JP6548652B2 - Pipa系燃焼修正ポリウレタン発泡体 - Google Patents
Pipa系燃焼修正ポリウレタン発泡体 Download PDFInfo
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Description
本願発明には以下の態様が含まれる。
項1.
燃焼修正エーテル(CME)ポリウレタン発泡体を形成するための方法であって、
PIPAポリオールの総重量に基づいて、10重量%〜75重量%の固体含量を有する分散物である前記PIPAポリオールを含むポリオール成分を提供することであって、前記PIPAポリオールが、少なくとも、80未満の数平均ヒドロキシル当量重量を有する低当量重量のポリオールと、225未満の数平均イソシアネート当量重量を有するポリイソシアネート化合物と、少なくとも200の数平均ヒドロキシル当量重量を有し、かつ液体ベースポリエーテルポリオール中のヒドロキシル基の総量に基づいて、少なくとも80%の二級ヒドロキシル基を有する前記液体ベースポリエーテルポリオールと、を含む混合物の反応生成物である、提供することと、
少なくとも1つのポリイソシアネートを含むイソシアネート成分を提供することと、
少なくとも1つの難燃剤を含む添加物成分を提供することと、
前記ポリオール成分と、前記イソシアネート成分と、前記添加物成分と、を含む反応混合物を形成して、CMEポリウレタン発泡体を形成することであって、前記反応混合物が90〜150のイソシアネート指数を有する、形成することと、を含む、前記方法。
項2.
前記液体ベースポリエーテルポリオールが、少なくとも90%の二級ヒドロキシル基を有する、項1に記載の前記方法。
項3.
前記PIPAポリオールが、少なくとも15重量%の固体含量を有し、スズ触媒の不在下で調製される、項1または項2に記載の前記方法。
項4.
前記PIPAポリオールが、PIPAポリオールの前記総重量に基づいて、15重量%〜25重量%の固体含量を有する、項1〜3のいずれか一項に記載の前記方法。
項5.
前記低当量重量のポリオールが、トリエタノールアミン、またはトリエタノールアミン及び80未満の数平均ヒドロキシル当量重量を有する別の低分子量のポリオールを含む混和物を含む、項1〜4のいずれか一項に記載の前記方法。
項6.
前記ベースポリオールが、80重量%〜99.5重量%のポリオキシプロピレン及び0.5重量%〜20重量%のポリオキシエチレンのポリオキシプロピレンホモポリマーまたはコポリマーであるトリオールであり、前記ベースポリオールの前記ヒドロキシル当量重量が900〜1350であり、前記ベースポリオールが、ヒドロキシル基の前記総量に基づいて、95%〜100%の二級ヒドロキシル基を有する、項1〜5のいずれか一項に記載の前記方法。
項7.
前記ポリオール成分が、前記PIPAポリオールと、3000〜3500の分子量を有し、ポリオキシプロピレン−ポリオキシエチレンポリエーテルトリオール中のヒドロキシル基の前記総量に基づいて、15%未満のポリオキシエチレン含量を有し、かつ10%未満の一級ヒドロキシル基を有する前記ポリオキシプロピレン−ポリオキシエチレンポリエーテルトリオールと、を含み、
前記ポリオール成分が、前記ポリオール成分の前記総重量に基づいて、2重量%〜50重量%の全固体含量を有する、項1〜6のいずれか一項に記載の前記方法。
項8.
前記PIPAポリオールを形成するための前記混合物が、前記PIPAポリオールとは異なる非シリコーン系安定剤を更に含む、項1〜7のいずれか一項に記載の前記方法。
項9.
前記PIPAポリオールを形成するための前記混合物が、PIPA/PHDコポリマー系粒子を得るために、前記低当量重量のポリオールとの共反応体として一級アミンを更に含む、項1〜8のいずれか一項に記載の前記方法。
項10.
前記発泡体密度が、15〜25kg/m3である、項1〜9のいずれか一項に記載の前記方法。
項11.
前記CMEポリウレタンが、クリブ5引火性試験要件を満たす、項1〜10のいずれか一項に記載の前記方法。
項12.
前記反応混合物が、15kg/m3〜50kg/m3の範囲内の異なる密度を各々有し、かつ前記クリブ5引火性試験要件を各々満たす様々な燃焼修正エーテルポリウレタン発泡体を調製することができる、項1〜10のいずれか一項に記載の前記方法。
項13.
前記添加物成分が、いかなる非ハロゲン化難燃剤も含まない、項1〜12のいずれか一項に記載の前記方法。
項14.
前記添加物成分が、いかなるハロゲン化難燃剤も含まない、項1〜12のいずれか一項に記載の前記方法。
項15.
前記添加物成分が、少なくとも1つの非ハロゲン化難燃剤及び少なくとも1つのハロゲン化難燃剤を含む、項1〜12のいずれか一項に記載の前記方法。
項16.
前記CMEポリウレタン発泡体が、45%未満の弾力性値を有する、項1〜12のいずれか一項に記載の前記方法。
項17.
項1〜16のいずれか一項に記載の前記方法に従って調製される、第1のCMEポリウレタン発泡体及び第2のCMEポリウレタン発泡体を含む、複数の燃焼修正エーテル(CME)ポリウレタン発泡体であって、
前記第1のCMEポリウレタン発泡体が、クリブ5引火性試験要件を満たし、15kg/m3〜25kg/m3の低密度を有し、
前記第2のCMEポリウレタン発泡体が、クリブ5引火性試験要件を満たし、25kg/m3超かつ100kg/m3未満の高密度を有する、前記複数の燃焼修正エーテル(CME)ポリウレタン発泡体。
Claims (15)
- 難燃性の向上したポリウレタン発泡体を製造する方法であって、
(1)(a)数平均水酸基当量が80未満であるポリオール、(b)数平均イソシアネート当量が225未満であるポリイソシアネート、及び(c)数平均水酸基当量が200以上、かつ全ヒドロキシ基のうち、80モル%以上が第2級ヒドロキシ基である液体ベースポリエーテルポリオールを混合して混合物(P1)を得た後、
(a)及び(b)を反応させて、(a)及び(b)の反応生成物であるポリイソシアネート重付加(PIPA)ポリオール及び(c)液体ベースポリエーテルポリオールを含むポリオール混合物(P2)を製造する工程であって、
前記ポリイソシアネート重付加ポリオールは、0.05μm〜5μmの粒子径を有するものであり、前記ポリオール混合物の固形分含量のうち、前記ポリイソシアネート重付加ポリオールの占める割合は10重量%〜75重量%である、工程、
(2)ポリイソシアネートを含む混合物を調製する工程、
(3)難燃剤及び発泡剤を含む添加剤混合物を調製する工程、
(4)前記ポリオール混合物(P2)、前記ポリイソシアネートを含む混合物、及び前記難燃剤及び発泡剤を含む添加剤混合物を混合して、重合反応混合物を調製し、さらに、重合反応を行い、ポリウレタン発泡体を製造する工程であって、
前記重合反応混合物のイソシアネート指数は90〜150である工程、
の前記(1)〜(4)の工程を含む、ポリウレタン発泡体を製造する方法。 - 前記液体ベースポリエーテルポリオールは、全ヒドロキシ基のうち、90モル%以上が第2級ヒドロキシ基であるポリオールである、請求項1に記載の方法。
- 前記ポリオール混合物の固形分含量のうち、前記ポリイソシアネート重付加ポリオールの占める割合は15重量%以上であり、前記(1)工程においては、スズ含有触媒は使用されないものである、請求項1または2に記載の方法。
- 前記ポリオール混合物の固形分含量のうち、前記ポリイソシアネート重付加ポリオールの占める割合は15重量%〜25重量%である、請求項1〜3のいずれか一項に記載の方法。
- 前記(a)数平均水酸基当量が80未満であるポリオールは、トリエタノールアミンを含む、請求項1〜4のいずれか一項に記載の方法。
- 前記(c)液体ベースポリエーテルポリオールはトリオールであり、前記トリオールは、ポリオキシプロピレンホモポリマー、または、プロピレンオキサイドに由来する繰り返し単位80重量%〜99.5重量%及びエチレンオキサイドに由来する繰り返し単位0.5重量%〜20重量%を含むコポリマーであり、
前記(c)液体ベースポリエーテルポリオールの水酸基当量は900〜1350であり、
前記(c)液体ベースポリエーテルポリオールの全ヒドロキシ基のうち、95モル%〜100モル%が第2級ヒドロキシ基である、請求項1〜5のいずれか一項に記載の方法。 - 前記ポリオール混合物が、前記ポリイソシアネート重付加(PIPA)ポリオールとともに、ポリオキシプロピレン−ポリオキシエチレンポリエーテルトリオールをさらに含み、
前記ポリオキシプロピレン−ポリオキシエチレンポリエーテルトリオールは3000〜3500の数平均分子量を有し、かつ、前記ポリオキシプロピレン−ポリオキシエチレンポリエーテルトリオールの全重量に対して、エチレンオキサイドに由来する繰り返し単位の占める割合は15%重量未満であり、
前記ポリオキシプロピレン−ポリオキシエチレンポリエーテルトリオール中の全ヒドロキシル基のうち、第1級ヒドロキシ基は10%モル未満であり、
前記ポリオール混合物は、固形分含有量が2重量%〜50重量%である、請求項1〜6のいずれか一項に記載の方法。 - 前記工程(1)において、前記混合物(P1)が、非シリコーン系安定剤を更に含む、請求項1〜7のいずれか一項に記載の方法。
- 前記工程(1)において、前記混合物(P1)が、(d)第1級アミン化合物を更に含み、
前記ポリイソシアネート重付加(PIPA)ポリオールは、前記(a)、(b)及び(d)の反応生成物であるポリイソシアネート重付加・ポリ尿素(PIPA/PHD)ポリオールとなる、請求項1〜8のいずれか一項に記載の方法。 - 前記ポリウレタン発泡体の密度は15〜25kg/m3である、請求項1〜9のいずれか一項に記載の方法。
- 前記ポリウレタン発泡体はクリブ5引火性試験に合格するものである、請求項1〜10のいずれか一項に記載の方法。
- 前記工程(3)において、添加剤混合物はハロゲンを含まない難燃剤を含まない、請求項1〜11のいずれか一項に記載の方法。
- 前記工程(3)において、添加剤混合物はハロゲンを含む難燃剤を含まない、請求項1〜11のいずれか一項に記載の方法。
- 前記工程(3)において、添加剤混合物は非ハロゲン含有難燃剤及びハロゲン含有難燃剤を含む、請求項1〜11のいずれか一項に記載の方法。
- 前記ポリウレタン発泡体が、ASTM3574に従って測定される45%未満の弾力性値を有する、請求項1〜11のいずれか一項に記載の方法。
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