JP5873653B2 - Strength improver for polyurethane foam production - Google Patents

Description

  The present invention relates to a strength improver for producing polyurethane foam.

In recent years, environmental considerations and cost reduction demands are strong, and there is a demand for lower density polyurethane foam. For example, in a vehicle application, a low density of flexible polyurethane foam is required to meet fuel efficiency regulations. In addition, in the use of heat insulating materials, low density is desired for cost reduction and environmental consideration.
At present, the amount of water used as a foaming agent tends to increase to meet the demand for lower density. Increasing the amount of water used (Non-Patent Document 1, etc.) can increase the amount of carbon dioxide generated during foam production and is effective in reducing the density of flexible polyurethane foam. As the hardness decreases, the foam hardness decreases. Specific techniques for improving the hardness of polyurethane foam include a method of increasing the amount of the crosslinking agent used (Non-patent Document 1) and a method of dispersing a polymer in a resin (Patent Document 1). In such a method, problems such as insufficient mechanical properties such as elongation and tensile strength of the flexible polyurethane foam remain, and a flexible polyurethane foam capable of improving the hardness and maintaining the mechanical properties is desired. .
It has also been proposed to use methylene chloride as a foaming agent together with water for reducing the density. However, methylene chloride is required to be used in a reduced amount from the viewpoint of environmental problems. Therefore, a method using monool or diol as a component of polyol has also been proposed. However, this method has a problem that other physical properties are impaired, such as an increase in compression set of the resulting foam (Patent Document 2).

JP-A-9-309937 JP-A-6-65346

Keiji Iwata, "Polyurethane Resin Handbook", Nikkan Kogyo, May 20, 1987, 1st Edition, 32 pages

  An object of the present invention is to provide a polyurethane foam-producing strength improver capable of producing a polyurethane foam having high mechanical properties (tensile strength, compressive strength), a polyurethane composition-producing polyol composition containing the strength improver, and It is to provide a method for producing a polyurethane foam using a strength improver or this polyol composition.

  As a result of intensive investigations to solve these problems, the inventors of the present invention have a specific structure, and the number average molecular weight is 250 to 800. The inventors have found that a polyurethane foam having mechanical properties (tensile strength, compressive strength) can be obtained, and reached the present invention.

That is, the first invention of the present invention is represented by the following general formula (I), which is a hydrogen atom (a) on an aromatic ring, adjacent to the carbon of the aromatic ring to which the hydrogen atom (a) is bonded. It is a strength improver (A) for producing polyurethane foam having two hydrogen atoms (a) in which carbonyl groups are bonded to two carbons in the molecule and having a number average molecular weight of 250 to 800.
[In the general formula (I), R1 represents a residue obtained by removing one active hydrogen from an active hydrogen-containing compound. A plurality of R1 may be the same or different. ; Y represents the residue remove | excluding the carboxyl group from trivalent or more aromatic polycarboxylic acid (C). The aromatic ring of Y is composed of carbon atoms. A is an integer satisfying 2 ≦ a ≦ (the number of aromatic ring substituents−2). Z represents a residue obtained by removing m active hydrogens from an active hydrogen-containing compound having a valence of at least m; At least one R1 and Z are different. M represents an integer of 1 or 2; ]

Moreover, 2nd invention of this invention is the polyol composition (H) for polyurethane foam manufacture containing the said intensity | strength improving agent (A) and polyol (P).
The third invention of the present invention is the presence of a foaming agent, a catalyst, and a foam stabilizer in the above strength improver (A) or the above polyol composition (H) and the organic polyisocyanate component (D). It is a manufacturing method of the polyurethane foam made to react below.

  When the strength improver for producing a polyurethane foam of the present invention is used, a polyurethane foam having high mechanical properties (tensile strength, compressive strength) can be obtained.

The strength improver for producing polyurethane foam of the present invention is represented by the following general formula (I), and is a hydrogen atom (a) on an aromatic ring, adjacent to the carbon of the aromatic ring to which the hydrogen atom (a) is bonded. In view of the handling of the strength improver and the mechanical properties (tensile strength, compressive strength) of the polyurethane foam, there are two hydrogen atoms (a) in which the carbonyl group is bonded to the two carbons.
The number average molecular weight of the strength improver (A) is 250 to 800 from the viewpoint of handling of the strength improver and mechanical properties (tensile strength, compressive strength) of the polyurethane foam produced using this strength improver. Yes, preferably 450 to 790, more preferably 550 to 780, and still more preferably 650 to 770.

  In general formula (I), R1 represents a residue obtained by removing one active hydrogen from an active hydrogen-containing compound. Examples of the active hydrogen-containing compound include a hydroxyl group-containing compound, an amino group-containing compound, a carboxyl group-containing compound, a thiol group-containing compound, and a phosphate compound; a compound having two or more active hydrogen-containing functional groups in the molecule. These active hydrogen-containing compounds can be used either alone or in combination. That is, the plurality of R1s may be the same or different.

Examples of the hydroxyl group-containing compound include monohydric alcohols, divalent to octavalent polyhydric alcohols, phenols and polyhydric phenols. Specifically, monohydric alcohols such as methanol, ethanol, butanol, octanol, benzyl alcohol, naphthylethanol; ethylene glycol, propylene glycol, 1,3 and 1,4-butanediol, 1,6-hexanediol, 1, Dihydric alcohols such as 10-decanediol, diethylene glycol, neopentyl glycol, cyclohexanediol, cyclohexanedimethanol, 1,4-bis (hydroxymethyl) cyclohexane and 1,4-bis (hydroxyethyl) benzene; glycerin and trimethylolpropane Trihydric alcohols such as pentaerythritol, sorbitol, mannitol, sorbitan, diglycerin, dipentaerythritol, sucrose, glucose, mannose, fructose, methyl 4- to 8-valent alcohols such as lucoside and derivatives thereof; phenol, phloroglucin, cresol, pyrogallol, catechol, hydroquinone, bisphenol A, bisphenol F, bisphenol S, 1-hydroxynaphthalene, 1, 3, 6 , 8-tetrahydroxynaphthalene, anthrol, phenols such as 1,4,5,8-tetrahydroxyanthracene and 1-hydroxypyrene; polybutadiene polyol; castor oil-based polyol; (co) heavy of hydroxyalkyl (meth) acrylate Examples thereof include polyfunctional polyols (for example, 2 to 15 functional groups) such as coalescence and polyvinyl alcohol, condensates of phenol and formaldehyde (novolaks), and polyphenols described in US Pat. No. 3,265,641.
(Meth) acrylate means methacrylate and / or acrylate, and the same applies hereinafter.

  Examples of the amino group-containing compound include amines, polyamines and amino alcohols. 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 the like.

  Examples of the carboxyl group-containing compound include aliphatic monocarboxylic acids such as acetic acid and propionic acid; aromatic monocarboxylic acids such as benzoic acid; aliphatic polycarboxylic acids such as succinic acid, fumaric acid, sebacic acid and adipic acid; phthalic acid , Isophthalic acid, terephthalic acid, trimellitic acid, naphthalene-1,4 dicarboxylic acid, naphthalene-2,3,6 tricarboxylic acid, pyromellitic acid, diphenic acid, 2,3-anthracene dicarboxylic acid, 2,3,6- Examples thereof include aromatic polycarboxylic acids such as anthracentricarboxylic acid and pyrene dicarboxylic acid; polycarboxylic acid polymers (functional group number: 2 to 15) such as (co) polymer of acrylic acid, and the like.

  Examples of the thiol group-containing compound include monofunctional phenylthiol, alkylthiol, and polythiol compounds. Examples of the polythiol 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.

  As the active hydrogen-containing compound, a compound having two or more active hydrogen-containing functional groups (hydroxyl group, amino group, carboxyl group, thiol group, phosphate group, etc.) in the molecule can also be used.

  Further, as the active hydrogen-containing compound, an alkylene oxide adduct of the active hydrogen-containing compound can also be used.

  Examples of the alkylene oxide (hereinafter abbreviated as AO) to be added to the active hydrogen-containing compound include AO having 2 to 6 carbon atoms such as ethylene oxide (hereinafter abbreviated as EO), 1,2-propylene oxide (hereinafter referred to as PO). Abbreviation), 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.

  Further, as the active hydrogen-containing compound, an active hydrogen-containing compound (polyester compound) obtained by a condensation reaction between the active hydrogen-containing compound and a polycarboxylic acid (aliphatic polycarboxylic acid or aromatic polycarboxylic acid) is used. Can do. In the condensation reaction, one type of active hydrogen-containing compound and polycarboxylic acid may be used, or two or more types may be used in combination.

The aliphatic polycarboxylic acid means a compound that satisfies the following (1) and (2).
(1) One molecule has two or more carboxyl groups.
(2) The carboxyl group is not directly bonded to the aromatic ring.

  Aliphatic polycarboxylic acids include succinic acid, adipic acid, sebacic acid, maleic acid and fumaric acid.

The aromatic polycarboxylic acid means a compound that satisfies the following (1) to (3).
(1) One molecule has one or more aromatic rings.
(2) The number of carboxyl groups in one molecule is 2 or more.
(3) The carboxyl group is directly bonded to the aromatic ring.

  Aromatic polycarboxylic acids include phthalic acid, isophthalic acid, terephthalic acid, 2,2'-bibenzyldicarboxylic acid, trimellitic acid, hemilitic acid, trimesic acid, pyromellitic acid and naphthalene-1,4 dicarboxylic acid, naphthalene Examples include aromatic polycarboxylic acids having 8 to 18 carbon atoms such as -2,3,6 tricarboxylic acid, diphenic acid, 2,3-anthracene dicarboxylic acid, 2,3,6-anthracentricarboxylic acid and pyrene dicarboxylic acid.

  From the viewpoint of handling the strength improver and improving the mechanical properties (elongation, tensile strength, compressive strength) of the polyurethane foam, the active hydrogen-containing compound R1 includes a hydroxyl group-containing compound, an amino group-containing compound, and addition of these AOs. And polyester compounds obtained by condensation reaction of active hydrogen-containing compounds and polycarboxylic acids, more preferably methanol, ethanol, butanol, ethylene glycol, propylene glycol, glycerin, pentaerythritol, sorbitol, sucrose, benzyl alcohol, Phenol, methylamine, dimethylamine, ethylamine, diethylamine, butylamine, dibutylamine, phenylamine, diphenylamine, their EO and / or PO adducts and their active hydrogen compounds and phthalic acid and / or Condensates of isophthalic acid is preferred.

  In general formula (I), Y represents the residue remove | excluding the carboxyl group from trivalent or more aromatic polycarboxylic acid (C). The aromatic ring of Y is composed of carbon atoms. The substituent of the aromatic ring may be a hydrogen atom or another substituent, but is a hydrogen atom (a) on the aromatic ring, and two carbons adjacent to the carbon of the aromatic ring to which the hydrogen atom (a) is bonded. The molecule has two hydrogen atoms (a) to which a carbonyl group is bonded.

  Other substituents are alkyl group, vinyl group, allyl group, cycloalkyl group, halogen atom, amino group, carbonyl group, carboxyl group, hydroxyl group, hydroxyamino group, nitro group, phosphino group, thio group, thiol group Aldehyde group, ether group, aryl group, amide group, cyano group, urea group, urethane group, sulfone group, ester group and azo group. From the viewpoint of improving mechanical properties (elongation, tensile strength, compressive strength) and cost, the other substituents are preferably an alkyl group, a vinyl group, an allyl group, an amino group, an amide group, a urethane group, and a urea group.

  Examples of the trivalent or higher-valent aromatic polycarboxylic acid (C) constituting Y include trimellitic acid, hemilitic acid, trimesic acid, and pyromellitic acid.

  From the viewpoint of handling the strength improver and improving the mechanical properties (tensile strength, tear strength, compressive strength) of polyurethane foam, (C) used for Y is preferably a monocyclic compound, more preferably trimellitic acid. And pyromellitic acid.

  A in the general formula (I) is an integer satisfying 2 ≦ a ≦ the number of aromatic ring substituents−2. The number of aromatic ring substituents is the number of substituents bonded to the carbon atoms constituting the aromatic ring. For example, in a monocyclic aromatic ring composed of 6 carbons, the number of aromatic ring substituents is 6, and a can be 2 to 4. When the aromatic ring is a monocyclic aromatic ring, a is preferably 2 or 3 from the viewpoint of improving mechanical properties (tensile strength, tear strength, compressive strength).

Z in the general formula (I) represents a residue obtained by removing m active hydrogens from an active hydrogen-containing compound having a valence of at least m. The active hydrogen-containing compound referred to here includes the active hydrogen-containing compound represented by R1 described above. However, the active hydrogen-containing compound represented by Z may be the same as a part of R1.
In general formula (I), m represents an integer of 1 or 2.
From the viewpoint of handling the strength improver and improving the mechanical properties (tensile strength, tear strength, compressive strength) of polyurethane foam, Z includes a hydroxyl group-containing compound, an amino group-containing compound, an AO adduct thereof, and these. It is preferable to use a condensate with a polycarboxylic acid.

The hydroxyl value (mgKOH / g) of the strength improver (A) for producing the polyurethane foam of the present invention is preferably from 0 to 700, more preferably from 0 to 650, from the viewpoints of handling (viscosity) and tensile strength during molding. Next, it is more preferably 0 to 600. In the present invention, the hydroxyl value is measured in accordance with JISK-1557.
Moreover, that the hydroxyl value of (A) is 0 means that none of R1, Y, and Z has a hydroxyl group in general formula (I).

  The polyol composition (H) for producing a polyurethane foam of the present invention comprises the above-mentioned strength improver (A) for producing a polyurethane foam and a polyol (P).

  Specific examples of the polyol (P) include known polyols such as the following polyhydric alcohols, polyether polyols, and polyester polyols, and those other than (A).

Examples of the polyhydric alcohol include a dihydric alcohol having 2 to 20 carbon atoms, a trihydric alcohol having 3 to 20 carbon atoms, and a 4 to 8 alcohol having 5 to 20 carbon atoms.
Examples of the dihydric alcohol having 2 to 20 carbon atoms include aliphatic diols (ethylene glycol, propylene glycol, 1,3- and 1,4-butanediol, 1,6-hexanediol, neopentyl glycol, etc.) and alicyclic Diols (cyclohexanediol and cyclohexanedimethanol etc.) are mentioned.
Examples of the trihydric alcohol having 3 to 20 carbon atoms include aliphatic triols (such as glycerin and trimethylolpropane).
Examples of the 4- to 8-valent polyhydric alcohol having 5 to 20 carbon atoms include aliphatic polyols (pentaerythritol, sorbitol, mannitol, sorbitan, diglycerin, dipentaerythritol and the like, and saccharides (sucrose, glucose, mannose, fructose, methyl). Glucoside and derivatives thereof).

  Examples of the polyether polyol include AO adducts of polyhydric alcohols. Examples of AO include the aforementioned AO, and PO, EO, and 1,2-butylene oxide are preferable from the viewpoint 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.

  Polyester polyols include polyhydric hydroxyl group-containing compounds (the above polyhydric alcohols and polyether polyols), aromatic polycarboxylic acids (such as those described above) and aliphatic polycarboxylic acids (such as those described above), and anhydrides thereof. Products and condensation reaction products of these lower alkyl (alkyl group having 1 to 4 carbon atoms) esters such as esters (phthalic anhydride and dimethyl terephthalate, etc.); And AO addition reaction products; these AO (EO, PO, etc.) addition reaction products; polylactone polyols {obtained by ring-opening polymerization of lactones (e.g., ε-caprolactone etc.) using the polyhydric alcohol as an initiator. And polycarbonate polyols (for example, the polyhydric alcohols and alkylene cars) Reactant) or the like and sulfonates and the like.

  Examples of other polyols other than these include polydiene polyols such as polymer polyols and polybutadiene polyols and hydrogenated products thereof; acrylic polyols, JP-A 58-57413 and JP-A 58-57414, etc. Hydroxyl group-containing vinyl polymers; natural oil polyols such as castor oil; modified natural oil polyols; and the like.

  The content of the strength improver (A) for polyurethane foam production based on the weight of the polyol composition (H) for polyurethane foam production is 0.1% by weight from the viewpoint of improving mechanical properties (elongation and tensile strength). The amount is preferably less than 100% by weight, more preferably 0.5 to 80% by weight, and particularly preferably 1.0 to 60% by weight. In the present invention, even when the polymer polyol to be used contains the strength improver (A), it is treated as if the polyol composition (H) contains (A).

  When the polyurethane foam to be produced is a flexible polyurethane foam, the hydroxyl value (mgKOH / g) of (H) is preferably from 5 to 200, more preferably from the viewpoint of handling of the polyol composition (H) and elongation properties of the resulting foam. Is 20-150. When the polyurethane foam to be produced is a rigid polyurethane foam, the hydroxyl value (mgKOH / g) of (H) is preferably 100 to 1000, more preferably from the viewpoint of handling of (H) and the compressive strength of the resulting foam. Is 150 to 800, more preferably 200 to 500.

  In producing the polyol composition (H) for producing polyurethane foam, any known method may be used as a method of mixing the strength improver (A) and the polyol (P).

In the polyurethane foam production method of the present invention, the polyurethane foam strength improver (A) or the polyurethane foam production polyol composition (H) and the organic polyisocyanate component (D) are reacted in the presence of a blowing agent and a catalyst. To form a polyurethane foam.
When (A) is used alone, that is, when (A) is not used in combination with polyol (P), (A) has a hydroxyl group, that is, in general formula (I), R1, Y, and Z Among these, it is preferable that any one or more have a hydroxyl group.

  As the organic polyisocyanate component (D), all organic polyisocyanates usually used in polyurethane foams can be used. Aromatic polyisocyanates, aliphatic polyisocyanates, alicyclic polyisocyanates, araliphatic polyisocyanates, these Modified products (urethane groups, carbodiimide groups, allophanate groups, urea groups, burette groups, isocyanurate groups, oxazolidone group-containing modified products, etc.) and mixtures of two or more of these.

  Aromatic polyisocyanates include aromatic diisocyanates having 6 to 16 carbon atoms (excluding carbons in NCO groups; the following polyisocyanates are also the same), aromatic triisocyanates having 6 to 20 carbon atoms, and crude products of these isocyanates. Thing etc. are mentioned. Specific examples include 1,3- and 1,4-phenylene diisocyanate, 2,4- and 2,6-tolylene diisocyanate (TDI), crude TDI, 2,4′- and 4,4′-diphenylmethane diisocyanate ( MDI), polymethylene polyphenylene polyisocyanate (crude MDI), naphthylene-1,5-diisocyanate, and triphenylmethane-4,4 ′, 4 ″ -triisocyanate.

  Examples of the aliphatic polyisocyanate include aliphatic diisocyanates having 6 to 10 carbon atoms. Specific examples include 1,6-hexamethylene diisocyanate, 2,2,4-trimethylhexamethylene diisocyanate, lysine diisocyanate, and the like.

  Examples of the alicyclic polyisocyanate include alicyclic diisocyanates having 6 to 16 carbon atoms. Specific examples include isophorone diisocyanate, 4,4'-dicyclohexylmethane diisocyanate, 1,4-cyclohexane diisocyanate, and norbornane diisocyanate.

Examples of the araliphatic isocyanate include araliphatic diisocyanates having 8 to 12 carbon atoms. Specific examples include xylylene diisocyanate and α, α, α ′, α′-tetramethylxylylene diisocyanate.
Specific examples of the modified polyisocyanate include carbodiimide-modified MDI.

  Among these, aromatic polyisocyanates are preferable from the viewpoints of reactivity and mechanical properties (tensile strength, tear strength, compressive strength) of polyurethane foam, and more preferably TDI, crude TDI, MDI, crude MDI and modified products of these isocyanates, particularly preferably TDI, MDI and crude MDI.

  Examples of the foaming agent include water, liquefied carbon dioxide, and low boiling point compounds having a boiling point of −5 to 70 ° C.

  Low boiling point compounds include hydrogen atom-containing halogenated hydrocarbons and low boiling point hydrocarbons. Specific examples of the hydrogen atom-containing halogenated hydrocarbon and low boiling point hydrocarbon include methylene chloride, HCFC (hydrochlorofluorocarbon) (HCFC-123, HCFC-141b, HCFC-142b, etc.); HFC (hydrofluorocarbon) (HFC- 152a, HFC-356mff, HFC-236ea, HFC-245ca, HFC-245fa and HFC-365mfc), butane, pentane and cyclopentane.

  Among these, from the viewpoint of moldability, water, liquefied carbon dioxide, methylene chloride, cyclopentane, HCFC-141b, HFC-134a, HFC-356mff, HFC-236ea, HFC-245ca, HFC-245fa, HFC-365mfc and It is preferable to use a mixture of two or more of these as a foaming agent.

Of the foaming agent, the amount of water used is the polyol component used in the production of urethane foam {strength improver for polyurethane foam production (A) and polyurethane foam production from the viewpoint of foam density during foam formation and suppression of scorch generation. The polyol composition (H)} is preferably 1.0 to 8.0 parts by weight, more preferably 1.5 to 7.0 parts by weight, based on 100 parts by weight. The amount of the low boiling point compound used is preferably 30 parts by weight or less, more preferably 5 to 25 parts by weight, with respect to 100 parts by weight of the polyol component, from the viewpoint of poor molding. The amount of liquefied carbon dioxide is preferably 30 parts or less, and more preferably 1 to 25 parts.
In addition, in the above and the following, a part means a weight part.

  As the catalyst, any catalyst that accelerates the urethanization reaction can be used. Tertiary amine {triethylenediamine, N-ethylmorpholine, diethylethanolamine, tetramethylethylenediamine, diaminobicyclooctane, 1,2-dimethylimidazole, 1 -Methylimidazole, 1,8-diazabicyclo- [5,4,0] -undecene-7, bis (N, N-dimethylamino-2-ethyl) ether and N, N, N ', N'-tetramethylhexa Methylenediamine and the like} and / or metal carboxylates (potassium acetate, potassium octylate, stannous octylate, dibutylstannic dilaurate, lead octylate, etc.). The amount of the catalyst used is 0.01 to 5.0 parts by weight with respect to 100 parts by weight of the polyol component used in the production of urethane foam from the viewpoint of improving mechanical properties (tensile strength, tear strength, compressive strength). Is more preferable, and 0.1 to 2.0 parts by weight is more preferable.

  As the foam stabilizer, all those used in the production of ordinary polyurethane foams can be used. Dimethylsiloxane foam stabilizers (“SRX-253”, “PRX-607”, etc., manufactured by Toray Dow Corning Co., Ltd.) and the like Polyether-modified dimethylsiloxane foam stabilizer [Momentive Performance Materials Japan GK “L-580”, Toray Dow Corning “SZ-1142”, “SRX-294A”, “SH-193”, "SZ-1720", "SZ-1675t", "SF-2936F" and "B-4900" manufactured by Evonik Degussa Japan Co., Ltd.]. The amount of foam stabilizer used is preferably 0.5 to 5.0 parts by weight with respect to 100 parts by weight of the polyol component from the viewpoint of mechanical properties (elongation, tensile strength) and foam stability during foaming. More preferably, it is 1.0-3.0 weight part.

In the method for producing the polyurethane foam of the present invention, if necessary, other auxiliary agents described below may be used and reacted in the presence thereof.
Other auxiliaries include colorants (dyes and pigments), plasticizers (phthalates and adipates, etc.), organic fillers (synthetic short fibers, hollow microspheres made of thermoplastic or thermosetting resins, etc.) And known auxiliary components such as flame retardants (such as phosphate esters and halogenated phosphate esters), anti-aging agents (such as triazole and benzophenone), and antioxidants (such as hindered phenol and hindered amine).

  As the addition amount of these auxiliaries, the colorant is preferably 1 part by weight or less based on 100 parts by weight of the polyol component. The plasticizer is preferably 10 parts by weight or less, more preferably 5 parts by weight or less. The organic filler is preferably 50 parts by weight or less, more preferably 30 parts by weight or less. The flame retardant is preferably 30 parts by weight or less, and more preferably 2 to 20 parts by weight. The anti-aging agent is preferably 1 part by weight or less, more preferably 0.01 to 0.5 part by weight. The antioxidant is preferably 1 part by weight or less, more preferably 0.01 to 0.5 part by weight. The total amount of auxiliary agent used is preferably 50 parts by weight or less, more preferably 0.2 to 30 parts by weight.

  In the production method of the present invention, the isocyanate index (index) [(equivalent ratio of NCO group / active hydrogen atom-containing group) × 100] in the production of polyurethane foam is determined from the viewpoint of moldability, mechanical properties (tensile strength, tearing). From the viewpoint of strength and compressive strength, 70 to 150 is preferable, 80 to 130 is more preferable, and 90 to 120 is particularly preferable.

  An example of a method for producing a polyurethane foam according to the method of the present invention is as follows. First, a predetermined amount of a polyol component for producing polyurethane foam, a foaming agent, a catalyst, a foam stabilizer, and other additives as necessary are mixed. The mixture and the organic polyisocyanate component are then rapidly mixed using a polyurethane foam foamer or stirrer. The obtained mixed liquid (foaming stock solution) can be continuously foamed to obtain a polyurethane foam. Alternatively, it can be poured into a sealed or open mold (made of metal or resin), subjected to a urethanization reaction, cured for a predetermined time, and then demolded to obtain a polyurethane foam.

  The polyurethane foam obtained by the method of the present invention is suitably used for vehicle cushions, furniture / building materials, clothing, electrical equipment, electronic equipment or packaging.

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

Example 1
In a stainless steel autoclave equipped with a stirrer and a temperature controller, polyethylene glycol (PEG-200 manufactured by Sanyo Chemical Industries, Ltd .; polyethylene glycol having a number average molecular weight of 200, hydroxyl value of 560), 1 mol of trimellitic anhydride and 2 mol of alkali catalyst Half esterification was carried out by charging 0.010 mol of (N-ethylmorpholine) with 2 mol of tetrahydrofuran (THF) and reacting at 0.20 MPa and 120 ± 10 ° C. for 1 hour in a nitrogen atmosphere. After half esterification, 4 mol of EO was added dropwise over 5 hours while controlling the pressure to be 90 ± 10 ° C. and a pressure of 0.50 MPa or less, followed by aging at 90 ± 10 ° C. for 1 hour. After completion of aging, the alkali catalyst and THF were removed under reduced pressure to obtain a strength improver A-1. Hydroxyl value (mgKOH / g) = 295, number average molecular weight = 760

Example 2
In a reaction vessel equipped with a cooling tube, a stirrer and a nitrogen introduction tube, 2 mol of THF, 2 mol of trimellitic anhydride, 1 mol of PEG-200, and 2 mol of alkali catalyst triethylamine were allowed to react at 80 ° C. for 2 hours. After that, 4 mol of chloromethane was added and reacted at 70 ° C. for 2 hours. Then, liquid separation and solvent removal were performed, and strength improver A-2 was obtained. Hydroxyl value (mgKOH / g) = 0, number average molecular weight = 640

Example 3
In Example 1, strength improver A-3 was obtained in the same manner as in Example 1 except that 1 mol of ethylene glycol was used instead of 1 mol of PEG-200. Hydroxyl value (mgKOH / g) = 321, number average molecular weight = 700

Example 4
In Example 2, strength improver A-4 was obtained in the same manner as in Example 2 except that 1 mol of ethylene glycol was used instead of 1 mol of PEG-200 and 4 mol of chlorobutane was used instead of 4 mol of chloromethane. It was. Hydroxyl value (mgKOH / g) = 0, number average molecular weight = 750

Example 5
In Example 4, strength improver A-5 was obtained in the same manner as in Example 4 except that 4 mol of chloromethane was used instead of 4 mol of chlorobutane. Hydroxyl value (mgKOH / g) = 0, number average molecular weight = 580

Example 6
In Example 1, strength improver A-6 was obtained in the same manner as in Example 1 except that 1 mol of diethylene glycol was used instead of 1 mol of PEG-200. Hydroxyl value (mgKOH / g) = 302, number average molecular weight = 750

Example 7
In Example 4, strength improver A-7 was obtained in the same manner as in Example 4 except that 1 mol of diethylene glycol was used instead of 1 mol of ethylene glycol. Hydroxyl value (mgKOH / g) = 0, number average molecular weight = 790

Example 8
In Example 7, strength improver A-8 was obtained in the same manner as in Example 7 except that 4 mol of chloromethane was used instead of 4 mol of chlorobutane. Hydroxyl value (mgKOH / g) = 0, number average molecular weight = 620

Example 9
In an autoclave similar to Example 1, 2 mol of THF, 2 mol of PEG-200, 1 mol of pyromellitic anhydride and 0.010 mol of alkali catalyst (N-ethylmorpholine) were charged, 0.20 MPa in a nitrogen atmosphere, Half-esterification was performed by reaction at 120 ± 10 ° C. for 1 hour. After half esterification, 2 mol of EO was added dropwise over 5 hours while controlling so that the pressure became 90 ± 10 ° C. and a pressure of 0.50 MPa or less, followed by aging at 90 ± 10 ° C. for 1 hour. After completion of aging, the alkali catalyst was removed under reduced pressure at 0.1 MPa for 1 hour to obtain a strength improver A-9. Hydroxyl value (mgKOH / g) = 325, number average molecular weight = 690

Example 10
In Example 9, strength improver A-10 was obtained in the same manner as in Example 7 except that EO4 mol was used instead of EO2 mol. Hydroxyl value (mgKOH / g) = 288, number average molecular weight = 780

Example 11
In the same reaction vessel as in Example 1, 2 mol of THF, 1 mol of pyromellitic anhydride, 2 mol of PEG-200 and 2 mol of triethylamine were added and reacted at 80 ° C. for 2 hours, and then 2 mol of chlorobutane was added. The reaction was carried out at 70 ° C. for 2 hours. Then, liquid separation and solvent removal were performed, and strength improver A-11 was obtained. Hydroxyl value (mgKOH / g) = 155, number average molecular weight = 720

Example 12
In Example 11, strength improver A-12 was obtained in the same manner as in Example 11 except that 2 mol of chloromethane was used instead of 2 mol of chlorobutane. Hydroxyl value (mgKOH / g) = 177, number average molecular weight = 630

Example 13
In Example 9, strength improver A-13 was obtained in the same manner as in Example 9 except that 2 mol of ethylene glycol was used instead of 2 mol of PEG-200. Hydroxyl value (mgKOH / g) = 542, number average molecular weight = 410

Example 14
In Example 13, strength improver A-14 was obtained in the same manner as in Example 13 except that EO was changed to 4 mol instead of 2 mol. Hydroxyl value (mgKOH / g) = 447, number average molecular weight = 500

Example 15
In Example 11, strength improver A-15 was obtained in the same manner as in Example 11 except that 2 mol of ethylene glycol was used instead of 2 mol of PEG-200. Hydroxyl value (mgKOH / g) = 256, number average molecular weight = 440

Example 16
In Example 15, strength improver A-16 was obtained in the same manner as in Example 15 except that 2 mol of chloromethane was used instead of 2 mol of chlorobutane. Hydroxyl value (mgKOH / g) = 317, number average molecular weight = 350

Example 17
In Example 14, strength improver A-17 was obtained in the same manner as in Example 14 except that 2 mol of methanol was used instead of 2 mol of ethylene glycol. Hydroxyl value (mgKOH / g) = 505, number average molecular weight = 440

Example 18
In Example 15, a strength improver A-18 was obtained in the same manner as in Example 15 except that 2 mol of methanol was used instead of 2 mol of ethylene glycol. Hydroxyl value (mgKOH / g) = 297, number average molecular weight = 380

Example 19
In Example 16, strength-improving agent A-19 was obtained in the same manner as in Example 16 except that 2 mol of methanol was used instead of 2 mol of ethylene glycol. Hydroxyl value (mgKOH / g) = 382, number average molecular weight = 290

Comparative Example 1
In the same autoclave as in Example 1, 2 mol of THF, 1 mol of diethylene glycol, 2 mol of trimellitic anhydride and 0.010 mol of alkali catalyst (N-ethylmorpholine) were charged, 0.20 MPa, 100 ± 10 in a nitrogen atmosphere. Half-esterification was performed by reacting at 1 ° C. for 1 hour. Thereafter, 8 mol of EO was added dropwise over 5 hours while controlling the pressure to be 120 ± 10 ° C. and a pressure of 0.50 MPa or less, followed by aging at 120 ± 10 ° C. for 1 hour. After completion of aging, the alkali catalyst was removed under reduced pressure at 0.1 MPa for 1 hour to obtain a polyol (B-1). Hydroxyl value (mgKOH / g) = 267, number average molecular weight = 840

Comparative Example 2
Half esterification was carried out in the same manner as in Example 1. Thereafter, 20 mol of EO was added dropwise over 5 hours while controlling the pressure to be 120 ± 10 ° C. and a pressure of 0.50 MPa or less, followed by aging at 120 ± 10 ° C. for 1 hour. After completion of aging, the alkali catalyst was removed under reduced pressure at 0.1 MPa for 1 hour to obtain a polyol (B-2). Hydroxyl value (mgKOH / g) = 164, number average molecular weight = 1400

Comparative Example 3
In Example 13, a polyol (B-3) was obtained in the same manner as in Example 13 except that EO was 20 mol instead of EO. Hydroxyl value (mgKOH / g) = 200, number average molecular weight = 1100

Comparative Example 4
In Example 1, instead of 2 moles of trimellitic anhydride, instead of 1 mole of trimellitic anhydride, 1 mole of PEG-200, 1 mole of butanol, and 4 moles of EO A polyol (B-4) was obtained in the same manner as in Example 1 except that EO was changed to 3 mol. Hydroxyl value (mgKOH / g) = 200, number average molecular weight = 540

<Examples 20 to 38 and Comparative Examples 5 to 9 Production of soft slab foam>
Using the strength improver A or polyol B, in accordance with the formulation shown in Table 1, foamed under the following foaming conditions to produce a flexible polyurethane foam, which was left overnight (temperature 25 ° C., humidity 50% for 24 hours) The core density (kg / m ³ ), hardness (25% ILD, N / 314 cm ² ), tear strength (N / cm), tensile strength (kPa), and elongation (%) of the subsequent foam were measured.

(Foaming conditions)
BOX SIZE: 250mm x 250mm x 250mm
Material: Wood Mixing method: Hand mixing (foaming method in which a necessary amount of necessary reagent is charged in a predetermined container, and then a stirring blade is inserted into the container and stirred for 6 to 20 seconds at a rotational speed of 5000 rpm)
Mixing time: 6 to 20 seconds, stirring blade rotation speed: 5000 rotations / minute

The polyurethane foam raw materials in Examples 20 to 38 and Comparative Examples 5 to 9 are as follows.
(1) Organic polyisocyanate component (D-1)
TDI: NCO% = 48.3 (trade name: Coronate T-80, manufactured by Nippon Polyurethane Industry Co., Ltd.)
(2) Blowing agent Blowing agent: Water (3) Catalyst catalyst-1: “DABCO-33LV” (33% by weight dipropylene glycol solution of triethylenediamine) manufactured by Air Products Japan Co., Ltd.
Catalyst-2: Tin octylate (trade name: “Neostan U-28” manufactured by Nitto Kasei Co., Ltd. (stannic octylate)
(4) Foam stabilizer Foam stabilizer-1: Momentive Performance Materials Japan “L-580”
(5) Polyol polyol (P-1): glycerin PO adduct, average number of functional groups 3, hydroxyl value 56.0.

<Test method>
The measurement method for each item is as follows. The obtained results are shown in Table 1.
-The measurement method and unit of foam physical properties are shown below.
Core density: Conforms to JIS K6400, unit is kg / m ³
Hardness (25% -ILD): Conforms to JIS K6400, unit is N / 314 cm ²
Elongation: Conforms to JIS K6400, unit is%
Tensile strength: Conforms to JIS K6400, unit is kPa
Tear strength: Conforms to JIS K6400, unit is N / cm

  In Table 1, the urethane foams of Examples 20 to 38 of the present invention have improved foam physical properties, particularly foam hardness and tensile strength, as compared with the urethane foams of Comparative Examples 5 to 9.

<Examples 39 to 57, Comparative Examples 10 to 14 Production of flexible HR foam>
According to the foaming formulation shown in Table 2, a flexible polyurethane foam was foamed in a mold under the following foaming conditions to form a foam, then taken out of the mold and allowed to stand overnight, and various physical properties of the flexible polyurethane foam were measured. The measured values of physical properties are also shown in Table 2, respectively.

(Foaming conditions)
Mold size: 400mm x 400mm x 100mm (height)
Mold temperature: 65 ° C
Mold material: Aluminum Mixing method: High pressure urethane foaming machine (manufactured by Polymer Engineering) Mixing polyol premix and isocyanate at 15 MPa

The raw materials of the flexible polyurethane foam in Examples 39 to 57 and Comparative Examples 10 to 14 are the same as those shown in the above Examples and Comparative Examples, and the other materials are as follows.
1. Catalyst catalyst-3: “TOYOCAT ET” manufactured by Tosoh Corporation (70% by weight dipropylene glycol solution of bis (dimethylaminoethyl) ether)
2. Foam stabilizer: Foam stabilizer-2: “TEGOSTAB B8737LF2” manufactured by Evonik Dexa Japan

3. Organic isocyanate component (D-2)
TDI-80 (2,4- and 2,6-TDI, ratio of 2,4-form is 80% / crude MDI = 80/20 (weight ratio)
4). Polyol (1) Polyol (P-2): Polyoxyethylene polyoxypropylene polyol (average functional group number 3.0, hydroxyl value 28, EO unit total = 16% obtained by block addition of PO and EO to glycerin ( 2) Polyol (P-3): Polyoxyethylene polyoxypropylene having an average functional group number of 4.0 obtained by block addition of PO and EO to pentaerythritol, a hydroxyl value of 34, and a total of EO units = 13.5% A polymer polyol (polymer content 30%) obtained by copolymerizing styrene and acrylonitrile (weight ratio: 33/67) in a polyol. Hydroxyl value 21.
(3) Polyol (P-4): Polyoxyethylene polyoxypropylene polyol having an average functional group number of 3.0 and a hydroxyl value of 24 obtained by randomly adding PO and EO to glycerin (4) Polyol (P-5) :ethylene glycol. Functional group number 2.0, hydroxyl value 1810.
(5) Polyol (P-6): polyoxyethylene polyol (6) polyol (P-) having an average number of functional groups of 3.0 obtained by adding EO to glycerin, a hydroxyl value of 841, and a total of EO units = 54% 7): Polyoxyethylene polyol having an average number of functional groups of 6.0 obtained by adding EO to sorbitol, a hydroxyl value of 1055, and a total of EO units = 33%

The measurement method for each item is as follows. The obtained results are shown in Table 2.
-The measurement method and unit of foam physical properties are shown below.
Core density: Conforms to JIS K6400, unit is kg / m ³
Elongation: Conforms to JIS K6400, unit is%
Tensile strength: Conforms to JIS K6400, unit is kPa
Hardness (25% -ILD): Conforms to JIS K6400, unit is N / 314 cm ²
Tear strength: Conforms to JIS K6400, unit is N / cm

  In Table 2, the urethane foams of Examples 39 to 57 of the present invention have improved foam physical properties, particularly foam hardness and tensile strength, as compared with the urethane foams of Comparative Examples 10 to 14.

<Examples 58 to 76, Comparative Examples 15 to 19>
According to the foaming formulation shown in Table 3, a rigid polyurethane foam was foamed in a mold under the following foaming conditions to form a foam. After demolding, the foam was allowed to stand overnight, and various properties of the rigid polyurethane foam were measured. The measured values of physical properties are also shown in Table 3.

(Foaming conditions)
Mold size: 400mm x 400m x 50mm (height)
Mold temperature: 35 ℃
Mold material: Aluminum Mixing method: High pressure urethane foaming machine (manufactured by Polymer Engineering Co., Ltd.) Mixing polyol premix and isocyanate at 12 MPa

The raw materials of the rigid polyurethane foams in Examples 58 to 76 and Comparative Examples 15 to 19 are the same as those shown in the above Examples and Comparative Examples, and other items are as follows.
1. Catalyst catalyst-4: “U-CAT 1000” (amine-based catalyst) manufactured by San Apro Co., Ltd.
2. Foam stabilizer Foam stabilizer-3: “SF-2936F” manufactured by Toray Dow Corning Co., Ltd.

3. Organic isocyanate component (D-3)
“Millionate MR-200” (Polymeric MDI) manufactured by Nippon Polyurethane Industry Co., Ltd.
4). Polyol (1) Polyol (P-8): Polyoxyethylene polyoxy having an average number of functional groups of 4, obtained by block addition of PO and EO to ethylenediamine, a hydroxyl value of 820, a total of EO units = 37%, and a hydroxyl value of 820 4. Propylene polyol (2) Polyol (P-9): Polyoxypropylene polyol having an average functional group number of 4.6 and a hydroxyl value of 450 obtained by adding PO to a mixture of glycerin, sucrose and triethylamine. Flame Retardant Flame Retardant-1: “TMCPP” manufactured by Daihachi Chemical Industry Co., Ltd. (Tris (β-chloropropyl phosphate 6. blowing agent blowing agent-1: “HFC-245fa” manufactured by Central Glass Co., Ltd. (1,1,1 , 3,3, -pentafluoropropane)

The measurement method for each item is as follows. The obtained results are shown in Tables 23 to 26.
Density: Conforms to JIS A9511, unit is kg / m ³
Compressive strength: Conforms to JIS A9511, unit is kPa

In Table 3, the urethane foams of Examples 58 to 76 of the present invention have improved foam properties, particularly compressive strength, as compared with the urethane foams of Comparative Examples 15 to 19.

  The polyurethane foam of the present invention can be used for all kinds of polyurethane foam for vehicle seats, furniture, building materials, bedding, apparel, electrical equipment, electronic equipment, packaging, and other uses (sanitary goods, cosmetics). Can be suitably used.

Claims (5)

A hydrogen atom (a) on the aromatic ring represented by the following general formula (I), and a carbonyl group is bonded to two carbons adjacent to the carbon of the aromatic ring to which the hydrogen atom (a) is bonded. A strength improver for producing polyurethane foam (A) having two hydrogen atoms (a) in the molecule and a number average molecular weight of 250 to 800.
[In the general formula (I), R1 represents a residue obtained by removing one active hydrogen from an active hydrogen-containing compound. A plurality of R1 may be the same or different. ; Y represents the residue remove | excluding the carboxyl group from trivalent or more aromatic polycarboxylic acid (C). The aromatic ring of Y is composed of carbon atoms. A is an integer satisfying 2 ≦ a ≦ (the number of aromatic ring substituents−2). Z represents a residue obtained by removing m active hydrogens from an active hydrogen-containing compound having a valence of at least m; At least one R1 and Z are different. M represents an integer of 1 or 2; ] A polyol composition (H) for producing a polyurethane foam comprising the strength improver (A) according to claim 1 and a polyol (P). The polyol composition for producing a polyurethane foam according to claim 2, wherein the content of the strength improver (A) based on the weight of the polyol composition (H) is 0.1 wt% or more and less than 100 wt%. A method for producing a polyurethane foam, comprising reacting the strength improver (A) according to claim 1 and the organic polyisocyanate component (D) in the presence of a foaming agent, a catalyst and a foam stabilizer. The manufacturing method of the polyurethane foam formed by making the polyol composition (H) of Claim 2 or 3 and organic polyisocyanate component (D) react in presence of a foaming agent, a catalyst, and a foam stabilizer.