JP5463231B2 - Method for producing flexible polyurethane slab foam - Google Patents

Description

  The present invention relates to a method for producing a flexible polyurethane slab foam.

  As a conventional technique, there is a method for producing a flexible polyurethane slab foam by reacting a polyol and an organic polyisocyanate in the presence of a foaming agent, a catalyst, a foam stabilizer, and the like.

  A polyoxyalkylene polyol is generally used as a polyol used for producing a flexible polyurethane slab foam. The polyoxyalkylene polyol uses an alkali metal such as potassium hydroxide as a catalyst, and an active hydrogen-containing compound such as 1,2-propylene oxide (hereinafter abbreviated as PO) or ethylene oxide (hereinafter abbreviated as EO). It can be obtained by addition polymerization of alkylene oxide (hereinafter abbreviated as AO). In addition polymerization of PO using an alkali metal catalyst, a by-product low molecular weight monool is produced by rearrangement of PO to allyl alcohol. This by-product low molecular weight monool causes a decrease in the number of functional groups of the polyoxyalkylene polyol, and a urethane resin using such a polyol has a problem that mechanical properties are deteriorated. Therefore, a method is known in which cesium hydroxide or double metal cyanide is used as a catalyst in order to reduce the amount of such by-product low molecular weight monool produced. (For example, see Patent Documents 1 and 2.)

  By the way, a polyoxyalkylene polyol obtained by addition polymerization of AO having 3 or more carbon atoms to an active hydrogen-containing compound in the presence of the above catalyst has a very low primary hydroxyl group primary ratio (for example, potassium hydroxide). When used, it is usually 2% or less), and most terminal hydroxyl groups are secondary hydroxyl groups. For this reason, this polyol has insufficient reactivity as a polyol component of a thermosetting resin. For example, the reactivity with an isocyanate group of an isocyanate group-containing compound (tolylene diisocyanate or the like) is low, and the reactivity is insufficient as a polyol component of a polyurethane slab foam.

  In order to ensure sufficient reactivity with an isocyanate group, the terminal hydroxyl group needs to be a primary hydroxyl group. For this purpose, polyoxyalkylene polyol obtained by addition polymerization of AO having 3 or more carbon atoms is used. Furthermore, a method is known in which EO is addition-polymerized to make the terminal hydroxyl group a primary hydroxyl group. However, since the polyethylene oxide part in the obtained polyoxyalkylene polyol is hydrophilic, this method reduces the hydrophobicity of the polyoxyalkylene polyol. When such a polyol is used, the resin physical properties of the polyurethane slab foam are reduced. There is a problem that it changes greatly depending on humidity. Then, the method of increasing the amount of primary hydroxyl groups in a terminal hydroxyl group is known by using a specific catalyst. (For example, see Patent Document 3)

  Furthermore, by first performing AO addition polymerization in the presence of cesium hydroxide or a double metal cyanide catalyst, and then performing AO addition polymerization using a specific catalyst, the amount of by-product low molecular weight monool produced can be reduced. It is known that a polyoxyalkylene polyol having a reduced reactivity with an isocyanate group can be obtained. (For example, see Patent Document 4)

  On the other hand, in general, in a flexible polyurethane slab foam, an aromatic isocyanate having high reactivity with a polyol is often used. However, since aromatic isocyanate contains an aromatic ring, it causes yellowing of the foam.

  Soft polyurethane slab foam is widely used for furniture, bedding mattresses, automotive seat cushions, clothing, etc., and the appearance of the foam is also important, so it is a problem that the foam turns yellow. A difficult form is required.

JP 2007-131845 A JP 2007-131845 A Japanese Patent No. 3076032 Japanese Patent No. 3688667

  The problem to be solved by the present invention is to provide a method for producing a flexible polyurethane slab foam which is excellent in physical properties and hardly yellows.

［一般式（１）中、Ｒ¹は、水素原子、炭素数１〜１２のアルキル基、シクロアルキル基又はフェニル基を表す。炭素数１〜１２のアルキル基、シクロアルキル基又はフェニル基は、ハロゲン原子若しくはアリール基で置換されていてもよい。］
ｙ≦２８．３×ｘ^-2×（１００−ｚ）／１００ （１）
［数式（１）中、ｘは単位ｍｇＫＯＨ／ｇで表される水酸基価、ｙは単位ｍｅｑ／ｇで表される総不飽和度を表す。ｚは、（Ｓ）の重量を基準とするエチレンオキサイド含有量であり、０〜５０重量％である。］ As a result of intensive studies to solve the above problems, the present inventors have reached the invention shown below.
That is, the method for producing a flexible polyurethane foam of the present invention comprises a flexible polyurethane obtained by reacting a polyol component (A) and an organic polyisocyanate component (B) in the presence of a foaming agent (C) and a urethanization catalyst (D). In the slab foam production method, the polyol component (A) contains the following polyoxyalkylene polyol (S), and the organic polyisocyanate component (B) contains aliphatic isocyanate and / or alicyclic isocyanate. To do.
Polyoxyalkylene polyol (S): an alkylene oxide adduct of an active hydrogen-containing compound (H), wherein 40% or more of the hydroxyl groups located at the terminals are primary hydroxyl group-containing groups represented by the following general formula (1) Yes, a polyoxyalkylene polyol in which the hydroxyl value x, the total unsaturation degree y, and the ethylene oxide content z satisfy the relationship of the formula (1).

[In General Formula (1), R ¹ represents a hydrogen atom, an alkyl group having 1 to 12 carbon atoms, a cycloalkyl group, or a phenyl group. The C1-C12 alkyl group, cycloalkyl group or phenyl group may be substituted with a halogen atom or an aryl group. ]
y ≦ 28.3 × x ⁻² × (100−z) / 100 (1)
[In Formula (1), x represents the hydroxyl value represented by the unit mgKOH / g, and y represents the total degree of unsaturation represented by the unit meq / g. z is the ethylene oxide content based on the weight of (S), and is 0 to 50% by weight. ]

  By the production method of the present invention, a soft polyurethane slab foam which is excellent in physical properties and hardly yellows can be produced.

It is a graph which shows the relationship between the hydroxyl value x of a polyoxyalkylene polyol, and the total unsaturation degree y. 1 is a view showing a reaction apparatus of Production Example 1. FIG. It is a figure which shows the reaction apparatus of manufacture example 2 and 4. It is a figure which shows the reaction apparatus of manufacture example 3. FIG. It is a figure which shows the reactor of comparative manufacture example 1,2,3.

  The present invention relates to a process for producing a flexible polyurethane slab foam obtained by reacting a polyol component (A) and an organic polyisocyanate component (B) in the presence of a foaming agent (C) and a urethanization catalyst (D). This is a method for producing a flexible polyurethane slab foam in which the component (A) contains the following polyoxyalkylene polyol (S) and the organic polyisocyanate component (B) contains an aliphatic isocyanate and / or an alicyclic isocyanate.

  The polyoxyalkylene polyol (S) is an alkylene oxide adduct of the active hydrogen-containing compound (H), and a primary hydroxyl group-containing group in which 40% or more of the terminal hydroxyl groups are represented by the general formula (1). And the hydroxyl value x, the total unsaturation degree y, and the ethylene oxide content z are polyoxyalkylene polyols satisfying the relationship of the formula (1).

y ≦ 28.3 × x ⁻² × (100−z) / 100 (1)

  In the above formula (1), the range of x is preferably 5 to 280 mgKOH / g, more preferably 10 to 115 mgKOH / g, and particularly preferably 25 to 75 mgKOH / g. When x is 5 mgKOH / g or more, the viscosity of the polyoxyalkylene polyol (S) is low, so that handling is easy. When x is 280 mgKOH / g or less, the stretched physical properties of the synthesized flexible polyurethane slab foam are good. In addition, x is calculated | required by JISK-1557.

  y is the total unsaturation degree (meq / g) of the polyoxyalkylene polyol (S), and is determined according to JISK-1557. From the viewpoint of the physical properties of the urethane resin, y is preferably 0 to 0.04, more preferably 0 to 0.03, and particularly preferably 0 to 0.02.

Z is the ethylene oxide content (% by weight) based on the weight of the polyoxyalkylene polyol (S). The range of z is 0-50, preferably 0-25, particularly preferably 0-20. If z exceeds 50, the resulting polyurethane resin has poor moisture resistance. z is determined by ¹ H-NMR measurement under normal conditions.

In addition, Numerical formula (1) can also represent the hydroxyl value x also by the hydroxyl equivalent w, In that case, the hydroxyl equivalent w, the total unsaturation degree y, and ethylene oxide content z satisfy | fill the relationship of Numerical formula (2). The hydroxyl group equivalent w can be obtained from the calculation formula of w = 56100 / x.
y ≦ (9.0 × 10 ⁻⁹ ) w ² × (100−z) / 100 (2)

As described above, the relationship among the hydroxyl value x, the total degree of unsaturation y, and the ethylene oxide content z of the polyoxyalkylene polyol (S) satisfies the relationship of Formula (1).
y ≦ 28.3 × x ⁻² × (100−z) / 100 (1)
In the present invention, the polyoxyalkylene polyol (S) is characterized by having sufficient reactivity with an isocyanate and hydrophobicity. The urethane resin obtained by using (S) has high reactivity at the time of production, and the mechanical properties (hardness, elongation at break, tensile strength, tear strength) and moisture resistance of the flexible polyurethane slab foam are good.

In the present invention, (S) more preferably satisfies the relationship of Equation (3).
y ≦ 18.9 × x ⁻² × (100−z) / 100 (3)
The polyoxyalkylene polyol (S) satisfying the mathematical formula (3) has a reduced amount of unsaturated monool as compared with the case where the mathematical formula (1) is satisfied, and a soft polyurethane produced using such a polyoxyalkylene polyol. The mechanical properties of the slab foam are further improved.

The right side is a value calculated from the hydroxyl value x and the ethylene oxide content z. The right side decreases as the hydroxyl value x increases, that is, decreases as the molecular weight per hydroxyl group of (S) decreases. Further, the right side becomes smaller as the ethylene oxide content z becomes larger.
The left side of the above formulas (1) and (3) is the total degree of unsaturation y.
By the way, the unsaturated group of the polyoxyalkylene polyol is produced by a rearrangement reaction of alkylene oxide (especially propylene oxide) other than ethylene oxide in this production process. Therefore, the smaller the ethylene oxide content in the polyoxyalkylene polyol, the total The degree of unsaturation y tends to increase, and the total degree of unsaturation y tends to increase as the molecular weight increases. Therefore, a polyoxyalkylene polyol having a small ethylene oxide content or a large molecular weight tends to have difficulty satisfying the formulas (1) and (3).
That is, the formula (1) or (3) indicates a region where the total degree of unsaturation y is smaller than the hydroxyl value x and the ethylene oxide content z. In addition, the said Formula (1) and (3) represents the range where the effect of this invention found experimentally is acquired.
The total degree of unsaturation y increases exponentially as the molecular chain length per OH group increases, that is, as the hydroxyl value x decreases. This is because during the addition reaction of AO, the reaction rate at which AO is rearranged into the unsaturated compound is constant, but the addition reaction rate becomes slower as the OH group concentration in the system decreases. From this theoretical analysis and curve fitting with experimental data, the coefficient of x ^{−2 in} the equations (1) and (3) was determined. FIG. 1 shows the case where the EO content z = 0, but since EO does not undergo a rearrangement reaction, (100−z) / 100 is a term to be corrected to the molecular chain length of the portion excluding EO from the hydroxyl group. Was added to formula (1).

In the present invention, the polyoxyalkylene polyol (S) is an alkylene oxide adduct of the active hydrogen-containing compound (H).
As the active hydrogen compound (H), a compound containing two or more active hydrogens, for example, a hydroxyl group-containing compound, an amino group-containing compound, a carboxyl group-containing compound, a thiol group-containing compound, a phosphate compound; And a compound having an active hydrogen-containing functional group; and a mixture of two or more thereof.

Examples of the hydroxyl group-containing compound include water, divalent to octavalent polyhydric alcohols, and polyhydric phenols. Specifically, ethylene glycol, propylene glycol, 1,4-butanediol, 1,6-hexanediol, diethylene glycol, neopentyl glycol, 1,4-bis (hydroxymethyl) cyclohexane and 1,4-bis (hydroxyethyl) Dihydric alcohols such as benzene; trihydric alcohols such as glycerin and trimethylolpropane; 4- to 8-valent alcohols such as pentaerythritol, sorbitol and sucrose; pyrogallol, catechol and hydroquinone Polyphenols; bisphenols such as bisphenol A, bisphenol F and bisphenol S; polybutadiene polyols; castor oil-based polyols; hydroxyalkyl (meth) acrylate (co) polymers and polyfunctionals such as polyvinyl alcohol (for example, Functional group 2 to 100) a polyol, and the like.
(Meth) acrylate means methacrylate and / or acrylate, and the same applies hereinafter.

  Examples of the amino group-containing compound include ammonia, amine, polyamine, amino alcohol and the like. Specifically, ammonia; monoamines such as C1-C20 alkylamine (butylamine and the like) and aniline; aliphatic polyamines such as ethylenediamine, hexamethylenediamine and diethylenetriamine; heterocyclics such as piperazine and N-aminoethylpiperazine Polyamines; alicyclic polyamines such as dicyclohexylmethanediamine and isophoronediamine; aromatic polyamines such as phenylenediamine, tolylenediamine and diphenylmethanediamine; alkanolamines such as monoethanolamine, diethanolamine and triethanolamine; and dicarboxylic acids Polyamide polyamine obtained by condensation with excess polyamine; polyether polyamine; hydrazine (such as hydrazine and monoalkylhydrazine), dihydrazide ( Etc. Haq acid dihydrazide and dihydrazide terephthalate), guanidine (butyl guanidine and 1-cyanoguanidine, etc.); dicyandiamide; and mixtures of two or more thereof.

  Examples of the carboxyl group-containing compound include aliphatic polycarboxylic acids such as succinic acid and adipic acid; aromatic polycarboxylic acids such as phthalic acid and trimellitic acid; polycarboxylic acid polymers such as (co) polymers of acrylic acid ( And the number of functional groups is 2 to 100).

Examples of the thiol group-containing compound include polythiol compounds, and examples include divalent to octavalent polyvalent thiols. Specific examples include ethylenedithiol and 1,6-hexanedithiol.
Examples of phosphoric acid compounds include phosphoric acid, phosphorous acid, and phosphonic acid.

  Among these active hydrogen-containing compounds (H), from the viewpoint of reactivity, a hydroxyl group-containing compound and an amino group-containing compound are preferable, and water, a polyhydric alcohol, and an amine are particularly preferable.

  Examples of the alkylene oxide (hereinafter abbreviated as AO) to be added to the active hydrogen-containing compound (H) include AO having 2 to 6 carbon atoms, such as ethylene oxide (hereinafter abbreviated as EO), 1,2-propylene oxide (hereinafter referred to as AO). , PO), 1,3-propyloxide, 1,2 butylene oxide, 1,4-butylene oxide, and the like. Of these, PO, EO, and 1,2-butylene oxide are preferable from the viewpoints of properties and reactivity. When two or more types of AO are used (for example, PO and EO), block addition or random addition may be used, or a combination thereof may be used.

  The alkylene oxide adduct of the active hydrogen-containing compound (H) includes a polyoxyalkylene polyol represented by the following general formula (2).

In General Formula (2), R ² is an m-valent group obtained by removing m active hydrogens from the active hydrogen-containing compound (H), m is the number of active hydrogens in (H), It is an integer of 100.
From the viewpoint of properties such as the viscosity of (S), m is preferably 50 or less, and more preferably 10 or less.

In the general formula (2), Z represents an alkylene group or cycloalkylene group having 2 to 12 carbon atoms, and these groups may be substituted with a halogen atom or an aryl group. When Z is an alkylene group having 2 to 12 carbon atoms, it is represented by the following general formula (3) or (4).

In general formulas (3) and (4), R ³ represents a hydrogen atom, an alkyl group having 1 to 10 carbon atoms, a cycloalkyl group, or a phenyl group, and an alkyl group, cycloalkyl group, or phenyl group having 1 to 10 carbon atoms. May be substituted with a halogen atom or an aryl group.

  Specific examples of Z include an ethylene group, a propylene group, a butylene group, a chloropropylene group, a phenylethylene group, and a 1,2-cyclohexylene group, and a plurality of Z may be the same or different. . Of these, a propylene group, a butylene group, and an ethylene group are preferable from the viewpoint of properties such as the viscosity of (S). When taking into consideration ensuring the hydrophobicity of the resulting polyoxyalkylene polyol (S), a propylene group, a butylene group or the like may be used, or an ethylene group and another alkylene group may be used in combination.

  In the general formula (2), A is an alkylene group or cycloalkylene group having 3 to 12 carbon atoms represented by the following general formula (5) or (6), and these groups are halogen atoms or aryl groups. May be substituted.

In general formulas (5) and (6), R ⁴ represents an alkyl group having 1 to 10 carbon atoms, a cycloalkyl group, or a phenyl group, and these groups may be substituted with a halogen atom or an aryl group.

  Specific examples of A include a propylene group, a butylene group, a chloropropylene group, a phenylethylene group, and a 1,2-cyclohexylene group, and a plurality of A may be the same or different. Of these, a propylene group and a butylene group are preferable from the viewpoint of properties such as the viscosity of (S).

In General formula (2), p and r are 0 or an integer of 1-200. q is an integer of 1 to 200.
From the viewpoint of the viscosity of the polyoxyalkylene polyol (S), p + q + r is preferably an integer of 1 to 400, and more preferably 200 or less.

  Among those represented by the general formula (2), those in which r is 0 represent that EO is not added to the terminal portion of the polyoxyalkylene polyol (S).

Among those represented by the general formula (2), 40% or more of the structure of A located at the terminal in the portion of (AO) _{q in} the general formula (2) is represented by the general formula (6). The structure is preferable, more preferably 60% or more, and still more preferably 65% or more. Within this range, it is easy to satisfy the relationship of Equation (1).

In the present invention, the polyoxyalkylene polyol (S) is a primary hydroxyl group-containing group in which 40% or more of the terminal hydroxyl groups are represented by the above general formula (1).
For example, when (S) is represented by the above general formula (2), the hydroxyl group-containing group located at the end includes a primary hydroxyl group-containing group represented by the above general formula (1) and r = 0. Two types of secondary hydroxyl group-containing groups represented by the following general formula (10) can be considered, but (S) is a hydroxyl group located at the terminal regardless of the value of r in the general formula (2). 40% or more is the primary hydroxyl group-containing group represented by the general formula (1).
In (S), the ratio of the primary hydroxyl group-containing group represented by the general formula (1) to the total hydroxyl groups at the terminals (this is the primary hydroxyl group ratio in the present specification. The same applies hereinafter. Is 40% or more based on the amount of all terminal hydroxyl groups of the polyoxyalkylene polyol (S), and preferably 60% or more, more preferably 65% or more from the viewpoint of the reactivity of (S). is there. When the primary hydroxyl group ratio is less than 40%, the reactivity as a polyol component is insufficient.

R ^{1 in} the general formula (1) represents a hydrogen atom, an alkyl group having 1 to 12 carbon atoms, a cycloalkyl group, or a phenyl group, and the alkyl group, cycloalkyl group, or phenyl group having 1 to 12 carbon atoms is , May be substituted with a halogen atom or an aryl group. R ⁹ in the general formula (10) represents an alkyl group having 1 to 12 carbon atoms, a cycloalkyl group, or a phenyl group, and these groups may be substituted with a halogen atom or an aryl group.
Specific examples of R ¹ include a hydrogen atom; a linear alkyl group such as a methyl group, an ethyl group, and a propyl group; a branched alkyl group such as an isopropyl group; a substituted phenyl group such as a phenyl group and a p-methylphenyl group; A substituted alkyl group such as a methyl group, a bromomethyl group, a chloroethyl group and a bromoethyl group; a substituted phenyl group such as a p-chlorophenyl group and a p-bromophenyl group; a cyclic alkyl group such as a cyclohexyl group; and a combination of two or more of these Is mentioned. Specific examples of R ⁹ include groups other than a hydrogen atom among the groups exemplified for R ¹ .

In the present invention, the primary hydroxyl group ratio is measured and calculated by the ¹ H-NMR method after pretreatment for esterifying the sample in advance.

The method for measuring the primary hydroxyl group ratio will be specifically described below.
<Sample preparation method>
About 30 mg of a measurement sample is weighed into an NMR sample tube having a diameter of 5 mm, and about 0.5 ml of deuterated solvent is added and dissolved. Thereafter, about 0.1 ml of trifluoroacetic anhydride is added to obtain a sample for analysis. Examples of the deuterated solvent include deuterated chloroform, deuterated toluene, deuterated dimethyl sulfoxide, and deuterated dimethylformamide, and a solvent that can dissolve the sample is appropriately selected.
<NMR measurement>
¹ H-NMR measurement is performed under normal conditions.

<Calculation method of primary hydroxyl group ratio>
By the pretreatment method described above, the terminal hydroxyl group of the polyoxyalkylene polyol reacts with the added trifluoroacetic anhydride to become a trifluoroacetic acid ester. As a result, a signal derived from a methylene group bonded with a primary hydroxyl group was observed at around 4.3 ppm, and a signal derived from a methine group bonded to a secondary hydroxyl group was observed at around 5.2 ppm (deuterated chloroform was used as a solvent). Used as). The primary hydroxyl group ratio is calculated by the following calculation formula.
Primary hydroxyl group ratio (%) = [a / (a + 2 × b)] × 100
In the formula, a is an integral value of a signal derived from a methylene group to which a primary hydroxyl group is bonded in the vicinity of 4.3 ppm; b is an integrated value of a signal derived from a methine group to which a secondary hydroxyl group is bonded in the vicinity of 5.2 ppm. .

  In the present invention, the number average molecular weight of the polyoxyalkylene polyol (S) is appropriately selected depending on the use of (S), for example, the required physical properties of the soft polyurethane slab foam to be produced, and is not particularly limited. Therefore, 400 to 100,000 is preferable, and 400 to 20,000 is preferable.

  Specific examples of the polyoxyalkylene polyol (S) include water PO adduct, glycerin PO adduct, water EO / PO copolymer adduct, water PO / butylene oxide copolymer adduct, glycerin EO / Examples thereof include a PO copolymer adduct, a water EO / PO / butylene oxide copolymer adduct, and a glycerin EO / PO / butylene oxide copolymer adduct.

The active hydrogen-containing compound (J) represented by the following general formula (11) can be produced by a generally known method. For example, an alkylene oxide having 2 to 12 carbon atoms is added to the active hydrogen-containing compound (H). It can manufacture by ring-opening addition polymerization, The catalyst of this polymerization is not specifically limited.
In the present invention, the polyoxyalkylene polyol (S) is an activity represented by the following general formula (12) by subjecting (J) to ring-opening addition polymerization of an alkylene oxide having 3 to 12 carbon atoms in the presence of the catalyst (C). It can be obtained by using a hydrogen compound (K). Moreover, you may carry out 0-50 weight% ring-opening addition polymerization of EO at the terminal of (K) as needed. The method for the ring-opening addition weight of EO to (K) may be the conditions known in the art, and the catalyst is not particularly limited. When EO is not subjected to addition polymerization at the terminal of (K), (K) is (S), and the hydroxyl value x and the total unsaturation y of (S) obtained satisfy the relationship of formula (1). Just do it.

In the general formula (11), R ² , Z, p, and m are the same as those in the general formula (2), and the above can be exemplified in the same manner.
In the general formula (12), R ² , Z, A, p, q, and m are the same as those in the general formula (2), and the above-described products can be exemplified similarly.

  Specific examples of the active hydrogen-containing compound (J) include those similar to those described above as the active hydrogen-containing compound (H) when p is 0.

When p is 1 or more, examples thereof include compounds obtained by adding an alkylene oxide having 2 to 12 carbon atoms to the aforementioned p having 0, that is, (H). The catalyst used in the addition reaction is not limited.
For example, specific examples of (J) include adducts such as EO, PO, and butylene oxide to (H), and more specifically, an EO adduct of water, a PO adduct of water, and glycerin. EO adduct, glycerin PO adduct, ammonia ethylene oxide adduct, ammonia propylene oxide adduct, water EO / PO copolymer adduct, water PO / butylene oxide copolymer adduct, glycerin EO / PO copolymer adduct, glycerin EO / butylene oxide copolymer adduct, glycerin PO / butylene oxide copolymer adduct, ammonia ethylene oxide / propylene oxide copolymer adduct, water EO / PO / butylene oxide co-adduct Polymerization adduct and copolymerization adduct of EO / PO / butylene oxide of glycerin, ammonia Copolymer adducts of EO · PO · butylene oxide.

Examples of the active hydrogen-containing compound (K) include compounds obtained by addition polymerization of an alkylene oxide having 3 to 12 carbon atoms to the active hydrogen-containing compound (J). Since the polyoxyalkylene polyol (S) can be easily obtained, the catalyst used in this addition polymerization is preferably the catalyst (C).
For example, (K) includes adducts such as PO and butylene oxide to (J).

  The catalyst (C) is a compound represented by the following general formula (7-1), (7-2) or (7-3). Using this, ring-opening addition polymerization of an alkylene oxide having 3 to 12 carbon atoms yields a ring-opening polymer with good yield, and a polyoxyalkylene polyol having a high primary hydroxyl group ratio of terminal hydroxyl groups can be obtained. is there.

  In the general formulas (7-1), (7-2), and (7-3), X represents a boron atom or an aluminum atom, respectively. From the viewpoint of reactivity, a boron atom is preferable.

R ⁵ in the general formula (7-1), (7-2) or (7-3) is represented by the (substituted) phenyl group represented by the following general formula (8) or the following general formula (9). When there are a plurality of R ⁵ groups, the plurality of R ⁵ groups may be the same or different.

Y in the general formula (8) represents a hydrogen atom, an alkyl group having 1 to 4 carbon atoms, a halogen atom, a nitro group, or a cyano group, which may be the same or different. Of these, a hydrogen atom, a halogen atom and a cyano group are preferable, and a halogen atom and a cyano group are more preferable.
Moreover, k represents the number of 0-5.
Specific examples of the phenyl group or substituted phenyl group represented by the general formula (8) include a phenyl group, a pentafluorophenyl group, a p-methylphenyl group, a p-cyanophenyl group, and a p-nitrophenyl group. A phenyl group, a pentafluorophenyl group and a p-cyanophenyl group are preferable, and a phenyl group and a pentafluorophenyl group are more preferable.

R ⁶ , R ⁷ or R ^{8 in the} general formula (9) each independently represents an alkyl group having 1 to 4 carbon atoms, which may be the same or different. Specific examples include a methyl group, an ethyl group, a propyl group, and an isopropyl group. Specific examples of the tertiary alkyl group represented by the general formula (9) include a t-butyl group and a t-pentyl group.

  Specific examples of the catalyst (C) include triphenylborane, diphenyl-t-butylborane, tri (t-butyl) borane, triphenylaluminum, tris (pentafluorophenyl) borane, and tris (pentafluorophenyl) aluminum. It is done. Of these, from the viewpoint of catalytic activity and selectivity, triphenylborane, tris (pentafluorophenyl) borane, and tris (pentafluorophenyl) aluminum are preferable.

  In the presence of the catalyst (C), the alkylene oxide is added to the active hydrogen-containing compound (J) to obtain the active hydrogen compound (K). It is preferably 1 to 200 mol, more preferably 1 to 100 mol per active hydrogen of J), and it is appropriately selected depending on the molecular weight of the ring-opening polymer to be produced and its use.

  Although the usage-amount of a catalyst (C) is not specifically limited, 0.0001-10 weight% is preferable with respect to the ring-opening polymer to manufacture, More preferably, it is 0.0005-1 weight%.

  When an active hydrogen compound (K) represented by the above general formula (12) is obtained by adding alkylene oxide to the active hydrogen-containing compound (J) in the presence of the catalyst (C), a pressure of 0.1 MPa It is preferable to continuously or intermittently remove the by-product low-boiling compound (t) having a boiling point of 150 ° C. or lower in which it is easy to obtain (S) satisfying the above-described formula (1). The removal method may be carried out by any of the commonly known methods. For example, a method of removing (t) from the reaction mixture by heating and / or decompressing, a method of removing the gas phase in the reaction vessel from the reaction vessel using a gas-phase circulation pump, and removing the (t) with an adsorbent, a reaction A method in which the gas phase in the tank is extracted from the reaction tank using a gas-phase circulation pump (t) is reacted with a catalyst to separate it as a high-boiling compound, and the gas phase in the reaction tank is extracted using a gas-phase circulation pump. For example, there is a method of extracting (t) from the reaction tank and separating it by distillation.

  Specific examples of the by-product low boiling point compound (t) having a boiling point of 150 ° C. or less at a pressure of 0.1 MPa include formaldehyde (boiling point−19 ° C.), acetaldehyde (boiling point 20 ° C.), propionaldehyde (boiling point 48 ° C.), and allyl alcohol. And compounds having 0 to 2 mol of AO added thereto. (T) is often generated in an amount of 0.0001 to 10% by weight based on the weight of the polyoxyalkylene polyol (S) when AO is added.

  When AO is added to the active hydrogen-containing compound (J), the active hydrogen-containing compound (J), AO, and the catalyst (C) may be charged together and reacted, or the active hydrogen-containing compound ( A) may be dropped to react with the mixture of J) and catalyst (C), or AO and the catalyst (C) may be dropped to react with the active hydrogen-containing compound (J). From the viewpoint of controlling the reaction temperature, AO is dropped into a mixture of the active hydrogen-containing compound (J) and the catalyst (C), or AO and the catalyst (C) are dropped into the active hydrogen-containing compound (J). Is preferred.

  The reaction temperature for adding AO to the active hydrogen-containing compound (J) is preferably 0 ° C to 250 ° C, more preferably 20 ° C to 180 ° C.

  The produced polyoxyalkylene polyol (S) contains the catalyst (C), and the decomposition and / or removal treatment of the catalyst (C) is carried out as necessary depending on its use.

  As a decomposition method, there is a method of adding water and / or an alcohol compound. As the alcohol compound, the aforementioned alcohol and / or phenol can be used. In the decomposition, the decomposition temperature is preferably 10 to 180 ° C, more preferably 80 to 150 ° C. The decomposition may be performed in a sealed state, may be performed while exhausting by connecting to a vacuum source, or may be performed while continuously adding water or an alcohol compound. Water or alcohol to be added may be added in a liquid state, or may be added in a vapor or solid state. The amount of water and / or alcohol compound used is preferably 0.1 to 100% by weight, more preferably 1 to 20% by weight, based on the weight of the addition product.

  As a removing method, any known method may be used. For example, hydrotalcite-based adsorbents {KYOWARD 500, KYOWARD 1000, KYOWARD 2000 etc. (all manufactured by Kyowa Chemical Industry Co., Ltd.)} and filter aids such as diatomaceous earth {Radiolite 600, Radiolite 800 and Radiolite 900 (Both manufactured by Showa Chemical Co., Ltd.)} and the like can be used. The filtration may be either pressure filtration or vacuum filtration, but pressure filtration is preferred because it is easy to prevent oxygen contamination. The material of the filter is not particularly limited. For example, paper, polypropylene, polytetrafluoroethylene, polyester, polyphenylene sulfide, acrylic, and meta-aramid are exemplified, and paper is preferable. The retained particle diameter of the filter is preferably 0.1 to 10 μm, more preferably 1 to 5 μm.

  Even if the catalyst (C) remains in the polyoxyalkylene polyol (S), the reactivity of the polyol and isocyanate in the subsequent urethanization reaction is greatly adversely affected as compared with the conventional alkaline catalyst. Absent. However, it is preferable to decompose and / or remove the remaining catalyst from the viewpoint of preventing coloring of the urethane foam.

The method for producing a flexible polyurethane foam of the present invention comprises reacting a polyol component (A) and an organic polyisocyanate component (B) in the presence of a foaming agent (C) and a urethanization catalyst (D) to produce a flexible polyurethane slab foam. In production, the polyol component contains the polyoxyalkylene polyol (S), and the organic polyisocyanate component (B) contains an aliphatic isocyanate and / or an alicyclic isocyanate.
That is, the polyoxyalkylene polyol polyol (S) is used as at least a part of the polyol component (A).

The use of (S) as at least a part of the polyol component includes the use of a polymer alcohol (W) obtained by polymerizing the vinyl monomer (g) in (S).
The polymer alcohol (W) is a polymer alcohol in which polymer particles (P) are dispersed in (S).
The polymer alcohol (W) can be produced by polymerizing the vinyl monomer (g) in (S) by a known method. For example, in (S), the vinyl monomer (g) is polymerized in the presence of a radical polymerization initiator, and the obtained polymer (g) is stably dispersed. Specific examples of the polymerization method include those described in US Pat. No. 3,383,351 and Japanese Examined Patent Publication No. 39-25737.
(G) is preferably styrene and / or acrylonitrile.

In the present invention, the polyol component (A) may contain an active hydrogen component (s) other than the polyoxyalkylene polyol (S). Examples of (s) include polyols other than (S) and mono Examples include all, amine, and a mixture thereof.
Examples of polyols other than (S) include polyether polyols, polyester polyols, and other polyols.

  Among the active hydrogen components (s), the polyether polyol is an AO adduct of an active hydrogen-containing compound, and includes those other than (S).

Among (s), examples of the polyester polyol include the following (1) to (5).
(1) Esterified product of polyhydric alcohol and polycarboxylic acid or ester-forming derivative thereof Polyhydric alcohol is dihydric alcohol (ethylene glycol, diethylene glycol, propylene glycol, 1,3- and 1,4-butanediol, 1 , 6-hexanediol and neopentyl glycol), polyether polyol (preferably diol), trihydric or higher polyhydric alcohol (such as glycerin and trimethylolpropane), and mixtures thereof. Examples of ester-forming derivatives of polycarboxylic acids include acid anhydrides and lower alkyl (alkyl group having 1 to 4 carbon atoms) esters. Examples of the polycarboxylic acid or its ester-forming derivative include adipic acid, sebacic acid, maleic anhydride, phthalic anhydride, and dimethyl terephthalate.
(2) Condensation reaction product with carboxylic anhydride and AO (3) AO (EO, PO, etc.) adduct of (1) and (2) above (4) Polylactone polyol: For example, polyhydric alcohol as an initiator Those obtained by ring-opening polymerization of a lactone (such as ε-caprolactone).
(5) Polycarbonate polyol: For example, a reaction product of the polyhydric alcohol and alkylene carbonate.

Of the other polyols and monools in (s), polydiene polyols such as polybutadiene polyol and hydrogenated products thereof; acrylic polyols, JP-A 58-57413 and JP-A 58-57414, etc. Hydroxyl group-containing vinyl polymers described in 1; natural fat polyols such as castor oil; modified natural fat polyols such as castor oil modified products (for example, polyhydric alcohol transesterification products and hydrogenated products); international publication WO 98/44016 Terminal-radically polymerizable functional group-containing active hydrogen compounds (including monools) described in the above publication; modified polyols obtained by combining polyether polyols with alkylene dihalides such as methylene dihalide to increase the molecular weight; polyethers OH-terminated prepolymers of polyols; the polyhydric alcohols described above; It is.
Among (s), examples of the amine include those described above.

  Of the active hydrogen components (s), polyether polyols are preferable from the viewpoint of productivity.

  In the present invention, the content (% by weight) of the polyoxyalkylene polyol (S) is preferably from 30 to 100, more preferably from the viewpoint of the mechanical properties of the flexible polyurethane slab foam, based on the weight of the polyol component (A). Is from 32 to 95, more preferably from 37 to 90, particularly preferably from 46 to 85.

  The hydroxyl value of the polyol component (A) is preferably 20 to 100 mgKOH / g, more preferably 25 to 90 mgKOH / g, and particularly preferably 30 to 60 mgKOH / g.

  The organic polyisocyanate component (B) contains an aliphatic isocyanate and / or an alicyclic isocyanate. As the aliphatic isocyanate and / or alicyclic isocyanate, those used for polyurethane production can be used. Examples of such isocyanates include aliphatic polyisocyanates, alicyclic polyisocyanates, and modified products thereof (for example, urethane group, carbodiimide group, allophanate group, urea group, burette group, isocyanurate group, or oxazolidone group-containing modification). And a mixture of two or more thereof.

  Examples of the aliphatic isocyanate include aliphatic diisocyanates having 6 to 10 carbon atoms (excluding carbon in the NCO group; the same as the following isocyanates). Specific examples include 1,6-hexamethylene diisocyanate and lysine diisocyanate.

  Examples of the alicyclic polyisocyanate include alicyclic diisocyanates having 6 to 16 carbon atoms. Specific examples include isophorone diisocyanate (IPDI), 4,4'-dicyclohexylmethane diisocyanate, norbornane diisocyanate, and the like.

  Isocyanates other than aliphatic isocyanates and / or alicyclic isocyanates may be used, and known ones used for the production of polyurethane foams can be used.

  In the method for producing a flexible polyurethane foam of the present invention, the content (% by weight) of aliphatic isocyanate and / or alicyclic isocyanate is the weight of the organic polyisocyanate component (B) from the viewpoint of yellowing of the flexible polyurethane slab foam. Is 99.9 to 100%, more preferably 99.95 to 100% by weight, and still more preferably 99.99 to 100% by weight.

In the method for producing a flexible polyurethane slab foam of the present invention, (A) and (B) are reacted in the presence of the foaming agent (C).
As the foaming agent (C), known foaming agents can be used, and examples thereof include water, hydrogen atom-containing halogenated hydrocarbons, low boiling point hydrocarbons, and liquefied carbon dioxide gas, and two or more kinds may be used in combination. .
Specific examples of the hydrogen atom-containing halogenated hydrocarbon include methylene chloride, HCFC (hydrochlorofluorocarbon) (for example, HCFC-123 and HCFC-141b); HFC (hydrofluorocarbon) (for example, HFC-245fa and HFC-365mfc), etc. Is mentioned.
The low boiling point hydrocarbon is a hydrocarbon having a boiling point of −5 to 70 ° C., and specific examples thereof include butane, pentane, and cyclopentane.

When the foaming agent is water, the amount of the foaming agent (C) used relative to 100 parts of the polyol component (A) is preferably 0.1 to 30 parts, and more preferably 1 to 20 parts. In the case of a hydrogen atom-containing halogenated hydrocarbon, it is preferably 50 parts or less, more preferably 10 to 45 parts. In the case of a low boiling point hydrocarbon, the amount is preferably 40 parts or less, more preferably 10 to 30 parts. In the case of liquefied carbon dioxide, it is preferably 30 parts or less, more preferably 1 to 25 parts.
In addition, in the above and the following, a part means a weight part.

Moreover, in the manufacturing method of the flexible polyurethane slab foam of this invention, (A) and (B) are made to react in presence of a urethanization catalyst (D). As a urethanization catalyst, a well-known catalyst can be used, for example, an amine catalyst, a metal catalyst, etc. are mentioned, You may use 2 or more types together.
Specific examples of the amine catalyst include triethylenediamine, N-ethylmorpholine, diethylethanolamine, N, N, N ′, N′-tetramethylhexamethylenediamine, tetramethylethylenediamine, diaminobicyclooctane, 1,2-dimethylimidazole, Examples include 1-methylimidazole and 1,8-diazabicyclo- [5,4,0] -undecene-7.
Examples of the metal catalyst include an organic tin catalyst and an organic lead catalyst. Specific examples of the organic tin catalyst include stannous octylate, dibutyl dilaurate, and tetraphenyltin. Specific examples of the organic lead catalyst include lead stannic octylate.

The content of the amine catalyst used as the urethanization catalyst (D) is preferably 10% by weight or less based on the weight of the polyol component (A) from the viewpoint of reducing the odor of the flexible polyurethane slab foam, and more preferably 0.8%. 2 to 5% by weight.
The content of the metal catalyst used as the urethanization catalyst (D) is preferably 0.01 to 5% by weight, more preferably 0.2 to 3% by weight, based on the weight of the polyol component (A).

  In the method for producing a flexible polyurethane slab foam of the present invention, if necessary, a foam stabilizer (dimethylsiloxane, polyether-modified dimethylsiloxane, etc.), a colorant (dye and pigment), a plasticizer (phthalate ester and adipine) Acid esters, etc.), organic fillers (such as synthetic short fibers, hollow microspheres made of thermoplastic or thermosetting resins), flame retardants (such as phosphates and halogenated phosphates), anti-aging agents (triazoles and benzophenones) Etc.) and antioxidants (such as hindered phenols and hindered amines) can be reacted in the presence of known additives.

  Regarding the usage-amount of these additives with respect to 100 parts of polyol components (A), the foam stabilizer is preferably 10 parts or less, more preferably 0.5 to 5 parts. The colorant is preferably 1 part or less. The plasticizer is preferably 10 parts or less, more preferably 5 parts or less. The organic filler is preferably 50 parts or less, more preferably 30 parts or less. The flame retardant is preferably 30 parts or less, more preferably 5 to 20 parts. The anti-aging agent is preferably 1 part or less, more preferably 0.01 to 0.5 part. The antioxidant is preferably 1 part or less, and more preferably 0.01 to 0.5 part. The total amount of additives used is preferably 50 parts or less, more preferably 0.2 to 30 parts.

  In the method for producing a flexible polyurethane slab foam of the present invention, the isocyanate index (NCO INDEX) [(NCO group / active hydrogen atom-containing group) equivalent ratio × 100] is preferably 80 to 150, more preferably 85 to 135, Especially preferably, it is 90-130.

Moreover, the reaction conditions of (A) and (B) may be known conditions that are usually used.
For example, using a polyurethane low pressure or high pressure injection foaming machine or a stirrer, a predetermined amount of the polyol composition (A), the foaming agent (C), the urethanization catalyst (D), and if necessary, are mixed. Subsequently, this mixture and polyisocyanate (B) are rapidly mixed. The obtained mixed liquid is discharged and foamed in a box (made of metal or resin) having an open top or on a belt conveyor. Let stand for a predetermined time and cure to obtain a flexible polyurethane slab foam.

  EXAMPLES Hereinafter, although an Example demonstrates this invention further, this invention is not limited by this.

Production Example 1
As in the embodiment shown in FIG. 2, a stainless steel autoclave as a reaction vessel (1) with a stirring device having a capacity of 2500 ml, a temperature control device, a raw material supply line (5), and a distillation column (3) (the number of theoretical plates) 50 stages, a stainless steel cylindrical tube, an inner diameter of 5.5 cm, and a length of 3 m) were connected by circulation lines (6) and (8).
After charging 400 g of glycerin PO adduct (hydroxyl value 280) (GA-1) and 0.09 g of tris (pentafluorophenyl) borane into the reaction tank (1), the reaction tank (1) and the circulation line (6) The inside of (8) was depressurized to 0.005 MPa. While controlling PO so that the reaction temperature is maintained at 50 to 60 ° C. through the raw material supply line (5), the gas phase in the reaction tank (1) is reduced to 5 L / L using a diaphragm pump. It was made to circulate in order of reaction tank (1)-> circulation line (6)-> distillation tower (3)-> circulation line (8)-> reaction tank (1) with the flow rate of min. By-product low-boiling compounds were separated from PO in the distillation column (3) and removed from the system. The separated by-product low-boiling compound was extracted from the bottom line (4) of the distillation column (3). When the amount of the liquid in the reaction tank (1) reaches 2,000 ml, PO charging is stopped, the gas phase circulation is terminated, aging is performed at 70 ° C. for 4 hours, 200 g of water is added, and heating is performed at 130 to 140 ° C. for 1 hour. did. Thereafter, water was distilled off at atmospheric pressure over 2 hours, and then the remaining water was distilled off under reduced pressure over 3 hours while maintaining the pressure at 30 to 50 torr while passing steam, and a liquid glycerin PO adduct ( S-1) was obtained.
The glycerin PO adduct used as a raw material was synthesized by a known method, that is, after adding a predetermined amount of PO to glycerin using potassium hydroxide as a catalyst, water and synthetic silicate [ Product name “KYOWARD 600”, manufactured by Kyowa Chemical Co., Ltd., and so on. ] Is added, followed by heat treatment, followed by filtration and dehydration under reduced pressure.

Production Example 2
As in the embodiment shown in FIG. 3, a stainless steel autoclave as a reaction tank (1) with a capacity of 2,500 ml of a stirring device, a temperature control device, a raw material supply line (5), and magnesium oxide (granule, diameter 2 to 2). Reaction tower (2) packed with 400 g of 0.1 mm) (stainless steel cylindrical tube, inner diameter 5.5 cm, two lengths of 30 cm used) and distillation tower (3) (theoretical plate number of 30, stainless steel cylindrical tube, inner diameter 5.5 cm and a length of 2 m) were connected by circulation lines (6), (7) and (8).
After charging 666 g of glycerin PO adduct (hydroxyl value 168) (GA-2) and 0.09 g of tris (pentafluorophenyl) borane in the reaction tank (1), the reaction tank (1) and the reaction tower (2) And the inside of the circulation lines (6), (7), (8) was depressurized to 0.005 MPa. While controlling PO so that the reaction temperature is maintained at 50 to 60 ° C. through the raw material supply line (5), the gas phase in the reaction tank (1) is reduced to 5 L / L using a diaphragm pump. At a flow rate of min, circulate in the order of reaction tank (1) → circulation line (6) → reaction tower (2) → circulation line (7) → distillation tower (3) → circulation line (8) → reaction tank (1). It was. While controlling the reaction tower (2) at 75 ° C. and 0.08 to 0.15 MPa, the by-product low-boiling compound is continuously brought into contact with magnesium oxide to form a high-boiling compound. In the distillation tower (3) It was removed from the system by separating from PO. The separated high boiling point compound was extracted from the bottom line (4) of the distillation column (3). When the amount of the liquid in the reaction tank (1) reaches 2,000 ml, PO charging is stopped, the gas phase circulation is terminated, aging is performed at 70 ° C. for 4 hours, 200 g of water is added, and heating is performed at 130 to 140 ° C. for 1 hour. did. Thereafter, water was distilled off at atmospheric pressure over 2 hours, and then the remaining water was distilled off under reduced pressure over 3 hours while maintaining the pressure at 30 to 50 torr while passing steam, and a liquid glycerin PO adduct ( S-2) was obtained.

Production Example 3
As in the embodiment shown in FIG. 4, a vacuum line (10) was connected to a stainless steel autoclave as a reaction tank (1) with a 2500 ml stirring device, a temperature control device, and a raw material supply line (5). After charging 400 g of (GA-1) and 0.09 g of tris (pentafluorophenyl) borane into the reaction tank (1), PO is maintained at a reaction temperature of 50 to 60 ° C. through the raw material supply line (5). It was thrown in while controlling. However, PO was charged over 10 minutes, and then the pressure was reduced (0.01 MPa) from the pressure reduction line (10), and the process of distilling off the low-boiling volatile components for 15 minutes was repeated 20 times. At the time when the amount of liquid in the reaction tank (1) was 2,000 ml, the PO was stopped, aged at 70 ° C. for 4 hours, 200 g of water was added, and the mixture was heated at 130 to 140 ° C. for 1 hour. Thereafter, water was distilled off at atmospheric pressure over 2 hours, and then the remaining water was distilled off under reduced pressure over 3 hours while maintaining the pressure at 30 to 50 torr while passing steam, and a liquid glycerin PO adduct ( S-3) was obtained.

Production Example 4
A glycerin PO adduct (hydroxyl value 168) was synthesized in the same manner as in Production Example 2 except that glycerin PO adduct (hydroxyl value 280) 240 g was used instead of 666 g. S-4) was obtained.

Comparative production example 1
As shown in FIG. 5, 80 g of glycerin and 4 g of cesium hydroxide are charged into a stainless steel autoclave as a reaction tank (1) with a 2500 ml stirring device, a temperature control device, and a raw material supply line (5). Thereafter, PO was added through the raw material supply line (5) while controlling the reaction temperature so as to maintain 90 to 100 ° C. However, PO was continuously introduced over 6 hours. After the reaction vessel (1) was charged until the amount of liquid in the reaction vessel reached 2,000 ml, it was aged at 100 ° C. for 3 hours. Next, 30 g of synthetic silicate and 40 g of water were added and treated at 90 ° C. for 1 hour. After removing from the reaction tank (1), it was filtered through a 1 micron filter and dehydrated for 2 hours to obtain a liquid glycerin PO adduct. After charging 1,530 g of the obtained glycerin PO adduct and 0.09 g of tris (pentafluorophenyl) borane to the reaction tank (1) again, PO was reacted at a reaction temperature of 70 to 80 ° C. through the raw material supply line (5). It was added over 3 hours while controlling to keep. The reaction vessel (1) was charged until the amount of the liquid in the reaction vessel (2,000) reached 2,000 ml and aged at 70 ° C. for 3 hours. Subsequently, 200 g of water was added and heated at 130 to 140 ° C. for 1 hour. Thereafter, water was distilled off at atmospheric pressure over 2 hours, and then the remaining water was distilled off under reduced pressure over 3 hours while maintaining the pressure at 30 to 50 torr while passing steam, and a liquid glycerin PO adduct ( n-1) was obtained.

Comparative production example 2
As in the embodiment shown in FIG. 5, 61 g of glycerin and 4.0 g of potassium hydroxide were added to a stainless steel autoclave as a reaction tank (1) with a 2500 ml stirring device, a temperature control device, and a raw material supply line (5). Then, PO was added through the raw material supply line (5) while controlling the reaction temperature so as to maintain 90 to 100 ° C. However, PO was continuously introduced over 6 hours. After the reaction vessel (1) was charged until the amount of liquid in the reaction vessel reached 1,860 ml, it was aged at 100 ° C. for 3 hours. Subsequently, 140 g of EO was added through the raw material supply line (5) while maintaining the reaction temperature at 130 to 140 ° C. over 2 hours, followed by aging for 2 hours. After cooling to 90 ° C., 12 g of synthetic silicate and 40 g of water were added and treated for 1 hour. After taking out from reaction tank (1), it filtered using 1 micron filter paper, and it dehydrated under reduced pressure, and obtained liquid glycerin POEO adduct (n-2).

Comparative production example 3
The glycerin PO adduct (n- 3) was obtained.

The analysis results of the polyoxyalkylene polyols (S-1) to (S-4) of Production Examples 1 to 3 are shown in Table 1.
The verification result about Formula 1 [following, Formula (4)] of patent document 4 (patent 3688667 gazette) which the polyoxyalkylene polyol which is a prior art is satisfied was also described.

y ≦ (1.9 × 10 ⁻⁸ ) w ² (4)

Formula (4) is a formula representing the relationship between the hydroxyl equivalent weight w and the total degree of unsaturation y, and corresponds to the formulas (1) and (3) in the present invention, that is, the hydroxyl value x of (S) and the total unsaturation. When transformed into the relational expression of the saturation y, the mathematical expression (4 ′) is obtained.

y ≦ 60 × x ⁻² (4 ′)

  Table 2 shows the analysis results of the polyoxyalkylene polyols (n-1) to (n-3) of Comparative Production Examples 1 to 3. The verification results for the above formula (4) are also described.

The measurement method of the hydroxyl value and total unsaturation degree of the produced polyoxyalkylene polyol and these units are shown below.
Hydroxyl value: Conforms to JIS K1557, unit is mgKOH / g
Total unsaturation: Conforms to JIS K1557, unit is meq / g

In Tables 1 and 2, the hydroxyl equivalent w is defined by the following mathematical formula (5). Specifically, the hydroxyl value x is measured and determined by 56100 / x.

(Hydroxyl equivalent weight) = (Number average molecular weight) / (Average number of hydroxyl groups) (5)

Of the production examples and comparative production examples in Tables 1 and 2, those having an EO content z of 0 are shown in a graph in FIG. The axes, symbols, and curves of the graph shown in FIG. 1 will be described below.
X axis: hydroxyl value x of polyoxyalkylene polyol
Y axis: Total unsaturation y of polyoxyalkylene polyol y
○ mark: represents a polyoxyalkylene polyol described in the production examples of the present invention and does not contain EO at the terminal.
X mark: It is a polyoxyalkylene polyol described in the comparative production example, and represents one containing no EO at the terminal.
Curve 1: represents Formula 1 of the present invention.
Curve 2: represents Formula 3 of the present invention.
Curve 3: represents Formula 1 (Formula 4 ′) described in Patent Document 4 (Patent No. 3688667) relating to the polyoxyalkylene polyol which is the prior art.

Examples 1-6 and Comparative Examples 1-3
In accordance with the foaming formulation shown in Table 3, a polyurethane slab foam was foamed under the following foaming conditions, and the properties of the polyurethane slab foam were measured after standing overnight. The measured values of physical properties are also shown in Table 3, respectively.

(Foaming conditions)
Foam box size: 30 cm x 30 cm x 80 (height) cm Empty box Foam box material: wood Face material: Kraft paper (A kraft paper bag was set inside the box.)
Mixing method: Hand mixing

The polyurethane slab foam raw materials used in the examples and comparative examples are as follows.
1. Urethane catalyst (U)
(1) Urethane catalyst (U-1): “DABCO-33LV” (33% by weight dipropylene glycol solution of triethylenediamine) manufactured by Air Products Japan Co., Ltd.
(2) Urethane catalyst (U-2): “Neostan U-100” (dibutyltin dilaurate) manufactured by Nitto Kasei Co., Ltd.
(3) Urethane catalyst (U-3): “U-CAT1102” (DBN-octylate) manufactured by San Apro Co., Ltd.

2. Foaming agent (F)
Foaming agent (F-1): water

3. Foam stabilizer (D1)
Foam stabilizer (D1-1): “SH-190” (silicone oil) manufactured by Toray Dow Corning Co., Ltd.

4). Isocyanate Aliphatic isocyanate: “VESTANAT IPDI” manufactured by EVONIK

The measurement method and unit of foam physical properties are shown below.
1. Core density: Conforms to JIS K6400, unit is kg / m ³
2. Hardness (25% ILD): Conforms to JIS K6400, unit is N / 314 cm ²
3. Tensile strength: Conforms to JIS K6400, unit is kgf / cm ²
4). Elongation: Conforms to JIS K6400, unit is%
5. Tear strength: Conforms to JIS K6400, unit is kgf / cm
6). Compression residual strain ratio: Conforms to JIS K6400, unit is%
7). Humid heat compression residual strain rate: Conforms to JIS K6400, unit is%
8). Rebound resilience: Conforms to JIS K6400, unit is%
9. Curability: Determined by peeling the face material from the foam 30 minutes after foaming <Evaluation criteria>
○: Foam surface layer part does not peel off from foam block ×: Foam surface layer part peels off from foam block Ultraviolet discoloration: UV light was continuously irradiated for 40 hours with a fade meter tester, and the color difference (ΔYI) was compared.

In Table 3, the foam properties of the polyurethane foams of Examples 1 to 6 are improved as compared with the polyurethane foams of Comparative Examples 1 to 3.
In particular, even when compared with a polyurethane foam obtained by using a polyoxyalkylene polyol (Comparative Example 1) which is a conventional technique that satisfies Formula 1 described in Japanese Patent No. 3688667, the foam physical properties of the polyurethane foam obtained by the present invention are as follows. It has improved.
Furthermore, the polyurethane foams of Examples 1 to 6 have better curability and yellowing than the polyurethane foams of Comparative Examples 1 to 3.

  The flexible polyurethane slab foam obtained by the production method of the present invention is characterized by being excellent in mechanical properties, yellowing, and the like as compared with a conventional polyurethane slab foam. For these reasons, the flexible polyurethane slab foam obtained by the production method of the present invention can be widely used for furniture, bedding mattresses, automobile seat cushions, clothing, and the like, and is extremely useful.

1: Reaction tank 2: Reaction tower 3: Distillation tower 4: Bottom line 5: Raw material supply line 6: Circulation line 7: Circulation line 8: Circulation line 9: Decompression line

Claims (10)

In the method for producing a flexible polyurethane slab foam obtained by reacting a polyol component (A) and an organic polyisocyanate component (B) in the presence of a foaming agent (C) and a urethanization catalyst (D), the polyol component (A) Contains the following polyoxyalkylene polyol (S), and the organic polyisocyanate component (B) contains an aliphatic isocyanate and / or an alicyclic isocyanate (excluding bis (isocyanatomethyl) cyclohexane). Form manufacturing method.
Polyoxyalkylene polyol (S): an alkylene oxide adduct of an active hydrogen-containing compound (H), wherein 40% or more of the hydroxyl groups located at the terminals are primary hydroxyl group-containing groups represented by the following general formula (1) Yes, a polyoxyalkylene polyol in which the hydroxyl value x, the total unsaturation degree y, and the ethylene oxide content z satisfy the relationship of the formula (1).

[In General Formula (1), R ¹ represents a hydrogen atom, an alkyl group having 1 to 12 carbon atoms, a cycloalkyl group, or a phenyl group. The C1-C12 alkyl group, cycloalkyl group or phenyl group may be substituted with a halogen atom or an aryl group. ]
y ≦ 28.3 × x ⁻² × (100−z) / 100 (1)
[In Formula (1), x is a hydroxyl value represented by the unit mgKOH / g, and y is a unit meq / g.
The total degree of unsaturation represented by z is the ethylene oxide content based on the weight of (S), and is 0 to 50% by weight. ] The method for producing a flexible polyurethane slab foam according to claim 1, wherein the content of the aliphatic isocyanate is 99.9 to 100% by weight based on the weight of the organic polyisocyanate component (B). The method for producing a flexible polyurethane slab foam according to claim 1 or 2, wherein the polyoxyalkylene polyol (S) is represented by the following general formula (2).

[In General Formula (2), R ² is an m-valent group obtained by removing m active hydrogens from the active hydrogen-containing compound (H); Z is an alkylene group or cycloalkylene group having 2 to 12 carbon atoms; These groups may be substituted with a halogen atom or an aryl group. When Z is an alkylene group having 2 to 12 carbon atoms, it is represented by the following general formula (3) or (4); A is an alkylene group or cycloalkylene group having 3 to 12 carbon atoms, and these groups are It may be substituted with a halogen atom or an aryl group. When A is an alkylene group having 2 to 12 carbon atoms, it is represented by the following general formula (5) or (6). When there are a plurality of Z or A, each may be the same or different; m is an integer of 2 to 100; p is an integer of 0 or 1 to 200, q is an integer of 1 to 200; It is an integer from 1 to 200. ]

[In General Formulas (3) and (4), R ³ represents a hydrogen atom, an alkyl group having 1 to 10 carbon atoms, a cycloalkyl group, or a phenyl group, and an alkyl group, cycloalkyl group, or phenyl having 1 to 10 carbon atoms. The group may be substituted with a halogen atom or an aryl group. In general formulas (5) and (6), R ⁴ represents an alkyl group having 1 to 10 carbon atoms, a cycloalkyl group, or a phenyl group, and these groups may be substituted with a halogen atom or an aryl group. ] The method for producing a flexible polyurethane slab foam according to claim 3, wherein r is 0 in the general formula (2). The soft part according to claim 3 or 4, wherein 40% or more of the structure of A located at the terminal in the part of (AO) _{q in} the general formula (2) is a structure represented by the general formula (6). A method for producing polyurethane slab foam. In general formula (2), the-(AO) q- moiety is represented by a compound represented by the following general formula (7-1), a compound represented by (7-2), and (7-3). 6. The method according to claim 3, obtained by ring-opening addition polymerization of an alkylene oxide having 3 to 12 carbon atoms in the presence of at least one catalyst (C) selected from the group consisting of the following compounds: A method for producing a flexible polyurethane slab foam.

[In General Formula (7-1), (7-2) or (7-3), X represents a boron atom or an aluminum atom, respectively. F is a fluorine atom. R ⁵ represents a (substituted) phenyl group represented by the following general formula (8) or a tertiary alkyl group represented by the following general formula (9), which may be the same or different. ]

[In General Formula (8), Y represents a hydrogen atom, a C1-C4 alkyl group, a halogen atom, a nitro group, or a cyano group. K represents a number from 0 to 5, and when k is 2 or more, the plurality of Y may be the same or different from each other; ]

[In General Formula (9), R ⁶ , R ⁷ or R ⁸ each independently represents an alkyl group having 1 to 4 carbon atoms. ] The method for producing a flexible polyurethane slab foam according to any one of claims 1 to 6, wherein the hydroxyl value x of the polyoxyalkylene polyol (S) is 10 to 115 mgKOH / g. The soft polyurethane slab according to any one of claims 1 to 7, wherein 60% or more of the hydroxyl group-containing group located at the terminal of the polyoxyalkylene polyol (S) is a primary hydroxyl group-containing group represented by the general formula (1). Form manufacturing method. The method for producing a flexible polyurethane slab foam according to any one of claims 1 to 8, wherein the content of the polyoxyalkylene polyol (S) is 30 to 100% by weight based on the weight of the polyol component (A). The method for producing a flexible polyurethane slab foam according to any one of claims 1 to 9, wherein the polyol component (A) has a hydroxyl value of 20 to 100 mgKOH / g.

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