JPH07206962A - Production of flexible polyurethane foam - Google Patents

Abstract

PURPOSE:To obtain a flexible polyurethane foam markedly improved in compression set, excellent in flame retardancy, thus useful as e.g. an automotive cushioning material, by using each specific polyhydroxy compound and additive, organic polyisocyanate, catalyst, foam stabilizer and foaming agent. CONSTITUTION:This flexible polyurethane foam can be obtained by using (A) a polyhydroxy compound consisting of a polyol such as polyether polyol, containing aldehyde-condensed resin fine particles, (B) an organic polyisocyanate such as tolylene diisocyanate (C) a catalyst such as a tertiary amine, (D) a foam stabilizer such as a polydialkylsiloxane, (E) water as a foaming agent, and (F) as an additive, a castor oil or a fatty acid ester at 0.1-15wt.% based on the component A.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a flame-retardant polyurethane using a stable condensation resin-dispersed polyol, particularly a polyol in which a solid condensation resin condensed with an aldehyde is dispersed.

[0002]

2. Description of the Related Art Conventionally, phosphorus, halogen flame retardants, polyether flame retardants, etc. have been added to foam formulations in order to obtain flame retardant polyurethane foams. However, in view of environmental problems, halogen-based flame retardants have a problem of releasing halogen-containing gas when they burn. Further, there is a problem that the polyether flame retardant has poor compatibility with the high molecular weight polyol.

In order to solve the problem, a production method in which an aldehyde condensation resin is dispersed in an active hydrogen compound having two or more active hydrogen-containing groups (JP-A-2-91116) and an aminoplast condensate in an organic polyhydroxy compound. A method for producing the dispersion (Japanese Patent Publication No. 57-14708) is proposed. However, the polyurethane foam produced by using the polyol in which the aldehyde condensation resin is dispersed has insufficient physical properties and flowability of raw materials.

[0004]

SUMMARY OF THE INVENTION It is an object of the present invention to eliminate the above-mentioned drawbacks, to provide a method for producing a flexible urethane foam which has high flame retardancy and is excellent in foam physical properties, moldability and surface cure property. And

[0005]

The present invention provides a flexible polyurethane foam from a polyhydroxy compound consisting of a polyol containing aldehyde condensation resin fine particles, an organic polyisocyanate, a catalyst, a foam stabilizer, water as a foaming agent and additives. In the production, castor oils or fatty acid esters are added as additives to the polyhydroxy compound in an amount of 0.
The method for producing a flexible polyurethane foam is characterized by using 1 to 15% by weight.

The polyhydroxy compound used in the present invention is a polyol containing a polyol containing aldehyde condensation resin fine particles as an essential component. The hydroxyl value of the polyol is preferably 10 to 280, particularly preferably 10 to 90, and can be selected according to the application.

The method for producing a flexible foam is roughly classified into a hot cure foam and a cold cure foam according to a curing method, but the present invention can be applied to any foam.

When used for hot cure foam,
The average hydroxyl value of the polyol is usually in the range of about 40 to 90, especially about 50 to 80. Therefore, it is preferable that the average hydroxyl value of the polyol is within this normally used range. Suitably the average number of hydroxyl groups in the polyol is about 2-8, especially about 2-4, most preferably about 2.5-.
It is preferably 3.5.

When used for the cold cure foam in the present invention, the average hydroxyl value of the polyol is usually in the range of about 10 to 70, especially about 15 to 65. Therefore, it is preferable that the average hydroxyl value of the polyol is within this normally used range. Suitably the average number of hydroxyl groups in the polyol is about 2-8, especially about 2-4, most preferably about 2.5-4.5.

The polyol containing fine aldehyde condensation resin particles is preferably a dispersed polyol in which fine aldehyde condensation resin particles are dispersed using a polyether polyol as a dispersion medium. In the present invention, it is preferable that the polyhydroxy compound in the present invention preferably substantially consists only of an aldehyde condensation resin fine particle-containing polyether polyol or a mixture of an aldehyde condensation resin fine particle-containing polyether polyol and a polyether polyol. However, a polyol having a low molecular weight (usually about 600 or less) called a cross-linking agent or a chain extender is not included in the polyol as used herein.

The polyether polyol may be a mixture of two or more kinds, and the polyether polyol may be ester-modified or urethane-modified.
Further, it may contain a polyester-based polyol, a polydiene-based (especially butadiene homopolymer or copolymer) having a divalent or higher hydroxyl group, or a polyolefin-based polyol.

The polyether polyol may be a so-called primary polyether polyol containing a primary hydroxyl group obtained by capping ethylene oxide at the terminal as described later, and an oxyethylene group may be provided inside the oxyalkylene chain. It may be a polyether polyol having ethylene oxide capped or uncapped at its end.

At least 2 is a polyether polyol.
It is a polyether polyol obtained by adding an alkylene oxide to a compound having a hydrogen atom to which one alkylene oxide can be added (hereinafter referred to as an initiator).

A small amount of other monoepoxides such as halogen-containing alkylene oxides, styrene oxides, glycidyl ethers, etc. may be added with the alkylene oxide, but preferably substantially only the alkylene oxide is used.

The alkylene oxide has 2 to 4 carbon atoms.
The alkylene oxide of is suitable, and propylene oxide alone or a combination of propylene oxide and ethylene oxide is particularly preferable. When propylene oxide and ethylene oxide are used in combination, a mixture of both may be added, they may be added separately in sequence, or they may be combined. The hydroxyl value of the polyether polyol is adjusted by the amount of alkylene oxide added.

When ethylene oxide is added last, it is a cap of ethylene oxide. Also, the proportion of primary hydroxyl groups can be adjusted by further adding a small amount of propylene oxide after the ethylene oxide cap.

As the initiator, polyhydric alcohols, polyhydric phenols, mono- or polyamines and others can be used, but polyhydric alcohols and polyhydric phenols are suitable, and polyhydric alcohols are particularly preferable. Also, two or more initiators can be used in combination. Specific examples of the initiator are shown below, but the initiator is not limited to these. A particularly preferred initiator is a trihydric polyhydric alcohol, or a mixture thereof with a dihydric or tetrahydric or higher polyhydric alcohol-based initiator.

Divalent initiator; ethylene glycol,
Diethylene glycol, propylene glycol, dipropylene glycol, 1,4-butanediol, bisphenol A: trivalent initiator; glycerin, trimethylolpropane, hexanetriol: tetravalent or more initiators: pentaerythritol, diglycerin, ditrimethylolpropane, dextrose, Sorbitol,
Sucrose, novolak.

The polyether polyol may be a urethane-modified polyether polyol or an ester-modified polyether polyol. The urethane-modified polyether polyol is preferably a urethane-modified polyether polyol obtained by reacting a polyether polyol with less than an equivalent amount of an aromatic polyisocyanate. In this case, other polyols such as polyhydric alcohol may be used together with the polyether polyol. This urethane-modified polyether polyol can be regarded as a hydroxyl group-terminated polyurethane prepolymer, but may contain a relatively large amount of unreacted polyether polyol.

The urethane-modified polyether polyol is
This polyether polyol and a polyol having an aromatic nucleus (which may be a polyether polyol or a low-molecular weight polyol) have about 0.1 to 0.8 equivalent of a fragrance with respect to the total equivalent of both. Urethane-modified polyether polyols obtained by reacting group polyisocyanates are preferred.

As the ester-modified polyether polyol, the polyether polyol is reacted with a compound having a carboxyl group or a reactive derivative group such as an acid anhydride group, and if there is a residual carboxyl group, an alkylene oxide is reacted. What is obtained by this is preferable.

For example, an ester-modified polyether polyol obtained by reacting a polyether polyol with a polycarboxylic acid anhydride and then reacting an equivalent amount or more of alkylene oxide with respect to the remaining carboxyl groups, a polyether polyol and a polycarboxylic acid. Examples include ester-modified polyether polyols obtained by reacting an acid or its reactive derivative with a polyhydric alcohol. Further, the ester-modified polyether polyol can also be obtained by a method of reacting a polyether polyol with a cyclic ester such as caprolactone.

The above-mentioned polycarboxylic acid anhydride is preferably a dicarboxylic acid anhydride, and particularly preferably an aromatic dicarboxylic acid anhydride such as phthalic anhydride. As the above-mentioned polycarboxylic acid or its reactive derivative, similarly, a derivative of dicarboxylic acid or its acid halide, anhydride, ester or the like is preferable. 2-3 as polyhydric alcohol
A low valent polyol having a low molecular weight is preferable, and a diol having 8 or less carbon atoms such as ethylene glycol and 1,4-butanediol is particularly preferable.

Polyether polyols containing aldehyde condensation resin fine particles are known. It can be produced by adding fine particles of an aldehyde condensation resin to a polyol (Japanese Patent Publication No. 51-122193), but preferably the fine particles are obtained by condensing a substance capable of forming an aldehyde condensation resin in a polyol. A method of precipitating (Japanese Patent Publication No. 57-14708) or a method of condensing a substance capable of forming an aldehyde condensation resin in a dispersion medium other than polyol to precipitate fine particles and then convert the dispersion medium into a polyol. (Japanese Patent Laid-Open No. 2-9111
No. 6). The fine particle-dispersed polyol produced by these two methods has a small particle size of fine particles to be produced, and is highly stable in dispersion because it does not easily settle in the polyol.

One of the raw materials for forming the aldehyde condensation resin is an aldehyde. As the aldehydes, aliphatic, alicyclic, heterocyclic aldehyde compounds, other aldehydes and their condensates can be used alone or in combination. Preferred aldehydes are lower aliphatic aldehydes and their derivatives, for example, formaldehyde, acetaldehyde, propionaldehyde, butyraldehyde, isobutyraldehyde, paraformaldehyde, paraacetaldehyde and the like, preferably formaldehyde. A particularly preferred solvent is water, but is not limited to this. In the present invention, it is particularly preferable to use an aqueous formaldehyde solution, that is, formalin.

The other raw material for forming the aldehyde condensation resin is a compound which can be condensed with aldehydes to form a solid aldehyde condensation resin (hereinafter referred to as aldehyde condensation compound), which can react with aldehydes. Basically, two positions (hereinafter referred to as reaction sites) are required. The reaction site is typically a hydrogen-bonded carbon atom in an aromatic group or a hydrogen-bonded nitrogen atom in an amino group or an amide group. The aromatic reaction site is particularly preferably an aromatic ortho position or para position to which a hydroxyl group or an amino group is bonded, and has two or more reaction sites.
In other words, it is suitable to have no substituent at this site,
As a compound having an amino group or an amide group, a polyamine compound having two or more of them is basically suitable.
Therefore, as the aldehyde-condensable compound, aromatic compounds such as phenols and aromatic amines, and urea, melamine, guanidine compounds and other polyamine compounds are preferable. Compounds that can react with these aldehydes are 2
A combination of two or more species may be used, and a compound having only one reaction site may be used in combination therewith.

Among the above aromatic compounds, examples of the phenols include phenol, cresol, xylenol, p-alkylphenol, p-phenylphenol, bisphenol A, resorcin, and the like. Particularly preferred is phenol, and aromatic Examples of amines include aniline, diaminobenzene, p-alkylaniline, N-substituted alkylaniline, diphenylaniline,
There are diaminodiphenylmethane and the like, and they can be used alone or in combination of two or more as in the case of the phenolic compound. Since the amino group and amide group of the aromatic amine are themselves reactive sites, they may be regarded as one of the following diamine compounds,
Reactive sites other than aromatic amine groups and amide groups are 1
May be one. A particularly preferred aromatic amine is aniline.

The aromatic compounds are not limited to the above compounds, but aromatic hydrocarbons such as benzene and xylene, and other compounds can also be used. Further, phenols and aromatic amines can be used in combination, and at least one of them can be further combined with other aromatic compounds.

The polyamine compound is preferably a compound basically having two or more amino groups or amide groups, and particularly preferably a compound having two or more amino groups, such as urea,
Urea such as thiourea and N-substituted urea, melamine, melamine compounds such as N-alkyl substituted melamine and S-triazines having two or more amino groups represented by guanamine compounds such as benzoguanamine and acetoguanamine, guanidine, Guanidines such as dicyandiamide are preferred, and among these, particularly preferred are urea, melamine,
It is benzoguanamine. These polyamine compounds are 2
Combinations of more than one species, such as urea-thiourea, urea-melamine, urea-benzoguanamine, urea-melamine-benzoguanamine, melamine-dicyandiamide combinations can also be used.

It is also possible to use the above polyamine compound and the above aromatic compound in combination, and examples of such a combination include phenol-melamine, aniline-urea, aniline-melamine, phenol-aniline-melamine, phenol-urea-. Examples include melamine and other combinations.

Further, as the aldehyde-condensable compound, in addition to the above compounds, a ketone compound known as a raw material for a ketone resin may be used. Further, the compound having at least two reaction sites with aldehydes described above is a compound having one reaction site or a compound having two or more active reaction sites which are not aldehyde-condensable compounds themselves. For example, it can be used in combination with dialkanolamine, monoalkanolamine, aliphatic amine and the like.

An initial condensate of an aldehyde condensable compound and aldehydes such as dimethylol urea, hexamethylol melamine, hexamethoxymethyl melamine, etc. can also be used as a forming raw material.

The ratio of the aldehyde-condensable compound and the aldehydes in the reaction for forming the aldehyde-condensation-based resin particles is not limited as long as it is a ratio that theoretically forms the aldehyde-condensation-based resin. This is because even if the unreacted aldehyde condensable compound remains, it may be contained in the resulting dispersion unless the amount is too large, and the unreacted aldehyde can be removed when the dispersion medium is replaced. Preferably, 5 to 5 aldehydes are added to 100 parts by weight of the aldehyde condensable compound.
00 parts by weight, especially 10 to 100 parts by weight are used.

The aldehyde condensation resin produced by this reaction is considered to be similar to or the same as a cured product of a conventionally known condensation thermosetting resin such as phenol resin, urea resin, melamine resin, etc. The reaction is also believed to be similar. In the case of using formaldehyde as the aldehyde, for example, the aldehyde condensable compound and formaldehyde are subjected to addition condensation in the initial stage of the reaction to produce various methylol group-containing compounds. The above-mentioned initial condensate, which is one of the forming raw materials of the present invention, corresponds to the methylol addition compound at this stage.
After that, it is considered that the methylol group-containing compound is dehydrated and condensed, so that the methylol group becomes a methylene group and is condensed to become a three-dimensionally crosslinked solvent-insoluble and infusible aldehyde condensation resin.

The particle diameter of the sufficiently crosslinked aldehyde condensation resin particles is preferably in the range of 0.01 to 5 μ, and particularly preferably in the range of 0.1 to 2 μ. If it exceeds 5μ, it tends to settle in the dispersion solvent. It is preferable that the aldehyde condensation resin particles do not substantially settle for at least one month, preferably two months or more when left standing. The aldehyde condensed resin dispersion is preferably a white or colored translucent or opaque viscous liquid in which aldehyde condensed resin particles having a particle diameter of 0.1 to 5 μm are dispersed,
The viscosity varies depending on the viscosity of the dispersion medium used, the ratio of the aldehyde condensation resin in the dispersion, and the type of the aldehyde condensation resin. However, for a flexible polyurethane foam raw material, one having a viscosity of 50000 cps or less at 25 ° C. is usually suitable. Is. Even if the viscosity is higher than this, it may be usable by reducing the viscosity by means such as dilution with various polyols or additives.

The fine particle-dispersed polyol containing the aldehyde condensation resin fine particles as described above improves the flame retardancy of the flexible polyurethane foam. Especially phenol compounds, urea compounds, melamine compounds, guanamine compounds,
Alternatively, a fine particle-dispersed polyol containing an aldehyde condensation resin dispersion mainly containing a guanidine compound is particularly effective for improving the flame retardancy of flexible polyurethane foam.

In the present invention, castor oils or fatty acid esters are used as additives: As castor oils,
It may be purified castor oil, semi-refined castor oil, unrefined castor oil, or a derivative of castor oil such as hydrogenated castor oil to which hydrogen is added. Specifically, UR made by Ito Oil
IC • H-30, etc., but not limited to this.

The fatty acid esters include esters of monocarboxylic acids or polyhydric carboxylic acids with monoalcohols or polyhydric alcohols. For example, there are esters of monocarboxylic acid and monoalcohol, esters of dicarboxylic acid and monoalcohol, esters of monocarboxylic acid and dialcohol, and the like. More specific examples include, but are not limited to, the following compounds (A) to (E): (A) RCOO- (R ² -O) _k -COR ¹ where k is ^{1 to} 60, R, R ¹ represents a C _{1 to} C ₃₀ hydrocarbon group, and R ² represents a C _{2 to} C ₄ hydrocarbon group. Where k
Each R ² may be the same or different.

As k, 5 to 50 is particularly preferable, and 10 to 40 is most preferable. R and R ¹ have 1 to 3 carbon atoms
It is an alkyl group or an alkenyl group of 0 and may be the same or different. R ² is an ethylene group, a propylene group,
Butylene group and the like. Especially as (R ² —O) _k ,
A polyoxyethylene chain, a polyoxypropylene chain, or a polyoxyethylene / polyoxypropylene copolymer chain is preferable. The copolymer chain may be either random or block copolymer chain. These polymer chains can also be obtained by ring-opening polymerization of ethylene oxide and / or propylene oxide with water, propylene glycol, ethylene glycol, 1,4-butanediol and the like.
(A) Specifically, Unisafe NKL made by NOF Corporation
However, it is not limited to these.

(B) H ₂ C = C (CH ₃ ) -COO-
(R ³ —O) _m —CH ₃ Here, m represents 1 to 25, and R ³ represents a C _{2 to} C ₄ hydrocarbon group. However, m R ^{3 s} may be the same or different.

As m, 1 to 20 is particularly preferable, and 1 to 10 is most preferable. R ³ is an ethylene group, a propylene group, a butylene group or the like. Particularly, as (R ³ —O) _k , a polyoxyethylene chain, a polyoxypropylene chain, or a polyoxyethylene / polyoxypropylene copolymer chain is preferable. The copolymer chain may be either random or block copolymer chain. It is particularly preferably a polyoxyethylene chain. Specific examples of (B) include Bremmer PME-400 manufactured by NOF CORPORATION, but are not limited thereto.

(C) R ⁴ --COO--R ⁵ wherein R ⁴ is a C _{5 to} C ₂₅ hydrocarbon group, and R ⁵ is C _{1 to} C
₁₅ hydrocarbon groups are shown.

R ⁴ is a carboxylic acid residue having 5 to 25 carbon atoms, particularly a carboxylic acid residue such as oleic acid, stearic acid, palmitic acid, lauric acid and erucic acid. R ⁵ is an alkyl group, particularly a methyl, ethyl, butyl, octyl group or the like. Specific examples thereof include Unistar MB-816 manufactured by NOF CORPORATION, but are not limited thereto.

(D) R ⁶ COO- (CH ₂ ) _n -OCO
R ⁷ Here, n is 1 to 10, and R ⁶ and R ⁷ are C _{5 to} C ₂₅ hydrocarbon groups.

R ⁶ and R ⁷ are residues of a carboxylic acid having 5 to 25 carbon atoms, particularly carboxylic acid residues such as oleic acid, stearic acid, palmitic acid, lauric acid and erucic acid. R ⁶ and R ⁷ may be the same or different. Particularly, n is preferably 3 to 6.

(E) R ⁸ OCO-R ⁹ -COOR ¹⁰ where R ⁸ and R ¹⁰ = C _{1 to} C ₂₅ hydrocarbon group, R ⁹ = C
Indicates a _2- C ₁₂ hydrocarbon group.

R ⁸ and R ¹⁰ are the residues of alcohols having 1 to 25 carbon atoms, and the residues of ethanol, butanol, octyl alcohol and dodecyl alcohol are particularly preferred. R ⁸
And R ¹⁰ may be the same or different. R ⁹ is a dicarboxylic acid residue having 2 to 12 carbon atoms, and particularly preferably a dicarboxylic acid residue such as maleic acid, fumaric acid, succinic acid, adipic acid, or sebacic acid.

The amount of the above additives used is 0.1 to 15% by weight based on the polyhydroxy compound. Preferably 0.5 to 10% by weight, especially 2 based on the polyhydroxy compound.
-12 wt% is preferred. Among the above additives, it is particularly effective to use (E).

The other main raw material for the production of flexible polyurethane foam is a polyisocyanate compound. As the polyisocyanate compound, various compounds having two or more isocyanate groups can be used, but aromatic polyisocyanates are particularly suitable. As the aromatic polyisocyanate, a mononuclear or polynuclear compound having an isocyanate group bonded to an aromatic nucleus or a modified product thereof is suitable.

Specific examples include tolylene diisocyanate, diphenyl diisocyanate, polymethylene diisocyanate, diphenylmethane diisocyanate, polymethylene polyphenyl isocyanate, naphthalene diisocyanate, xylylene diisocyanate, tolidine diisocyanate and triphenylmethane triisocyanate. Also, in some cases with these,
Alternatively, a polyisocyanate compound having no aromatic nucleus alone, such as hexamethylene diisocyanate or isophorone diisocyanate, may be used. As the modified product, not only a prepolymer modified product modified with a polyhydric alcohol such as trimethylolpropane but also a carbodiimide modified product, a urea modified product, a trimerized modified product, a dimerized modified product and the like can be adopted.

Two or more of these polyisocyanate compounds can be used in combination. The amount of the polyisocyanate compound used is preferably about 85 to 120, particularly about 90 to 110, expressed as 100 times the number of isocyanate groups with respect to the number of active hydrogens of all active hydrogen-containing compounds (usually called isocyanate index).

The polyhydroxy compound is mainly a polyol such as the above polyether polyol, but it also contains a small amount of water as a foaming agent, and in some cases,
A small amount of the above-mentioned chain extender or crosslinking agent can be used. These are usually compounds having a molecular weight of about 600 or less and having two or more active hydrogens, and particularly include polyhydric alcohols having a molecular weight of 400 or less, low molecular weight polyether polyols, alkanolamines and polyamines.

Another one of the essential components of the foamable mixture is a catalyst. As a catalyst for producing a flexible polyurethane foam, a tertiary amine catalyst and an organic metal compound, especially an organic tin compound are usually used, and they are usually used in combination. Various tertiary amine-based catalysts can be used as the tertiary amine-based catalyst.

For example, triethylenediamine, N-ethylmorpholine, N, N-dimethylaminoethylmorpholine, triethylamine, N, N, N ', N'-tetramethylhexamethylenediamine, bis (2-dimethylaminoethyl) ether, N, N ', N'-trimethylaminoethylethanolamine, and the like.

Two or more of these can be used in combination.
A particularly preferred tertiary amine-based catalyst is triethylenediamine, and a mixture of triethylenediamine and dipropylene glycol in a weight ratio of 1: 2 which is well known under the trade name of "Dabco-33LV" is most suitable.

The amount used can be varied depending on the desired reaction conditions and the like, but is usually about 0.01 to 2.0 parts by weight, preferably 0.02, relative to 100 parts by weight of the polyol.
.About.1.5 parts by weight is suitable, especially "Dabco-33.
It is suitable to use 0.1 to 1.0 parts by weight as "LV".

The organometallic compound catalyst is most preferably an organotin compound catalyst, for example, stannas octoate, stannas laurate, dibutyltin dilaurate,
Examples include dibutyltin dimaleate, dibutyltin diacetate and dioctyltin diacetate. In particular, stanna octoate, dibutyltin dilaurate and the like are preferable.

The amount of the organotin compound catalyst used is usually 0.01 to 1.0 part by weight based on 100 parts by weight of the polyol. However, the amount of this catalyst used needs to be delicately changed depending on the type of the polyol, reactivity, and other conditions, and various optimum ranges are relatively narrow.

Another component added to the foamable mixture is a foaming agent. Water is preferably used as the foaming agent, but a halogenated hydrocarbon-based foaming agent, a low boiling point gas such as air, or another foaming agent may be used in combination.

Examples of the halogenated hydrocarbon blowing agent include trichlorofluoromethane, dichlorodifluoromethane, methylene chloride, monochlorodifluoromethane, 1,1-dichloro-2,2,2-trifluoroethane, 1,1- Dichloro-1-fluoroethane and the like.

The amount of the foaming agent used may vary depending on the density of the desired foam, but is usually about 1 to 10 parts by weight, particularly about 2 to 8 parts by weight, based on 100 parts by weight of the polyol.

Still another normally required component is a siloxane-based foam stabilizer such as polydialkylsiloxane and polydialkylsiloxane-polyoxyalkylene block copolymer. Other optional components include, for example, colorants, antioxidants, UV absorbers, light stabilizers, flame retardants, and other additives that may be used in the production of cure foam.

The flexible polyurethane foam with high skin strength obtained by the present invention is particularly suitable as a cushion sheet material for automobiles. However, the material is not limited to the seat material for automobiles, and can be applied as a cushion seat material for other uses, or to the field where the flexible polyurethane foam is conventionally used.

[0064]

EXAMPLES The present invention will be specifically described below with reference to Examples and Comparative Examples. Parts indicate parts by weight. The additives A to D used here are shown in Table 1.

(Synthesis Example) Polyol A: 3000 g of polyoxypropylenetriol having a hydroxyl value of 56, 400 g of a diol obtained by reacting 1 mol of bisphenol A with 3 mol of propylene oxide, and 0.2 g of triethylenediamine were charged, and 100 Heated to ° C.
Then add 174 g of tolylene diisocyanate and add 1
After reacting at 00 ° C. for 8 hours, 2400 parts of the obtained product, 600 parts of melamine, and 700 parts of a 35% formalin aqueous solution were charged and reacted at 100 ° C. for 4 hours while stirring. After that, dehydration under reduced pressure was performed to obtain a white viscous polyol A. The viscosity of this polyol A was 4000 cps, and the melamine resin fine particles therein were stable in the polyol for 6 months or more without any separation.

Polyol B: 2400 parts of polyoxypropylenetriol having a hydroxyl value of 34.6, 500 parts of urea,
1070 parts of 35% formalin aqueous solution was charged and reacted at 100 ° C. for 4 hours while stirring. After that, dehydration under reduced pressure was performed to obtain a white viscous polyol B. The viscosity of this polyol B was 3500 cps, and the urea resin fine particles therein were stable in the polyol without separation for 6 months or longer.

Example 1 95 parts of polyol A, 5.0 parts of additive A, 5.5 parts of water, amine catalyst [Dabco
-33LV (made by Sankyo Air Products) 0.36 parts, Da
bco-XDM (manufactured by Sankyo Air Products) 0.05 part,
And NC-IM (Sankyo Air Products) 0.05 part mixture], foam stabilizer S-736-08 (Nippon Unicar)
TDI-80 (2,4-TDI / 2,6-TDI = 8) in a mixture of 1.5 parts and 0.12 parts of stanna octoate.
0/20 mixture) was mixed under the conditions of a liquid temperature of 25 ° C. and an isocyanate index of 95.

Next, 350 mm × 350 mm × 100 mm
Foaming was performed at a mold temperature of 40 ° C. using the aluminum mold. After curing in a 170 ° C. oven for 10 minutes, the temperature was kept at 150 ° C. and the mold was removed. The physical properties of the soft hot mold foam after demolding were evaluated, and the results are shown in Table 2.

Examples 2 to 4 Flexible hot mold foams were produced in the same manner as in Example 1 except that the polyols and additives shown in Table 2 were used. The evaluation results are shown in Table 2.

Comparative Example 1 A soft hot mold foam was produced in the same manner as in Example 1 except that the additive was not added in Example 1. The evaluation results are shown in Table 2.

Comparative Example 2 A flexible hot mold foam was produced in the same manner as in Example 1 except that Polyol B was used instead of Polyol A in Example 1. The evaluation results are shown in Table 2.

As shown in Table 2, various properties are improved by using the additive of the present invention, and particularly compression set is remarkably improved.

[0073]

[Table 1]

[0074]

[Table 2]

[0075]

EFFECTS OF THE INVENTION The use of the additive of the present invention has the effect that a foam having excellent physical properties can be obtained without impairing flame retardancy. Further, the flowability of the raw material is improved, and good foaming can be achieved even in mold foaming of complicated shapes. The effect that the body is obtained is also recognized.

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Claims (3)

[Claims] 1. A method for producing a flexible polyurethane foam from a polyhydroxy compound consisting of a polyol containing fine particles of an aldehyde condensation resin, an organic polyisocyanate, a catalyst, a foam stabilizer, water as a foaming agent and an additive, castor as an additive. A method for producing a flexible polyurethane foam, which comprises using 0.1 to 15% by weight of oils or fatty acid esters with respect to the polyhydroxy compound. 2. The method according to claim 1, wherein the polyol containing the aldehyde condensation resin fine particles is a dispersed polyol in which the aldehyde condensation resin fine particles are dispersed using a polyether polyol as a dispersion medium. 3. The method according to claim 2, wherein the polyether polyol is a urethane-modified polyether polyol or an ester-modified polyether polyol.