JPS6176324A - Composite of aqueous mold release agent - Google Patents

Abstract

PURPOSE:To enable to obtain an aqueous mold release agent having performance which is not inferior to a solvent series mold release agent, by making the softening point and the melting viscosity of nonvolatile content fall within a specific range, in an emulsion obtained by emulsifying wax by making use of an emulsifying agent by loading a small quantity of an organic solvent to the wax. CONSTITUTION:The title agent is an emulsion to be obtained by emulsifying a mixture of wax obtained by loading a 5-20wt part organic solvent to the 1,000wt part wax containing more than 70wt part polyethylene wax whose acid value is less than 1 by an emulsifying agent having volatile amine salt or ammonium salt of aliphatic acid having 12-20 pieces of carbon atoms for its indispensable ingredient and aliphatic acid ester of multivalent alcohol for its optional ingredient and is a composite of aqueous mold release agent for molding soft polyurethane foam made of the composite whose softening point of nonvolatile content is 50-100 deg.C and melting point is 20-100CP at the temperature of 120 deg.C. When wax content in the wax other than the polyethylene wax exceeds 30wt%, mold release characteristics are deteriorated.

Description

DETAILED DESCRIPTION OF THE INVENTION Field of Industrial Application Foam The present invention relates to an aqueous mold release agent composition for molding flexible polyurethane foam, and therefore can be used in the field of oil production and the field of polyurethane foam molding.

Conventional technology The production of flexible polyurethane foam requires polyether polyols, diisocyanates, and catalysts.

Pour the stock solution mixed with flame retardant etc. into the mold, and heat it in the mold for 80~
A so-called hot molding process is widely used, in which the foam is heated at 130° C. for about 15 minutes and then removed. In order to smoothly release the foam in this process, a release agent is usually applied to the mold before the stock solution is injected. Compositions made by adding wax to organic solvents have often been used as mold release agents for this purpose, but water-based mold release agents are preferred due to the risk of ignition, explosion, and deterioration of the working environment. has been done. As a water-based mold release agent, emulsions made by emulsifying wax, especially oxidized wax, with various emulsifiers have been tried, but these have the following drawbacks and are difficult to put to practical use.

(1) Bad M type property.

(2) There is a lot of deposits on the mold.

Problems to be Solved by the Invention In light of the above-mentioned current situation, it is an object of the present invention to improve the drawbacks of aqueous mold release agents and to provide an aqueous mold release agent that has performance comparable to that of solvent-based gI type agents. be.

Means for Solving the Problems In order to achieve the above object, the present inventors have conducted extensive research and have created an emulsion in which a small amount of an organic solvent is added to a specific wax and emulsified using a specific emulsifier. The present invention was completed based on the discovery that a composition in which the physical properties of nonvolatile components, particularly the softening point and melt viscosity, are within a specific range has excellent effects.

That is, in the present invention, (A) (B) polyethylene wax with an acid value of 1 or less is
A wax mixture prepared by adding (b) 5 to 20 parts by weight of an organic solvent to 100 parts by weight of 7772 containing 0% by weight or more, (b) (c) a volatile amine salt of a fatty acid having 12 to 20 carbon atoms. Or with ammonium salt as an essential ingredient,
(d) An emulsion obtained by emulsifying with an emulsifier containing a fatty acid ester of a polyhydric alcohol as an optional component, the softening point of nonvolatile components is 50 to 100°C, and the melt viscosity is 20 to 1 oocp at 120°C. This is an aqueous mold release agent composition for molding flexible polyurethane foam.

The configuration of the present invention will be explained in detail below.

(Wax) Wax is polyethylene wax with an acid value of 1 or less.
As the wax other than polyethylene wax that must be contained at 0% by weight or more, various natural waxes can be used within a range not exceeding 30% by weight in the wax component.

Among these waxes, carnauba wax has the effect of facilitating emulsification of a composition.

The acid value of the polyethylene wax must be 1 or less; if the acid value is greater than 1, more deposits will be deposited on the mold surface. This deposit firmly adheres and accumulates as a resin-like substance on the mold surface during repeated molding processes.
This makes it difficult to control the temperature of the mold and demold the foam, resulting in inconveniences such as the surface of the molded foam not being finished according to specifications.

If wax other than polyethylene wax exceeds 30% by weight in the wax component, mold releasability decreases.

(Organic solvent) Organic solvents are used to improve the emulsion stability of the composition and when applying a mold release agent using an airless unit.

Particularly when the spray pressure is low, it has the effect of preventing wax from adhering to the piston of the airless unit's pump, thereby preventing the piston from operating insufficiently.

The organic solvent is preferably one that has good wax solubility and is low in toxicity and odor.Also, since the constituent components are heated to around 120°C when preparing the composition, it is desirable that the boiling point is 120°C or higher. Minetulterpen can be cited as a product that meets these conditions. The amount of organic solvent is 5 to 100 parts by weight of wax.
It is desirable that the amount is 20 parts by weight; if it is less than 5 parts by weight, the above-mentioned effects cannot be obtained, and if it exceeds 20 parts by weight, the effect will not improve, which is uneconomical.

(Emulsifier) As the emulsifier, (c) a volatile amine salt or ammonium salt of a fatty acid having 12 to 20 carbon atoms is used alone, or a combination of the volatile amine salt and (d) fatty acid ester of a polyhydric alcohol is used. do. The substance (c) has excellent emulsification of the composition and wettability to the mold, and the substance (d) is mainly used as an auxiliary to improve emulsion stability. However, the substance in 2) is 2 parts by weight per 100 parts by weight of the substance in (c).
It is desirable that the amount is within 0 parts by weight; if it exceeds 20 parts by weight, the mold releasability will deteriorate. The fatty acid used to make the volatile amine salt or ammonium salt may be a saturated acid or an unsaturated acid, but those with a carbon atom number in the range of 12 to 20 exhibit excellent emulsifying power. Desirably, if the number of carbon atoms is less than 12, the wettability of the composition to the mold will be reduced, and if it exceeds 20, the emulsification of the emulsion will become unstable.

Examples of substances reacted with fatty acids to produce salts include ammonia and volatile amines such as methylamine, ethylamine, propylamine, morpholine, ethylmorpholine, and methylmorpholine, which have excellent emulsifying power and relatively low odor. Morpholine is superior in this regard.

As the fatty acid ester of polyhydric alcohol as an optional component, monoester, diester, or a mixture thereof can be used. Glycerin is a polyhydric alcohol,
Pentaerythritol, neopentyl glycol, diethylene glycol and the like can be mentioned.

(Other components) In addition to the above-mentioned essential components and optional components, an antioxidant that has been used in conventional mold release agents can be optionally contained.

(Physical properties of non-volatile components) The aqueous mold release agent composition of the present invention has a softening point of non-volatile components of 50
~100°C, and the melt viscosity is 20-120°C.
It needs to be 100 cp.

If the softening point of the non-volatile content is lower than 50°C, the surface of the foam tends to become rough, and if it is higher than 100°C, the non-volatile content solidifies during demolding, resulting in increased demolding resistance.

If the melt viscosity of the non-volatile content is lower than 20 cP at 120° C., the coating film will shift to foam more and the AI-type property will decrease. When it is higher than 100 cp, mold release resistance becomes large due to viscosity, making work difficult.

(Production method) To produce the composition of the present invention, a wax component, an organic solvent, and if necessary, a fatty acid ester as an emulsifier are mixed, heated to -120°C to melt, and then melted at 90°C or higher. The solution is gradually added to an aqueous solution of a volatile amine salt or ammonium salt of a fatty acid heated to a temperature of 20° C. while stirring. In this manner, a preliminary emulsion having a component concentration of 30 to 40% by weight is prepared, which is then homogenized to form fine emulsion particles. The emulsion thus obtained at a temperature of 90°C or higher is heated to a temperature close to room temperature 1. % temperature to create a stable emulsion composition.

(How to use) When applying the above composition to a mold, prepare an emulsion with a component concentration of about 10% by diluting it with water, and
After air spraying or airless spraying is applied to a mold heated to 30°C, a uniform release agent film is formed on the mold within a few seconds. Then, after cooling the mold to 35-40°C, the foam raw material was injected into the mold and heated to 120-tao°C, lO-
After curing for 20 minutes, the mold is demolded at 80 to 120°C. The above steps can be carried out using the same equipment and conditions as when using a solvent-based mold release agent.

EXAMPLES Next, the present invention will be described with reference to Examples in order to make the present invention easier to understand. However, the following examples do not limit the present invention in any way. In the following description, 1 part means part by weight, and % means % by weight.

Example 1 Wax mixture Polyethylene wax-1 (Note-1) 18 parts Polyethylene wax-2 (Note-2) 9 parts Stearic acid monoglyceride 0.5 parts Mineral turpentine 4 parts Emulsifier Stearic acid 2 parts Morpholine 1.5 parts Water
65
Part (Note-1) Softening point 55℃, melt viscosity 180cp/12
0℃, acid value 0 (Note-2) Softening point 87℃, melt viscosity 5cp/120
°C, acid number O Heat the wax mixture to 120 °C to melt it, and then heat it to 95 °C.
A preliminary emulsion was prepared by gradually adding the emulsifier into an aqueous solution of morpholine stearate heated to C while stirring. The mixture was then emulsified (processing pressure: 5000 psi) using a homogenizer (manufactured by Galarin Co., Ltd.), and then rapidly cooled to 40° C. using a heat exchanger to obtain a composition with a nonvolatile content concentration of 30%.

The softening point of the non-volatile components of this composition is 60°C and 120°C.
The melt viscosity at °C was 60 cp. Add this composition to water
The diluted polyurethane foam raw material was diluted twice and applied to the inner surface of an aluminum mold heated to 80℃ using an airless sprayer, and after cooling to 40℃, the uniformly mixed polyurethane foam raw material was poured into the mold and the top lid was closed. After that, the mold was placed in an oven adjusted to 120° C. and foamed for 15 minutes. After zero foaming, the mold was taken out of the oven, and the mold releasability and surface finish of the foam were both extremely good. After repeating this operation five times, the amount of deposits in the mold was observed to be extremely small.

Example 2 An aqueous mold release agent composition having a non-volatile content concentration of 30% was prepared for the cold molding process in the same manner as in Example 1 using the following raw materials.

Wax mixture Polyethylene wax - 118 parts Paraffin (melting point 155°F) 6 parts Polyethylene wax - 23 parts Stearic acid monoglyceride 1 part Oxidation inhibitor 0.1 part Mineral turpentine
2 parts emulsifier oleic acid 2 parts morpholine 1.5 parts water
35 parts The softening point of the non-volatile components of this composition is 50°C and 120°C.
The melt viscosity of was 50 cp.

This composition was diluted 3 times with water and applied to the inner surface of an aluminum mold heated to 70°C using an airless spray.
After cooling to 5℃, uniformly mixed polyurethane foam raw materials were poured into the mold, the top lid was closed, and 1.
After foaming for 15 minutes in an oven adjusted to 00°C, the mold was removed from the oven, cooled to 60°C, and the polyurethane foam was taken out. The mold releasability and surface finish of the foam were excellent. It was good. After repeating this operation five times, the amount of deposits in the mold was observed to be extremely small.

Example 3 In a special case of the foam molding process, that is, when foaming is performed at about 200°C, if the melt viscosity of the nonvolatile component is low, the wettability to the mold is poor, and the mold release agent may migrate to the inner surface of the foam. Taking this into consideration, the following mold release agent composition was prepared.

Wax mixture Polyethylene wax-3 (Note-3) 21 parts Polyethylene wax-4 (Note-4) 6 parts Pentaerythrift dioleate 0.5 parts Antioxidant 0.1 part Mineral turpentine
4 parts Emulsifier Stearic acid 2 parts Morpholine 1.4 parts Water
65 copies (Note-
3) Softening point 78℃, melt viscosity 180cp/120℃, acid value 0 (Note-4) Softening point 102℃, melt viscosity 7cp/120℃
, acid value 0 The above components were treated in the same manner as in Example 1 to prepare an aqueous mold release agent composition.

The softening point of the nonvolatile components of the composition was 90°C, and the melt viscosity at 120°C was 70 cp.

This composition was diluted 3 times with water, applied by airless spraying to the inner surface of the mold at 130°C, cooled to 40°C, and the uniformly mixed polyurethane foam raw material was uniformly poured into the mold. After the mold was covered with a lid, it was foamed for 15 minutes in an oven adjusted to 200° C. After zero foaming, the mold was taken out of the oven, and the mold releasability and surface finish of the foam were both extremely good. After repeating this operation five times, the amount of deposits on the mold was observed and was found to be extremely small.

Example 4 Wax mixture Polyethylene wax - 124fi Polyethylene wax - 210 parts Carnauba wax 4 parts Mineral turpentine 4 parts Emulsifier Stearic acid 3 parts Morpholine 2 parts Water
An aqueous mold release agent composition having a nonvolatile content concentration of 41% was prepared in the same manner as in Example 1 using 53 parts of the above raw materials. The reason why it was possible to create a composition with a higher nonvolatile content concentration than in Example 1 was due to the inclusion of Carnara/<wax.

The softening point of the non-volatile components of this composition is 60°C and 120°C.
The melt viscosity at °C was 60 cp.

When this composition was diluted 4 times and worked in the same manner as in Example 1, both the mold releasability and the surface finish of the foam were extremely good. The amount of t(1 stack) in the mold was slightly larger than in Example 1, but the amount was not a problem in practice.

Comparative Example 1 A wax emulsion composition having the composition of Example 1 except that the organic solvent was removed was prepared in the same manner as in Example 1. When a foam was molded using a 3-fold dilution of this composition under the same conditions as in Example 1, wax adhered to the piston of the airless unit, causing malfunction of the piston, and the mold release agent was applied to the mold. It was not possible to apply it evenly.

Comparative Example 2 Wax mixture Oxide 2x-1 (Note-5) 10 parts Polyethylene wax - 1io parts Polyethylene wax - 28 parts Emulsifier Stearic acid 2 parts Morpholine 1.4 parts Water
69 copies (
Note-5) Acid value 40. Softening point 102℃, melt viscosity 30c
p/120℃.

The above wax mixture was heated to 120°C to melt it, and
The emulsifier was gradually added to a solution of morpholine stearate heated to 5°C while stirring to form an emulsion, and the emulsion was rapidly cooled to 40°C to obtain a composition with a nonvolatile content of 30%.

The softening point of the non-volatile components of this composition is 80°C and 120°C.
The melt viscosity at °C was 40 cp. Add this composition to water
Polyurethane foam was foamed under the same conditions as in Example 1 using the diluted solution as an M type agent. As a result, the moldability was poor, and after repeating this operation five times, the amount of deposits in the mold was observed to be significantly large.

Comparative Example 3 Polyethylene wax - 118 parts Polyethylene wax - 29, 1 part Stearic acid monoglyceride 0.5 parts Stearyl alcohol ethylene oxide 8 mole adduct 2 parts Stearyl alcohol ethylene oxide 12 mole adduct 2 parts Antioxidant 0.15 part Above a mixture of 120
The mixture was heated to 0.degree. C. to melt it and gradually poured into hot water at 95.degree. C. while stirring to prepare a preliminary emulsion. Thereafter, the same treatment as in Example 1 was carried out to obtain a composition having a non-volatile content concentration of 30%.

An attempt was made to mold a foam using a 3-fold dilution of this composition in the same manner as in Example 1, but the foam adhered to the mold and could not be molded.

Effects of the Invention By using the aqueous mold release agent composition of the present invention, the problems that arise when using a solvent-based mold release agent in the molding of flexible polyurethane foam, namely, the danger of ignition and explosion, and the deterioration of the working environment can be avoided. Eliminate. In addition, the disadvantages of conventionally attempted aqueous mold release agents, such as a decrease in mold release properties and an increase in deposits on the mold, can be improved. Furthermore, polyurethane foam molded using the aqueous mold release agent composition of the present invention does not emit scraping noise.

Claims (1)

[Claims] (A) (B) Polyethylene wax with an acid value of 1 or less is 7
For 100 parts by weight of wax containing 0% by weight or more (b)
A wax mixture to which 5 to 20 parts by weight of an organic solvent has been added is prepared by adding a volatile amine salt or ammonium salt of a fatty acid having 12 to 20 carbon atoms as an essential component;
(d) An emulsion obtained by emulsifying with an emulsifier containing a fatty acid ester of a polyhydric alcohol as an optional component, the softening point of nonvolatile components is 50 to 100°C, and the melt viscosity is 20 to 100 cp at 120°C. An aqueous mold release agent composition for molding flexible polyurethane foam.