Molded article, soundproof material, and disposer cover

Abstract

Provided are: a molded article comprising a polyurethane foam, the polyurethane foam being a molded article of a composition for polyurethane foam, the composition comprising a plant-derived polyol and a polyether polyol as raw material polyols, wherein the total amount of the plant-derived polyol and the polyether polyol is 85% by mass or more based on the total raw material polyols, and the amount of the plant-derived polyol is 60% by mass or less based on the total raw material polyols; a soundproof material; and a disposer cover.

Description

Molded product, soundproofing material, and disposer cover

[0001] The present disclosure relates to a molded product, a soundproofing material, and a disposer cover.

[0002] Since polyurethane foam has internal air bubbles, molded products containing polyurethane foam are used for the purpose of inhibiting sound transmission. For example, by arranging it inside the wall material of a house, or around an instrument panel of an automobile, a disposer in a kitchen, etc., a soundproofing material provided with a molded product containing polyurethane foam is arranged in the sound vibration transmission path to suppress the transmission of noise. Generally, for soundproofing materials of the same material, as the thickness increases with respect to the sound transmission path, the soundproofing effect tends to increase. However, for example, in the case of a disposer cover, since it is generally arranged in a household sink, the size including the main body and the soundproofing material is limited, and there is also a limit to the volume of the soundproofing material. In addition, from the perspective of reducing environmental impact in recent years, the use of plant-derived resins obtained from plant resources has been required instead of petroleum-derived resins using petroleum resources as raw materials.

[0003] As a vibration damping and sound absorbing material using a plant-derived resin obtained from plant resources, a vibration damping and sound absorbing material containing a plant-derived polyol and a polyoxyalkylene polyol produced using a raw material obtained from a plant, and a polymer-dispersed polyol in which polymer fine particles are dispersed is known (for example, Japanese Patent No. 5224715). Also, in a polyurethane foam obtained from a composition for polyurethane foam containing a polyol component, a polyisocyanate, a foaming agent, and a catalyst, a soundproofing material using a polyurethane foam containing a plant-derived polyol and a polymer polyol in the polyol component has been proposed (International Publication No. 2024-24845).

[0004] Conventional soundproofing materials offer good sound insulation when they are about 20 mm thick, but for applications such as garbage disposal covers, thinner materials are required. Furthermore, if polymer polyols are used as the polyol component to ensure hardness, the viscosity of the raw material composition becomes too high, impairing its flowability and thus compromising its moldability. This disclosure addresses these issues and aims to provide a molded product containing polyurethane foam that offers good moldability even when molded into thin shapes, provides good sound insulation, and contributes to reducing environmental impact, as well as a soundproofing material and a garbage disposal cover using the said molded product.

[0005] The first embodiment is a molded article containing polyurethane foam, which is a molded article of a polyurethane foam composition comprising a plant-derived polyol and a polyether polyol as raw material polyols, wherein the total amount of the plant-derived polyol and the polyether polyol is 85% by mass or more of the total raw material polyol, and the amount of the plant-derived polyol is 60% by mass or less of the total raw material polyol.

[0006] The second embodiment is the first embodiment, wherein the polymer polyol content in the total mass of the raw material polyol is 10% by mass or less.

[0007] The third aspect is that, in the first or second aspect, the viscosity of the polyurethane foam composition at 25°C is 1000 mPa·s or less.

[0008] The fourth embodiment is one of the first to third embodiments, wherein the surface hardness of the polyurethane foam is 20 or less on the Asker C hardness scale (JIS K 7312:1996).

[0009] The fifth aspect is that, in any one of the first to fourth aspects, the maximum value of the normal incidence sound absorption coefficient (JIS A1405-2:2007) for a thickness of 10 mm at frequencies of 3000 to 6000 Hz is 0.85 or higher.

[0010] The sixth embodiment is an embodiment of any one of the first to fifth embodiments, wherein the density of the polyurethane foam is 100 kg / m³. ３ More than 200kg / m ３ The following applies:

[0011] The seventh embodiment is an embodiment of any one of the first to sixth embodiments, wherein the raw material isocyanate in the polyurethane foam composition includes a carbodiimide-modified isocyanate.

[0012] The eighth embodiment is a soundproofing material comprising a molded product according to any one of the first to seventh embodiments.

[0013] The ninth aspect is a disposer cover comprising a molded product according to any one of the first to eighth aspects.

[0014] According to this disclosure, a polyurethane foam that exhibits good moldability even when molded into a thin shape, provides good sound insulation, and contributes to reducing environmental impact, as well as a sound insulation material and a disposer cover using the polyurethane foam, can be obtained.

[0015] Figure 1 is a schematic diagram showing one embodiment of a disposer placed in a household sink. Figure 2A is a schematic diagram showing one embodiment of the inside of a molded product with the disposer cover of the present disclosure unfolded. Figure 2B is a schematic diagram showing the outside of the molded product with the disposer cover shown in Figure 2A unfolded. Figure 3A is a schematic diagram showing one embodiment of a disposer for which the disposer cover of the present disclosure is placed. Figure 3B is a schematic diagram showing one embodiment of the molded product of the present disclosure placed in the disposer shown in Figure 3A.

[0016] This disclosure can be understood more fully by the following detailed description. The further scope of applications of this disclosure will become apparent from the following detailed description. However, the detailed description and specific embodiments are preferred embodiments of this disclosure and are described for illustrative purposes only, for various changes and modifications will be apparent to those skilled in the art within the intent of this disclosure. The applicant has no intention of dedicating any of the described embodiments to the public, and any modifications or alternatives, even those not explicitly included in the claims, are part of the invention under the doctrine of equivalents.

[0017] Embodiments of the present invention will be described below. <Molded Article> The molded article of the present disclosure includes a polyurethane foam which is a molded article of a polyurethane foam composition in which the raw material polyol includes a plant-derived polyol and a polyether polyol, the total amount of the plant-derived polyol and the polyether polyol is 85% by mass or more of the total raw material polyol, and the amount of the plant-derived polyol is 60% by mass or less of the total raw material polyol. The polyurethane foam composition generally includes a raw material polyol, polyisocyanate, a blowing agent, and a catalyst, and may also include other components. That is, the polyurethane foam contained in the molded article is obtained from a polyurethane foam composition containing a raw material polyol, polyisocyanate, a blowing agent, and a catalyst. By stirring the polyurethane foam composition, the raw material polyol and polyisocyanate react and foam, forming a polyurethane foam. The following describes each component contained in the polyurethane foam composition that serves as the raw material for the molded article of the present disclosure.

[0018] [Raw material polyol] The raw material polyol comprises a plant-derived polyol and a polyether polyol, wherein the total amount of the plant-derived polyol and the polyether polyol is 85% by mass or more of the total raw material polyol, and the amount of the plant-derived polyol is 60% by mass or less of the total raw material polyol.

[0019] Examples of polyether polyols include polyols having alkylene groups with 2 to 5 carbon atoms, and compounds in which some or all of the hydroxyl groups of a polyether polyol are alkyl etherified. Examples of alkylene groups include alkylene groups with 2 to 4 carbon atoms, such as polyethylene polyols and polypropylene polyols.

[0020] The oxyalkylene units in one molecule of polyether polyol may be one type or two or more types. The polyether polyol is preferably a compound containing at least oxypropylene units in one molecule, and polypropylene polyol is more preferably preferred. The polyether polyol is a petroleum-derived polyol. The raw material polyol may include a petroleum-derived polyether polyol, considering moldability, productivity, etc. The polyether polyol preferably has a functional group number in the range of 2.5 to 3.0, and more preferably 3.0. The molecular weight of the polyether polyol is preferably 3000 to 5000, and more preferably 4500 to 5000. The hardness of the resulting urethane foam can be controlled by adjusting the molecular weight.

[0021] Plant-derived polyols are polyols produced using plant-derived raw materials, such as vegetable oils. Plant-derived polyols preferably have 2 to 4 functional groups. Furthermore, the molecular weight of plant-derived polyols is preferably 600 to 5000, more preferably 800 to 4000, and even more preferably 900 to 3000.

[0022] Examples of plant-derived raw materials include castor oil, sunflower oil, rapeseed oil, linseed oil, cottonseed oil, tung oil, coconut (palm) oil, poppy oil, corn oil, and soybean oil. Among these, it is preferable that the plant-derived polyol contains either a castor oil-derived polyol or a soybean-derived polyol. A castor oil-derived polyol is a polyol produced using castor oil as a raw material, and a soybean oil-derived polyol is a polyol produced using soybean oil as a raw material. Among these, castor oil polyol is more preferable as the plant-derived polyol.

[0023] Castor oil polyols may be modified castor oil polyols, unmodified castor oil polyols, or both. Modified castor oil polyols include transesterification products of castor oil with other oils and fats, transesterification products of castor oil with fatty acids, transesterification products of castor oil with polyhydric alcohols, esterification products of castor oil fatty acids with polyhydric alcohols, esterification products of some of the hydroxyl groups contained in castor oil with monocarboxylic acids such as acetic acid, reaction products obtained by addition polymerization of these with alkylene oxide, and hydrogenated products obtained by adding hydrogen to these. Unmodified castor oil polyols include refined castor oil polyols, semi-refined castor oil polyols, and unrefined castor oil polyols.

[0024] In addition, some plant-derived polyols include, for example, polyols obtained by modifying castor oil with petroleum-derived compounds. In the case of such plant-derived polyols modified with petroleum-derived compounds (hereinafter sometimes referred to as "modified polyols"), the plant-derived component of the modified polyol, excluding the modified portion, shall be treated as the "plant-derived polyol." For example, if 100 parts by mass of a raw material polyol is used, where 80% by mass of the raw material polyol is plant-derived polyol (unmodified) and 20% by mass is a modified polyol obtained by modifying the plant-derived polyol with a petroleum-derived compound (15% modified polyol), then 97 parts by mass of the raw material polyol shall be treated as the "plant-derived polyol."

[0025] Multiple types of plant-derived polyols may be used. The amount of the plant-derived polyol is 60% by mass or less of the total raw material polyol, preferably 50% by mass or less, and more preferably 40% by mass or less. From the viewpoint of reducing environmental impact, the amount of plant-derived polyol can be 10% by mass or more of the total raw material polyol, and preferably 15% by mass or more.

[0026] In this disclosure, the plant-derived polyol content, expressed as a mass percentage, is 15% to 40%, and preferably 19% to 35%. The plant-derived polyol content (%) in this disclosure is a value expressed as the mass percentage of plant-derived polyol contained in the polyurethane foam composition, and is calculated using the following formula: Plant-derived polyol content (%) = [(Mass of plant-derived polyol / Total mass of polyurethane foam composition)] × 100

[0027] The content of polyether polyol and plant-derived polyol in the raw material polyol is preferably adjusted within a range where the plant content calculated by the above formula is between 15% and 40%.

[0028] In the raw material polyols of this disclosure, in addition to the polyether polyol and the plant-derived polyol, other polyols may also be included. However, from the viewpoint of ease of viscosity adjustment and moldability of the polyurethane foam composition (raw material composition), the polymer polyol content is preferably 10% by mass or less of the total mass of the raw material polyol, more preferably 5% by mass or less, and even more preferably 1% by mass or less. As a raw material for polyurethane foam, polymer polyols used for purposes such as increasing the hardness of polyurethane foam are known to be obtained by graft polymerization of acrylonitrile, styrene, etc., to a polyether polyol, and then finely dispersing the acrylonitrile, styrene, etc. The molded articles suitable for sound-absorbing materials of this disclosure do not particularly need to have high hardness, and it is preferable that they have good moldability even when molded into thin films. From such a viewpoint, the polymer polyol content of the raw material polyol is preferably 10% by mass or less of the total mass of the raw material polyol, more preferably 5% by mass or less, and more preferably free of polymer polyol except for unavoidable impurities.

[0029] In addition to polyether polyols and plant-derived polyols, the raw material polyol may also contain other petroleum-derived polyols. Examples of other petroleum-derived polyols include polyether polyols, polyester polyols, and polyether ester polyols. The other petroleum-derived polyols preferably have 2 to 4 functional groups and a molecular weight of 100 to 10,000, more preferably 400 to 8,000, and even more preferably 700 to 7,000. The amount of other petroleum-derived polyols is the remainder of the blending amount of polyether polyols and plant-derived polyols in 100% by mass of the raw material polyol, for example, preferably 15% by mass or less, more preferably 12% by mass or less, and even more preferably 10% by mass or less, relative to the total raw material polyol.

[0030] In particular, the raw material polyol in this disclosure preferably consists of a polyether polyol and a plant-derived polyol, and does not contain other polyols.

[0031] [Polyisocyanates] Polyisocyanates are not particularly limited as long as they are compounds having two or more isocyanate groups, and those used for polyurethane foams can be used. Not limited to one type of polyisocyanate, two or more types may be used in combination. Examples of polyisocyanates include aromatic, aliphatic, and alicyclic isocyanate compounds, and modified versions thereof.

[0032] Aromatic isocyanate compounds include diphenylmethane diisocyanate (MDI), crude diphenylmethane diisocyanate, tolylene diisocyanate (TDI), naphthalene diisocyanate (NDI), p-phenylene diisocyanate (PPDI), xylene diisocyanate (XDI), tetramethyl xylene diisocyanate (TMXDI), and tolidine isocyanate (TODI). Aliphatic isocyanate compounds include hexamethylene diisocyanate (HDI), lysine diisocyanate (LDI), and lysine triisocyanate (LTI). Alicyclic isocyanate compounds include isophorone diisocyanate (IPDI), cyclohexyl diisocyanate (CHDI), hydrogenated XDI (H6XDI), and hydrogenated MDI (H12MDI). Examples of modified isocyanate compounds include urethane-modified, dimer-modified, trimer-modified, carbodiimide-modified, allophanate-modified, biuret-modified, urea-modified, isocyanurate-modified, oxazolidone-modified, and isocyanate-terminated prepolymers of isocyanate compounds. In particular, it is preferable that the raw material isocyanate includes carbodiimide-modified isocyanate.

[0033] The amount of polyisocyanate blended is preferably such that the isocyanate index is between 70 and 110. If the isocyanate index is less than 70, the polyurethane foam will have too little strength and poor durability, and gas will not escape easily, resulting in shrinkage and poor molding. On the other hand, if the isocyanate index exceeds 110, the polyurethane foam will become too hard and will not easily deform to the shape of the mating surface. The isocyanate index is a value that expresses the equivalent ratio of the isocyanate groups of polyisocyanate to the total active hydrogen groups in the polyurethane foam composition (e.g., hydroxyl groups of polyols, active hydrogen groups of water used as a blowing agent), and is an index used in the field of polyurethane foam.

[0034] [Foaming Agent] Examples of foaming agents include water, hydrocarbons, halogenated compounds, etc., and one or more of these may be used. Examples of hydrocarbons include cyclopentane, isopentane, and n-pentane. Examples of halogenated compounds include methylene chloride, trichlorofluoromethane, dichlorodifluoromethane, nonafluorobutyl methyl ether, nonafluorobutyl ethyl ether, pentafluoroethyl methyl ether, and heptafluoroisopropyl methyl ether. Among these, water is preferred as a foaming agent. The amount of water used as a foaming agent is preferably about 1% to 10% by mass per 100% by mass of the raw material polyol, and more preferably about 1% to 7% by mass, which allows for adjustment of the density of the polyurethane foam. Alternatively, it may be 1 to 10 parts by mass or 1 to 7 parts by mass per 100 parts by mass of the raw material polyol.

[0035] [Catalyst] Examples of catalysts include amine-based catalysts and metal catalysts. Examples of amine-based catalysts include N,N-dimethylcyclohexylamine, N,N-dimethylbenzylamine, N,N-dimethylaminoethanol, N,N',N'-trimethylaminoethylpiperazine, and triethylenediamine. Examples of metal catalysts include tin catalysts such as stas octoate and dibutyltin dilaurate, phenylmercury propionate, and lead octenoate. The amount of catalyst is preferably about 0.1% to 8.0% by mass, more preferably about 1.0% to 5.0% by mass, and even more preferably about 1.5% to 3.5% by mass, per 100% by mass of the raw material polyol. Alternatively, the amount may be 0.1 to 8.0 parts by mass, 1.0 to 5.0 parts by mass, or 1.5 to 3.5 parts by mass per 100 parts by mass of the raw material polyol.

[0036] In addition, the polyurethane foam composition may appropriately contain additives such as crosslinking agents, foam stabilizers, flame retardants, colorants, and degassing agents.

[0037] Examples of crosslinking agents include polyhydric alcohols such as ethylene glycol, diethylene glycol, glycerin, butanetetraol, and polyoxypropylene glycol, as well as diethanolamine and polyamine. When a polyurethane foam composition contains a crosslinking agent, it may contain one type of crosslinking agent or multiple types. The amount of crosslinking agent is preferably about 0.1% to 3% by mass, and more preferably about 0.2% to 2% by mass, based on 100% by mass of the raw material polyol. Alternatively, it may be 0.01 to 3 parts by mass or 0.05 to 2 parts by mass, based on 100 parts by mass of the raw material polyol.

[0038] Any foam stabilizer used in polyurethane foams is acceptable, including silicone-based foam stabilizers, fluorine-containing compound-based foam stabilizers, and known surfactants. Silicone-based foam stabilizers are preferred. The amount of foam stabilizer is preferably about 0.01% to 3% by mass, and more preferably about 0.05% to 2% by mass, based on 100% by mass of the raw material polyol. Alternatively, it may be 0.01 to 3 parts by mass or 0.05 to 2 parts by mass, based on 100 parts by mass of the raw material polyol.

[0039] Examples of degassing agents (communicating agents) include polyether polyols with a high EO (ethylene oxide) addition ratio, polyethylene glycol, etc. The amount of degassing agent is preferably about 0.5% to 3% by mass per 100% by mass of the raw material polyol. Alternatively, it may be 0.5 to 3 parts by mass per 100 parts by mass of the raw material polyol. In this disclosure, when a degassing agent consisting of a polyol is used, the amount used is very small, so the content of such a degassing agent is not included in the content of the raw material polyol.

[0040] [Preferred Physical Properties] It is preferable that the viscosity of the raw material polyol, which is the raw material of the molded product of the present disclosure, at 25°C is 1000 mPa·s or less. When the content of the polymer polyol in the total mass of the raw material polyol is 10% by mass or less, it is effective for the viscosity of the raw material polyol at 25°C to be 1000 mPa·s or less. For the same reason, the content of the polymer polyol in the total mass of the raw material polyol is preferably 1% by mass or less, more preferably not containing the polymer polyol (that is, 0% by mass). Also, when the content of the polymer polyol in the total mass of the raw material polyol is 10% by mass or less, the fluidity during filling of the polyurethane foam composition containing the raw material polyol, raw material isocyanate, etc. into the molding die is good, and it has the advantage that it can be easily filled into dies with complex shapes, thin-walled dies, etc. In particular, since the sound-absorbing material for the disposer described later is required to have a thin thickness, the polyurethane foam composition according to the present disclosure, which can be easily filled as compared with the conventional polyurethane foam composition, is suitable. The viscosity of the raw material polyol used in the polyurethane foam composition at 25°C is preferably 1000 mPa·s or less, more preferably 990 mPa·s or less. In the present disclosure, the viscosity of the raw material polyol is the viscosity measured at 25°C using an E-type viscometer (product name "EV-25 typeH") based on JIS K 7117-2. Note that JIS (Japanese Industrial Standards) is the Japanese standard regarding industrial and mining products, processing technologies, magnetic recordings, services, business management, etc.

[0041] The surface hardness of the polyurethane foam contained in the molded product of the present disclosure is preferably 20 or less, more preferably 10 or less, according to the Asker C hardness (JIS K 7312:1996). By setting the surface hardness of the polyurethane foam within the above range, the polyurethane foam easily adheres along the wall shape of the sound transmission path, and the sound insulation effect can be enhanced.

[0042] Further, the polyurethane foam contained in the molded product of the present disclosure preferably has a surface hardness according to Asker F hardness of 95 or less, and more preferably 94 or less. The Asker F hardness is measured under the same conditions as the Asker C hardness, except that an F-type Asker hardness meter is used.

[0043] The molded product of the present disclosure preferably has a maximum value of the normal incidence sound absorption coefficient (JIS A1405-2:2007) at a thickness of 10 mm in the frequency range of 3000 to 6000 Hz of 0.85 or more, more preferably 0.90 or more, and even more preferably 0.95 or more. The normal incidence sound absorption coefficient in the frequency range of 3000 to 6000 Hz is evaluated to be higher as it is larger. The normal incidence sound absorption coefficient can be measured, for example, by applying the 2-channel transfer function method (reflection method: JIS A1405-2) using a system of Bruel&Kjaer. The specific measurement method of the normal incidence sound absorption coefficient will be described later.

[0044] The molded product of the present disclosure has a density of 100 kg / m ３ or more and 200 kg / m ３ or less, preferably 120 kg / m ３ or more and 150 kg / m ３ or less. The density of the polyurethane foam can be measured in accordance with JIS K7222:2005.

[0045] The production of the molded product of the present disclosure is carried out by mold molding in which a composition for polyurethane foam is stirred, injected into a foaming mold, and foamed. Mold molding is a method frequently used as a molding method for polyurethane foam. By setting the inner surface of the foaming mold to the product shape, a molded product including a polyurethane foam having a desired product shape can be obtained without performing post-processing.

[0046] When molding polyurethane foam, first, a release agent is applied to the inner surface of the foam molding mold (e.g., upper mold, lower mold) using a brush or spray. The foam molding mold has heating means such as an electric heater or heat transfer medium circulation pipe embedded in it, and the temperature can be adjusted to a predetermined mold temperature by hot water or heated oil flowing through the electric heater or heat transfer medium circulation pipe. A mold temperature of around 50°C to 70°C is preferable. If the mold temperature is lower than 50°C, reactivity and moldability will be poor, resulting in poor productivity. Conversely, if the temperature is higher than 70°C, the reactivity of the polyurethane foam composition will be too high, resulting in poor flowability of the polyurethane foam composition, which may cause defects in the polyurethane foam or a rough surface appearance.

[0047] As a mold release agent, one containing linear hydrocarbon wax is used so that the surface of the molded product has an open-cell structure. Examples of linear hydrocarbon waxes include paraffin wax, Fischer-Tropsch wax, and sazole wax. Such linear hydrocarbon waxes can be used in the form of solvent-based mold release agents dispersed in an organic solvent, or aqueous mold release agents dispersed in water using an emulsifier.

[0048] The amount of release agent to be applied is, for example, 10 g / m². ２ ~100g / m ２ It is preferable.

[0049] After applying a release agent to the inner surface of the foam molding die, the polyurethane foam composition is stirred and injected into the foam molding die, and the foam molding die is closed. The amount of polyurethane foam composition injected into the foam molding die is determined according to the density of the resulting polyurethane foam (JIS K7222:2005). After the polyurethane foam composition has foamed, the foam molding die is opened and the polyurethane foam is demolded.

[0050] The polyurethane foam composition used for molding the molded articles of this disclosure has good liquid flow properties when filling into a mold, and can be easily filled even in a mold with a thickness of about 10 mm. Furthermore, the polyurethane foam composition according to this disclosure has good curability, and even when the foaming time after injection of the polyurethane foam composition is about 3 minutes, the polyurethane foam can be demolded, and it has excellent moldability. The molded articles of this disclosure include integrally molded articles in which different materials (e.g., metal materials, resin materials, etc.) are placed on the inner surface of a foam molding die and then molded together as a whole.

[0051] <Soundproofing Material> The soundproofing material of this disclosure is a soundproofing material comprising the molded product of this disclosure as described above. As described above, the molded product of this disclosure is lightweight and has good soundproofing, i.e., sound absorption, even when thin. Furthermore, the molded product of this disclosure has good sound insulation performance as well as sound absorption performance, making it suitable for use as a soundproofing material. The soundproofing material of this disclosure may consist only of the molded product of this disclosure, or it may be made by laminating a sheet-shaped molded product with any substrate to form a soundproofing material, or it may be made by covering the molded product with a cover to form a soundproofing material. The thickness of the molded product in the soundproofing material is appropriately selected according to the soundproofing performance. Since the molded product of this disclosure has good sound absorption and sound insulation performance, the thickness can be, for example, 30 mm or less, or 20 mm or less. Furthermore, as described above, it shows excellent sound absorption performance even at a thickness of 10 mm, making it suitable for applications requiring thin-walled soundproofing materials.

[0052] <Disposal Cover> The disposal cover of this disclosure comprises the molded product of this disclosure as described above. The disposer is installed connected to the drain of a household sink, as shown in Figure 1. Figure 1 is a schematic diagram showing one embodiment of a disposer 14 placed in a household sink 12. The disposer 14 is covered with a sound-insulating material 10 as a disposer cover. Waste such as vegetable scraps that flows from the sink 12 to the drain is crushed by the disposer 14, which has, for example, rotating blades, and flows into the sewer. The vibration and noise emitted by the disposer 14 are mitigated by the disposer cover 10. As shown in Figure 1, the placement position of the disposer 14 is limited, and the size of the disposer cover 10 is also limited. As described above, the molded product of this disclosure can achieve a good sound absorption coefficient even in a thin layer of about 10 mm in thickness, and is therefore suitable as a sound-absorbing material for a disposer cover. The disposer cover of this disclosure typically comprises a disposer body 14, a disposer cover 10 made from the molded product of this disclosure, and a resin cover (not shown) for fixing the disposer cover 10, wherein the disposer cover 10 made from the molded product is positioned in the space between the disposer body 14 and the resin cover. Figure 2A is a schematic diagram showing one aspect of the inside of the molded product as a disposer cover of this disclosure when it is unfolded, i.e., the side that contacts the disposer. Figure 2B is a schematic diagram showing the outside of the molded product as a disposer cover shown in Figure 2A when it is unfolded, i.e., the side opposite to the surface that contacts the disposer 14. In this disclosure, the inner surface of the disposer cover shown in Figure 2A is formed by the mold surface of the upper mold of a mold comprising an upper mold and a lower mold, and the outer surface of the disposer cover shown in Figure 2B is formed by the mold surface of the lower mold of the mold. In the case of a molded product obtained using a mold comprising an upper and lower mold, the surface formed on the mold surface of the upper mold has better sound absorption than the surface formed on the mold surface of the lower mold. In Figures 2A and 2B, the disposer cover is composed of two parts, but the disposer cover of this disclosure is not limited to these drawings and may be a single cover or composed of three or more parts.

[0053] Figure 3A is a schematic diagram showing one embodiment of the main body of a disposer 14 on which a soundproofing material, which is a disposer cover 10, is placed, and Figure 3B is a schematic diagram showing one embodiment of the disposer 14 shown in Figure 3A on which the soundproofing material 10, which is a disposer cover of this disclosure, is placed. The waste generated in the sink is crushed in the main body of the disposer 14 and discharged into the sewer system along with water and other substances from the discharge port of the disposer 14.

[0054] As will be clear from the embodiments described later, the molded product of this disclosure exhibits a high sound absorption coefficient, with a normal incidence sound absorption coefficient of 0.85 or higher, even in a thin layer of about 10 mm in thickness. Therefore, the molded product of this disclosure is particularly suitable as a sound-absorbing material for a disposer cover, where the thickness and size are limited by the placement location.

[0055] Examples 1 to 8, Comparative Examples 1 to 4: From the polyurethane foam compositions consisting of the formulations described in Tables 1 to 2, which are composed of the following raw materials, a mixture of raw material polyol, additives and water was prepared, and isocyanate was prepared separately. A 15 cm square foam molding mold with a rectangular parallelepiped shape was prepared, heated to 60°C, and a linear hydrocarbon wax-based mold release agent (product name: W-955, manufactured by Chukyo Oils Co., Ltd.) was sprayed on as a mold release agent.

[0056] Isocyanate was added to the prepared raw material polyol mixture and stirred in a mixer for 5 seconds. Immediately after stirring, the mixture was poured into a mold, the upper mold was closed and secured with clamps, and held for 3 minutes. Then the clamps were removed, the upper mold was opened, and the molded product containing the molded polyurethane foam was taken out. At this point, samples of the molded product that could be removed as a finished product when the upper mold was opened were subjected to various evaluations.

[0057] In Tables 1 and 2, the amount of each component is expressed in "parts by mass," and "total parts" refers to the total mass of the polyurethane foam composition. "-" indicates that the component is not included. Details of each component (raw material name) in Tables 1 and 2 are shown below.

[0058] • Polyol A-1: ​​Plant-derived, castor oil polyol (plant-derived component: 98% by mass), unmodified (purified), molecular weight 945, number of functional groups 2.7, hydroxyl value 161 mg KOH / g, product name: VerOH Plus, manufactured by Acme Hardesty. • Polyol A-2: Plant-derived, soybean oil polyol (plant-derived component: 95% by mass or more), unmodified (purified), molecular weight 144, number of functional groups 3, hydroxyl value 117 mg KOH / g, product name: BiOH5300, manufactured by Cargill. • Polyol B-1: Petroleum-derived, polyether polyol, molecular weight approximately 5000, number of functional groups 3, hydroxyl value 34 mg KOH / g, product name: Voranol (registered trademark, same below)-4701, DOW Corporation. Polyol B-2: Petroleum-derived, polyether polyol, molecular weight approximately 3000, number of functional groups 3, hydroxyl value 56 mg KOH / g, product name: GP3050NS, manufactured by Sanyo Chemical Industries, Ltd. Polyol B-3: Petroleum-derived, polymer polyol; molecular weight 5000, solids content 42% by mass, hydroxyl value 22 mg KOH / g, product name: NC701, manufactured by DOW Corporation Crosslinking agent 1: Ethylene glycol Crosslinking agent 2: Diethanolamine Catalyst 1: Resinization catalyst, product name: DABCO 2040, manufactured by Evonik Japan; Catalyst 2: Resin-based catalyst, product name: DABCO 3040; Catalyst 4: Foaming catalyst, product name: BL11; Foam stabilizer: product name: B8738LF2; Degassing agent: product name: Voranol-4053; Foaming agent: water, polyisocyanate: carbodiimide-modified MDI, NCO%: 29.5%, product name: Rubinate 1680; manufactured by Huntsman.

[0059] For each example and comparative example, the moldability, biomass, density, viscosity of the raw material polyol used in the polyurethane foam composition at 25°C (POL viscosity), liquid flowability of the polyurethane foam composition, appearance after molding (shrinkage, cell roughness), surface hardness, and normal incidence sound absorption coefficient were measured, and the sound insulation performance was evaluated based on the results. The results are shown in Tables 1 and 2 below. The meaning of the symbols in the evaluation criteria representing the evaluation results in Tables 1 and 2 is as follows: Symbols "A" and "B" are at a level that is not problematic in practical use, and symbol "A" is at a preferred level. [Evaluation Criteria] "A": Good "B": Average "C": Poor

[0060] Moldability was evaluated by visually inspecting the demolded polyurethane foam to determine the presence or absence of shrinkage, etc., according to the following criteria: [Evaluation Criteria] "A": No shrinkage present "B": Slight shrinkage present, or roughness of the skin layer present "C": Shrinkage or roughness of the skin layer clearly present

[0061] The plant content was calculated as ([(parts of plant-derived polyols considering the content of plant-derived components / total parts of the polyurethane foam composition)] × 100). Density was measured according to JIS K7222:2005. Specifically, it was calculated as [sample mass / sample volume (mold volume)].

[0062] The normal incidence sound absorption coefficient was measured using a molded product, which was formed from the polyurethane foam composition according to this disclosure into a 10 mm thick sheet, as a sample. The measurement was performed using a 2-channel transfer function method (reflection method: JIS A1405-2) with a system from Bruel & Kjaer. The evaluation was performed at 1000 Hz to 6300 Hz, and the peak frequency and the highest value of sound absorption coefficient at the peak frequency were measured. In each example, two samples were prepared, and measurements were taken at two locations for each sample. In other words, the normal incidence sound absorption coefficient for each example was the average of a total of four measured values. The above measurements were performed on the surface formed on the mold surface of the upper mold of the sample (molded product). A maximum value of 0.85 or higher for the normal incidence sound absorption coefficient is considered to provide sufficient sound insulation, and preferably, the maximum value is 0.90 or higher.

[0063] The viscosity of the polyurethane foam composition was measured at a temperature of 25°C using an E-type viscometer (product name "EV-25 type H") in accordance with JIS K7117-2. Liquid flowability was evaluated according to the following evaluation criteria: [Evaluation Criteria] "A": When the viscosity of the raw material polyol is 990 mPa·s or less, and the polyurethane foam composition spreads well after being poured into the mold. "B": When the viscosity of the raw material polyol exceeds 990 mPa·s and is 1090 Pa·s or less, and the polyurethane foam composition spreads relatively well after being poured into the mold. "C": When the viscosity of the raw material polyol exceeds 1090 mPa·s, and the polyurethane foam composition spreads poorly after being poured into the mold.

[0064] The surface hardness of the molded polyurethane foam was measured using an Asker C hardness tester and an Asker F hardness tester.

[0065]

[0066]

[0067] ・Comparative Examples 1 and 2 Comparative Example 1 is an example that does not contain plant-derived polyols but contains 15 parts by mass of polymer polyols, and Comparative Example 2 is an example that contains plant-derived polyols and polyether polyols, plus an additional 25 parts by mass of polymer polyols. It was confirmed that the polyurethane foams of Comparative Examples 1 and 2 both had high viscosity and low liquid flowability at 25°C. ・Comparative Examples 3 and 4 Comparative Examples 3 and 4 did not contain polymer polyols, but the plant content exceeded 40%, resulting in problems with curability. The polyurethane foam was not sufficiently cured 3 minutes after being put into the mold, so the demolding performance was evaluated as "C". In Comparative Examples 3 and 4, although urethane foam molded articles were obtained, the appearance (shrinkage) and demolding performance were both evaluated as "C", so surface hardness and sound absorption coefficient were not evaluated.

[0068] In the examples where the polymer polyol was not included and the plant-derived content of the foam was 15% to 40%, the molded articles all exhibited good productivity in terms of moldability and demolding properties, and it was confirmed that the obtained molded articles showed excellent sound absorption even at a thickness of 10 mm. Comparing Examples 1 to 4, which used castor oil-derived polyol as the plant-derived polyol, with Examples 5 to 8, which used soybean-derived polyol, it can be seen that both had good moldability, and although the peak frequencies differed, both had good sound absorption properties.

[0069] Thus, according to this disclosure, a molded product containing polyurethane foam can be obtained that has good sound insulation even with a thin thickness, good moldability, and contributes to reducing environmental impact. Furthermore, the molded product of this disclosure is suitable not only for placement on walls and spaces where sound insulation is required, but also for filling gaps in sound transmission paths, as it has good liquid flow properties, making it suitable for sound insulation applications that fill narrow gaps. Insofar as this disclosure is included in its spirit, the present invention is not limited to the examples and can be modified without departing from the spirit of the invention.

[0070] All documents cited herein, including publications, patent applications, and patents, are incorporated herein by reference, each document being specifically identified and referred to, and all of their contents being incorporated herein by reference, to the same extent as described herein.

[0071] The use of nouns and similar demonstrative pronouns in connection with the description of the present invention (particularly in connection with the following claims) shall be construed as both singular and plural unless otherwise specifically noted herein or if it is clearly inconsistent with the context. The words “equip,” “have,” “include,” and “incorporate” shall be construed as open-ended terms (i.e., “include but not limited to”) unless otherwise specifically noted herein. The numerical ranges described herein are intended solely as abbreviations for referring individually to each value falling within that range, unless otherwise specifically noted herein, and each value is incorporated into the specification as if it were individually enumerated herein. All methods described herein may be performed in any appropriate order unless otherwise specifically noted herein or if it is clearly inconsistent with the context. Any examples or illustrative phrases used herein (e.g., “etc.”) are intended solely to better illustrate the present invention and not to impose any limitations on the scope of the present invention, unless otherwise specifically asserted. No phrase in the specification shall be construed as indicating any non-claimed element essential to the practice of the present invention.

[0072] This specification describes preferred embodiments of the Invention, including the best mode known to the inventors for carrying out the Invention. Those skilled in the art will see, after reading the above description, that variations of these preferred embodiments will become apparent. The inventors anticipate that skilled persons will apply such variations as appropriate, and that the Invention will be carried out in ways other than those specifically described herein. Accordingly, the Invention includes all modifications and equivalents of the claims appended herein, as permitted by applicable law. Furthermore, any combination of the above elements in all variations is incorporated into the Invention unless otherwise specifically noted herein or is obviously inconsistent with the context.

Claims

1. A molded article containing polyurethane foam, which is a molded article of a polyurethane foam composition comprising a plant-derived polyol and a polyether polyol as raw material polyols, wherein the total amount of the plant-derived polyol and the polyether polyol is 85% by mass or more of the total raw material polyol, and the amount of the plant-derived polyol is 60% by mass or less of the total raw material polyol.

2. The molded article according to claim 1, wherein the content of polymer polyol in the total mass of the raw material polyol is 10% by mass or less.

3. The molded article according to claim 1 or claim 2, wherein the viscosity of the raw material polyol at 25°C is 1000 mPa·s or less.

4. The molded article according to claim 1 or claim 2, wherein the surface hardness of the polyurethane foam is 20 or less on the Asker C hardness scale (JIS K 7312:1996).

5. The molded article according to claim 1 or claim 2, wherein the maximum value of the normal incidence sound absorption coefficient (JIS A1405-2:2007) for a thickness of 10 mm at frequencies of 3000 to 6000 Hz is 0.85 or greater.

6. The density of the polyurethane foam is 100 kg / m³ ３ More than 200kg / m ３ The molded article according to claim 1 or claim 2, which is as follows:

7. The molded article according to claim 1 or claim 2, wherein the raw material isocyanate in the polyurethane foam composition comprises a carbodiimide-modified isocyanate.

8. A soundproofing material comprising a molded article according to claim 1 or claim 2.

9. A disposer cover comprising a molded product according to claim 1 or claim 2.

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