Polyurethane foam and vehicular interior member

Abstract

The present invention improves the ventilation properties of a polyurethane foam by reducing or not using cyclic siloxane.　The polyurethane foam is obtained from a composition obtained by mixing a polyol, a polyisocyanate, and a tin catalyst. The composition contains a hydrocarbon having a carbon number of 5-50, inclusive.

Description

Polyurethane foam and vehicle interior components

[0001] This disclosure relates to polyurethane foams and vehicle interior components. This application is based on and claims the benefit of priority from Japanese Patent Application No. 2023-35388, filed March 8, 2023, the entire contents of which are incorporated herein by reference.

[0002] Patent Document 1 discloses a technique for adding cyclic siloxane to polyurethane foam to improve its breathability.

[0003] JP 2011-037987 A

[0004] However, cyclic siloxanes are subject to various regulations. The 19th SVHC (Substances of Very High Concern) list of the European REACH Regulation includes decamethylcyclopentasiloxane, dodecamethylcyclohexasiloxane, and octamethylcyclotetrasiloxane. The present disclosure has been made in light of the above-mentioned circumstances, and aims to improve the breathability of polyurethane foams by reducing the amount of cyclic siloxanes or by using no cyclic siloxanes at all. The present disclosure can be realized in the following forms.

[0005] [1] A polyurethane foam obtained from a composition comprising a polyol, a polyisocyanate, and a tin catalyst, wherein the composition contains a hydrocarbon having 5 to 50 carbon atoms.

[0006] According to the present disclosure, the breathability of polyurethane foam can be improved by reducing the amount of cyclic siloxane or by not using cyclic siloxane at all.

[0007] 1 is a diagram of a vehicle interior component with polyurethane foam according to one embodiment.

[0008] Hereinafter, preferred examples of the present disclosure will be described. [2] The polyurethane foam according to [1], wherein the polyol comprises a polyester polyol. [3] The polyurethane foam according to [1] or [2], wherein the composition comprises a flame retardant. [4] The polyurethane foam according to any one of [1] to [3], wherein the air permeability according to JIS K6400-7 Method A:2012 is 25 L / min or more. [5] The polyurethane foam according to any one of [1] to [4], wherein the composition contains 5.0 parts by mass or less of the hydrocarbon per 100 parts by mass of the polyol. [6] A vehicle interior component comprising the polyurethane foam according to any one of [1] to [5].

[0009] The present disclosure will be described in detail below. In this specification, when a numerical range is indicated using "-", it is assumed that the range includes 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.

[0010] 1. Polyurethane Foam Polyurethane foam is obtained from a composition (hereinafter also referred to as a "polyurethane resin composition") that contains a polyol, a polyisocyanate, and a tin catalyst. The composition contains a hydrocarbon having 5 to 50 carbon atoms.

[0011] (1) Polyol The polyol is not particularly limited. Various polyols may be used alone or in combination of two or more. 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 glycol. Examples of polyester polyols include aliphatic or aromatic polycondensation polyester polyols and polycaprolactone polyols. Examples of polyols having a carbon-carbon bond main chain include polyolefin polyols such as polybutadiene polyols and isoprene polyols, and acrylic polyols.

[0012] (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.

[0013] (1.1.1) Initiator (1.1.1.1) Polyhydric alcohols and alkylene oxide adducts of polyhydric alcohols Examples of polyhydric alcohols: [Bifunctional alcohols] ethylene glycol, propylene glycol, diethylene glycol, triethylene glycol, dipropylene glycol, trimethylene glycol [Trifunctional alcohols] glycerin, trimethylolpropane [Tetrafunctional alcohols] pentaerythritol [Hexafunctional alcohols] sorbitol [Octafunctional alcohols] sucrose (1.1.1.2) Alkylene oxide adducts of polyhydric phenols Examples of alkylene oxide adducts of polyhydric phenols: alkylene oxide adduct of bisphenol A (1.1.1.3) Polyhydric hydroxy compounds Examples of polyhydric hydroxy 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.

[0014] (1.1.2) Polymer Polyol 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.

[0015] (1.2) Polyester Polyols Polyester polyols are polyester polyols 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 ring-opening polymers of cyclic esters such as caprolactone and methylvalerolactone.

[0016] (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-butanediol, 1,4-butanediol, tetramethylene glycol, neopentyl glycol, methylpentanediol, butylethylpropanediol, hexamethylene glycol, decamethylene glycol, glycerin, trimethylolpropane, pentaerythritol, sorbitol

[0017] (1.2.2) Examples of compounds having 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.

[0018] (1.3) Polycarbonate Polyols 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.

[0019] (1.4) Polyolefin-Based Polyols Examples of polyolefin-based polyols include polybutadiene polyols, polyisoprene polyols, hydrogenated polybutadiene polyols, and hydrogenated polyisoprene polyols.

[0020] (1.5) Plant-Derived Polyols In addition to the above polyols, the polyol may 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 usually have 2-3 functional hydroxyl groups per molecule. Examples of castor oil-based polyols include castor oil, a reaction product of castor oil with a polyol, and an esterification reaction product of a castor oil fatty acid with a polyol. Examples of polyols to be reacted with castor oil or castor oil fatty acids include divalent polyols such as ethylene glycol, diethylene glycol, and propylene glycol, and trivalent 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.

[0021] (1.6) Application to Frame Lamination When polyurethane foam is used in a frame lamination method, it is preferable that the polyol contains a polyester polyol. The frame lamination method is a technique for adhering other components, such as a surface material, to a polyurethane foam. In the frame lamination method, a flame (frame) is applied to the surface of the polyurethane foam to melt it, and the melted portion develops adhesiveness, thereby adhering other components to the polyurethane foam. When a polyester polyol is contained, the polyurethane foam is more easily melted by the flame (frame), and sufficient adhesiveness can be obtained. Note that the use of polyester polyol is not limited to the frame lamination method. For example, polyester polyol may be used for purposes such as adjusting the physical properties of the polyurethane foam.

[0022] The content of the polyester polyol is not particularly limited, and is preferably 0.5 parts by mass or more and 20 parts by mass or less, more preferably 1 part by mass or more and 15 parts by mass or less, and even more preferably 3 parts by mass or more and 10 parts by mass or less, based on 100 parts by mass of the total polyol.

[0023] The weight-average molecular weight of the polyester polyol is not particularly limited. The number-average molecular weight of the polyester polyol is preferably 200 or more and 4,500 or less, more preferably 500 or more and 3,500 or less, and even more preferably 800 or more and 2,500 or less. The weight-average molecular weight of the polyester polyol can be measured by gel permeation chromatography (GPC). When the polyol is a commercially available product, the catalog value may be used as the weight-average molecular weight. The hydroxyl value of the polyester polyol is not particularly limited. The hydroxyl value of the polyester polyol is preferably 80 mgKOH / g or more and 350 mgKOH / g or less, more preferably 100 mgKOH / g or more and 300 mgKOH / g or less, and even more preferably 150 mgKOH / g or more and 250 mgKOH / g or less. The number of functional groups of the polyester polyol is not particularly limited. The number of functional groups of the polyester polyol is preferably 2.0 or more, more preferably 2.1 or more, and even more preferably 2.2 or more. The number of functional groups of the polyester polyol is, for example, 4.0 or less.

[0024] The polyester polyol is preferably used in combination with a polyether polyol in order to ensure the flexibility of the polyurethane foam. The polyether polyol used in combination with the polyester polyol is not particularly limited. For example, the content of the polyether polyol used in combination is preferably 80 parts by mass or more and 99.5 parts by mass or less, more preferably 85 parts by mass or more and 99 parts by mass or less, and even more preferably 90 parts by mass or more and 97 parts by mass or less, based on 100 parts by mass of the total polyol.

[0025] The weight average molecular weight, hydroxyl value, and number of functional groups of the polyether polyol used in combination are not particularly limited. The weight average molecular weight of the polyether polyol is preferably 500 or more and 10,000 or less, more preferably 1,000 or more and 6,000 or less, and even more preferably 1,500 or more and 4,000 or less. The weight average molecular weight of the polyether polyol can be measured by gel permeation chromatography (GPC). The hydroxyl value of the polyether polyol is preferably 40 mg KOH / g or more and 300 mg KOH / g or less, more preferably 45 mg KOH / g or more and 150 mg KOH / g or less, and even more preferably 50 mg KOH / g or more and 80 mg KOH / g or less. The number of functional groups of the polyether polyol is preferably 2.0 or more, more preferably 2.1 or more, and even more preferably 2.2 or more. The number of functional groups of the polyester polyol is, for example, 4.0 or less.

[0026] (2) Catalyst The polyurethane resin composition contains a tin catalyst. The present inventors conducted extensive research based on the finding that the breathability of polyurethane foam decreases as the amount of tin catalyst added increases. They then discovered that the breathability of polyurethane foam can be improved by adding a hydrocarbon, even when a tin catalyst is added, and developed the technology of the present disclosure.

[0027] As the tin catalyst, one or more selected from the group consisting of tin(II) octoate (tin 2-ethylhexanoate, stannous dioctoate), tin(II) acetate, tin(II) octanoate, tin(II) dioleate, tin(II) neodecanoate, stannous dilaurate, dibutyltin oxide, dibutyltin diacetate, dibutyltin dilaurate, dibutyltin dichloride, dioctyltin dilaurate, dibutyltin dimaleate, and dioctyltin diacetate can be used.

[0028] The amount of tin catalyst in the polyurethane resin composition is not particularly limited. From the viewpoint of sufficiently promoting the polyurethane-forming reaction, the amount of tin catalyst is preferably 0.01 parts by mass or more, more preferably 0.03 parts by mass or more, and even more preferably 0.06 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 1.0 part by mass or less, more preferably 0.5 parts by mass or less, and even more preferably 0.2 parts by mass or less. From these viewpoints, the amount of tin catalyst is preferably 0.01 parts by mass or more and 1.0 parts by mass or less, more preferably 0.03 parts by mass or more and 0.5 parts by mass or less, and even more preferably 0.06 parts by mass or more and 0.2 parts by mass or less, per 100 parts by mass of polyol. Furthermore, the amount of tin catalyst may be 0.17 parts by mass or less, 0.15 parts by mass or less, or 0.13 parts by mass or less.

[0029] The tin catalyst may be used alone or in combination with other catalysts. Examples of other catalysts that can be used include amine catalysts and quaternary ammonium salt catalysts. 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-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.

[0030] 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 0.09 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 3.0 parts by mass or less, more preferably 2.0 parts by mass or less, and even more preferably 1.0 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 3.0 parts by mass or less, more preferably 0.05 parts by mass or more and 2.0 parts by mass or less, and even more preferably 0.01 parts by mass or more and 1.0 parts by mass or less, per 100 parts by mass of polyol.

[0031] The polyurethane resin composition may contain a metal catalyst other than a tin catalyst. As the metal catalyst other than a tin catalyst, any conventionally known metal catalyst can be used without any particular limitation. Examples of metal catalysts other than a tin catalyst include metal salts of Pb (lead), Bi (bismuth), Ni (nickel), Co (cobalt), Fe (iron), Zr (zirconium), Cu (copper), Zn (zinc), and the like, and organic acid metal salts. More specifically, the following metal catalysts can be used. Pb catalysts: lead octoate, lead naphthenate, etc. Bi catalysts: bismuth octoate, bismuth naphthenate, bismuth neodecanoate, bismuth rosinate, etc. Fe catalysts: iron acetylacetonate, etc. Zr catalysts: zirconium acetylacetonate, etc. Ni catalysts: nickel acetylacetonate, nickel octoate, nickel naphthenate, etc. Co catalysts: cobalt acetylacetonate, cobalt octoate, cobalt naphthenate, etc.

[0032] (3) Flame Retardant The polyurethane resin composition preferably contains a flame retardant. The flame retardant is not particularly limited. Examples of the flame retardant include one or more selected from the group consisting of phosphate ester flame retardants, phosphate-containing flame retardants, red phosphorus, bromine-containing flame retardants, boric acid-containing flame retardants, antimony-containing flame retardants, and metal hydroxides.

[0033] From the viewpoint of improving flame retardancy, the flame retardant is preferably a phosphate ester-based flame retardant. The phosphate ester-based flame retardant may be a halogen-based phosphate ester-based flame retardant or a non-halogen-based phosphate ester-based flame retardant. As the halogen-based phosphate ester-based flame retardant, for example, one or more selected from the group consisting of a condensate of tris-1-chloro-2-propyl phosphate (TCPP), a condensate of tris-2-chloroethyl phosphate (TCEP), and a condensate of tris-1,3-dichloro-2-propyl phosphate (TDCP) are preferred. Among these, a TCPP condensate is more preferred from the viewpoints of safety, flame retardancy, and fogging resistance.

[0034] The blending amount of the flame retardant is not particularly limited. From the viewpoint of ensuring sufficient flame retardancy, the blending amount of the flame retardant is preferably 3 parts by mass or more, more preferably 8 parts by mass or more, and even more preferably 13 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 blending amount is preferably 28 parts by mass or less, more preferably 25 parts by mass or less, and even more preferably 22 parts by mass or less. From these viewpoints, the blending amount of the flame retardant is preferably 3 parts by mass or more and 28 parts by mass or less, more preferably 8 parts by mass or more and 25 parts by mass or less, and even more preferably 13 parts by mass or more and 22 parts by mass or less, per 100 parts by mass of polyol.

[0035] (4) 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, and silicone-grease copolymer; anionic surfactants such as sodium dodecylbenzenesulfonate and sodium lauryl sulfate; polyethersiloxane; and phenolic compounds. These foam stabilizers may be used alone or in combination of two or more. The amount of the foam stabilizer is not particularly limited. The amount of the foam stabilizer 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.

[0036] (5) Foaming Agent The polyurethane resin composition may contain a foaming agent. The foaming agent is not particularly limited. Suitable foaming agents include water, pentane, cyclopentane, hexane, cyclohexane, dichloromethane, and carbon dioxide gas. When the foaming 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.

[0037] (6) 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 per molecule, or a trifunctional or higher polyisocyanate having three or more isocyanate groups per 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.

[0038] 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 a 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].

[0039] (7) Hydrocarbons with 5 to 50 Carbon atoms The hydrocarbons with 5 to 50 carbon atoms are not particularly limited as long as the number of carbon atoms is within this range. The hydrocarbons may be either saturated hydrocarbons or unsaturated hydrocarbons. The hydrocarbons may be either hydrocarbons having a branched structure or cyclic hydrocarbons. Suitable examples of hydrocarbons include n-paraffins with 5 to 50 carbon atoms and isoparaffins with 5 to 50 carbon atoms. The hydrocarbons with 5 to 50 carbon atoms may be used alone or in combination of two or more.

[0040] (7.1) n-Paraffins Having 5 to 50 Carbon Atoms 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.

[0041] (7.2) Isoparaffins having 5 to 50 carbon atoms 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.

[0042] (7.3) Amount of Hydrocarbon Having 5 to 50 Carbon Atoms The amount of hydrocarbon having 5 to 50 carbon atoms in the polyurethane resin composition is not particularly limited, as long as it is present. From the viewpoint of ensuring sufficient breathability of the polyurethane foam, the 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, it is preferably 5.0 parts by mass or less, more preferably 3.0 parts by mass or less, and even more preferably 1.0 part by mass or less. From these viewpoints, the amount of hydrocarbon is preferably 0.1 parts by mass or more and 5.0 parts by mass or less, more preferably 0.2 parts by mass or more and 3.0 parts by mass or less, and even more preferably 0.3 parts by mass or more and 1.0 part by mass or less, per 100 parts by mass of polyol. Note that when two or more hydrocarbons are used, the above amount refers to the total amount of all hydrocarbons.

[0043] (8) Other Additives The polyurethane resin composition may contain other additives as appropriate, such as crosslinking agents, plasticizers, fillers, antioxidants, ultraviolet absorbers, defoamers, compatibilizers, colorants, stabilizers, antibacterial agents, antifungal agents, deodorizers, deodorizers, fragrances, and flavorings. Examples of crosslinking agents include short-chain diol crosslinking agents such as ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, 1,4-butanediol, glycerin, and trimethylolpropane. Examples of coloring agents include pigments, dyes, and coloring agents.

[0044] (9) Reasons for the improvement of breathability of polyurethane foam The reasons for the improvement of breathability will be explained. It is presumed that the inclusion of hydrocarbons having 5 to 50 carbon atoms in the polyurethane resin composition causes many cell membranes to be broken during foam molding of the polyurethane foam. This is thought to ensure high breathability of the polyurethane foam.

[0045] (10) 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: (10.1) Apparent Density The apparent density (JIS K7222:2005) is 8 kg / m ３ -120 kg / m ３ is preferred, and 10 kg / m ３ -80 kg / m ３ More preferably, 15 kg / m ３ -45 kg / m ３ is more preferable. (10.2) Hardness The hardness (JIS K6400-2 D method: 2012) is preferably 10N-600N, more preferably 50N-300N, and even more preferably 80N-150N. Within this range, the polyurethane foam is highly flexible and is preferable as a flexible polyurethane foam. (10.3) Rebound Resilience The rebound resilience (JIS K6400-3: 2011) is preferably 1%-80%, more preferably 5%-70%, and even more preferably 15%-60%. (10.4) Tensile Strength, Elongation, and Tear Strength The tensile strength (JIS K6400-5: 2012) is preferably 30 kPa or more, more preferably 50 kPa or more, and even more preferably 70 kPa or more. The upper limit of the tensile strength is not particularly limited, and is, for example, 500 kPa or less. The elongation (JIS K6400-5:2012) is preferably 80% to 500%. If it is 80% or more, the flexibility is high and it is preferable as a flexible polyurethane foam. The tear strength (JIS K6400-5:2012) is preferably 2.0 N / cm or more, more preferably 3.0 N / cm or more, and even more preferably 4.0 N / cm or more. The upper limit of the tear strength is not particularly limited, and is, for example, 50 N / cm or less. (10.5) Air Permeability The air permeability (JIS K6400-7 Method A:2012) is preferably 25 L / min or more, more preferably 60 L / min or more, and even more preferably 100 L / min or more. The air permeability is usually 300 L / min or less.

[0046] 2. Production of Polyurethane Foam 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.

[0047] 3. Uses of Polyurethane Foam There are no particular limitations on the uses of the polyurethane foam. The hydrocarbons used in the polyurethane foam of this embodiment are easily decomposable and have a low environmental impact, making them useful for a variety of uses.

[0048] The polyurethane foam of the present embodiment is suitable for use as a vehicle interior component because it can improve the breathability of the polyurethane foam with a reduced amount of cyclic silicone or without using any cyclic silicone. The polyurethane foam of the present embodiment is also suitable for use as a vehicle interior component because it can contribute to reducing volatile organic compounds (VOCs) and the like.

[0049] The vehicle interior component is not particularly limited. Examples of vehicle interior components include components used in vehicle seats and vehicle interior materials. FIG. 1 shows a cover material 10 used in a vehicle seat as an example of a vehicle interior component. This cover material 10 includes a surface material made of, for example, genuine leather, synthetic leather, or fabric, and polyurethane foam bonded to the surface material. Such a cover material is suitable as a cover material for an air-conditioned seat equipped with a heater unit, a cooling unit, or the like. In other words, when the polyurethane foam of this embodiment is used as a cover material for an air-conditioned seat, sufficient breathability of the cover material can be ensured, thereby improving the energy efficiency of the air-conditioned seat. The arrows in FIG. 1 schematically represent the air flow in the air-conditioned seat. Note that the air flow may be in the opposite direction to the arrows in FIG. 1.

[0050] 1. Production of Polyurethane Foams Polyurethane resin compositions were prepared according to the blending ratios in Table 1, and polyurethane foams of Comparative Example, Reference Example, and Examples were produced by slab foaming. The Reference Example is a comparative example in which the composition does not contain hydrocarbons having 5 to 50 carbon atoms. Details of each raw material are as follows: Polyol 1: polyether polyol, functionality 3, weight average molecular weight 3000, hydroxyl value 56 mg KOH / g Polyol 2: polyester polyol, weight average molecular weight 2400, hydroxyl value 205 mg KOH / g, DG196AX, manufactured by COIM Blowing agent: water Amine catalyst: N,N-dimethylaminohexanol Foam stabilizer: silicone-based foam stabilizer, product name: SZ-1136, manufactured by Dow Corning Toray Flame retardant: condensate of tris-1-chloro-2-propyl phosphate (TCPP), CR-504L, manufactured by Daihachi Chemical Industry Co., Ltd. Antioxidant 1: phenol-based antioxidant, Songox 1135, manufactured by Songwon Antioxidant 2: CS-25LF, manufactured by Momentive Pigment: black 4114TT Isocyanate: tolylene diisocyanate (a mixture of 80% by mass of 2,4-tolylene diisocyanate and 20% by mass of 2,6-tolylene diisocyanate) Tin catalyst: tin(II) octoate Cyclic siloxane: cyclopentasiloxane, SH245, manufactured by Dow Corning Toray Co., Ltd. Hydrocarbon: n-dodecane, C １２ H ２６

[0051] Specifically, the polyurethane foam was produced by the following procedure: Raw materials other than polyisocyanate were weighed and stirred in a cup container to prepare a mixed solution, and polyisocyanate was added to the mixed solution and stirred to prepare a polyurethane resin composition.

[0052]

[0053] 2. Evaluation Methods (1) Apparent Density (Density) Apparent density was measured according to JIS K7222:2005. (2) Hardness (25% ILD Hardness) Hardness was measured according to JIS K6400-2 Method D:2012. (3) Rebound Resilience Rebound resilience was measured according to JIS K6400-3:2011. (4) Tensile Strength, Elongation, and Tear Strength Tensile strength, elongation, and tear strength were measured according to JIS K6400-5:2012. (5) Compression Set (Compression Set) Compression set was measured according to JIS K6400-4 Method A:2004, 50% compression, 70°C, and 22 hours. (6) Air Permeability Air permeability was measured according to JIS K6400-7 Method A.

[0054] (7) VOC Values ​​For the measurement of the VOC values, a 7 mg test piece was prepared from each sample, placed in a glass tube, and a thermal desorption apparatus was used to carry out the VOC measurement method specified in "German Association of the Automotive Industry VDA 278." Specifically, each test piece was heated at 90°C for 30 minutes, and the gas generated during heating was analyzed by a gas chromatograph mass spectrometer to calculate the VOC values.

[0055] (8) Flammability Flame retardancy was measured in accordance with the US Automobile Safety Standard (FMVSS-302). A product was deemed "Pass" if it met any of the following criteria: - Self-extinguishing before the marked line - Burning distance within 51 mm (within 60 seconds) - Burning rate 102 mm / min or less

[0056] 3. Results The results are also shown in Table 1. Comparative Examples 1 to 3 show the results for polyurethane foams containing 0.11 parts by mass, 0.13 parts by mass, and 0.18 parts by mass of tin catalyst, respectively, without any additive (cyclic siloxane or hydrocarbon). The air permeability for Comparative Examples 1 to 3 was 120 L / min, 82 L / min, and 27 L / min, respectively. It was found that the air permeability decreased as the amount of tin catalyst increased. Reference Examples 1 to 4 show the results for polyurethane foams containing 0.11 parts by mass, 0.13 parts by mass, 0.18 parts by mass, and 0.23 parts by mass of tin catalyst, respectively, and 0.5 parts by mass of cyclic siloxane. Reference Examples 1 to 3 showed improved air permeability compared to Comparative Examples 1 to 3, which contained the same amount of tin catalyst.

[0057] Examples 1 to 4 show the results of polyurethane foams to which 0.11 parts by mass, 0.13 parts by mass, 0.18 parts by mass, and 0.23 parts by mass of tin catalyst were added, respectively, and 0.5 parts by mass of n-dodecane was added. Examples 1 to 4 had improved breathability compared to Comparative Examples 1 to 3, which added the same amount of tin catalyst. Furthermore, Examples 1 to 4 had approximately the same breathability compared to Reference Examples 1 to 4, which added the same amount of tin catalyst. Therefore, it was confirmed that Examples 1 to 4 could improve breathability even when no cyclic siloxane was added.

[0058] Furthermore, the total VOC of Example 1 was 445.6 ppm. It was confirmed that Example 1 had a practically acceptable VOC value. The total VOC of Comparative Example 1 was 439.5 ppm. The total VOC of Reference Example 1 was 527.0 ppm. Furthermore, dodecane was detected in the polyurethane foam of Example 1. In other words, it can be seen that the polyurethane foam of the present disclosure can be understood as a polyurethane foam containing hydrocarbons having 5 to 50 carbon atoms and a tin catalyst.

[0059] Furthermore, the flammability of Example 1 was "pass." It was confirmed that Example 1 had flammability suitable for practical use. The flammability of Comparative Example 1 and Reference Example 1 was also "pass."

[0060] According to the above examples, the breathability of polyurethane foams could be improved without using cyclic siloxanes. It was also confirmed that hydrocarbons can be used as an alternative to cyclic siloxanes to improve the breathability of polyurethane foams.

[0061] 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, a tin catalyst; A polyurethane foam obtained from a composition comprising: The composition includes a hydrocarbon having 5 to 50 carbon atoms, A polyurethane foam having an air permeability of 25 L / min or more based on JIS K6400-7 A Method: 2012.

2. The polyurethane foam according to claim 1 , wherein the composition comprises a hydrocarbon having from 9 to 50 carbon atoms.

3. 2. The polyurethane foam according to claim 1, 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.

4. 2. The polyurethane foam of claim 1, wherein the hydrocarbon is an isoparaffin.

5. The polyol includes a polyester polyol, The polyurethane foam according to claim 1, wherein the content of the polyester polyol is 20 parts by mass or less, based on 100 parts by mass of the total polyols.

6. The composition further comprises water; 2. The polyurethane foam according to claim 1, wherein the composition contains 1.0 part by mass or less of the hydrocarbon and 1 part by mass or more and 10 parts by mass or less of the water per 100 parts by mass of the polyol.