JPH06271643A - Production of polyurethane foam - Google Patents

Abstract

PURPOSE:To obtain the subject product having high-density skin properties, surface smoothness, etc., in high productivity without using chlorofluorocarbon by using a specific organic active hydrogen compound and a specific polyisocyanate compound. CONSTITUTION:The objective product is obtained by using (A) an organic active hydrogen compound composed of a polymer polyol having 2-4 average functional groups and 14-80mgKOH/g hydroxyl number, (B) a polyisocyanate compound composed of a polyisocyanate prepared by subjecting (i) part of diphenylmethane diisocyanat and/or a carbodiimide-modified diphenylmethane diisocyanate to urethane modification with (ii) a polyhydroxy compound having 2-3 average functional groups and 10-399mgKOH/g hydroxyl number and (iii) a polyhydroxy compound having 2-38 average functional groups and 400-2,000mgKOH/g hydroxyl number, (C) a blowing agent, (D) a catalyst and optionally (E) a foam stabilizer.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a method for producing a polyurethane foam, and more particularly to a method for producing a polyurethane foam having a high-density skin layer with improved surface smoothness, physical properties and the like. Is.

[0002]

2. Description of the Related Art Generally, a polyurethane foam molded article having a high-density skin layer, so-called integral skinned foam, is often used for interior parts of automobiles including steering wheels because of its high productivity, mechanical properties, and feel. Has been used. Conventionally, in producing this integral skinned foam, by using a chlorofluorocarbon such as CFC-11 or CFC-113 as a foaming agent, a high-density skin layer can be easily formed, and a machine for a polyurethane foam obtained. Good physical properties and touch.

[0003]

However, in recent years,
It has become known that these chlorofluorocarbons seriously affect the global environment by depleting the ozone layer, and hydrochlorofluorocarbons (HCFC-1), which has less influence than CFC-11 and CFC-113.
23, HCFC-141b, HCFC-22, etc.), or a polyurethane foam molding in which hydrofluorocarbons (HFC-134a, etc.), water, and other low-boiling compounds, which are said to have no influence, are partially or wholly used as a blowing agent. The manufacturing method of the product is being studied. However, it has been known that hydrochlorofluorocarbon will destroy the ozone layer although it is small, and eventually it cannot be used. Also, hydrofluorocarbons are expensive and difficult to use at present. JP-A-2-55516 discloses a method using a low boiling point compound,
Problems such as toxicity and flammability of this low boiling point compound have not been solved, and when only water is used as a foaming agent, there is a problem that the skin forming ability and the physical properties of the resulting molded article are significantly reduced. Yes, there has never been a decisive factor.

[0004]

Means for Solving the Problems The inventors of the present invention have conducted diligent studies for the purpose of solving these problems, and as a result, found that a specific compound is used as a polyisocyanate compound or an organic active hydrogen compound. As a result, the present invention has been completed. That is, the present invention is an organic active hydrogen compound,
In the method for producing a polyurethane foam from a polyisocyanate compound, a foaming agent, a catalyst, and optionally a foam stabilizer, the organic active hydrogen compound has an average functional group number of 2 to
4, a high molecular weight polyol having a hydroxyl value of 14 to 80 mgKOH / g, or this high molecular weight polyol and an average number of functional groups of 2
4 and a low molecular weight active hydrogen compound having a hydroxyl value of 500 to 2000 mgKOH / g, wherein the polyisocyanate compound is a part of diphenylmethane diisocyanate and / or carbodiimide-modified diphenylmethane diisocyanate having an average number of functional groups of 2 to 3 and a hydroxyl value of 10 ~ 39
With a polyhydroxy compound (A1) of 9 mgKOH / g and a polyisocyanate (A) urethane-modified with a polyhydroxy compound (A2) having an average number of functional groups of 2 to 8 and a hydroxyl value of 400 to 2000 mgKOH / g, or this polyisocyanate (A) The method is characterized in that it is a mixture with polymethylene polyphenylene polyisocyanate.

The contents of the present invention will be described in more detail. Among the organic active hydrogen compounds used in the present invention, polymer polyols have an average number of functional groups of 2 to 4 and 14 to 80 mgKOH / g.
It has a hydroxyl value of 3 and is roughly classified into three types: polyether polyols, polyester polyols, and polymer polyols other than these. Polyether polyol is water, ethylene glycol, diethylene glycol, glycerin, trimethylolpropane, pentaerythritol, ethylenediamine, diglycerin, diethanolamine, triethanolamine, sorbitol, saccharose, etc., or a mixture thereof, to which an alkylene oxide is added. Is. The polyester polyol is a liquid terminal hydroxy compound obtained by reacting a polycarboxylic acid or its acid anhydride with glycols. Polymer polyols other than these are those obtained by dispersing polymers such as polystyrene, polyacrylonitrile and polyurea in the above polyether polyol. You may use these compounds individually or in mixture.

Among the organic active hydrogen compounds, the low molecular weight active hydrogen compounds have an average number of functional groups of 2 to 4 and 500 to 2000 mg.
It has a hydroxyl value of KOH / g, and examples thereof include the following compounds having two or more hydroxyl groups and / or amino groups in one molecule. That is, glycols such as ethylene glycol, diethylene glycol, 1,4-butanediol, glycerin, trimethylolpropane, triethanolamine, tetrakis (hydroxymethyl) methane, polyhydric alcohols such as diglycerin, ethylenediamine, hexamethylenediamine, Propanediamine,
Examples include diamines such as toluenediamine and diethyltoluenediamine, alkanolamines such as monoethanolamine and diethanolamine, and alkylene oxide adducts thereof. You may use these compounds individually or in mixture. The blending ratio of the high molecular weight polyol and the low molecular weight active hydrogen compound is such that the low molecular weight active hydrogen compound is 0 to 100 parts by weight of the high molecular weight polyol.
It is preferably 40 parts by weight, and particularly preferably 0.5 to 30 parts by weight.

The polyisocyanate compound used in the present invention is diphenylmethane diisocyanate (hereinafter referred to as MD
I) and / or carbodiimide-modified diphenylmethane diisocyanate (hereinafter referred to as carbodiimide-modified MDI)
Polyisocyanate (A) obtained by urethane-modifying a part of polyhydroxy compound (A1) and (A2)
A single or a mixture of this polyisocyanate (A) and polymethylene polyphenylene polyisocyanate (hereinafter referred to as polymeric MDI).

The polyhydroxy compound (A1) has an average number of functional groups of 2 to 3 and a hydroxyl value of 10 to 399 mg KO.
H / g, the average number of functional groups of the polyhydroxy compound (A2) is 2 to 8, and its hydroxyl value is 400 to 2000 mg KO.
H / g. Specific examples of the polyhydroxy compound (A1) include ethylene glycol, diethylene glycol,
Examples thereof include alkylene oxide adducts of glycols such as 1,4-butanediol, alkylene oxide adducts of triols such as glycerin, trimethylolpropane and triethanolamine, and polyester polyols. You may use these compounds individually or in mixture. Specific examples of the polyhydroxy compound (A2) include ethylene glycol, diethylene glycol,
1,4-butanediol, glycols such as dipropylene glycol, glycerin, trimethylolpropane,
Triols such as triethanolamine, diglycerin, tetrakis (hydroxymethyl) methane, sorbitol, polyhydric alcohols such as sucrose, and alkylene oxide adducts thereof, alkylene oxide adducts of polyamines such as ethylenediamine and tolylenediamine, Examples thereof include polyester polyols. You may use these compounds individually or in mixture. The amount of the polyhydroxy compound (A2) is preferably in the range of 5 to 95% by weight based on the total amount of (A1) and (A2).
The isocyanate group content of this polyisocyanate (A) is preferably in the range of 15.1 to 33.0% by weight, and if it is higher than this, sufficient physical properties cannot be obtained, and if it is lower than this, the viscosity becomes high. It is difficult to handle. In the polyisocyanate compound of the present invention, the content of polyisocyanate (A) is preferably in the range of 100 to 30% by weight, and particularly preferably 98 to 33% by weight.

Water is desirable as the foaming agent used in the present invention, but if necessary, known ones that have less serious influence on the global environment and less other problems can also be used. This known foaming agent includes two types, an inert low-boiling solvent and a reactive foaming agent, and the former include dichloromethane, hydrochlorofluorocarbon,
Hydrofluorocarbon, acetone, hexane, isopentane, etc., and nitrogen gas, carbon dioxide gas, air, etc. may be mentioned. Examples of the latter include those such as azo compounds that decompose at a temperature higher than room temperature to generate a gas. A particularly preferred blowing agent in the present invention is water.

As the catalyst used in the present invention, any known catalyst used in the production of polyurethane can be used. Examples thereof include tertiary amines, diazabicycloalkenes and salts thereof, and organometallic compounds described in U.S. Pat. No. 3,799,898 and Japanese Examined Patent Publication No. 54-15599, all of which are used as a mixture. Is also possible.

As the foam stabilizer which can be used in the present invention, there can be mentioned known foam stabilizers which are generally used in the production of polyurethane foam. Examples thereof include polydimethylsiloxane-polyalkylene oxide block polymer and vinylsilane-polyalkylene polyol polymer.

In carrying out the present invention, pigments and dyes, reinforcing materials and fillers such as mica and glass fibers, flame retardants, antioxidants, ultraviolet absorbers, other auxiliaries and additives are added as necessary. It can also be used. In the method of the present invention, the polyurethane molded article is produced by means such as casting or injection (RIM technology) in the range of NCO index 70 to 140, preferably 90 to 120.
Can be manufactured in the range of. In this case, the reaction can be promoted by heating the raw material and the mold as needed.

[0013]

As described above, according to the production method of the present invention, the conventionally used blowing agent chlorofluorocarbon, which has an adverse effect on the global environment, is not used, and there are problems such as toxicity and flammability. Even if the use of low boiling point foaming agents, etc. is greatly reduced or not used, it has good high-density skin layer and surface smoothness, does not deform when demolding, and has excellent physical properties. Polyurethane foam can be produced with high productivity.

[0014]

EXAMPLES The present invention will be described in more detail with reference to examples below, but the present invention is not limited thereto. In the examples, all parts and percentages are by weight unless otherwise specified. 1. Preparation of polyisocyanate (A) in which a part of MDI and / or carbodiimide-modified MDI is urethane modified A predetermined amount of MDI and / or MDI and / or was added to a 2-liter glass three-necked flask equipped with a thermometer, a stirrer, and a nitrogen seal tube. The carbodiimide-modified MDI and the polyol were charged in the proportions shown in Table 1, the air in the flask was replaced with nitrogen, and the mixture was heated at 75 ° C. for 3 hours while stirring. Table 1 shows the isocyanate group content of the obtained polyisocyanate (A). The relationship between the abbreviations of the raw materials in Table 1 and the compound names is as follows. Millionate MT: MDI Millionate MTL: Carbodiimide modified MDI polyol al: Polypropylene glycol (OH value =
56 mgKOH / g) Polyol a2: polyether triol (OH value = 3
4 mgKOH / g) Polyol a3: dipropylene glycol (OH value = 8
36 mg KOH / g) Polyol a4: Polyether polyol obtained by adding propylene oxide to tetrakis (hydroxymethyl) methane (OH value = 400 mg KOH / g) Polyol a5: Polyether polyol obtained by adding propylene oxide to sorbitol (OH value = 560 mg KO)
H / g)

[Table 1] 2. Preparation of Polyisocyanate Compound From the polyisocyanate (A) obtained as described above and the polymeric MDI (Millionate MR-200), a polyisocyanate compound having the composition shown in Table 2 was obtained.

[Table 2]

Examples 1 to 3 and Comparative Examples 1 and 2 100 parts of polyoxypropyleneoxyethylene glycol having an OH value of 28 mgKOH / g, 5 parts of ethylene glycol having an OH value of 1808 mgKOH / g, 0.6 part of water, a catalyst (Tosoh ( Manufactured by TEDA-L33) premix consisting of 1.0 part and the polyisocyanate compound shown in Table 2 are used.
10 × 300 × 300 m heated to 50 ° C. at the same time as heated to 50 ° C. and poured into the open mold the mixture mixed at a ratio of NCO index 105 to allow free foaming.
m into a mold to obtain a polyurethane foam molded product. Table 3 shows the foaming speed during free foaming and the physical properties of the polyurethane foam molded product.

[Table 3]

Examples 4 to 9 and Comparative Examples 3 and 4 Polyethertriol 100 having an OH value of 28 mgKOH / g
Parts, OH number 1058 mg KOH / g diethylene glycol 9
Parts, 0.6 parts of water, catalyst (TEDA-L3 manufactured by Tosoh Corporation)
3) The premix consisting of 1.0 part and the polyisocyanate compound shown in Table 2 were heated to 25 ° C.
At the same time as pouring the mixture with the ratio of CO index 105 into the open mold for free foaming, it is poured into the mold of 10 × 300 × 300 mm heated to 50 ° C.,
A polyurethane foam molded product was obtained. Table 4 shows the foaming speed during free foaming and the physical properties of the polyurethane foam molded product.

[Table 4] Examples 10 to 12 and Comparative Example 5 Polyethertriol 100 having an OH value of 34 mgKOH / g
Parts, 0.6 parts of water, catalyst (TEDA-L3 manufactured by Tosoh Corporation)
3) A polyurethane foam molded product was obtained in the same manner as in Example 1 from 1.0 part of the premix and the polyisocyanate compound shown in Table 2. Table 5 shows the foaming speed during free foaming and the physical properties of the polyurethane foam molded product.

[Table 5] <Performance test> The skin properties and surface smoothness of the polyurethane foam molded product were visually determined. Skin property: ◯ when the skin portion has a high density and a thickness of 0.5 mm or more, and x when the thickness is less than that. Surface smoothness: O when voids having a diameter of 0.1 mm or more do not exist on the surface, and X when voids exist.

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Claims (1)

[Claims] 1. A method for producing a polyurethane foam from an organic active hydrogen compound, a polyisocyanate compound, a foaming agent, a catalyst and, if desired, a foam stabilizer, wherein the organic active hydrogen compound has an average number of functional groups of 2 to 4 and a hydroxyl value. 14-80 mgKOH / g polymer polyol, or a mixture of this polymer polyol and a low-molecular active hydrogen compound having an average number of functional groups of 2-4 and a hydroxyl value of 500-2000 mgKOH / g, wherein the polyisocyanate compound is diphenylmethane diisocyanate. And / or a part of the carbodiimide-modified diphenylmethane diisocyanate is used as an average functional group number of 2 to 3
And polyhydroxy compound (A1) having a hydroxyl value of 10 to 399 mgKOH / g, an average number of functional groups of 2 to 8 and a hydroxyl value of 40
0-2000mgKOH / g polyhydroxy compound (A2)
The urethane-modified polyisocyanate (A) or a mixture of the polyisocyanate (A) and polymethylene polyphenylene polyisocyanate.