KR101915274B1 - The polyurethane foam composition and Polyurethane foam prepared through the same - Google Patents

Abstract

The present invention relates to a polyurethane foam composition and polyurethane foam prepared through the same. The polyurethane foam composition contains a polyol mixture (X) and an isocyanate mixture (Y), wherein the polyol mixture (X) includes polyol (A) and polyol (B), which are different from each other; and the isocyanate mixture (Y) is a mixture of methylene diphenyl diisocyanate (MDI). According to the present invention, polyurethane foam suitable for children′s bedding can be produced.

Description

[0001] The present invention relates to a polyurethane foam composition and a polyurethane foam prepared therewith,

The present invention relates to a polyurethane foam composition and a polyurethane foam prepared thereby, and more particularly, to a polyurethane foam composition capable of producing a latex like foam exhibiting characteristics similar to those of a latex foam, ≪ / RTI >

The polyurethane foam is obtained by preparing a resin premix usually containing a polyol, a catalyst for producing a polyurethane foam, a foaming agent and the like, and reacting the resin premix with a polyisocyanate.

BACKGROUND ART Polyurethane foams are widely used as seat cushions, seat backs, head rests for automobiles and the like due to their excellent cushioning properties, heat insulating materials such as electric refrigerators, freezers, freezing warehouses, Arm rests, instrument panels, interior trimings such as door trim and ceiling materials, seat materials for motorcycles, airplanes, railway vehicles, and office supplies such as furniture, bedding, office cushions, .

Generally, petroleum-based synthetic polyols are mainly used for the production of urethane foams. Efforts have been made to manufacture environmentally friendly polyurethanes by replacing these conventional petroleum-based synthetic polyols with vegetable oil-based natural polyols. However, most of the urethane foam manufacturing technology using vegetable oil is about hard urethane foam, and in the field of soft urethane foam, research on the production of urethane foam using vegetable oil is poor. Although some soybean oil based polyols have been studied for the synthesis of flexible foams, a large amount of closed cells have actually been found.

On the other hand, flexible polyurethane foam has an open cell structure and excellent elasticity, and is excellent in mechanical strength (elongation, tensile strength, abrasion resistance) and used in various industrial fields such as packaging materials. Particularly, they are widely used as cushioning materials for bedding, and polyurethane foams having various physical properties according to the purpose of using bedding materials have been produced. Accordingly, it has been an issue to develop a polyurethane foam composition having an optimum ratio so that the polyurethane foam has properties suitable for the purpose.

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and it is an object of the present invention to provide a composition for a polyurethane foam.

Another aspect of the present invention is to provide a polyurethane foam produced through the composition for polyurethane foam.

According to an aspect of the present invention, there is provided a composition for a polyurethane foam.

The composition for polyurethane foam may comprise polyol mixture (X) and isocyanate mixture (Y).

The polyol mixture (X) may contain a polyol (A) and a polyol (B).

The polyol (A) may be a polyol having an oxyethylene group in the range of 8 to 18% at the end of a polyol having an average hydroxyl value of 20 to 35 mg KOH / g and a number average molecular weight of 5500 to 7500.

The polyol (B) may be a polyol having an average hydroxyl value of 40 to 60 mg KOH / g and a polyol having a number average molecular weight of 3000 to 4000 and containing 5% or less of oxyethylene groups at the terminals.

The isocyanate mixture (Y) may be a mixture of methylene diphenyl diisocyanate (MDI).

The polyol mixture (X) may further contain a silicone foam stabilizer, a urethanation catalyst and water.

The polyol (A) may be 50 to 90% by mass based on 100% by mass of the polyol mixture (X).

Based on 100% by mass of the polyol mixture (X), the polyol (B) may be 10 to 50% by mass.

The polyol (A) has a structure represented by the following formula (1), and a + c + e: b + d + f = 72-92: 8-18.

[Chemical Formula 1]

The polyol (B) has a structure represented by the following formula (2), and g + i + k: h + j + 1 = 95 to 99: 1 to 5.

(2)

The isocyanate mixture (Y) may contain MDI (A), MDI (B), MDI (C) and MDI (D).

The MDI (A) may be diphenyl methane diisocyanate.

The MDI (B) may be an isocyanic acid polymethylenepolyphenylene ester.

The MDI (C) may be 1-isocyanato-2 - [(4-isocyanatophenyl) methyl) benzene.

The MDI (D) may be isocyanic acid polymethylenepolyphenylene ester polymer with methyloxirane polymer with oxirane ether with 1,2,3-propanetriol (3: 1).

The MDI (A) may be 50 to 60% by mass based on 100% by mass of the isocyanate mixture (Y).

Based on 100 mass% of the isocyanate mixture (Y), the MDI (B) may be 20 to 30 mass%.

Based on 100 mass% of the isocyanate mixture (Y), the MDI (C) may be 10 to 20 mass%.

Based on 100 mass% of the isocyanate mixture (Y), 5 to 10 mass% of MDI (D).

The isocyanate mixture (Y) may be 40 to 80 mass% based on 100 mass% of the polyurethane foam composition.

According to another aspect of the present invention, there is provided a polyurethane foam.

The polyurethane foam may be made of the composition for polyurethane foam described above.

The polyurethane foam may be used in baby bedding.

The elasticity of the polyurethane foam may be 50 to 60 (Ball Rebound,%).

According to the present invention, a polyurethane foam suitable for use as an infant bed can be produced by preparing a polyurethane foam through a composition for a polyurethane foam having an optimum ratio.

In addition, a polyurethane foam having self-extinguishing properties can be produced by preparing a polyurethane foam through a composition for a polyurethane foam having an optimum ratio.

In addition, polyurethane foams having a heavy metal content lower than the detection limit can be produced by preparing polyurethane foams through a polyurethane foam composition having an optimum ratio.

In addition, a polyurethane foam having a far infrared ray emissivity of 88% or more can be produced by preparing a polyurethane foam through a polyurethane foam composition having an optimum ratio.

In addition, a polyurethane foam excellent in antibacterial property can be produced by preparing a polyurethane foam through a polyurethane foam composition having an optimum ratio.

The technical effects of the present invention are not limited to those mentioned above, and other technical effects not mentioned can be clearly understood by those skilled in the art from the following description.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a view showing a mixing process in a preferred process for producing a polyurethane foam of the present invention. FIG.
FIG. 2 is a view showing a foaming and molding process in the process of manufacturing the preferred polyurethane foam of the present invention.
Figure 3 is an image of a preferred polyurethane foam of the present invention.
4 is an image showing the results of measurement of the antibacterial degree of the polyurethane foam of the present invention.

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.

While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. Rather, the intention is not to limit the invention to the particular forms disclosed, but rather, the invention includes all modifications, equivalents and substitutions that are consistent with the spirit of the invention as defined by the claims.

It will be appreciated that when an element such as a layer, region or substrate is referred to as being present on another element "on," it may be directly on the other element or there may be an intermediate element in between .

Although the terms first, second, etc. may be used to describe various elements, components, regions, layers and / or regions, such elements, components, regions, layers and / And should not be limited by these terms.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a view showing a mixing process in a preferred process for producing a polyurethane foam of the present invention. FIG.

Referring to FIG. 1, it can be seen that the step of mixing polyol and MDI is carried out to prepare a composition for polyurethane foam.

A preferred polyurethane foam composition according to an embodiment of the present invention comprises a polyol mixture (X) and an isocyanate mixture (Y), wherein the polyol mixture (X) contains a polyol (A) and a polyol (B).

The polyol (A) according to an embodiment of the present invention is a polyol having an average hydroxyl value of 20 to 35 mg KOH / g and a number average molecular weight of 5500 to 7500 and containing oxyethylene groups in the range of 8 to 18% Is the structure of the following formula (1).

[Chemical Formula 1]

A + c + e: b + d + f = 82 to 92: 8 to 18 in the above formula (1).

The polyol (B) according to an embodiment of the present invention is a polyol having an average hydroxyl value of 40 to 60 mgKOH / g and a number average molecular weight of 3000 to 4000, (2).

(2)

+ I + k: h + j + 1 = 95 to 99: 1 to 5 in the above formula (2).

The polyol mixture (X) according to one preferred embodiment of the present invention is mixed with an optimal combination range of the polyol (A) which is a relatively high molecular polyol and the polyol (B) which is a relatively low molecular polyol, When foamed, the polyurethane foam can exhibit a soft surface and elasticity similar to latex foam.

The polyol mixture (X) according to one preferred embodiment of the present invention may contain 50 to 90 mass% of the polyol (A) and 10 to 50 mass% of the polyol (B) based on 100 mass% of the polyol mixture . More preferably 75 to 80% by mass of the polyol (A) and 20 to 25% by mass of the polyol (B).

In the meantime, the polyol mixture (X) according to an embodiment of the present invention is combined with a diisocyanate (denoted as MDI) to form a foam, And water.

The silicone foam stabilizer, urethanization catalyst and water can be used without limitation as long as they do not deviate from the object of the present invention.

The isocyanate mixture (Y) of the present invention is a mixture of methylene diphenyl diisocyanate (MDI).

When a polyurethane foam is prepared using a mixture of methylene diphenyl diisocyanate (MDI) as an isocyanate mixture (Y), a soft surface similar to a latex foam and elasticity may be exhibited.

On the other hand, at least one selected from the group consisting of tolylene diisocyanate (TDI), phthalene diisocyanate (NDI), xylylene diisocyanate (XDI), isophorone diisocyanate (IPDI), hexamethylene diisocyanate (HMDI) Isocyanate and the above-mentioned polyol mixture (X) are foamed together, a rough polyurethane foam is produced, which is also unsuitable in terms of economy.

Thus, the isocyanate mixture (Y) for making a polyurethane foam similar to latex foam is a mixture of methylene diphenyl diisocyanate (MDI).

More particularly, the preferred isocyanate mixture (Y) according to one embodiment of the invention contains MDI (A), MDI (B), MDI (C) and MDI (D).

Wherein the MDI (A) is diphenyl methane diisocyanate, the MDI (B) is isocyanic acid polymethylenepolyphenylene ester, the MDI (C) is 1-isocyanato-2- (4-isocyanatophenyl) ) Is isocyanic acid polymethylenepolyphenylene ester polymer with methyloxirane polymer with oxirane ether with 1,2,3-propanetriol (3: 1).

In order to prepare a polyurethane foam having properties similar to those of latex foam, the isocyanate mixture (Y) contains 50 to 60% by mass of MDI (A), 20 to 60% by mass of MDI (B) 20 To 30 mass%, MDI (C) 10 to 20 mass%, and MDI (D) 5 to 10 mass%.

Lastly, in order to exhibit characteristics similar to latex foam and to exhibit desired hardness in baby bedding, a certain range of foaming liquid is prepared. The composition for a polyurethane foam according to an embodiment of the present invention preferably comprises a polyurethane foam composition 100 40 to 80 mass% of the isocyanate mixture (Y) is used based on the mass%. When the isocyanate mixture (Y) is used in an amount of less than 40 mass% or more than 80 mass%, foams are not formed due to the shrinkage of polyurethane foam, collapse, or the like, .

Therefore, by using the composition ratio according to one preferred embodiment of the present invention, a polyurethane foam suitable for use in infant bedding for the purpose of the present invention can be produced.

FIG. 2 is a view showing a foaming and molding process in the process of manufacturing the preferred polyurethane foam of the present invention.

Referring to FIG. 2, it can be seen that a polyurethane foam according to one preferred embodiment of the present invention is produced after the raw material of a polyurethane foam is put into a foaming mold, followed by foaming, aging and molding, The raw material of the foam is the above-mentioned polyurethane foam composition.

Figure 3 is an image of a preferred polyurethane foam of the present invention.

Referring to FIG. 3, a polyurethane foam was produced through the above-described manufacturing process. Applicants have conducted various experiments with the polyurethane foam to confirm whether it is a polyurethane foam suitable for use in infant bedding, Respectively.

First, the prepared polyurethane foam was subjected to a flammability test, and the results are shown in Table 1 below.

1 time Episode 2 3rd time 4 times 5 times condition - Combustion distance (mm) 0 0 0 0 0 - Burning time (s) 0 0 0 0 0 - Burning speed (mm / min) SE SE SE SE SE Judgment pass

The combustibility test was carried out after leaving the polyurethane foam at a temperature of 16 to 26 DEG C and a humidity of 50 to 60% for 24 hours or more.

Referring to Table 1, a total of five flammability tests were conducted using the polyurethane foam according to one preferred embodiment of the present invention. As a result, it can be seen that the polyurethane foam has a self-extinguishing property (SE). Accordingly, it can be seen that the polyurethane foam according to one preferred embodiment of the present invention is a polyurethane foam suitable for use in bedding.

The heavy metal content of the polyurethane foam thus prepared was measured, and the results are shown in [Table 2] below.

ingredient content Test Methods Detection limit Cadmium (Cd) Not detected KS C IEC 62321: 2009 One Lead (Pb) Not detected 10 Mercury (Hg) Not detected 0.1 Chromium VI (Cr VI) Not detected 0.1

(Not detected = less than detection limit)

The content of heavy metals was measured by the Korean standard IEC 62321: 2009.

Referring to Table 2, the polyurethane foam according to one preferred embodiment of the present invention is characterized in that cadmium (Cd), lead (Pb), mercury (Hg), and chromium VI (Cr VI) I did. Accordingly, it can be seen that the polyurethane foam according to one preferred embodiment of the present invention is a polyurethane foam suitable for use in bedding.

The far-infrared emissivity of the prepared polyurethane foam was measured, and the results are shown in Table 3 below.

Emissivity Radiant energy (W / m ² ) 0.888 3.58 X 10 ²

The far-infrared emissivity was measured at a wavelength of 5 to 20 μm at a temperature of 40 ° C. The result is a measurement of a black body using FT-IR spectrum.

Referring to Table 3, it can be seen that the polyurethane foam according to an exemplary embodiment of the present invention has a relatively high far infrared ray emissivity of 0.888. Therefore, when the polyurethane foam according to the preferred embodiment of the present invention is used for bedding, it can be seen that various effects that far-infrared rays have on the body can be obtained.

4 is an image showing the results of measurement of the antibacterial degree of the polyurethane foam of the present invention.

The antimicrobial activity was determined by the method of bacterium absorption and plate culture. Strain 1 was staphylococcus aureus ATCC 6538 (Staphylococcus aureus), and strain 2 was Klebsiella pneumoniae ATCC 4352 (pneumoniae).

Fig. 4 (a) is an image after 18 hours of culturing the strain 1 on a 100% cotton sample, Fig. 4 (b) is a photograph showing that the strain 1 was cultured on the polyurethane foam according to the preferred embodiment of the present invention, It is a later image.

Fig. 4 (c) is an image after 18 hours of culturing the strain 2 on the 100% cotton control specimen. Fig. 4 (d) shows the result of culturing the strain 2 on the polyurethane foam according to one preferred embodiment of the present invention It is an image after 18 hours.

The results of the antimicrobial activity measurement of the prepared polyurethane foam and the control sample are shown in Table 4 below.

100% cotton In one embodiment Strain 1 Initial number of bacteria 4.0 X 10 ⁴ 4.0 X 10 ⁴ After 18 hours, the number of bacteria 7.8 X 10 ⁶ <20 Antibacterial activity value - 5.6 Strain 2 Initial number of bacteria 4.0 X 10 ⁴ 4.0 X 10 ⁴ After 18 hours, the number of bacteria 3.7 X 10 ⁷ <20 Antibacterial activity value - 6.3

Referring to FIGS. 4 and 4, the polyurethane foam according to one embodiment of the present invention has an antibacterial effect of 95% or more. It can be seen that the propagation of &lt; RTI ID = 0.0 &gt;

In addition, the compression set of the polyurethane foam prepared, the permanent compression set ratio and the elasticity were measured, and the results are shown in Table 5 below.

Invention Compression Permanent Rowing Rate (KS M 6672: 2016) 5.2% Repetitive Permanent Compression Ratio (KS M 6672: 2016) 1.2% Elasticity (Ball Rebound,%) 50 to 60%

The measurement of the compression set length was carried out under the conditions of 50% compression for 22 hours at a temperature of 69 to 71 캜, and the cyclic compression set was performed under the conditions of 50,000 compression and 80000 times of compression.

Referring to Table 5, it can be seen that the polyurethane foam according to an exemplary embodiment of the present invention has a compression set ratio of 5.2% and a cyclic compression ratio of 1.2%. It can be seen that the lower the rate of permanent banding, the better the elasticity and the more flexible polyurethane foam. The elasticity of the polyurethane foam actually produced was in the range of 50 to 60 (Ball Rebound,%).

In addition, the apparent density of the polyurethane foam according to one embodiment of the present invention was 59.9 kg / m 2, and the hardness was measured to be 150 N (15.8 kgf).

The present applicant has prepared a composition for a polyurethane foam having an optimum ratio for producing a polyurethane foam applicable to a backflow preventing cushion block and a baby bed using the same, in which the polyurethane foam is manufactured Thereby obtaining a polyurethane foam suitable for use as a bedding for infants.

However, the application of the polyurethane foam made of the polyurethane foam composition of the present invention is not limited to bedding for infants, and it can be applied to a seat cushion, a seat back, a head rest, an arm rest, Panels, door trim, interior materials such as ceiling materials, saddles for motorcycles, airplanes, seat materials for railway cars, office furniture such as furniture, bedding, and office cushions for office chairs.

Claims (14)

1. A polyurethane foam composition for the production of polyurethane foam, comprising a polyol mixture (X) and an isocyanate mixture (Y)
The polyol mixture (X) contains the following polyol (A) and the following polyol (B)
Wherein the isocyanate mixture (Y) contains MDI (A), MDI (B), MDI (C) and MDI ), 50 to 60 mass% of MDI (B), 20 to 30 mass% of MDI (B), 10 to 20 mass% of MDI (C) and 5 to 10 mass% of MDI (D).
Polyol (A): A polyol having an average hydroxyl value of 20 to 35 mg KOH / g and a number average molecular weight of 5500 to 7500, a polyol having an oxyethylene group in the range of 8 to 18%
Polyol (B): A polyol having an average hydroxyl value of 40 to 60 mgKOH / g and a number average molecular weight of 3000 to 4000 and a polyol containing 5% or less of an oxyethylene group at the terminal
MDI (A): Diphenyl methane diisocyanate
MDI (B): isocyanic acid polymethylenepolyphenylene ester
MDI (C): 1-isocyanato-2 - [(4-isocyanatophenyl) methyl) benzene
MDI (D): isocyanic acid polymethylenepolyphenylene ester polymer with methyloxirane polymer with oxirane ether with 1,2,3-propanetriol (3: 1) The method according to claim 1,
Wherein the polyol mixture (X) further comprises a silicone foam stabilizer, an urethanation catalyst, and water. The method according to claim 1,
Wherein the polyol (A) is 50 to 90% by mass based on 100% by mass of the polyol mixture (X). The method according to claim 1,
Wherein the polyol (B) is contained in an amount of 10 to 50 mass% based on 100 mass% of the polyol mixture (X). The method according to claim 1,
Wherein the polyol (A) has a structure represented by the following formula (1), and a + c + e: b + d + f = 82-92: 8-18.
[Chemical Formula 1]

The method according to claim 1,
Wherein the polyol (B) has a structure represented by the following formula (2), and g + i + k: h + j + 1 = 95 to 99: 1 to 5.
(2)

delete delete delete delete delete The method according to claim 1,
Wherein the isocyanate mixture (Y) is 40 to 80% by mass based on 100% by mass of the polyurethane foam composition. A polyurethane foam produced from the composition for polyurethane foam according to any one of claims 1 to 6 and 12,
Wherein the polyurethane foam is used in infant bedding. 14. The method of claim 13,
Wherein the elasticity of the polyurethane foam is 50 to 60 (Ball Rebound,%).

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