JPWO2013141207A1 - 被覆ポリウレタンフォームの製造方法、被覆ポリウレタンフォーム、衣料材料、ブラジャーのパッド、および、ブラジャーのカップ - Google Patents
被覆ポリウレタンフォームの製造方法、被覆ポリウレタンフォーム、衣料材料、ブラジャーのパッド、および、ブラジャーのカップ Download PDFInfo
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- JPWO2013141207A1 JPWO2013141207A1 JP2014506227A JP2014506227A JPWO2013141207A1 JP WO2013141207 A1 JPWO2013141207 A1 JP WO2013141207A1 JP 2014506227 A JP2014506227 A JP 2014506227A JP 2014506227 A JP2014506227 A JP 2014506227A JP WO2013141207 A1 JPWO2013141207 A1 JP WO2013141207A1
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- Prior art keywords
- polyurethane foam
- coating layer
- polyisocyanate
- molecular weight
- raw material
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
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Abstract
Description
(式中、R1は、上記したカルボン酸無水物の残基である。R2は、上記したアルキレンオキサイドの残基である。nは、1以上の整数(好ましくは、1〜20の整数)である。)
高分子量ポリオール中における、上記したポリエステルポリオール、ビニル重合体含有ポリオキシアルキレンポリオールまたはポリオキシアルキレンポリエステルブロック共重合体の割合は、ポリオキシアルキレンポリオール100質量部に対して、例えば、50質量部以下、好ましくは、30質量部以下である。
また、被覆層原料には、好ましくは、整泡剤、硬化触媒が含まれる。
1.原料
(1)ポリイソシアネート
(ポリイソシアネートA)
国際公開2009−51114号の製造例3に従って、ポリイソシアネート1として1,4−ビス(イソシアナトメチル)シクロヘキサンを合成した。
1,3−ビス(イソシアナトメチル)シクロヘキサン(三井化学社製、商品名:タケネート600)
ガスクロマトグラフィー測定による純度は99.9%であり、13C−NMR測定によるトランス/シス比は26/74であった。
1,4−ビス(イソシアナトメチル)シクロヘキサンと1,3−ビス(イソシアナトメチル)シクロヘキサンとを80/20(質量比)で混合した。
イソホロンジイソシアネート(エボニック デグサ ジャパン社製、商品名:VESTANAT IPDI)
(2)高分子量ポリオール
(高分子量ポリオールA)
グリセリンを開始剤として、常法に従い水酸化カリウムを触媒として用いてプロピレンオキサイド、次いでエチレンオキサイドを付加重合したポリオキシアルキレントリオール(水酸基価:33.0mgKOH/g、オキシエチレンユニット含量:14%、総不飽和度:0.065meq./g)。
特許第3905638号の実施例1に従い、ホスファゼニウム化合物を触媒として、グリセリンを開始剤として、水酸基価が38.4mgKOH/gになるまでプロピレンオキサイドを付加重合した後、水酸基価が33.1mgKOH/gになるまでエチレンオキサイドを付加重合したポリオキシアルキレントリオール(水酸基価:33.1mgKOH/g、オキシエチレンユニット含量:14%、総不飽和度:0.012meq./g)。
プロピレングリコールを開始剤として、常法に従い水酸化カリウムを触媒としてプロピレンオキサイドを付加重合したポリオキシプロピレングリコール(水酸基価:56.1mgKOH/g、総不飽和度:0.035meq./g)。
(3)低分子量活性水素化合物
(低分子量活性水素化合物A)
1、4−ブタンジオール(1,4−BD、三菱化学社製)とトリメチロールプロパン(TMP、三菱ガス化学社製)とを70/30(質量比)の比率で容器に秤量し、80℃で2時間加熱して溶解させた後、減圧脱水することにより得られた1、4−ブタンジオールとトリメチロールプロパンとの混合液。
1、4−ブタンジオール(1、4−BD、三菱化学社製)
(4)硬化触媒
ジオクチルスズチオグリコレート(モメンティブパフォーマンスマテリアルズ社製、商品名:FOMREZ UL−29)
(5)整泡剤
シリコーン整泡剤(モメンティブパフォーマンスマテリアルズ社製、商品名:Niax L−5614)
(6)酸化防止剤
(酸化防止剤A)
ヒンダードフェノール化合物(BASF社製、商品名:イルガノックス(Irganox)1135)
(酸化防止剤B)
有機リン化合物(城北化学工業社製、商品名:JP−308E)
(7)顔料
ルチル型酸化チタン(石原産業社製、商品名:CR−50、製造方法:塩素法、平均粒子径:0.25μm)
なお、顔料は、高分子量ポリオールCに予備分散された予備分散液(顔料ペースト)として被覆層原料に配合した。予備分散液は、顔料50質量部と、高分子量ポリオールC50質量部とを配合し、三本ロールで混練することにより調製した。
(8)ポリウレタンフォーム基材
ポリウレタンフォーム基材として、トリレンジイソシアネート(TDI)を含む基材原料から調製したスラブフォームを用いた。
(8)布帛
材質:木綿
通気量(JIS K6400−7(2004)B法に従って測定した。)は、95ml/cm2/secであった。
2.各実施例
(1)実施例1
(被覆ポリウレタンフォーム)
上記した原料(硬化触媒および整泡剤以外)を表1に示す部数、秤量し、23℃、相対湿度55%の実験室内で、それらが均一になるまで混合した。
(布帛を有する被覆ポリウレタンフォーム)
オーブンから離型シート/被覆層原料/ポリウレタンフォーム基材の積層物を取り出した後、直ちに、離型シートを剥離して、被覆層原料の上に、隙間が生じないように布帛を密着させた。
(被覆層単体)
別途、上記の被覆材原料の調製と同様にして、被覆層単体の物性評価に供する試料(気泡された被覆材原料)を調製した。
(2)実施例2〜10
表1に示す原料を表1に示す配合量で配合した以外は、実施例1と同様にして、被覆ポリウレタンフォーム、被覆層単体、および、布帛を有する被覆ポリウレタンフォーム(実施例2、実施例7)を調製した。
(3)実施例11
窒素導入管、温度計、冷却管および攪拌装置を備えた反応容器に、ポリイソシアネートA、高分子量ポリオールAおよび高分子量ポリオールCを表2の部数に従って秤量し、よく攪拌しながら80〜85℃で約2時間反応させた。次いで、イソシアネート基含量が7.1質量%まで低下していることを確認して、イソシアネート基末端プレポリマーを得た。
(4)実施例12
表2に示す原料を表2に示す配合量で配合した以外は、実施例11と同様にして、イソシアネート基末端プレポリマー(イソシアネート基含量は12.17%)、レジンプレミックスを調製した後、両者を100:49.4の質量比でカールミキサーに供給し、被覆層原料を起泡させた。
(5)実施例13
表2に示す原料を表2に示す配合量で配合した以外は、実施例11と同様にして、イソシアネート基末端プレポリマー(イソシアネート基含量は17.19%)とレジンプレミックスを調製した後、両者を100:56.8の質量比でカールミキサーに供給し、被覆層原料を起泡させた。
3.評価方法
(1)被覆層原料の粘度(単位:mPa・s/30℃)
ICIコーンプレート型粘度計(東亜工業社製、商品名:CV−1S)を使用し、ASTM D4287記載の方法に基づいて測定した。
(2)起泡された被覆層原料の密度(単位:g/cc)
ステンレス製の円筒容器に、起泡された被覆層原料を、体積が10ccになるように秤量し、その質量を測定した。
(3)被覆層単体の見かけ密度(単位:g/cc)および厚み(単位:mm)
得られた被覆層単体を3cm×7cmのサイズに打ち抜いた後、JIS K7222(2005)に記載の方法に基づいて見かけ密度を測定した。厚みは実測した。結果を表3および表4に示す。
(4)被覆層単体の引張強さ(TS、単位:kPa)および破断伸び(EL、単位:%)
被覆層単体の引張試験を、JIS K−6400−5(2004)に記載の方法に基づいて実施した。
(5)被覆層単体の動的粘弾性測定による被覆層単体の触感(貯蔵弾性率、単位:MPa/25℃)および熱圧縮成形性(単位:℃)
動的粘弾性測定装置(アイティー計測制御社製、商品名:DVA−200)を使用し、5mm幅に裁断した被覆層単体の貯蔵弾性率を、空気雰囲気下、3℃/minの速度で−100℃から250℃まで昇温させながら、10Hzの周波数で測定した。
(6)通気量(単位:ml/cm2/sec)
被覆層単体、被覆ポリウレタンフォーム、および、布帛を有する被覆ポリウレタンフォーム(実施例1、実施例2、実施例7、実施例11、実施例12)の通気量を、JIS K6400−7(2004)B法に記載の方法に基づいて測定した。結果を表3および表4に示す。
(7)耐光性(単位:無し)
被覆層単体、被覆ポリウレタンフォーム、および、布帛を有する被覆ポリウレタンフォーム(実施例1、実施例2、実施例7、実施例11、実施例12)から、3cm×7cmのサイズの試験片を切り出して、測定試料とした。
(8)接着強度(平均はく離力(単位:N))
JIS K6854−3(1999)に記載の方法に基づき、布帛を有する被覆ポリウレタンフォーム(実施例1、実施例2、実施例7、実施例11、実施例12)から、布帛を10mm/分の速度ではく離するときのはく離力を3回測定し、その平均値を平均はく離力とした。結果を表3および表4に示す。
(9)被覆ポリウレタンフォームの熱圧縮試験(単位:無し)
厚み10mmの被覆ポリウレタンフォームを3cm×7cmのサイズに打ち抜き、試験片とした。この試験片を、200℃に加熱したアルミ製のプレス板で、厚みが4mmになるまで圧縮した後、その状態を2分間保持した。試験前後の試験片の外観変化について、次の基準に従って点数付けを行った。結果を表3および表4に示す。
3点‥外観の変化は殆ど無かった。
(10)被覆ポリウレタンフォームの触感(単位:無し)
F型硬度計(高分子計器株式会社製、商品名:アスカーゴム硬度計F型)を使用して、ポリウレタンフォーム基材と被覆ポリウレタンフォームとのF型硬度を測定した。
Claims (10)
- 脂肪族ポリイソシアネート、脂環族ポリイソシアネートおよび芳香脂肪族ポリイソシアネートから選択される少なくとも1種類のポリイソシアネートと、高分子量ポリオールと、低分子量活性水素基含有化合物とを含有する被覆層原料を機械的に起泡させる工程と、
芳香族ポリイソシアネートを含有する基材原料から得られるポリウレタンフォーム基材の表面に、起泡された前記被覆層原料を積層する工程と、
積層された前記被覆層原料を硬化させて、前記ポリウレタンフォーム基材の表面に、ポリウレタンフォーム被覆層を形成する工程と
を含むことを特徴とする、被覆ポリウレタンフォームの製造方法。 - 前記ポリウレタンフォーム被覆層のハードセグメント濃度は、8〜45%であることを特徴とする、請求項1に記載の被覆ポリウレタンフォームの製造方法。
- 前記低分子量活性水素基含有化合物は、
1分子中に2つの活性水素基を有する第1低分子量活性水素基含有化合物と、
1分子中に3つ以上の活性水素基を有する第2低分子量活性水素基含有化合物と
を含有することを特徴とする、請求項1に記載の被覆ポリウレタンフォームの製造方法。 - 前記被覆層原料は、ポリイソシアネートとして、1,3−ビス(イソシアナトメチル)シクロヘキサンおよび/または1,4−ビス(イソシアナトメチル)シクロヘキサンを含有することを特徴とする、請求項1に記載の被覆ポリウレタンフォームの製造方法。
- 前記ポリウレタンフォーム被覆層の通気量は、10〜120ml/cm2/secであることを特徴とする、請求項1に記載の被覆ポリウレタンフォームの製造方法。
- 前記ポリウレタンフォーム被覆層の表面に布帛を積層する工程を含むことを特徴とする、請求項1に記載の被覆ポリウレタンフォームの製造方法。
- 脂肪族ポリイソシアネート、脂環族ポリイソシアネートおよび芳香脂肪族ポリイソシアネートから選択される少なくとも1種類のポリイソシアネートと、高分子量ポリオールと、低分子量活性水素基含有化合物とを含有する被覆層原料を機械的に起泡させる工程と、
芳香族ポリイソシアネートを含有する基材原料から得られるポリウレタンフォーム基材の表面に、起泡された前記被覆層原料を積層する工程と、
積層された前記被覆層原料を硬化させて、前記ポリウレタンフォーム基材の表面に、ポリウレタンフォーム被覆層を形成する工程と
を含む被覆ポリウレタンフォームの製造方法により得られる
ことを特徴とする、被覆ポリウレタンフォーム。 - 脂肪族ポリイソシアネート、脂環族ポリイソシアネートおよび芳香脂肪族ポリイソシアネートから選択される少なくとも1種類のポリイソシアネートと、高分子量ポリオールと、低分子量活性水素基含有化合物とを含有する被覆層原料を機械的に起泡させる工程と、
芳香族ポリイソシアネートを含有する基材原料から得られるポリウレタンフォーム基材の表面に、起泡された前記被覆層原料を積層する工程と、
積層された前記被覆層原料を硬化させて、前記ポリウレタンフォーム基材の表面に、ポリウレタンフォーム被覆層を形成する工程と
を含む被覆ポリウレタンフォームの製造方法により得られる被覆ポリウレタンフォームから形成される
ことを特徴とする、衣料材料。 - 脂肪族ポリイソシアネート、脂環族ポリイソシアネートおよび芳香脂肪族ポリイソシアネートから選択される少なくとも1種類のポリイソシアネートと、高分子量ポリオールと、低分子量活性水素基含有化合物とを含有する被覆層原料を機械的に起泡させる工程と、
芳香族ポリイソシアネートを含有する基材原料から得られるポリウレタンフォーム基材の表面に、起泡された前記被覆層原料を積層する工程と、
積層された前記被覆層原料を硬化させて、前記ポリウレタンフォーム基材の表面に、ポリウレタンフォーム被覆層を形成する工程と
を含む被覆ポリウレタンフォームの製造方法により得られる被覆ポリウレタンフォームから形成される衣料材料から形成される
ことを特徴とする、ブラジャーのパッド。 - 脂肪族ポリイソシアネート、脂環族ポリイソシアネートおよび芳香脂肪族ポリイソシアネートから選択される少なくとも1種類のポリイソシアネートと、高分子量ポリオールと、低分子量活性水素基含有化合物とを含有する被覆層原料を機械的に起泡させる工程と、
芳香族ポリイソシアネートを含有する基材原料から得られるポリウレタンフォーム基材の表面に、起泡された前記被覆層原料を積層する工程と、
積層された前記被覆層原料を硬化させて、前記ポリウレタンフォーム基材の表面に、ポリウレタンフォーム被覆層を形成する工程と
を含む被覆ポリウレタンフォームの製造方法により得られる被覆ポリウレタンフォームから形成される衣料材料から形成されるブラジャーのパッドを備える
ことを特徴とする、ブラジャーのカップ。
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US10913251B2 (en) | 2015-09-01 | 2021-02-09 | Mitsui Chemicals, Inc. | Buffer material, buffer material for coating robot, robot with buffer material, and coating robot with buffer material |
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