JP2005307144A - Rigid polyurethane foam - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a complete water-blown rigid polyurethane foam foamed by using carbon dioxide gas generated by the reaction of water and a polyisocyanate as a foaming agent, having improved storage stability of a polyol premix and keeping high reactivity over a long period. <P>SOLUTION: The rigid polyurethane foam is produced by mixing a polyisocyanate component with a formulation liquid containing a polyol component, water, a catalyst, a flame retardant and other assistant and foaming the mixture by carbon dioxide gas generated by the reaction of the polyisocyanate component with water. An amine catalyst having low basicity is used as the catalyst and the pH of the formulation liquid immediately after the formulation is set to 8-9. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  In the present invention, a polyisocyanate component and a blending solution containing a polyol component, water, a catalyst, a flame retardant and other auxiliary agents are mixed, and foaming is performed using carbon dioxide gas generated by the reaction of the polyisocyanate component and water as a blowing agent. In particular, the present invention relates to a completely water-foamed rigid polyurethane foam that does not use any fluorocarbon foaming agent as a foaming agent.

  Rigid polyurethane foam is widely used as a heat insulating material for houses, refrigerators and the like because it is excellent in heat insulation and self-adhesion.

  Rigid polyurethane foams used for these applications are generally blended liquids (hereinafter referred to as “polyol premix”) in which a polyisocyanate component and a polyol component, a foaming agent, a catalyst, a flame retardant, a foam stabilizer and other auxiliaries are mixed. Is obtained by airless spray foaming by mixing with a mixing head and foaming. With this method, heat insulation of a good rigid polyurethane foam can be achieved by a simple operation of spraying directly onto the construction object. A layer can be formed.

  In rigid polyurethane foam, dichloromonofluoroethane (HCFC-141b), which is currently used as the main blowing agent, has a problem of ozone layer destruction. Hydrofluorocarbons (HFCs) that do not destroy the ozone layer are listed as candidates for next-generation foaming agents that can replace them, but on the other hand, they have a problem of strong global warming action.

  For this reason, development of technology for foaming without using these fluorocarbon foaming agents is considered as one issue, and complete water foaming using carbon dioxide gas generated by the reaction of water and polyisocyanate as the foaming agent. A rigid polyurethane foam was proposed (for example, JP 2000-256434 A).

  By the way, flame retardance is mentioned as one of the most important performances required for a rigid polyurethane foam for a heat insulating material. Conventionally, in order to increase the flame retardancy of rigid polyurethane foam, a flame retardant is blended and used. Although self-digestibility can be obtained by blending flame retardant, flame retardant can be achieved only by blending flame retardant using the surface test method shown in JIS A1321 "Flame retardance test method for interior materials and construction methods of buildings". Since flame retardancy of tertiary or higher cannot be obtained, conventionally, phthalic acid-based polyester polyols obtained by esterifying phthalic acid or phthalic acid derivatives are used as the polyol component, and the isocyanate index is increased to increase the isocyanate. By performing nurate modification, flame retardancy is ensured.

  By the way, in the case of a completely water-foamed rigid polyurethane foam using carbon dioxide gas generated by the reaction of water and polyisocyanate as a blowing agent, in order to increase the expansion ratio and obtain a low-density rigid polyurethane foam, a large amount of water is used. Need to use. On the other hand, when a large amount of water is used, the isocyanate index is lowered, and isocyanurate modification cannot be performed.

In the conventional completely water-foamed rigid polyurethane foam, a highly active and highly basic amine catalyst is usually used as a catalyst in order to maintain high reactivity.
JP 2000-256434 A

  The conventional rigid polyurethane foam using an amine catalyst has the following problems. That is, by using a highly basic amine catalyst, the pH of the polyol premix is increased. As a result, the decomposition of the polyester polyol blended as the polyol component is accelerated, and the acid component and amine catalyst generated by the decomposition are further promoted. By causing the neutralization reaction, the reactivity between the polyol premix and the polyisocyanate is impaired in a short period of time.

  In general, polyol premixes for airless spray foaming are usually stored for a period of 1 to 2 months from when they are blended until they are actually used, thus increasing the resistance to hydrolysis of polyester polyols during storage. It is extremely important to maintain high reactivity after storage, that is, to maintain pot life.

  Therefore, the present invention improves the storage stability of the polyol premix and increases its reactivity over a long period of time in a completely polyurethane foamed rigid polyurethane foam using carbon dioxide gas generated by the reaction of water and polyisocyanate as a blowing agent. An object is to provide a rigid polyurethane foam that can be maintained.

  The rigid polyurethane foam of the present invention is a mixture of a polyisocyanate component and a blending solution containing a polyol component, water, a catalyst, a flame retardant and other auxiliaries, and generates carbon dioxide generated by the reaction of the polyisocyanate component and water. A rigid polyurethane foam obtained by foaming as a foaming agent, wherein a pH immediately after blending of the blended liquid is 9 or less.

  By setting the blending liquid, that is, the pH immediately after blending the polyol premix to 9 or less, preferably 8 to 9, hydrolysis of the polyester polyol can be prevented and the storage stability of the polyol premix can be improved.

  In addition, although the pH of the polyol premix using the conventional highly basic amine catalyst is 10 or more immediately after blending, neutralization of the acid and amine catalyst produced by hydrolysis and hydrolysis of polyester polyol over time The reaction lowers the pH of the polyol premix. Therefore, in the present invention, it is important that the pH immediately after blending the polyol premix is 9 or less, particularly 8-9. The term “immediately after blending” means that a polyol premix is prepared by mixing a polyol component, water, a catalyst, a flame retardant, and other auxiliaries, and when this is kept at room temperature, it means at most 24 hours.

  In the present invention, in order to set the pH of the polyol premix to 9 or less, preferably 8 to 9, it is preferable to use a low basic catalyst, for example, potassium salt catalyst, formic acid block catalyst, piperazine series It is preferable to use together one or more selected from the group consisting of a catalyst, a morpholine catalyst, an imidazole catalyst, bisdimethylaminoethyl, and a bismuth salt catalyst.

  As the flame retardant, triisobutyl phosphate (TiBP) is preferably used alone or in combination with trismonochloropropyl phosphate (TMCPP). That is, conventionally, as a flame retardant for rigid polyurethane foam, a halogen flame retardant such as a halogen-containing phosphate ester such as TMCPP or a phosphate ester flame retardant such as TEP (triethyl phosphate) is used. Since halogen-based flame retardants need to be dehalogenated when disposed of, it is desirable that halogen-based flame retardants are not used or the amount used is reduced.

  On the other hand, as described above, when a phosphoric ester-based flame retardant such as TEP is used in place of a halogen-based flame retardant in a completely water-foamed rigid polyurethane foam, the following problems occur. That is, phosphate ester-based flame retardants such as TEP are easily hydrolyzed in the presence of water and a catalyst, and the reactivity between the polyol premix and the polyisocyanate decreases due to the presence of an acid generated by hydrolysis. For this reason, the storage stability of the polyol premix is inferior. Conventionally, TBP (tri-n-butyl phosphate) may be used as a plasticizer, but this TBP also has a problem of hydrolysis.

  If it is TiBP, good flame retardancy can be imparted to the rigid polyurethane foam, and JIS A1321 flame retardant grade 3 or higher can be used without using a halogen flame retardant or in combination with a small amount of a halogen flame retardant. Flame retardancy can be obtained. Moreover, TiBP is difficult to hydrolyze, and the problem of reduced reactivity of the polyol premix due to hydrolysis such as other phosphate ester flame retardants or plasticizers is improved.

  Moreover, in this invention, it is preferable that a polyol component contains polyester polyol and polyether polyol, and content of the polyester polyol in a polyol component is 50 weight% or more. In this case, the polyester polyol was obtained from a phthalic acid component mainly composed of one or more selected from the group consisting of o-phthalic acid, m-phthalic acid, p-phthalic acid and derivatives thereof. A phthalic polyester polyol is preferable, and the polyether polyol is preferably a polyether polyol having a Mannich structure.

  In particular, in the present invention, the polyol component is 60 to 80% by weight of a phthalic polyester polyol, 15 to 35% by weight of the Mannich modified polyether polyol and / or 5 to a polyether polyol other than the Mannich modified polyether polyol. It is preferable that a powder component obtained by copolymerizing an ethylenically unsaturated nitrile and a carboxylic acid vinyl ester monomer is dispersed in the polyol component. In this case, the polyether polyol other than the Mannich-modified polyether polyol is one kind selected from the group consisting of an ethylenediamine-based polyether polyol, a glycerin-based polyether polyol, a sorbitol-based polyether polyol, and a tolylenediamine-based polyether polyol. There are two types. Moreover, it is preferable that the dispersion | distribution density | concentration of a powder component is 0.1 to 10 weight% in all the polyol components.

  In the present invention, the ratio of water to 100 parts by weight of the polyol component is preferably 2 to 6 parts by weight, and isocyanurate modification is preferably performed with an isocyanate index of 100 to 200, preferably 100 to 140.

  Further, the volume mixing ratio of the polyol component and the isocyanate component: The value of the polyol component / isocyanate component is preferably 0.9 to 1.1.

  The present invention is particularly suitable for a rigid polyurethane foam obtained by airless spray foaming in which a polyisocyanate component and a blended liquid in which a polyol component, water, a catalyst, a flame retardant and other auxiliaries are mixed are mixed with a mixing head and foamed. It is.

Such a rigid polyurethane foam of the present invention preferably exhibits the following characteristics.
(1) A flame retardant material whose flame retardancy performance is specified by JIS A1321 or higher flame retardant grade 3 and / or the Building Standard Law Enforcement Ordinance Article 6 No. 6.
(2) The self-adhesive strength of the rigid polyurethane foam molded at the atmospheric temperature and the temperature of the housing surface of 0 to 10 ° C. is 10 N / cm ² or more in the method specified in JIS A 9526.
(3) The density of the core portion of the molded rigid polyurethane foam having a total thickness of 30 to 50 mm is 20 to 40 kg / m ³ or less in the method defined in JIS A9526.
(4) The ratio of closed cells to all bubbles (hereinafter referred to as “closed cell ratio”) is 10 to 65% by volume.

  According to the rigid polyurethane foam of the present invention, in a completely water-foamed rigid polyurethane foam using a carbon dioxide gas generated by the reaction of water and polyisocyanate as a foaming agent, the storage stability of the polyol premix is increased, and the A rigid polyurethane foam excellent in flame retardancy and other physical properties can be provided while maintaining high reactivity.

  Hereinafter, embodiments of the rigid polyurethane foam of the present invention will be described in detail.

  In the present invention, the catalyst is not a highly basic amine catalyst, but preferably a potassium salt catalyst, a formic acid block catalyst, a piperazine catalyst, a morpholine catalyst, an imidazole catalyst, bisdimethylaminoethyl, and bismuth. The pH of the polyol premix is adjusted to 9 or less, preferably 8 to 9, by using one or more selected from the group consisting of salt catalysts in combination. By making the pH of the polyol premix lower than before and having a pH of 9 or less, preferably pH 8 to 9, decomposition of the polyester polyol can be prevented, and the storage stability of the polyol premix can be enhanced.

  As a potassium salt catalyst, 1 type (s) or 2 or more types, such as potassium octylate and potassium acetate, can be used.

The formic acid block catalyst is a catalyst in which a formic acid is capped on an amine (a form in which an amine group is neutralized with formic acid), and has a structure of —NH ⁺ · HCOO ⁻ . Specific examples of the formic acid block catalyst include adducts of N, N, N, N, N-pentamethyldiethylenetriamine with formic acid (TOYOCAT-TMF). As the piperazine-based catalyst, piperazine, N, N, N-trimethylaminoethylpiperazine (TOYOCAT-NP, Caorizer No. 8) or the like can be used. Examples of the morpholine-based catalyst include morpholine, N-ethylmorpholine (Cauraiser No. 21), N-methylmorpholine (Caoraiser No. 22), N, N-dimethylaminoethylmorpholine (Dabco XDM) and the like. Can be used. As the imidazole catalyst, 1-isobutyl-2-methylimidazole, 1-methylimidazole, 1,2-dimethylimidazole and the like can be used. As the bismuth salt catalyst, bismuth octylate, bismuth neodecanoate, or the like can be used. These catalysts may be used individually by 1 type, and may mix and use 2 or more types.

  The amount of the catalyst used is not particularly limited and is appropriately determined so as to obtain the required reactivity depending on the type of catalyst used, but is usually 5 to 20 parts by weight, particularly 100 parts by weight of the polyol component. It is preferable to set it as 10-18 weight part.

  As the polyol component used in the present invention, those containing a polyester polyol and a polyether polyol are preferable. As the polyester polyol, phthalic acid-based polyester polyols, particularly phthalic acid other than phthalic anhydride (o-phthalic acid), That is, it is preferable to use a phthalic acid-based polyester polyol whose main component is m-phthalic acid (isophthalic acid) and / or p-phthalic acid (terephthalic acid) and derivatives thereof.

  That is, when phthalic anhydride having a low cohesive energy is used, there is a drawback that it is easier to burn than foams obtained from polyols using other phthalic acids (m, p-phthalic acid). On the other hand, good flame retardancy can be obtained by using a polyester polyol made of m, p-phthalic acid.

  Such phthalic acid-based polyester polyols, preferably m, p-phthalic acid-based polyester polyols, preferably have a hydroxyl value of 100 to 400 mg-KOH / g and a viscosity of 500 to 1500 mPa · s. The phthalic acid-based polyester polyol preferably has a p-phthalic acid content of 40 to 80% by weight. When the phthalic acid-based polyester polyol has a p-phthalic acid content of less than 40% by weight, the flame retardancy decreases. If the weight percentage is exceeded, pot life will drop.

  If the proportion of such a phthalic polyester polyol in the polyol component is small, a sufficient flame retardancy improving effect cannot be obtained. Therefore, the content in the polyol component is preferably 50% by weight or more. However, if this content is excessively large, the stability of the premix is deteriorated or the reactivity is lowered, so that it is contained in the polyol component in an amount of 50 to 90% by weight, particularly 60 to 85% by weight. Is preferred.

  The polyether polyol in the polyol component is a polyether polyol obtained by modifying Mannich with phenol and / or its derivative (hereinafter referred to as “Mannich-modified polyol”), that is, phenol, phenol such as nonylphenol, alkylphenol or the like. A polyether polyol obtained by subjecting the derivative to Mannich modification using secondary amine such as formaldehyde and diethanolamine, ammonia, primary amine or the like, and ring-opening addition polymerization of alkylene oxide such as ethylene oxide or propylene oxide is preferable. Such a Mannich-modified polyol has a high self-reactive activity and a relatively high flame retardancy. Therefore, by using a Mannich-modified polyol, for example, in an airless spray foam type rigid polyurethane foam, flame retardancy performance is exerted at the time of blowing and foaming. The reaction can proceed promptly without significant loss. In addition, it is preferable that the hydroxyl value of such Mannich modified polyol is 300-500 mg-KOH / g, and a viscosity is 500-1500 mPa * s.

  Furthermore, in addition to phthalic polyester polyols and Mannich modified polyols, a polyol compound of an initiator different from Mannich modified polyols such as ethylenediamine, tolylenediamine, sucrose, amino alcohol, diethylene glycol and the like within a range not impairing the object of the present invention. You may use together in the range of 40 weight% or less in a polyol component.

  In particular, in the present invention, the polyol component used is 60 to 80% by weight of a phthalic polyester polyol, 15 to 35% by weight of a Mannich modified polyether polyol and / or 5 to 20 polyether polyols other than the Mannich modified polyether polyol. It is preferable that a powder component obtained by copolymerizing an ethylenically unsaturated nitrile and a carboxylic acid vinyl ester monomer is dispersed.

  When the polyol component contains the phthalic polyester polyol and the Mannich modified polyether polyol and / or the polyether polyol other than the Mannich modified polyether polyol, the effect of simultaneously realizing flame retardancy and workability is achieved. The When the proportion of the phthalic polyester polyol in the polyol component exceeds 80% by weight, the reactivity is lowered and the construction becomes difficult, or the number of functional groups of the polyol is lowered and the dimensional stability of the foam is impaired. To do. If it is less than 60% by weight, the flame retardancy of the foam tends to decrease. If the ratio of Mannich-modified polyether polyol exceeds 35% by weight, the reaction balance will be lost and it will be difficult to apply, and if it is less than 15% by weight, the dimensional stability of the foam tends to be impaired. When the proportion of polyether polyols other than Mannich-modified polyether polyol exceeds 20% by weight, the flame retardancy of the foam may often decrease, and when it is less than 5% by weight, sufficient reaction activity cannot be ensured particularly in winter construction. There is. Polyether polyols other than this Mannich-modified polyether polyol include ethylenediamine-based polyether polyols obtained by ring-opening addition polymerization of propylene oxide or ethylene oxide to ethylenediamine, and ring-opening addition polymerization of propylene oxide or ethylene oxide to glycerin. The resulting glycerin-based polyether polyol, sorbitol-based polyether polyol obtained by ring-opening addition polymerization of propylene oxide or ethylene oxide to sorbitol, and tri-amine obtained by ring-opening addition polymerization of propylene oxide or ethylene oxide to tolylenediamine. Obtained by aminomethylation of range amine polyether polyol and piperazine and ring-opening addition polymerization of propylene oxide and ethylene oxide One or more selected from the group consisting of piperazines polyether polyols and the like.

  In addition, by dispersing a powder component obtained by copolymerizing an ethylenically unsaturated nitrile and a carboxylic acid vinyl ester monomer in a polyol component, a part of the bubbles can be efficiently formed under high reaction activity required for spray foaming. It is possible to achieve continuation, and a great advantage is obtained that shrinkage of the foam is suppressed.

  As a foaming machine used for airless spray foaming, a general-purpose spray foaming machine such as “HF-1600” manufactured by Gasmer (two-component mixing volume ratio 100: 100) and a variable liquid ratio such as “H-2000” manufactured by Gasmer. There are type spray foaming machines, and among these, popular type foaming machines such as “FF-1600” and “HF-1600” have a two-component ratio fixed at a polyol component: isocyanate component = 100: 100.

  In a non-fluorocarbon hard polyurethane foam that does not use a fluorocarbon foaming agent, the flame retardancy of the foam obtained is usually not stable at a liquid ratio of polyol component: isocyanate component = 100: 100. This is because the water used as the blowing agent has a large amount of active hydrogen, so that it was difficult to calculate flame retardancy by isocyanurate modification in the liquid ratio of 100: 100 in terms of equivalent calculation.

  Although it is possible to increase the flame retardancy by making the excess isocyanate component isocyanurate reaction by changing the liquid ratio, it is obtained because the isocyanurate reaction does not proceed easily in construction in an environment where the ambient temperature is low. There was a problem that the foam was easily peeled off from the casing immediately after spraying because the foam flyability increased. In addition, since it is necessary to discharge excess isocyanate, the pressure balance between the two liquids tends to be easily lost.

  On the other hand, if molding with polyol component: isocyanate component = 100: 100, the problems of flyability and pressure balance in winter construction are also solved, and flame retardant properties, foam physical properties, etc., which were difficult to realize in the past The required characteristics can be satisfied at the same time, and there is also an advantage that a popular foaming machine can be applied as it is, which is highly practical.

  In the present invention, by using the polyol component having the above composition, the structure of the bubbles (independent / continuous) can be controlled, and the flame shrinkage and workability can be simultaneously achieved while greatly suppressing the shrinkage of the foam, and the two-component ratio ( Molding with polyol component: isocyanate component = 100: 100) is possible, which is industrially very advantageous.

  In the present invention, examples of the ethylenically unsaturated nitrile constituting the powder component include methacrylonitrile and acrylonitrile, and examples of the carboxylic acid vinyl ester monomer include vinyl acetate and vinyl propionate. The vinyl carboxylate component is partially saponified to have a structure having a hydroxyl group and can be incorporated into the reaction.

  In addition, the dispersion concentration of such a powder component is 0.1 to 10% by weight, particularly 0.5 to 5.0% by weight, based on the total polyol component (that is, the total of the polyol component and the powder component). Is preferred. If the dispersion concentration of the powder component is less than 0.1% by weight, there is no effect on the continuation of bubbles, and if it exceeds 10% by weight, the effect reaches a peak.

  In the present invention, the polyisocyanate component includes aromatic polyisocyanate compounds such as diphenylmethane diisocyanate and tolylene diisocyanate, alicyclic polyisocyanates such as isophorone diisocyanate, and aliphatic polyisocyanates such as hexamethylene diisocyanate. 1 type (s) or 2 or more types can be used, Preferably, 4,4'- diphenylmethane diisocyanate is a main component.

  In the present invention, it is preferable that the polyisocyanate component has an isocyanate index of 100 to 200, particularly 100 to 140, and ensures flame retardancy as an isocyanurate foam in the presence of a trimerization catalyst.

  In the present invention, the volume ratio of the polyol component and the isocyanate component, that is, the value of the polyol component / isocyanate component corresponding to the aforementioned two-component ratio is preferably 0.9 to 1.1. If this value is less than 0.9, the flame retardancy of the foam tends to be reduced or the dimensional stability tends to be impaired, and if it exceeds 1.1, the reaction activity particularly at low temperatures in winter decreases due to excess isocyanate. May be impaired.

  In the present invention, as the flame retardant, TiBP or TiBP and a small amount of a halogen-based flame retardant such as a halogen-containing phosphate ester such as TMCPP are preferably used in combination. If the amount of the flame retardant used is too small, sufficient flame retardancy cannot be obtained, but there are cases where the amount of TiBP used is large and sufficient flame retardancy cannot be obtained even if the amount of TMCPP used is small. Moreover, when there is too much TiBP, it exists in the tendency for foam strength to fall by the plasticizing effect. Accordingly, the amount of TiBP used varies depending on the presence or absence of combined use with TMCPP and the required flame retardancy, but when TiBP is used alone, it is 10 to 60 parts per 100 parts by weight of the polyol component. It is preferable to set it as a weight part, especially 15-30 weight part. When TiBP and a halogen-based flame retardant such as a halogen-containing phosphate ester such as TMCPP are used in combination, TiBP is 5 to 40 parts by weight, particularly 10 to 30 parts by weight with respect to 100 parts by weight of the polyol component. It is preferable that the halogen-based flame retardant such as a halogen-containing phosphate ester such as TMCPP is 1 to 20 parts by weight, particularly 5 to 15 parts by weight with respect to 100 parts by weight of the polyol. If the amount of halogenated flame retardant used is larger than this range, dehalogenation treatment is required, which is not preferable.

  In addition, as a flame retardant, a conventionally known flame retardant may be further used in combination. However, in order to obtain the effect of the present invention by using TiBP, as the flame retardant, TiBP may be used alone, or TiBP and It is preferable to use a small amount of a halogen-based flame retardant such as TMCPP.

  In this invention, it is preferable that the usage-amount of the water used as a foaming agent shall be 2-6 weight part with respect to 100 weight part of polyol components. If the amount of water used is lower than 2 parts by weight with respect to 100 parts by weight of the polyol component, the resulting foam has a high density, which increases the cost and is not practical. If the ratio of water is higher than 6 parts by weight, the adhesiveness with the casing surface will be reduced in the construction of airless spray foaming, and the hydrolysis of the polyol will be accelerated by the reaction of water and polyester polyol. It is not preferable because the pot life of the mix is lowered. Therefore, the amount of water used is preferably 2 to 6 parts by weight, particularly 3 to 5 parts by weight, based on 100 parts by weight of the polyol component.

  A foam stabilizer may be further added to the polyol premix. Any foam stabilizer that is effective for producing rigid polyurethane foam can be used. For example, silicone-based materials such as polyoxyalkylene alkyl ether can be used.

  Moreover, in this invention, arbitrary components other than the above, for example, a filler etc., can be used in the range which does not interfere with the objective of this invention.

  When producing the rigid polyurethane foam of the present invention by airless spray foaming using a mixing head, a compounded liquid in which the polyisocyanate component is mixed with a polyol component, water, a catalyst, a flame retardant, a foam stabilizer and other auxiliaries. Can be manufactured by mixing with a mixing head at 30 to 50 ° C., spraying the surface to be processed with a discharge pressure of 3.9 to 7.8 MPa, and repeatedly blowing until a predetermined thickness is achieved. .

In addition, the rigid polyurethane foam of the present invention, particularly the molded rigid polyurethane foam having a layer thickness of 30 to 50 mm, has a foam core density of 15 to 45 kg / m ³ in the method defined in JIS A9526. preferable. When the core density (core density) is less than 15 kg / m ³ , the strength is remarkably reduced and shrinks, and when it exceeds 45 kg / m ³ , the amount of combustion of the rigid polyurethane foam increases to increase the density and flame retardancy. Is significantly reduced. Accordingly, the core density is 15 to 45 kg / m ^3, preferably 20 to 40 kg / m ³ .

  The rigid polyurethane foam of the present invention is preferably a flame retardant material whose flame retardancy performance is 3 or higher as defined in JIS A1321, and / or shown in Building Code Act Enforcement Ordinance No. 1-6.

Moreover, it is preferable that the self-adhesion strength of the rigid polyurethane foam molded at the ambient temperature and the temperature of the housing surface of 0 to 10 ° C. is 10 N / cm ² or more in the method defined in JIS A 9526.

  The rigid polyurethane foam of the present invention preferably has a closed cell ratio of 10 to 65% by volume. If the closed cell ratio is less than 10% by volume, the strength of the foam may be reduced and the standard value shown in JIS A9526 may not be satisfied. If it exceeds 65% by volume, the dimensional stability of the foam is impaired, and the foam tends to shrink. There is.

  Hereinafter, the present invention will be described more specifically with reference to Examples and Comparative Examples. The raw materials used in the following examples and comparative examples are as follows.

Polyisocyanate: “C1155” manufactured by Nippon Polyurethane Co., Ltd.
Polymethylene polyphenyl polyisocyanate
(NCO%: 30.0)
Polyol A: Mannich modified polymer polyol “XR7202” manufactured by Asahi Glass Co., Ltd.
(Powder component obtained by copolymerizing acrylonitrile and vinyl acetate
Contains 1.4% by weight. Composition ratio of acrylonitrile and vinyl acetate 1: 3)
Hydroxyl value: 380 mg-KOH / g
Viscosity: 1400 mPa · s
Polyol B: p-phthalic acid-based polyester polyol manufactured by Toho Rika Co., Ltd.
"B65W"
Hydroxyl value: 200 mg-KOH / g
Viscosity: 820 mPa · s
p-phthalic acid content: 62.5% by weight
Polyol C: Polyether polyol “SO300” manufactured by Mitsui Takeda Chemical Co., Ltd.
Hydroxyl value: 310 mg-KOH / g
Viscosity: 830 mPa · s
Polyol D: Polyether polyol “NE240” manufactured by Sanyo Chemical Industries
Hydroxyl value: 970 mg-KOH / g
Viscosity: 3800 mPa · s
Flame Retardant A: “TMCPP” (Tris Monochloropropyl Phosphate) manufactured by Daihachi Chemical Co., Ltd.
G)
Flame retardant B: “TEP” (triethyl phosphate) manufactured by Daihachi Chemical Co., Ltd.
Flame retardant C: “DAIGUARD-400” (Triisobutylphosphine) manufactured by Daihachi Chemical Co., Ltd.
Yate)
Foam stabilizer: “SH193” manufactured by Toray Dow Corning Silicon Co., Ltd.
(Block copolymer of dimethylsiloxane and polyether)
Catalyst A: Kao Riser No. 1 manufactured by Kao Corporation
(N, N, N ′, N′-tetramethylhexanediamine)
Catalyst B: Kao Riser No. 3 manufactured by Kao Corporation
(N, N, N ′, N ″, N ″ -pentamethyldiethylenetriamine)
Catalyst C: “Nikka Octic Lead 17%” manufactured by Nippon Chemical Industry Co., Ltd.
(Dioctyl phthalate solution of lead octylate (lead concentration 17% by weight))
Catalyst D: “TOYOCAT-NP” manufactured by Tosoh Corporation
(Trimethylaminoethylpiperazine)
Catalyst E: “TOYOCAT-TMF” manufactured by Tosoh Corporation
(Pentamethyldiethylenetriamine formic acid cap-containing product)
Catalyst F: "Pucat 25" manufactured by Nippon Chemical Industry Co., Ltd.
(Component 1: Bismuth 2-ethylhexylate (25% by weight as bismuth))
Component 2: Octylic acid (20% by weight))
Catalyst G: Nippon Chemical Industry Co., Ltd. “Pucat 15G”
(Potassium octylate in diethylene glycol (potassium concentration 15% by weight
))
Catalyst H: “TOYOCAT-DM70” manufactured by Tosoh Corporation
Foaming agent: water

Examples 1-7, Comparative Examples 1-5
In accordance with the formulation shown in Tables 1 and 2, first, Compounded Liquid A was prepared. Mixing and foaming by weighing 40 g of compounded liquid A and an amount of polyisocyanate commensurate with this (both adjusted to a liquid temperature of 10 ° C.) and stirring at 6000 to 8000 rpm for 3 seconds with manual stirring to achieve a predetermined isocyanate index To produce a rigid polyurethane foam. The blending ratio of each example, the viscosity of the blending liquid A, and the isocyanate index were as shown in Tables 1 and 2. Further, the volume ratio, that is, the ratio of the volume of the isocyanate component to the volume of the polyol component was as shown in Tables 1 and 2.

  At this time, the pH and reactivity immediately after the blending of the blended liquid A and after the acceleration test (after high-temperature storage) were examined according to the following methods, and the results are shown in Tables 1 and 2.

[PH]
Measurement was performed at 20 ° C. using a pH meter “H9224” manufactured by Hanna Instruments.
[Reactivity (Cream Time / Rise Time)]
After the start of stirring and mixing of the blended liquid A and the polyisocyanate, the time when the stirred raw material turned white and foaming started was recorded as the foaming start time (cream time). Further, the time when foaming ended in appearance was defined as the foaming end time (rise time).
[Accelerated test]
Compounding liquid A was put in a plastic container and sealed, heated at 60 ° C. for 72 hours, and then the pH and reactivity were examined in the same manner as described above.

  In addition, for hard polyurethane foam obtained by airless spray foaming under the following spray construction conditions with the composition shown in Tables 1 and 2, according to the following method, workability, molded core density, compressive strength, dimensional stability, closed cell The rate, adhesiveness and flame retardancy were examined and the results are shown in Tables 1 and 2. In addition, the hard polyurethane foam was used as a sample after spraying down a 5 mm-thick calcium plate under the following construction conditions, spraying it on it with an appropriate amount of thickness, and curing it at room temperature for one day or more.

<Spray construction conditions>
Spray foaming machine: “H-2000” manufactured by Gasmer
"FF-1600" (mixing volume ratio 100: 100)
(Mixing head: D gun)
Hose heater set temperature: 30-45 ° C
Main heater set temperature: 30 ~ 45 ℃
[Workability]
Atmospheric temperature: As shown in Tables 1 and 2.
Flyability: After molding, in the form when cured for 20-25 minutes at each ambient temperature
The presence or absence of “powder” was qualitatively evaluated by touch.
[Core density]
It measured according to JIS A9526.
[Compressive strength]
A sample cut into a size of 50 mm × 50 mm × 30 mm and collected was measured according to JIS A9526.
[Dimensional stability]
A core portion cut into a size of 100 mm × 100 mm × 30 mm was collected and placed in a high-humidity heat environment (temperature 50 ° C./humidity RH 95%) for 24 hours, and the dimensional change rate before and after was examined.
[Closed cell ratio]
Measured according to ASTM D2856.
[Adhesiveness]
It measured according to JIS A9526.
[Flame retardance]
According to the surface test method shown in JIS A1321 “Interior material of building and flame retardancy test method of construction method”, a surface test was carried out by using a flammability tester manufactured by Toyo Seiki Seisakusho.

In addition, the flame retardant third grade standard by the surface test method shown in JIS A1321 “Interior material of building and flame retardant test method of construction method” is as follows.
Exhaust temperature time ≧ 180sec
Smoke coefficient ≦ 120
Temperature time area ≤350 (℃ ・ min)
Afterflame time ≤ 30 sec
No significant melting, cracking or deformation of the specimen

Examples 8-10, Comparative Examples 6, 7
In the same manner as in Example 1, 40 g of Compound A and 60 g of polyisocyanate (both adjusted to a liquid temperature of 10 ° C.) were weighed so that the weight ratio would be 1: 1.5, and manually stirred. A rigid polyurethane foam was produced by mixing and foaming by stirring at 6000 to 8000 rpm for 5 seconds. The blending ratio and isocyanate index of each example were as shown in Table 3.

  At this time, the pH and reactivity immediately after the blending of the blended liquid A and after the acceleration test (after high-temperature storage) were examined according to the following method, and the results are shown in Table 3.

[PH]
Measurement was performed at 20 ° C. using a pH meter “H9224” manufactured by Hanna Instruments.
[Reactivity (Cream Time / Gel Time / Rise Time)]
After the start of stirring and mixing of the blended liquid A and the polyisocyanate, the time when the stirred raw material turned white and foaming started was recorded as the foaming start time (cream time). Further, the time for inserting the needle into the foam and drawing the yarn was defined as gel time (gel time), and the time when foaming was finished in appearance was defined as foaming end time (rise time).

As is clear from Tables 1 to 3, in the rigid polyurethane foam according to the example, the decrease in reactivity (change in rise time) of the polyurethane foam after high-temperature storage can be suppressed at a free density of about 22 kg / cm ^3. it can. Therefore, according to the present invention, there is provided a rigid polyurethane foam using water as a foaming agent, and excellent in storage stability of the polyol premix, and also excellent in flame retardancy and other physical properties. You can see that it is provided.

Claims (20)

It is obtained by mixing a polyisocyanate component with a blending solution containing a polyol component, water, a catalyst, a flame retardant and other auxiliary agents, and foaming carbon dioxide generated by the reaction of the polyisocyanate component and water as a foaming agent. Rigid polyurethane foam,
A rigid polyurethane foam having a pH of 9 or less immediately after blending of the blended liquid.   The rigid polyurethane foam according to claim 1, wherein a pH immediately after blending of the blended liquid is 8 to 9.   3. The catalyst according to claim 1, wherein the catalyst is a potassium salt catalyst, a formic acid block catalyst, a piperazine catalyst, a morpholine catalyst, an imidazole catalyst, bisdimethylaminoethyl, and a bismuth salt catalyst. A rigid polyurethane foam characterized by using more than one species.   The rigid polyurethane foam according to any one of claims 1 to 3, wherein the flame retardant contains triisobutyl phosphate.   The rigid polyurethane foam according to claim 4, wherein the flame retardant comprises triisobutyl phosphate and trismonochloropropyl phosphate.   The rigid polyurethane foam according to any one of claims 1 to 5, wherein the polyol component contains a polyester polyol and a polyether polyol, and the content of the polyester polyol in the polyol component is 50% by weight or more.   In Claim 6, polyester polyol is obtained from the phthalic acid component which has as a main component 1 type, or 2 or more types chosen from the group which consists of o-phthalic acid, m-phthalic acid, p-phthalic acid, and these derivatives. Rigid polyurethane foam characterized by being a phthalic polyester polyol.   The rigid polyurethane foam according to claim 6 or 7, wherein the polyether polyol is a polyether polyol having a Mannich structure.   The polyol component according to any one of claims 6 to 8, wherein the polyol component is 60 to 80% by weight of a phthalic polyester polyol, 15 to 35% by weight of a Mannich modified polyether polyol, and / or a polymer other than the Mannich modified polyether polyol. A hard component comprising 5 to 20% by weight of an ether polyol, and a powder component obtained by copolymerizing an ethylenically unsaturated nitrile and a vinyl carboxylate monomer dispersed in the polyol component Polyurethane foam.   In Claim 9, polyether polyols other than Mannich modified polyether polyol are selected from the group consisting of ethylenediamine-based polyether polyols, glycerin-based polyether polyols, sorbitol-based polyether polyols, and tolylenediamine-based polyether polyols. A rigid polyurethane foam characterized by being a seed or two or more.   The rigid polyurethane foam according to claim 9 or 10, wherein the dispersion concentration of the powder component is 0.1 to 10% by weight in the total polyol component.   The rigid polyurethane foam according to any one of claims 1 to 11, wherein the ratio of water to 100 parts by weight of the polyol component is 2 to 6 parts by weight.   The rigid polyurethane foam according to any one of claims 1 to 12, wherein the isocyanate index is 100 to 200.   The rigid polyurethane foam according to claim 13, wherein the isocyanate index is 100 to 140.   The rigid polyurethane foam according to any one of claims 1 to 14, wherein a value of volume mixing ratio of polyol component to isocyanate component: polyol component / isocyanate component is 0.9 to 1.1.   The airless spray foaming according to any one of claims 1 to 15, wherein the polyisocyanate component and a blended liquid obtained by mixing a polyol component, water, a catalyst, a flame retardant and other auxiliary agents are mixed and foamed by a mixing head. A rigid polyurethane foam characterized by being obtained.   The flame retardant material according to any one of claims 1 to 16, wherein the flame retardant performance is a flame retardant grade 3 or higher as defined in JIS A1321, and / or a flame retardant material indicated in Article 1-6 of the Building Standard Law Enforcement Ordinance. Rigid polyurethane foam characterized by being. In Claim 16 or 17, the self-adhesion strength of the rigid polyurethane foam molded at an ambient temperature and a temperature of the casing surface of 0 to 10 ° C is 10 N / cm ² or more in the method defined in JIS A 9526. Hard polyurethane foam. The density of the core part of the molded rigid polyurethane foam having a total thickness of 30 to 50 mm according to any one of claims 16 to 18 is 20 to 40 kg / m ³ or less in the method defined in JIS A9526. Rigid polyurethane foam characterized by that.   The rigid polyurethane foam according to any one of claims 1 to 19, wherein a ratio of closed cells to total cells is 10 to 65% by volume.