanolamine, tributylamine, trioctylamine, hexadecyldimethylamine, N-methylmorpholine, N-ethylmorpholine, N-octadecylmorpholine, monoethanolamine, diethanolamine, triethanolamine, N-methyldiethanolamine, N,N-dimethylethanolamine, N,N-dimethylaminohexanol, N,N-dimethylaminoethoxyethoxyethanol, and N,N-dimethylaminoethoxyethanol; formate and other salts of triethylenediamine; oxyalkylene adducts of amino groups of primary and secondary amines; azacyclic compounds such as N,N',N'-dialkylpiperazines; various N,N',N'-trialkylaminoalkylhexahydrotriazines; and amine catalysts having an amino group as a functional group such as N,N,N",N"-tetramethyldiethylenetriamine. Further, quaternary ammonium salt catalysts such as tetraalkylammonium halides such as tetramethylammonium chloride, tetraalkylammonium hydroxides such as tetramethylammonium hydroxide salts, and tetraalkylammonium organic acid salts such as tetramethylammonium 2-ethylhexanoate, 2-hydroxypropyltrimethylammonium formate, and 2-hydroxypropyltrimethylammonium 2-ethylhexanoate can also be used. The amount of one or more catalysts selected from the group consisting of amine catalysts and quaternary ammonium salt catalysts in the polyurethane resin composition is not particularly limited. From the viewpoint of sufficiently promoting the polyurethane-forming reaction, the amount of these catalysts is preferably 0.01 parts by mass or more, more preferably 0.05 parts by mass or more, and even more preferably 0.07 parts by mass or more, per 100 parts by mass of polyol. On the other hand, from the viewpoint of maintaining the various physical properties of the polyurethane foam and from the viewpoint of production costs, the amount is preferably 1 part by mass or less, more preferably 0.8 parts by mass or less, and even more preferably 0.5 parts by mass or less. From these viewpoints, the amount of one or more catalysts selected from the group consisting of amine catalysts and quaternary ammonium salt catalysts is preferably 0.01 parts by mass or more and 1 part by mass or less, more preferably 0.05 parts by mass or more and 0.8 parts by mass or less, and even more preferably 0.07 parts by mass or more and 0.5 parts by mass or less, per 100 parts by mass of polyol.

[0021] As the catalyst, a metal catalyst (organometallic catalyst) can be used. As the metal catalyst, any conventionally known metal catalyst can be used without any particular limitation. Examples of usable metal catalysts include metal salts of Sn (tin), Pb (lead), Bi (bismuth), Ni (nickel), Co (cobalt), Fe (iron), Zr (zirconium), Cu (copper), Zn (zinc), etc., and organic acid metal salts. More specifically, the following metal catalysts can be used: Sn catalysts: tin(II) octoate (tin 2-ethylhexanoate, stannous dioctoate), tin(II) acetate, stannous diacetate, tin(II) octoate, tin stannous dioleate, tin(II) neodecanoate, stannous dilaurate, dibutyltin oxide, dibutyltin diacetate, dibutyltin dilaurate, dibutyltin dichloride, dioctyltin dilaurate, dibutyltin dimaleate, dioctyltin diacetate, etc. Pb catalyst: lead octoate, lead naphthenate, etc. Bi catalyst: bismuth octoate, bismuth naphthenate, bismuth neodecanoate, bismuth rosinate, etc. Fe catalyst: iron acetylacetonate, etc. Zr catalyst: zirconium acetylacetonate, etc. Ni catalyst: nickel acetylacetonate, nickel octylate, nickel naphthenate, etc. Co catalyst: cobalt acetylacetonate, cobalt octylate, cobalt naphthenate, etc.

[0022] The amount of metal catalyst in the polyurethane resin composition is not particularly limited. From the viewpoint of sufficiently promoting the polyurethane-forming reaction, the amount of metal catalyst is preferably 0.01 parts by mass or more, more preferably 0.05 parts by mass or more, and even more preferably 0.1 parts by mass or more, per 100 parts by mass of polyol. On the other hand, from the viewpoint of suppressing volatile organic compounds (e.g., 2-ethylhexanoic acid) derived from the metal catalyst, the amount is preferably 1.0 part by mass or less, more preferably 0.5 parts by mass or less, and even more preferably 0.3 parts by mass or less. From these viewpoints, the amount of metal catalyst is preferably 0.01 parts by mass or more and 1.0 parts by mass or less, more preferably 0.05 parts by mass or more and 0.5 parts by mass or less, and even more preferably 0.1 parts by mass or more and 0.3 parts by mass or less, per 100 parts by mass of polyol.

[0023] (3) Foam stabilizer The polyurethane resin composition may contain a foam stabilizer. The foam stabilizer is not particularly limited. Specific examples of the foam stabilizer include silicone compounds such as organopolysiloxane, organopolysiloxane-polyoxyalkylene copolymer, polyalkenylsiloxane having a polyoxyalkylene side chain, silicone-grease copolymer, etc., anionic surfactants such as sodium dodecylbenzenesulfonate and sodium lauryl sulfate, polyether siloxane, phenolic compounds, etc. These foam stabilizers may be used alone or in combination of two or more. The amount of the foam stabilizer to be added is not particularly limited, but is preferably 0.03 parts by mass or more and 5.0 parts by mass or less per 100 parts by mass of the polyol.

[0024] (4) Foaming agent The polyurethane resin composition may contain a blowing agent. The blowing agent is not particularly limited. Suitable blowing agents include water, pentane, cyclopentane, hexane, cyclohexane, dichloromethane, and carbon dioxide gas. When the blowing agent is water, the amount added is determined within a range that allows the polyurethane foam to have a desired density and a good foaming state, and is usually preferably 1 part by mass or more and 10 parts by mass or less per 100 parts by mass of polyol.

[0025] (5) Polyisocyanate The polyisocyanate is not particularly limited. At least one selected from the group consisting of aromatic isocyanates, alicyclic isocyanates, and aliphatic isocyanates is preferably used as the polyisocyanate. One or more aliphatic isocyanates and one or more aromatic isocyanates may be used in combination. The polyisocyanate may be a bifunctional polyisocyanate having two isocyanate groups in one molecule, or a trifunctional or higher polyisocyanate having three or more isocyanate groups in one molecule, and may be used alone or in combination. For example, bifunctional polyisocyanates include 2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate, m-phenylene diisocyanate, p-phenylene diisocyanate, 4,4'-diphenylmethane diisocyanate, 2,4'-diphenylmethane diisocyanate, 2,2'-diphenylmethane diisocyanate, xylylene diisocyanate, 3,3'-dimethyl-4,4'-biphenylene diisocyanate, and 3,3'-dimethoxy-4,4'-biphenylene diisocyanate. Examples of the isocyanate include aromatic isocyanates such as phenylene diisocyanate, alicyclic isocyanates such as cyclohexane-1,4-diisocyanate, isophorone diisocyanate, dicyclohexylmethane-4,4'-diisocyanate, and methylcyclohexane diisocyanate, and aliphatic isocyanates such as butane-1,4-diisocyanate, hexamethylene diisocyanate, isopropylene diisocyanate, methylene diisocyanate, and lysine isocyanate. Examples of tri- or higher functional polyisocyanates include 1-methylbenzene-2,4,6-triisocyanate, 1,3,5-trimethylbenzene-2,4,6-triisocyanate, biphenyl-2,4,4'-triisocyanate, diphenylmethane-2,4,4'-triisocyanate, methyldiphenylmethane-4,6,4'-triisocyanate, 4,4'-dimethyldiphenylmethane-2,2',5,5'tetraisocyanate, triphenylmethane-4,4',4"-triisocyanate, and polymeric MDI. Additionally, urethane prepolymers, carbodiimide-modified isocyanates, isocyanurate-modified isocyanates, and biuret-modified isocyanates can also be used.

[0026] The mixing ratio of polyisocyanate and polyol is not particularly limited. The isocyanate index is preferably 80 or more and 120 or less. The isocyanate index (INDEX) is the value obtained by multiplying the number of moles of isocyanate groups per mole of active hydrogen groups contained in a polyurethane resin composition by 100, and is calculated by [(isocyanate equivalent in the composition / active hydrogen equivalent in the composition) × 100].

[0027] (6) Hydrocarbons with 5 to 50 carbon atoms The hydrocarbon having 5 to 50 carbon atoms is not particularly limited as long as the carbon number is within this range. The hydrocarbon may be either a saturated hydrocarbon or an unsaturated hydrocarbon. The hydrocarbon may be either a hydrocarbon having a branched structure or a cyclic hydrocarbon. Suitable examples of the hydrocarbon include n-paraffins having 5 to 50 carbon atoms and isoparaffins having 5 to 50 carbon atoms. The hydrocarbon having 5 to 50 carbon atoms may be used alone or in combination of two or more.

[0028] (6.1) n-Paraffins with carbon numbers of 5 to 50 Examples of n-paraffins having 5 to 50 carbon atoms include at least one selected from the group consisting of n-nonane, n-decane, n-undecane, n-dodecane, n-tridecane, n-tetradecane, n-pentadecane, n-hexadecane, n-heptadecane, n-octadecane, n-nonadecane, and n-eicosane.

[0029] (6.2) Isoparaffins with carbon numbers of 5 to 50 Examples of isoparaffins having 5 to 50 carbon atoms include at least one selected from the group consisting of isodecane, isododecane, 7-methyldecane, and 7-n-hexylitridecane.

[0030] (6.3) Amount of hydrocarbons containing 5 to 50 carbon atoms The amount of hydrocarbon having 5 to 50 carbon atoms blended in the polyurethane resin composition is not particularly limited, as long as it is blended. From the viewpoint of ensuring sufficient breathability of the polyurethane foam, the blended amount of hydrocarbon is preferably 0.1 parts by mass or more, more preferably 0.2 parts by mass or more, and even more preferably 0.3 parts by mass or more, per 100 parts by mass of polyol. On the other hand, from the viewpoint of maintaining the various physical properties of the polyurethane foam and from the viewpoint of production costs, the blended amount is preferably 7.0 parts by mass or less, more preferably 5.0 parts by mass or less, and even more preferably 3.0 parts by mass or less. From these viewpoints, the blended amount of hydrocarbon is preferably 0.1 parts by mass or more and 7.0 parts by mass or less, more preferably 0.2 parts by mass or more and 5.0 parts by mass or less, and even more preferably 0.3 parts by mass or more and 3.0 parts by mass or less, per 100 parts by mass of polyol. When two or more hydrocarbons are used, the blended amount refers to the total amount of all hydrocarbons.

[0031] (7) Polyolefin resin powder The polyolefin resin contained in the polyolefin resin powder is a resin obtained by homopolymerization or copolymerization of α-olefins such as ethylene, propylene, etc. The polyolefin resin is preferably one or more selected from the group consisting of polyethylene, polypropylene, and propylene-ethylene copolymer. Examples of polyolefin resin powders include polyethylene powder, polypropylene powder, etc., and one or more of these can be used. From the viewpoint of melting point, polyethylene powder is preferred. The particle size of the polyolefin resin powder is not particularly limited. From the viewpoint of maintaining the feel of the foam, the median particle size of the polyolefin resin powder is preferably 1 μm or more and 1000 μm or less, more preferably 5 μm or more and 800 μm or less, and even more preferably 10 μm or more and 600 μm or less. The amount of polyolefin resin powder in the polyurethane resin composition is not particularly limited, as long as it is present. From the viewpoint of endothermic effect, the amount of polyolefin resin powder is preferably 1 part by mass or more, more preferably 5 parts by mass or more, and even more preferably 10 parts by mass or more, per 100 parts by mass of polyol. On the other hand, from the viewpoint of maintaining the various physical properties of the polyurethane foam, the amount is preferably 50 parts by mass or less, more preferably 35 parts by mass or less, and even more preferably 20 parts by mass or less. From these viewpoints, the amount of polyolefin resin powder is preferably 1 part by mass or more and 50 parts by mass or less, more preferably 5 parts by mass or more and 25 parts by mass or less, and even more preferably 10 parts by mass or more and 20 parts by mass or less, per 100 parts by mass of polyol. Note that when two or more types of polyolefin resin powder are used, the above amount refers to the total amount of all polyolefin resin powders.

[0032] (8) Hydroxycarboxylic acids The polyurethane resin composition may contain a hydroxycarboxylic acid from the viewpoint of suppressing discoloration of the polyurethane foam. Hydroxycarboxylic acids are compounds having both a hydroxy group and a carboxyl group in the molecule. In the present disclosure, lactones, which are cyclic compounds formed by intramolecular dehydration condensation of the hydroxy group and the carboxyl group of a hydroxycarboxylic acid, and lactides, which are cyclic compounds formed by dehydration condensation of the hydroxy group and the carboxyl group of two molecules of a hydroxycarboxylic acid, are also included in the term hydroxycarboxylic acids. Examples of hydroxycarboxylic acids include lactic acid, glycolic acid, propionic acid, hydroxybutyric acid, hydroxyvaleric acid, hydroxypentanoic acid, hydroxycaproic acid, hydroxyheptanoic acid, 2-hydroxyethoxyacetic acid, 1,3-propanediol, 1-carbonate, and derivatives thereof; lactones formed by intramolecular dehydration condensation of one or more of these; and lactides formed by intermolecular dehydration condensation of one or more of these. One or more of these hydroxycarboxylic acids can be used. The amount of hydroxycarboxylic acid in the polyurethane resin composition is not particularly limited. From the viewpoint of effectively suppressing discoloration of the polyurethane foam, the amount of hydroxycarboxylic acid is preferably 0.01 parts by mass or more, more preferably 0.03 parts by mass or more, and even more preferably 0.05 parts by mass or more, per 100 parts by mass of polyol. On the other hand, from the viewpoint of maintaining the physical properties of the polyurethane foam and from the viewpoint of production costs, the amount is preferably 5 parts by mass or less, more preferably 3 parts by mass or less, and even more preferably 1 part by mass or less. From these viewpoints, the amount of lactic acid is preferably 0.01 parts by mass or more and 5 parts by mass or less, more preferably 0.03 parts by mass or more and 3 parts by mass or less, and even more preferably 0.05 parts by mass or more and 1 part by mass or less, per 100 parts by mass of polyol.

[0033] (9) Other additives The polyurethane resin composition may contain other additives, such as crosslinkers, plasticizers, flame retardants, fillers, antioxidants, ultraviolet absorbers, defoamers, compatibilizers, colorants, stabilizers, antibacterial agents, antifungal agents, deodorizers, deodorizers, fragrances, and flavorings, as appropriate. Examples of crosslinkers include short-chain diol crosslinkers such as ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, 1,4-butanediol, glycerin, and trimethylolpropane. Examples of colorants include pigments, dyes, and coloring agents.

[0034] (10) Action of hydrocarbons with carbon numbers between 5 and 50 It is believed that the inclusion of hydrocarbons with 5 to 50 carbon atoms in the polyurethane resin composition causes many cell membranes to be broken during foam molding of the polyurethane foam, which is believed to ensure the polyurethane foam's high breathability. It is also speculated that hydrocarbons with 5 to 50 carbon atoms suppress static electricity during processing of polyurethane foam. Additionally, it is believed that hydrocarbons with carbon numbers between 5 and 50 exhibit an endothermic effect when vaporized during the foaming process of polyurethane foam. This effect is thought to lower the internal temperature of polyurethane foam and prevent discoloration.

[0035] (11) Physical properties of polyurethane foam The physical properties of the polyurethane foam can be appropriately set depending on the application, etc. The polyurethane foam is preferably a flexible polyurethane foam. The polyurethane foam preferably has the following physical properties: (11.1) Apparent density Apparent density (JIS K7222) is 8 kg / m 3 -150kg / m 3 is preferred, and 10 kg / m 3 -100kg / m 3 More preferably, 12 kg / m 3 -80kg / m 3 is more preferred. (11.2) Hardness The hardness (JIS K6400-2 D method) is preferably 10N to 600N, more preferably 20N to 400N, and even more preferably 30N to 200N. If the hardness is within this range, the foam is highly flexible and is preferable as a flexible polyurethane foam. (11.3) Rebound Resilience The impact resilience (JIS K6400-3) is preferably 1% to 80%, more preferably 5% to 70%. (11.4) Tensile strength and elongation The tensile strength (JIS K6400-5) is preferably 30 kPa or more, more preferably 50 kPa or more. The elongation (JIS K6400-5) is preferably 50% to 500%. If it is 50% or more, the polyurethane foam is highly flexible and is preferable as a flexible polyurethane foam. (11.5) Airflow The ventilation rate (JIS K6400-7 Method A: 2012) is preferably 80 L / min or more, more preferably 100 L / min or more, and even more preferably 120 L / min or more. The ventilation rate is usually 300 L / min or less. (11.6) Hue (YI value) The YI value measured in accordance with the method based on JIS Z8722 is preferably 5 or less, more preferably 1 or less, and even more preferably 0 or less. The YI value is usually -3 or more. The higher the YI value, the higher the degree of yellowness.

[0036] 2. Polyurethane foam (part 2) The polyurethane foam (type 2) is a polyurethane foam containing a polyolefin resin and a hydrocarbon having 5 to 50 carbon atoms. This polyurethane foam (type 2) is usually obtained from a composition obtained by mixing a polyol, a catalyst, a foam stabilizer, a blowing agent, a polyisocyanate, a hydrocarbon having 5 to 50 carbon atoms, and a polyolefin resin powder. In the polyurethane foam (type 2), the hydrocarbon having 5 to 50 carbon atoms remains in the composition even after foam molding. In polyurethane foam (part 2), the explanations in the "Polyurethane foam (part 1)" section apply as is to the "Polyolefin resin," "Hydrocarbons with 5 to 50 carbon atoms," and "Physical properties of polyurethane foam," and the descriptions thereof are omitted. In other words, the "Polyolefin resin" (more specifically, the explanation of "Polyolefin resin contained in polyolefin resin powder" in the explanation of "Polyolefin resin powder"), "Hydrocarbons with 5 to 50 carbon atoms," and "Physical properties of polyurethane foam" explained in the "Polyurethane foam (part 1)" section apply as is.

[0037] 3. Polyurethane foam manufacturing Polyurethane foam can be produced by a known foaming method in which a polyurethane resin composition is stirred and mixed to react a polyol and a polyisocyanate. Foaming methods include slab foaming and mold foaming, and either molding method may be used. Slab foaming is a method in which a mixed polyurethane resin composition is discharged onto a belt conveyor and foamed at atmospheric pressure and room temperature. On the other hand, mold foaming is a method in which a mixed polyurethane resin composition is filled into a mold (forming die) and foamed within the mold. [Example]

[0038] 1. Polyurethane foam manufacturing Polyurethane resin compositions were prepared according to the proportions shown in Tables 1 and 2, and polyurethane foams of Examples and Comparative Examples were produced by slab foaming. The details of each raw material are as follows: Polyol: Polyether polyol, functionality 3, molecular weight 3000, hydroxyl value 56 mg KOH / g Amine catalyst: N,N-dimethylaminohexanol Foam stabilizer: Silicone foam stabilizer, product name: L-595, manufactured by Momentive Polyethylene powder (PE powder): Product name: Mipelon XM-330, manufactured by Mitsui Chemicals, Inc. Metal catalyst: tin(II) octoate Polyisocyanate: Toluene diisocyanate (TDI)

[0039] Specifically, the polyurethane foam was produced by the following procedure. The raw materials other than the polyisocyanate were weighed and stirred in a cup container to prepare a mixed solution. Polyisocyanate was added to the mixed solution and stirred to prepare a polyurethane resin composition.

[0040] [Table 1]

[0041] [Table 2]

[0042] 2. Evaluation Method (1) Apparent density (density) The apparent density was measured according to JIS K7222. (2) Hardness The hardness was measured according to JIS K6400-2 D method. (3) Rebound elasticity The impact resilience was measured according to JIS K6400-3. (4) Tensile strength and elongation The tensile strength and elongation were measured according to JIS K6400-5. (5) Ventilation The air permeability was measured according to the JIS K6400-7B method. (6) Hue (YI value) The color (YI value) was measured in accordance with the method based on JIS Z 8722. The inside of the polyurethane foam to be tested was also measured the day after production. (7) Processability The polyurethane foam was sliced ​​into multiple pieces with a thickness of 5 mm. The sliced ​​polyurethane foam was then stacked on top of each other and evaluated. The processability was evaluated according to the following criteria. Good: Even when sliced ​​foam is layered on top of each other, static repulsion between the foams is weak, making it easy to process. Bad: When sliced ​​foam is stacked on top of each other, static electricity causes strong repulsion between the foams, making it difficult to process.

[0043] 3.Results The results are shown in Tables 1 and 2. The internal temperature in the tables refers to the maximum temperature inside the polyurethane foam during slab foaming. Comparative Example 1-3 shows the results for a flexible polyurethane foam to which n-pentadecane was not added. Comparative Example 1-3 had poor processability. Examples 1-8 show the results when 0.5 parts by mass to 5 parts by mass of n-pentadecane was added. Examples 1-8 had improved breathability compared to Comparative Example 2, and breathability was sufficiently ensured. Examples 1-8 also had good processability. Furthermore, Example 3-8, which contained lactic acid, a hydroxycarboxylic acid, had a lower YI value than Example 1-2, which did not contain lactic acid. This confirms that discoloration can be suppressed by incorporating a hydroxycarboxylic acid together with n-pentadecane.

[0044] According to the above examples, polyurethane foams are provided which have sufficient breathability and are highly processable.

[0045] The present disclosure is not limited to the above-described embodiments, and various modifications and variations are possible within the scope of the present disclosure.

Claims

1. A polyol, Polyisocyanate, Polyolefin resin powder, a method for producing a polyurethane foam, comprising foaming a composition obtained by mixing the above components, The composition includes a hydrocarbon having 5 to 50 carbon atoms, the hydrocarbon is at least one selected from the group consisting of n-nonane, n-decane, n-undecane, n-dodecane, n-tridecane, n-tetradecane, n-pentadecane, n-hexadecane, n-heptadecane, n-octadecane, n-nonadecane, and n-eicosane; The ventilation rate based on JIS K6400-7 A Method: 2012 is 80 L / min or more, A method for producing a polyurethane foam that satisfies one or more of the following (1) to (4): (1) The hardness of the polyurethane foam (JIS K6400-2 D method) is 30N or more and 200N or less. (2) The impact resilience (JIS K6400-3) of the polyurethane foam is 5% or more and 46% or less. (3) The tensile strength (JIS K6400-5) of the polyurethane foam is 30 kPa or more and 112 kPa or less. (4) The elongation of the polyurethane foam (JIS K6400-5) is 50% or more and 500% or less.

2. The method for producing a polyurethane foam according to claim 1, wherein the composition contains more than 0 parts by mass and not more than 10 parts by mass of the hydrocarbon per 100 parts by mass of the polyol.

3. A polyolefin resin, hydrocarbons having 5 to 50 carbon atoms; the hydrocarbon is at least one selected from the group consisting of n-nonane, n-decane, n-undecane, n-dodecane, n-tridecane, n-tetradecane, n-pentadecane, n-hexadecane, n-heptadecane, n-octadecane, n-nonadecane, and n-eicosane; The ventilation rate based on JIS K6400-7 A Method: 2012 is 80 L / min or more, A polyurethane foam that satisfies one or more of the following (1) to (4): (1) The hardness of the polyurethane foam (JIS K6400-2 D method) is 30N or more and 200N or less. (2) The impact resilience (JIS K6400-3) of the polyurethane foam is 5% or more and 46% or less. (3) The tensile strength (JIS K6400-5) of the polyurethane foam is 30 kPa or more and 112 kPa or less. (4) The elongation of the polyurethane foam (JIS K6400-5) is 50% or more and 500% or less.

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