KR20050101252A - Polyurethane foam having deodoring or antibacterial property - Google Patents

Abstract

 The present invention provides a polyurethane foam which can visually notify the user that additives such as deodorant and antimicrobial agent are blended in the polyurethane foam while being excellent in adsorption performance and antibacterial properties such as odor and moisture. The polyurethane foam of the present invention is characterized by containing a carbon powder and / or an inorganic antibacterial agent in the polyurethane foam. As the polyurethane foam, a low-elasticity polyurethane foam is preferable.

Description

Polyurethane foam having deodorant or antibacterial property

The present invention relates to polyurethane foams having deodorant or antibacterial properties. More specifically, the present invention provides a polyurethane foam which can visually notify the user that additives such as deodorant and antimicrobial agent are blended in the polyurethane foam with excellent adsorption and antibacterial performance against odor and moisture. .

Polyurethane foam is used in a wide range of fields, such as shoe soles, shoe insoles, bedding such as mattresses and pillows, cushioning materials for home chairs and automobile seats, or flooring or walling materials.

When polyurethane foam is used as a cushion material for bedding such as a mattress or a pillow, a home chair or a car seat, by a user's sweat and in the environment of the high temperature and humidity such as summer, it is mite and a mold Etc., tends to occur. Polyurethane foam used in the above-described applications have a lot of opportunities for direct contact with users, so the occurrence of mites and molds is not hygienic. In some cases, mites and fungi multiply in large quantities, causing atopic dermatitis and allergic diseases such as asthma.

Therefore, it has been attempted to add an antimicrobial agent for the purpose of suppressing the reproduction of mites and mold in the polyurethane foam.

For example, Japanese Patent No. 3322140 discloses an imidazole antifungal agent such as 2-methoxycarbonylaminobenzimidazole or 2-methylcarbonylaminobenzimidazole and carbamate or phthalate as an antibacterial antifungal agent. A method for producing a foamed urethane containing an organic antimicrobial antifungal agent, in which a mid-based antimicrobial agent is once liquefied with ethanol and dried and micropowdered is disclosed.

Japanese Patent No. 2672973 discloses N- (fluorodichloromethylthio) -phthalimide and 2-benzimidazolecarbamic acid lower alkyl ester and / or 2- (4-thiazolyl) -benzimidazole as an antibacterial agent. Antimicrobial urethane foams are disclosed

However, the following problems exist with the antimicrobial polyurethane foam described above.

Even if the above-mentioned antimicrobial agent is added to the polyurethane foam, the antimicrobial agent alone may have a low antimicrobial activity. In particular, when the humidity is high in summer, it may be difficult to suppress the growth of mold and the like, and odor may occur. There was.

It is difficult for the user to know that the antimicrobial agent is blended even if the antimicrobial agent is added to the polyurethane foam, and the user could not realize whether the antimicrobial agent or the like was added to the polyurethane foam.

Furthermore, the organic antimicrobial agent as described above is not necessarily high in the safety of the human body or the environment, and in some cases, may be the causative agent of allergic diseases.

This invention is made | formed in order to solve the said subject, The polyurethane foam which concerns on this invention contains the carbon powder and / or an inorganic antimicrobial agent in its inside.

In the polyurethane foam according to the present invention, the carbon powder is porous carbon powder and / or carbon black. In addition, an inorganic antimicrobial agent is supported in the porous carbon powder, and the inorganic antimicrobial agent is made of silver and / or titanium dioxide.

Polyurethane foam according to the present invention is a low repulsion, isocyanate component, a polyol having an average functionality of 2 to 4, a hydroxyl value of 30 to 60 mgKOH / g, an average functional group of 2 to 4, a hydroxyl value of 200 to 270 It may be formed of a polyol component of a polyol that is mgKOH / g.

In addition, the polyurethane foam according to the present invention is an isocyanate component, a polyol having an average functional group of 2-4, a hydroxyl value of 80-120 mgKOH / g, an average functional group of 2-4, a hydroxyl value of 150-210 mgKOH / g It may be formed of a polyol component of a polyol.

Hereinafter, the polyurethane foam which concerns on this invention is explained in full detail. The polyurethane foam according to the present invention is characterized in that the polyurethane foam contains carbon powder and / or an inorganic antibacterial agent.

By containing the carbon powder, the carbon powder can squeeze odor, moisture, etc. in the polyurethane foam, and also has excellent far-infrared radiation performance.

As it contains an inorganic antimicrobial agent, the antimicrobial effect of the inorganic antimicrobial agent can be obtained.

As the carbon powder and the inorganic antimicrobial agent are included together, the carbon powder adsorbs moisture in the polyurethane foam, so that the superior antimicrobial effect can be obtained as compared with the inorganic antimicrobial agent alone. In addition, as the inorganic antimicrobial agent and the carbon powder are contained together, the metal color of the inorganic antimicrobial agent is prominent against the background of the black carbon powder, and the user can easily know that the inorganic antimicrobial agent is incorporated in the polyurethane foam.

In the polyurethane foam according to the present invention, a polyurethane foam containing a carbon powder and / or an inorganic antibacterial agent dispersed therein may be used a conventional flexible polyurethane foam.

More specifically, the polyurethane foam used in the present invention is formed from at least a polyol component, an isocyanate component, a blowing agent and a catalyst.

As the polyol component, any polyol component can be used as long as it is used for the production of a normal flexible polyurethane foam. Specifically, ethylene glycol, propylene glycol, diethylene glycol, dipropylene glycol, glycerin, trimetholpropane, 1,2,6-hexanetriol, triethanolamine, pentaerythritol ethylenediamine, trilene diamine, diphenylmethane diamine ， Temethyrrolecyclohexane, methyl glucoside, 2,2,6,6-tetrakis (hydroxymethyl) cyclo hexanol, diethylene triamine and the like are epoxides such as propylene oxide, ethylene oxide, butylene oxide Polyether polyols with extended chains, polyurea dispersion polyols, amine-modified polyols, polytetramethylene ether glycols, polyester polyols obtained by polycondensation of polyhydric alcohols and dibasic acids, and the like. In this invention, only one type of the said polyol component may be used, and 2 or more types may be mixed and used for it.

The isocyanate component can be used as long as it can be used for producing polyurethane foam. For example, aliphatic polyisocyanate, toluene diisocyanate, such as hexamethylene diisocyanate, trimethylhexamethylene diisocyanate, isophorone diisocyanate, dicyclo hexyl methane diisocyanate, cyclohexyl diisocyanate, lysine diisocyanate, methylcyclohexane diisocyanate, Diphenyl methane diisocyanate, phenylene diisocyanate, dimethyl diphenyl diisocyanate, dianidine diisocyanate, xylene diisocyanate, tetramethyl xylene diisocyanate, naphthalene diisocyanate, dimethyltriphenylmethane tetraisocyanate, triphenylmethane triisocyanate, tris Aromatic polyisocyanates such as (isocyanate phenyl) thiophosphate, polymeric diphenylmethane diisocyanate or these It may be exemplified by hydrous product. In this invention, only one type of the said isocyanate component may be used, and 2 or more types may be mixed and used for it.

What is necessary is just to mix | blend the compounding quantity of an isocyanate component in manufacture of a normal polyurethane foam, Specifically, it is good to adjust so that the index may be normally 60-130, preferably 80-120 with respect to 100 weight part of polyol components. This is because good urethane foam cannot be obtained both when the index is less than 60 and when it exceeds 130.

In particular, in the present invention, it is preferable to use a low-elasticity polyurethane foam as the polyurethane foam. The low-elasticity polyurethane foam has a modulus of elasticity of 30% or less, preferably 0 to 20%, more preferably 0 to Polyurethane foam adjusted to 15%. When the resilience modulus exceeds 30%, a good low resilience foam cannot be obtained.

In addition, a low-elasticity polyurethane foam adjusted to a point pressure recovery time of less than 35 seconds, preferably 5 to 30 seconds, and more preferably 7 to 25 seconds under a temperature condition of 20 ° C is preferable. This is excellent in low repulsion property by adjusting the point pressure recovery time under the temperature condition of 20 degreeC to 35 second or less, for example, when using it as a cushioning material, extremely good usability can be obtained and excellent deodorization property ， Hygroscopicity can be obtained. On the other hand, "point pressure recovery time" means that the test piece (length 10 cm, diameter 25 mm) of the tip is sharply compressed under a certain temperature condition to remove the load after maximum compression of 50 x 380 x 380 (mm). Then the time from the original thickness to restoration.

In the case of a mold foam, it is preferable that a viscous pressure recovery time is 20 second or less under the temperature condition of 20 degreeC, and in the case of slab foam, it is preferable that a viscous pressure recovery time is 10 second or less under the temperature condition of 20 degreeC. Moreover, although the polyurethane foam used in this invention may be either a mold foam or a slab foam, a mold foam is more preferable.

The above-mentioned low-elasticity polyurethane foam can use the low-elasticity polyurethane foam manufactured by the conventional manufacturing method, Especially in this invention, as a polyol component, an average functional group number is 2-4 and a hydroxyl value is 30-60 mgKOH / g. It is preferable to use a low-elasticity polyurethane foam produced using a mixture of a polyol and a polyol having an average number of functional groups of 2 to 4 and a hydroxyl value of 200 to 270 mgKOH / g.

Although the compounding quantity of the former polyol and the latter polyol is not specifically limited, It is preferable to mix | blend and use so that the former polyol may be 34-75 weight% and the latter polyol may be 25-66 weight%. This means that when the compounding amount of the former polyol is less than 34% by weight (the compounding amount of the latter polyol exceeds 66% by weight), the foam becomes too hard to obtain good low repulsion, and the compounding amount of the former polyol If the content exceeds 75% by weight (when the amount of the latter polyol is less than 25% by weight), the foam becomes too soft to obtain good low repulsion.

Examples of polyols having an average functional number of 2 to 4 and a hydroxyl value of 30 to 60 mgKOH / g include Borolol V3022 '(trade name) manufactured by Mitsubishi Chemical Dow Corporation. Moreover, the average functional group number is 2 to 4 and the hydroxyl value is 200. As a polyol of -270 mgKOH / g, MN700 (brand name) manufactured by Mitsui Takeda Chemical can be illustrated.

Moreover, in this invention, it is good to adjust the viscosity of a polyol component to 400-600cp, Preferably 450-550cp under 25 degreeC temperature conditions. In the case where the viscosity of the polyol component is less than 400 cps and in the case where the viscosity of the polyol component is more than 600 cps, a polyurethane foam having good resilience may not be formed in some cases.

In the present invention, a polyol component is prepared using a mixture of a polyol having an average functional number of 2 to 4 and a hydroxyl value of 80 to 120 mgKOH / g, and a polyol having an average functional group of 2 to 4 and a hydroxyl value of 150 to 210 mgKOH / g. One low-elasticity polyurethane foam can be used.

Although the compounding quantity of the former polyol and the latter polyol is not specifically limited, It is preferable to mix | blend and use so that the former polyol may be 34-75 weight% and the latter polyol may be 25-66 weight%. This means that the former polyol content is less than 34% by weight (the latter polyol content exceeds 66% by weight) and the former polyol content is more than 75% by weight (the latter polyol is less than 25% by weight). In this case, it is because it becomes difficult to obtain good low repulsion.

As a polyol with an average functional group number of 2-4 and a hydroxyl value of 80-120 mgKOH / g, the brand name Actcol LR-00 by Mitsui Takeda Chemical Company can be illustrated.

As a polyol with an average functional number of 2-4 and a hydroxyl value of 150-210 mgKOH / g, the brand name Actcol LR-03 by Mitsui Takeda Chemical Company can be illustrated.

In addition, in the present invention, as a polyol component, a polyol having an average functional group number of 2 to 4 and a hydroxyl value of 20 to 60 mgKOH / g, a polyol having an average functional group of 1.5 to 4.5 and a hydroxyl value of 200 to 300 mgKOH / g, and an average functional group number of 2 It is also possible to use a low-elasticity polyurethane foam produced using a mixture of polyols having a hydroxyl value of 80 to 150 mgKOH / g.

The content of the polyol having an average number of functional groups of 2 to 4 and a hydroxyl value of 20 to 60 mgKOH / g is not particularly limited, but is preferably 40 to 80% by weight and preferably 50 to 70% by weight of the total polyol component.

The content of the polyol having an average functional number of 1.5 to 4.5 and a hydroxyl value of 200 to 300 mgKOH / g is not particularly limited, but is preferably 15 to 40% by weight and preferably 20 to 35% by weight in the total polyol component.

The content of the polyol having an average number of functional groups of 2 to 4 and a hydroxyl value of 80 to 150 mgKOH / g is not particularly limited, but is 1 to 15% by weight of the total polyol component, preferably 5 to 13% by weight.

As the isocyanate component used in producing the low-elasticity polyurethane foam, it is preferable to use toluene diisocyanate (TDI-80, TDI-65), unpurified diphenyl methane diisocyanate (Crude-MDI), etc .. Taketake 80 (brand name) manufactured by Mitsui Nippon Urethane Co., Ltd. can be illustrated.

Any blowing agent can be used as long as it can be used for the production of polyurethane foam. Specifically, water, acid amide, nitro alkanes, sodium bicarbonate, ammonium carbonate and the like can be exemplified in addition to protonic compounds such as trichloro fluoromethane, methylene chloride, dichloro difluoro methane, and the like. It is preferable to use a mixture of low boiling point organic compounds such as chloride. In the present invention, only one kind of the blowing agent may be used, or two or more kinds thereof may be mixed and used.

What is necessary is just to mix | blend the compounding quantity of a foaming agent in the manufacture of a normal polyurethane foam, Specifically, it may adjust so that it may be 1.0-6.0 weight part with respect to 100 weight part of polyol components, Preferably it is 1.8-5.0 weight part. This is because neither the case where the compounding quantity of a foaming agent is less than 1.0 weight part and when it exceeds 6.0 weight part can foam favorably, and neither case is preferable.

The catalyst may be any catalyst as long as it can be used for the production of polyurethane foam. Specifically, tin-based catalysts such as dibutyl tin dilaurate, dibutyl tin diacetate, and stanas oleate, tripropyl amine, and tree In addition to the tertiary amine catalysts such as ethylene diamine, dimethyl ethanol amine, triethyl amine, tetramethyl hexamethylene diamine, N-methyl morpholine and N-ethyl morpholine, already known urethanization catalysts, for example, organic metals, organic acids, etc. In the present invention, only one kind of the catalyst may be used, or two or more kinds may be mixed and used.

What is necessary is just to mix | blend the compounding quantity in the manufacture of a normal polyurethane foam, Specifically, it is good to adjust so that it may be 0.01-5.0 weight part with respect to 100 weight part of polyol components, Preferably it is 0.5-3.0 weight part. This is because a good urethane foam cannot be obtained both when the blending amount of the catalyst is less than 0.01 part by weight and when it exceeds 5.0 parts by weight.

In the present invention, in addition to the above-described components, polyalcohols, chain extenders, plasticizers, flame retardants, foam stabilizers, organic powders, metal hydroxides, inorganic powders, pigments, dyes, coloring agents, inorganic extenders, organic solvents, antioxidants, ultraviolet absorbers, Each component, such as a hydrolysis inhibitor, can be mix | blended suitably arbitrarily.

Moreover, although the foaming ratio of a polyurethane foam is not specifically limited, It is preferable to set it as 50 to 90%.

In this invention, carbon content is contained in a urethane foam.

As the carbon powder contained in the urethane foam, all carbon powders can be used as long as the particle size is 0.01 µm or more, and carbon powders having a particle size of 500 µm or more can also be used.

In the present invention, the particle diameter of the carbon powder is not particularly limited as long as the particle diameter is 0.01 µm or more, but when the carbon powder of 1 µm or less is used, it is 0.01 to 1 µm, preferably 0.01 to 0.8 µm, and more preferably 0.05 to 0.5 µm. ． The main purpose of carbon powder of 1 micrometer or less is to color almost the entire urethane foam to black uniformly. When the particle size is less than 0.01 μm, the preparation becomes difficult, and when it exceeds 1 μm, it becomes difficult to obtain a nearly uniformly dispersed coloring effect.

Moreover, when mix | blending the carbon powder of 1-500 micrometers, Preferably it is 10-400 micrometers, More preferably, you may be 100-300 micrometers. The main purpose of blending the carbon powder of 1 to 500㎛ is to effectively obtain the deodorizing action and the humidity control action of the carbon powder. In the case where the particle diameter is 1 µm or less, the deodorizing action and the humidity control action are lowered. In addition, in the case of 500 µm or more, the particle size may not be dispersed and retained in the form, which is not preferable in any case.

Moreover, when carbon powder of 500 micrometers or more is used, 500-2000 micrometers, Preferably it is 600-1500 micrometers, More preferably, you may be 750-1000 micrometers. The main purpose of using carbon powder having a particle diameter of 500 µm or more is to obtain a visual effect that visually informs the user that carbon powder is blended in addition to the hygroscopic and deodorizing action. In the case where the particle size is less than 500 m, the visual effect is not sufficiently obtained, and in the case where the particle size is more than 2000 m, it is possible to drop out of the foam.

As carbon powder, the white coal obtained by burning wood at 750-1200 degreeC, carbonizing it at 350-520 degreeC, and the black coal obtained by burning wood at 400-750 degreeC and carbonizing at 250-450 degreeC can be used preferably.

Examples of charcoal include charcoal baked at around 1200 ° C using oak and quercus phillyraeoides as solid wood. Black charcoal includes charcoal made of oak (Quercus acutissima) and oak (Quercus serrata Thunb). Furthermore, bamboo charcoal using bamboos belonging to the family Gramineae, or carbon black or activated carbon can also be suitably used. In particular, in the present invention, it is preferable to use porous carbon powder such as charcoal or bamboo charcoal, and more preferably to use charcoal charcoal.

In the present invention, it is also possible to use charcoal and / or a mixture of bamboo charcoal and carbon black. This is because charcoal and bamboo charcoal dispersibility is excellent by mixing carbon black. In addition, by combining carbon black, the entire polyurethane foam can be colored black, and the effect of visually identifying the inorganic antibacterial agent is excellent. When mix | blending carbon black, the particle diameter is although it does not specifically limit, It shall be 0.01-1 micrometer.

The mixing ratio of charcoal and bamboo charcoal and carbon black is not particularly limited, but the charcoal and / or bamboo charcoal: carbon black = 1: 0.5-5, preferably 1: 1-3, more preferably 1: 1.5-2.5 by weight ratio. Shall be. If the blending amount of carbon black is less than 0.5 weight times of the blending amount of charcoal and / or bamboo charcoal, the effect of the blending of carbon black is not obtained, and the blending amount of carbon black exceeds 5 weight times of the blending amount of charcoal and / or bamboo charcoal. If it mix | blends, since the compounding quantity of charcoal and / or bamboo charcoal relatively falls and hygroscopicity and deodorization property fall, neither case is preferable.

It is preferable that the compounding quantity of carbon powder shall be 0.01-30 weight% with respect to all the compounding components. This is because when the blending amount of the carbon powder is less than 0.01% by weight, the effect of blending the carbon powder is not obtained, and when the blending amount is more than 30% by weight, the dispersibility is not good and foaming may not be performed well. The case is also undesirable. In addition, when the particle size of the carbon powder is 0.01 to 1 µm, preferably 0.1 to 20% by weight, more preferably 0.5 to 15% by weight. In addition, when the particle size of the carbon powder is 1 µm or more, preferably 0.1 10 weight%, More preferably, you may be 0.5-5 weight%.

In the polyurethane foam according to the present invention, the inorganic antibacterial agent is contained in the polyurethane foam.

As an inorganic antimicrobial agent which can be used by this invention, a metal ion antimicrobial agent is preferable, for example, silver, copper, zinc, titanium dioxide, etc.

Especially in this invention, it is preferable to mix | blend silver and / or titanium dioxide. This is because silver and titanium dioxide are excellent in antimicrobial activity. When it mix | blends with carbon powder, the superior antibacterial effect is acquired.

In addition, in the present invention, it is preferable to mix silver and titanium dioxide together as an inorganic antibacterial agent. This is because by combining silver and titanium dioxide together, the antimicrobial performance can be remarkably excellent compared to the case where each is individually mixed.

Although the compounding quantity of an inorganic antimicrobial agent is not specifically limited, It is 0.01-30 weight% with respect to the whole compounding component, Preferably it is 0.1-10 weight%. If the content is less than 0.01% by weight, antimicrobial activity cannot be imparted to the polyurethane foam, and if it is blended in excess of 30% by weight, foaming may be inhibited at the time of polyurethane foam production, and it may be eliminated from the polyurethane foam. There is a case.

When the inorganic antimicrobial agent is blended with silver and titanium dioxide together, the compounding ratio is not particularly limited, but the amount of the total amount of silver and titanium dioxide is within the range of the above compounding amount and the silver: titanium dioxide = 1 weight ratio. It is preferable to mix | blend so that it may be 1: 0.3-5.

The particle size of the inorganic antimicrobial agent is not particularly limited, but is 0.1 to 300 µm, more preferably 0.5 to 100 µm. In addition, the particle size of the inorganic antimicrobial agent is preferably smaller than the carbon powder to be described later. This is because the inorganic antimicrobial agent can be supported on the carbon powder and the visual effect of notifying the user that the inorganic antimicrobial agent is blended is excellent.

Titanium dioxide includes anatase, rutile and brookite titanium dioxide. Although any type of titanium dioxide can be used in the present invention, the anatase type titanium dioxide can be preferably used because it is excellent in antibacterial activity.

In the present invention, only one of the carbon powder and the inorganic antibacterial agent may be blended, or the carbon powder and the inorganic antibacterial agent may be blended together.

In the present invention, the inorganic antimicrobial agent can be dispersed in the polyurethane foam by being supported in the porous carbon powder. By dispersing and supporting the inorganic antimicrobial on the surface of the porous carbon powder or the surface of the fine pores in the carbon powder, the inorganic antimicrobial agent is excellent in dispersibility, and the porous carbon powder has a large specific surface area, so that the inorganic antimicrobial agent can be mixed in large quantities. It is possible to increase the odor, deodorization and hygroscopicity.

When the inorganic antimicrobial agent is supported in the porous carbon powder, the porous carbon powder has a particle size larger than that of the inorganic antimicrobial agent.

The method of supporting the inorganic antimicrobial agent in the porous carbon powder is not particularly limited. However, the method of supporting the inorganic antimicrobial agent by mixing the carbon powder and the inorganic antimicrobial agent in water or mixing the wood powder and the inorganic antimicrobial agent as raw materials of the carbon powder with the temperature condition of 500 to 1000 ° C The method of carrying out by baking under these etc. can be illustrated. When mixing wood flour and an inorganic antibacterial agent, a prosthetic agent such as clay or adhesive can be added as necessary.

Further, in the present invention, as a method of supporting the inorganic antimicrobial agent on the surface of the porous carbon powder or the inner surface of the pores, a precipitation precipitation method, a gas phase graphite method, an electroless plating method, and a deposition method can be adopted.

The above-mentioned inorganic antimicrobial agent and carbon powder may be blended within the range of the above-mentioned compounding amount. In particular, in the present invention, the inorganic antimicrobial agent and carbon powder may be blended within the range of the above-mentioned compounding amount, and the inorganic antimicrobial agent and carbon powder may be contained in a weight ratio of from 1: 0.1 to 1. 10, It is preferable to mix | blend so that it may become 1: 0.5-5. This is because the visual effect of notifying the user that the inorganic antimicrobial agent is blended is insufficient when the amount of the carbon powder is less than 0.1 wt. Times the amount of the inorganic antimicrobial agent. If the blending amount of carbon exceeds 10 weight times of the blending amount of the inorganic antimicrobial agent, the blending amount of the carbon powder is large compared to the blending amount of the inorganic antimicrobial agent, and the visual effect is also insufficient in this case.

1-4 is a schematic diagram which shows the cross section of the polyurethane foam which concerns on this invention. On the other hand, in the polyurethane foam 1 according to the present invention shown in Figs. 1 and 2, the carbon powder 3 is contained in the polyurethane foam 2. The polyurethane according to the present invention shown in Figs. In the foam (1), the carbon foam (3) and the inorganic antibacterial agent (4) are contained in the polyurethane foam (2).

The polyurethane foam (1) according to the present invention is dispersed in such a manner that the carbon powder (3) and / or the inorganic antimicrobial agent (4) is almost uniform in the polyurethane foam (2), as shown in the schematic cross-sectional view shown in Figs. It is held. In addition, as shown in the schematic sectional drawing shown in FIG. 2 or 4, the carbon powder 3 and / or the inorganic antibacterial agent 4 dispersed and retained in the polyurethane foam 2 are concentrated and retained on the surface.

Polyurethane foam according to the present invention is excellent in deodorization, hygroscopicity, antibacterial because carbon powder adsorbs odor or moisture in the polyurethane foam, and the inorganic antimicrobial agent inhibits the growth of mold and the like.

Furthermore, in addition to the odor and moisture in the polyurethane foam, the odor and moisture contained in the air passing through the polyurethane foam can also be adsorbed. For example, the polyurethane foam according to the present invention is used as a cushioning material for automobile seats. In this case, odors peculiar to automobiles can be reduced.

In addition, since the carbon powder has a far infrared ray effect, for example, when polyurethane foam is used as a bedding, the thermal insulation can be improved.

Polyurethane foam according to the present invention is not only the surface of the polyurethane foam, but also carbon powder and inorganic antimicrobial agent is dispersed and retained in the polyurethane foam, so that the specific surface area of the carbon powder or inorganic antimicrobial agent is increased compared to the case where it is partially concentrated Deodorization, hygroscopicity, and antibacterial properties can be improved.

Polyurethane foam according to the present invention can be used for all applications, but in particular, in anticipation of its excellent deodorization, hygroscopicity, and antibacterial properties, as a cushioning material for bedding, bedding, flooring, wall, shoe soles, etc. It can be used very suitably.

Hereinafter, a description will be given of a very suitable method for producing the polyurethane foam according to the present invention described above.

A very suitable method for producing the polyurethane foam according to the present invention will be described according to the particle size of the carbon powder.

First, when the particle diameter of the carbon powder is 0.01 to 1 µm, the carbon powder and / or the inorganic antimicrobial agent are mixed at the same time when the polyol component and the isocyanate component are mixed, heated and foamed to be molded. By simultaneously mixing the polyol component, the isocyanate component, the carbon powder and / or the inorganic antibacterial agent, the catalyst can be satisfactorily foamed without being adsorbed to the carbon powder. In addition, when using the carbon powder whose particle diameter is 0.01-1 micrometer, it is preferable to mix and use carbon black. This is because the dispersibility of carbon powder can be improved.

As an example of this manufacturing method, when both a polyol component and an isocyanate component are solid form, it heats and fuses. The heating temperature at this time is the same as the temperature in the manufacture of ordinary polyurethane foam, specifically, it is 50-80 degreeC. Moreover, dehydration and degassing are performed in a pressure-reduced state as needed.

Next, a catalyst, a foaming agent, or other additives are mixed with the polyol component. The temperature at this time is the same as the temperature in the production of ordinary polyurethane foam, specifically, 15 to 60 ° C.

Finally, the carbon powder and the inorganic antimicrobial agent are blended at the same time when the polyol component and the isocyanate component mixed with various additives are mixed. The polyurethane foam according to the present invention can be produced by molding after heating and foaming. The heating temperature is approximately 90 to 250 ° C.

Next, the manufacturing method in the case where the particle diameter of carbon powder exceeds 1 micrometer is demonstrated. This manufacturing method is characterized by mixing the carbon powder and / or the inorganic antimicrobial agent in advance into the polyol component and dispersing it, then mixing with the isocyanate component to heat, foam and mold.

This is because the carbon powder and / or the inorganic antimicrobial agent is mixed in advance in the polyol component, and then mixed with the isocyanate component and heated and foamed so that the carbon powder and the inorganic antimicrobial agent are dispersed and retained in the polyurethane foam without being biased in the polyurethane foam.

As an example of this manufacturing method, when both a polyol component and an isocyanate component are solid form, it heats and fuses. The heating temperature at this time is the same as the temperature in the manufacture of ordinary polyurethane foam, specifically, it is 50-80 degreeC. Moreover, dehydration and degassing are performed in a pressure-reduced state as needed.

Next, a catalyst, a foaming agent, or other additives are mixed with the polyol component. In addition, in this invention, carbon powder and an inorganic antimicrobial agent are previously mix | blended with a polyol component, and are disperse | distributed so that it may become substantially uniform. Although the temperature at this time is the same as the temperature in manufacture of a normal polyurethane foam, it is 15-60 degreeC specifically ,.

Finally, the polyurethane foam according to the present invention can be produced by mixing a polyol component and an isocyanate component mixed with various additives, heating and foaming, and then molding. The heating temperature is approximately 90 to 250 ° C.

This production method mixes and foams a polyol component and an isocyanate component dispersed in advance so that the carbon powder is blended and becomes almost uniform. If the particle size is 1 µm, the carbon powder of any particle size is dispersed and retained without being partially retained, and the polyurethane retained is dispersed. Foams can be prepared. In addition, when the carbon powder having a particle size of 500 µm or more is used, the carbon powder is dispersed in the polyurethane foam as shown in the schematic cross-sectional view of FIG.

Moreover, the manufacturing method of the polyurethane foam which concerns on this invention can employ | adopt both a discontinuous method and a continuous method suitably.

The polyurethane foam according to the present invention may be based on the slab foaming method or may be based on the mold foaming method. In particular, in the case of using a mixture of a polyol having an average functional group number of 2 to 4 and a hydroxyl value of 30 to 60 mgKOH / g, and a polyol having an average functional group number of 2 to 4 and a hydroxyl value of 200 to 270 mgKOH / g, the slab foaming method By the polyol component, a mixture of a polyol having an average number of functional groups of 2 to 4 and a hydroxyl value of 80 to 120 mgKOH / g and a polyol having an average functional group of 2 to 4 and a hydroxyl value of 150 to 210 mgKOH / g or an average functional group as a polyol component Polyols having 2-4, 20-60 mgKOH / g hydroxyl value, Polyols having 1.5-4.5 average functional groups, 200-300 mgKOH / g hydroxyl value, 2-4 having an average functional group 80-150 mgKOH / When the mixture of g polyol is used, it is preferable to manufacture by the mold foaming method.

On the other hand, in the case of the molding foaming method, a breathable thin film can be formed on the surface of the manufactured polyurethane foam. By forming a breathable thin film on the surface of the polyurethane foam, it is possible to adjust the delay time recovery time of the polyurethane foam.

Example

The present invention is explained in more detail by showing examples. However, this invention is not limited at all by the following example.

Preparation of Sample 1

According to the composition shown in Table 1, each sample of Examples 1-4 and Comparative Example 1 was prepared. In the preparation method, first, a component other than the isocyanate component is mixed with the polyol component in advance, and then the polyol component and the isocyanate component are mixed and reacted. Each sample is heated and aged for 10 minutes under a condition of 60 to 75 ° C in a heating furnace. I prepared it.

In addition, as a polyol component, the same amount was used and mixed with Boranol V3022 (brand name) manufactured by Mitsubishi Chemical Dow Corporation and MN700 (brand name) manufactured by Mitsudakeda Chemical. Toluene diisocyanate (TDI-80) was used as the isocyanate component. Stanas octoate was used as a catalyst and charcoal was used as charcoal, respectively.

Preparation of Sample 2

According to the composition of Table 1, the sample of Example 5 was prepared. In the preparation method, the components other than the carbon powder, the inorganic antimicrobial agent, and the isocyanate component were first mixed with the polyol component, and then the polyol component, the isocyanate component, the carbon powder, and the inorganic antibacterial agent were simultaneously mixed and reacted. The mixture was heated and aged for 10 minutes under a condition of 60 to 75 ° C. in a heating furnace. In addition, the carbon black used the particle diameter of less than 1 micrometer. The other raw material used the same thing as the sample of Examples 1-4.

Test Example 1 Measurement of hardness and recovery time

The hardness of each sample of the prepared Examples 1 to 5 and Comparative Example 1 was measured based on the method defined in JIS-K6400. That is, using a hardness tester equipped with a pressurized disk of 200 mmФ and pre-compressing the test piece of 50 x 380 x 380 (mm) to 75% of the thickness before pressing, the original thickness at the rate of 100 mm per minute The load value at the time of compressing to 25% was measured.

In addition, after a constant load was applied to each of the samples of Examples 1 to 5 and Comparative Example 1 prepared under a temperature condition of 20 ° C, the load was removed and the groove formed by the load was not loaded at all. The time to return (point pressure recovery time) was measured. Table 1 shows the results.

As a result of Table 1, it can be seen that the polyurethane foam according to the present invention has almost the same physical properties as the polyurethane foam containing no carbon powder or inorganic antibacterial agent.

In the sample of each example, the carbon powder and the inorganic antimicrobial agent are dispersed and held in the polyurethane foam.

Test Example 2 Antibacterial Test

First, according to the composition of Table 2, the sample of Example 6, 7 and the comparative example 2 was prepared by the method similar to Examples 1-4. In Example 7, silver powder was supported on charcoal and used.

Next, each prepared sample was cut into a size of 45 mm x 5 mm x 2 mm, and each cut sample was placed in a sterile chalet. Each of the samples was adjusted to a coliform bacterium of about 10 / mL. 0.5 mL was added dropwise to the sample. The outside of the chalet was covered with a film and stored at room temperature so as not to mix the cells with the cells.

After 24 hours, the bacterial solution was collected, transferred to the medium and cultured, and the number of bacteria in the sample was measured.

As a result of culturing, in the sample of the comparative example, the number of bacteria before the start of the test and the number of the bacteria after 24 hours were almost unchanged or slightly increased, but E. coli was hardly detected in the sample of the example. Therefore, it can be seen that the polyurethane foam according to the present invention has excellent antibacterial activity.

Test Example 3 Visual Effect Test

Ten panels were visually checked for samples having the same composition as in Example 6 except that Example 6 and charcoal prepared above were selected, so that many silver powders were selected.

As a result, nine of the ten panels felt that the sample of Example 6 had many silver powders blended.

Therefore, it can be said that the polyurethane foam containing the silver powder and the carbon powder has an excellent visual effect that informs the user that the additive is blended.

Preparation of Samples 3

According to the composition shown in Table 3, each sample of Examples 8-11 and Comparative Example 3 was prepared. The preparation method first mixes a component other than an isocyanate component with the polyol component, and then mixes and reacts this polyol component and an isocyanate component. I made it. Each sample was prepared by heating and maturing for 10 minutes under the conditions of 60-75 degreeC in the heating furnace.

In addition, as a polyol component, the brand name Act call LR-00 by Mitsui Takeda Chemical Co., Ltd., and the brand name Act call LR-03 manufactured by Mitsui Takeda Chemical Co., Ltd. were mixed and used for the same amount. Toluene diisocyanate (TDI-80) was used as the isocyanate component. Stanas octoate was used as a catalyst and charcoal was used as charcoal, respectively.

Preparation of Sample 4

According to the composition shown in Table 3, the sample of Example 12 was prepared. The preparation method first mixes a component other than a carbon powder, an inorganic antimicrobial agent, and an isocyanate component with the polyol component, and then simultaneously mixes a polyol component, an isocyanate component, a carbon powder, and an inorganic antimicrobial agent simultaneously. It mixed and reacted. It heated and aged for 10 minutes on 60-75 degreeC conditions in the heating furnace, and prepared. In addition, the carbon black used the particle diameter of less than 1 micrometer. The other raw material used the same thing as the sample of Examples 8-11.

Test Example 4 Measurement of hardness and recovery time

The hardness of each sample of Examples 8-12 and Comparative Example 3 prepared above was measured based on the method defined in JIS-K6400. In other words, using a hardness tester equipped with a pressurized disk of 200 mmФ, the test piece of 50 x 380 x 380 (mm) was pre-compressed to 75% of the pre-tension thickness, and then 25 times of the original thickness at a rate of 100 mm per minute. The load value at the time of compressing to% was measured.

Moreover, after applying a constant load to each sample of Examples 8-12 and Comparative Example 3 which were prepared above under the temperature condition of 20 degreeC, this load is removed and it is until the groove part formed by the load does not apply the load at all. The time to return (point pressure recovery time) was measured. The results are shown in Table 3.

As a result of Table 1, it can be seen that the polyurethane foam according to the present invention has almost the same physical properties as the polyurethane foam containing no carbon powder or inorganic antibacterial agent.

In the sample of each example, the carbon powder and the inorganic antimicrobial agent are dispersed and held in the polyurethane foam.

Test Example 5; Antimicrobial test

First, according to the composition shown in Table 4, the sample of Example 13, 14 and the comparative example 4 was prepared by the method similar to Examples 8-12. In Example 14, silver powder was supported on charcoal and used.

Next, each prepared sample was cut into a size of 45 mm x 5 mm x 2 mm, and each cut sample was placed in a sterile chalet. 0.5 mL each of the bacteria liquid adjusted to the number of coliform bacteria / mL was added to the sample in a chalet. The outside of the chalet was covered with a film and stored at room temperature so as not to mix the cells with the cell.

After 24 hours, the bacterial solution was collected, transferred to the medium and cultured, and the number of bacteria in the sample was measured.

As a result of culturing, in the sample of the comparative example, the number of bacteria before the start of the test and the number of the bacteria after 24 hours were almost unchanged or slightly increased, but E. coli was hardly detected in the sample of the example. Thus, it can be seen that the polyurethane foam according to the present invention has excellent antibacterial activity.

Polyurethane foam according to the present invention is excellent in the ability to adsorb odor, moisture and the like, far-infrared radiation performance, antibacterial performance and at the same time it is possible to actually inform the user that the additive is formulated.

In addition, when a low-elasticity polyurethane foam is used as the polyurethane foam, it is excellent in dispersibility of body pressure of the user, no local pressure feeling, and also effective in preventing blood flow inhibition or pressure sores.

1 is a schematic cross-sectional view of a polyurethane foam according to the present invention.

2 is a schematic cross-sectional view of the polyurethane foam according to the present invention.

3 is a schematic cross-sectional view of a polyurethane foam according to the present invention.

4 is a schematic cross-sectional view of the polyurethane foam according to the present invention.

<Brief description of the main references in the drawings>

1. Polyurethane foam according to the invention.

2 .. Polyurethane foam.

3. Carbon fraction.

4. Inorganic antibacterial agents.

Claims (7)

A polyurethane foam characterized by containing carbon powder and / or inorganic antibacterial agent therein. The polyurethane foam according to claim 1, wherein the carbon powder is porous carbon powder and / or carbon black. The polyurethane foam according to claim 2, wherein the inorganic antimicrobial agent is supported in porous carbon powder. The polyurethane foam according to any one of claims 1 to 3, wherein the inorganic antibacterial agent is silver and / or titanium dioxide. The polyurethane foam according to any one of claims 1 to 4, wherein the polyurethane foam is a low-elasticity polyurethane foam. The method of claim 5, wherein the low-elasticity polyurethane foam, With isocyanate component, Polyurethane comprising a polyol component consisting of a polyol having an average functional group of 2 to 4, a hydroxyl value of 30 to 60 mgKOH / g, and a polyol having an average functional group of 2 to 4, a hydroxyl value of 200 to 270 mgKOH / g Form. The method of claim 5, wherein the low-elasticity polyurethane foam, With isocyanate component, Polyurethane foam formed from a polyol component consisting of a polyol having an average functional group of 2 to 4, a hydroxyl value of 80 to 120 mgKOH / g, and a polyol having an average functional group of 2 to 4, a hydroxyl value of 150 to 210 mgKOH / g .