WO2013015242A1 - ポリウレタンフォーム用組成物、ポリウレタンフォーム用調製物、ポリウレタンフォーム用ポリマーポリオール調製物、それらの製造方法、およびポリウレタンフォーム - Google Patents
ポリウレタンフォーム用組成物、ポリウレタンフォーム用調製物、ポリウレタンフォーム用ポリマーポリオール調製物、それらの製造方法、およびポリウレタンフォーム Download PDFInfo
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- WO2013015242A1 WO2013015242A1 PCT/JP2012/068587 JP2012068587W WO2013015242A1 WO 2013015242 A1 WO2013015242 A1 WO 2013015242A1 JP 2012068587 W JP2012068587 W JP 2012068587W WO 2013015242 A1 WO2013015242 A1 WO 2013015242A1
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- polyol
- acid
- compound
- polyurethane foam
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Definitions
- the present invention relates to a composition for polyurethane foam, a preparation for polyurethane foam, a polymer polyol preparation for polyurethane foam, a production method thereof, and a polyurethane foam.
- polyurethane foam preparations and polyurethane foam polymer polyol preparations that have high coloration and discoloration inhibiting properties during storage over a long period of time, and polyurethane foam compositions that are excellent in storage stability and suitable for resin premixes About.
- Polyurethane foam has excellent heat insulation performance, moldability, self-adhesiveness, heat insulation materials such as electric refrigerators, freezers, refrigerated warehouses, building material panels, and excellent cushioning properties. Widely used in interior materials such as headrests, armrests, instrument panels, door trims, ceiling materials, motorcycle saddles, aircraft and railcar seat materials, and other office supplies such as furniture, bedding, cushions for office chairs, etc. Has been.
- Polyurethane foam is usually prepared by preparing a resin premix containing polyols such as polyoxyalkylene polyols and polymer polyols (polymer dispersion polyols), catalysts for polyurethane foam production, foaming agents, etc., and reacting this resin premix with polyisocyanate. Can be obtained.
- the polyoxyalkylene polyol is obtained, for example, by addition polymerization of an alkylene oxide compound to an active hydrogen compound using a basic catalyst.
- polyoxyalkylene polyols are usually stable for the purpose of preventing oxidative degradation of the polyols or for preventing the formation of peroxides that inhibit the reactivity of the polyurethane foam production catalyst.
- the agent is added.
- stabilizers include phenolic compounds (for example, Patent Document 1).
- the resin premix may be colored yellow or brown over time, or during the resin premix, There may be various problems such as crystallization of the contained components and precipitation, separation into an aqueous layer and an organic layer in the resin premix.
- the resin premix may affect the urethanization reaction in the production of polyurethane foam, which may make it difficult to control the reaction time, and may adversely affect foam performance and moldability. There is also a risk.
- phenolic compounds are widely used as additives to polyoxyalkylene polyols.
- resin-based premixes containing a basic catalyst used for polymerization, or poly-polyalkylene polyols are generally used under basic conditions. It tends to change color in oxyalkylene polyols.
- the polyoxyalkylene polyol containing the catalyst is not used as it is in the resin premix, but before being used in the resin premix, for example, the polyoxyalkylene polyol is neutralized with an acid or the like. It is commonly used to purify and reduce the catalyst and acid components to a certain level or less (Patent Documents 2 to 5, etc.).
- the resin premix contains catalysts, acids, stabilizers such as antioxidants, etc., the emergence of resin premixes that can produce urethane foam without problems and have excellent long-term storage stability Is desired.
- JP 2005-194362 A Japanese Patent Laid-Open No. 51-101099 Japanese Patent Laid-Open No. 10-30023 JP 2000-17070 A JP 2001-106780 A
- the present invention is intended to solve the problems associated with the prior art as described above, and can suppress coloration and discoloration during storage over a long period of time, so that precipitation of crystals and separation of an aqueous layer and an organic layer can be achieved. It is an object of the present invention to provide a polyurethane foam preparation, a polyurethane foam polymer polyol preparation, a polyurethane foam composition, a polyurethane foam composition and a method for producing the same, which are excellent in storage stability and suitable for a resin premix.
- R 1 represents a hydrocarbon group
- m represents the number of hydrogen atoms in the benzene ring substituted by R 1 and is any of 0 to 5].
- the manufacturing method of the composition for polyurethane foams is: A polyoxyalkylene polyol (p) obtained by addition polymerization of an alkylene oxide compound to an active hydrogen compound using the compound (ii) as a catalyst, and a compound (ii) used in the production of the polyol (p) In polyol (i), The antioxidant (iii) and the acid or salt (iv) thereof are combined with the compound (ii) (b) having a P ⁇ N bond used in the production of the polyol (p) and the acid or salt thereof ( iv)
- a polyurethane foam preparation (c) is obtained by adding a molar ratio (a / b) to (a) of 0.3 or more and 25 or less, and then to the preparation (c). It includes a step of adding the production catalyst (v) and the blowing agent (vi).
- the manufacturing method of the composition for polyurethane foam further includes the process of preparing a polymer polyol in the said preparation (c), and this polymer polyol has an unsaturated bond in this preparation (c). It is preferably obtained by dispersing polymer fine particles obtained by polymerizing a compound.
- the polyurethane foam of the present invention is obtained using the polyurethane foam composition of the present invention.
- the present invention it is possible to suppress coloring and discoloration during storage over a long period of time, and to obtain a polyurethane foam composition having excellent storage stability without causing crystal precipitation or separation of an aqueous layer and an organic layer. be able to.
- the composition can be stored for a long period of time as a resin premix prepared in the production of polyurethane foam.
- the resin premix can suppress the deterioration of the polyoxyalkylene polyol, and the polyurethane foam obtained by using the polyurethane foam composition of the present invention can maintain good physical properties for a long period of time. Moreover, since it is hard to produce the peroxide which inhibits the reactivity of the catalyst for polyurethane foam manufacture, the reactivity of urethanization at the time of manufacturing a polyurethane foam can be adjusted moderately. Furthermore, the obtained polyurethane foam hardly causes problems such as yellowing.
- composition of the present invention when the composition of the present invention is produced, a crude polyol obtained using a compound having a P ⁇ N bond as a catalyst can be used without purification, so that the process can be greatly omitted. Therefore, the environmental load can be reduced and the manufacturing cost can be greatly reduced.
- polyurethane foam preparation and the polyurethane polyol polymer polyol preparation have high coloration and discoloration suppressing properties during storage and excellent storage stability over a long period of time.
- the composition for polyurethane foam of the present invention comprises at least (i) a specific polyol, (ii) a compound having a P ⁇ N bond, (iii) an antioxidant having a hydroxyphenyl group, (iv) a specific acid or its A salt, (v) a catalyst for producing polyurethane foam, and (vi) a blowing agent, and optionally other auxiliary agents.
- the composition is suitable as a resin premix prepared in the production of polyurethane foam.
- the polyurethane foam preparation of the present invention (also referred to as preparation (c)) comprises at least (p) polymer fine particles obtained by polymerizing a specific polyoxyalkylene polyol and / or a compound having an unsaturated bond with the polyol.
- the preparation (c) is suitable for the polyurethane foam composition of the present invention.
- the polymer polyol preparation for polyurethane foam of the present invention (also referred to as preparation (pc)) contains the components contained in the preparation (c) of the present invention, and further contains unsaturated bonds in the preparation (c).
- the preparation (pc) is suitable for the polyurethane foam composition of the present invention.
- composition for polyurethane foam of the present invention contains at least one polyol selected from polyoxyalkylene polyols and polymer-dispersed polyols, which will be described later, and may contain other polyols as necessary.
- the polyol (i) may contain a catalyst used for producing a polyoxyalkylene polyol.
- the total polyol contained in the polyurethane foam composition is usually 80 to 98% by mass, preferably 82 to 97% by mass, and more preferably 85 to 96% by mass with respect to 100% by mass of the composition. .
- the polyol (i) is not particularly limited in the preparation (c) or the preparation (pc) as long as the effects of the present invention are exhibited, but the preparation (c) or the preparation (pc) is 100% by mass. On the other hand, it is usually 80.00 to 99.99% by mass, preferably 80.00 to 99.98% by mass, more preferably 90 to 99.98% by mass.
- the polyoxyalkylene polyol according to the present invention includes, for example, a compound having a P ⁇ N bond, potassium hydroxide, cesium hydroxide, and rubidium, which will be described later, as a catalyst, and an addition reaction of an alkylene oxide compound with an active hydrogen compound. can get.
- a catalyst As a catalyst, the total degree of unsaturation at the end of addition polymerization can be further reduced, and polyoxyalkylene polyol can be efficiently produced. Since the activity per mole is high, the amount of catalyst required for polymerization is small. In fact, a compound having a P ⁇ N bond is preferred in that the amount of acid to be added can be reduced.
- the polyoxyalkylene polyol has a molar ratio (a / b) between the compound (ii) (b) and the acid or salt (iv) (a) of the specified amount of acid or salt (iv), antioxidant. It is also preferable that the polyol (p) is obtained using the agent (iii) and the compound (ii) as a catalyst.
- the hydroxyl value of the polyoxyalkylene polyol is not particularly limited, but is preferably 10 to 80 mgKOH / g, more preferably 15 to 60 mgKOH / g, and most preferably 18 to 40 mgKOH / g.
- the hydroxyl value is in the above range, it is preferable from the viewpoint of obtaining an optimum balance of hardness, flexibility, mechanical strength, impact resilience, and the like as a polyurethane foam.
- the total degree of unsaturation of the polyoxyalkylene polyol is not particularly limited, but is preferably 0.050 meq / g or less, more preferably 0.040 meq / g or less, and still more preferably 0 in that a general polyurethane foam can be obtained. 0.030 meq / g or less.
- the lower limit of the total degree of unsaturation is not particularly limited, but is, for example, 0.001 meq / g. When the total degree of unsaturation is within the above range, it is preferable in that the resulting polyurethane foam has good resilience and wet heat permanent compression strain (wet (set).
- Examples of the active hydrogen compound include alcohols, phenol compounds, polyamines, alkanolamines, and thioalcohols.
- alcohols for example, water, ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, 1,5-pentanediol, neopentyl glycol, 2-methyl-1,5-pentanediol, 2-ethyl- 1,4-butanediol, 1,4-dimethylolcyclohexane, 1,3-propanediol, 1,4-cyclohexanediol, 1,3-butanediol, 1,4-butanediol, 1,6-hexanediol, Dihydric alcohols such as 1,4-cyclohexanediol, Alkanolamines such as monoethanolamine, diethanolamine, triethanolamine, Polyhydric alcohols such as
- active hydrogen compounds can be used in combination of two or more.
- the compound obtained by addition-polymerizing an alkylene oxide compound with these active hydrogen compounds by a conventionally well-known method can also be used.
- compounds having a number average molecular weight of up to 2,000 obtained by addition polymerization of dihydric alcohols and dihydric alcohols with alkylene oxide, trihydric alcohols and alkylene oxides with trihydric alcohols Is a compound having a number average molecular weight of up to 2,000, a tetravalent alcohol, and a compound having a number average molecular weight of up to 3,000.
- the number average molecular weight after addition of an alkylene oxide compound to a dihydric alcohol or trivalent alcohol exceeds 2,000.
- the number average molecular weight after addition of an alkylene oxide compound to a tetrahydric alcohol is 3,000. Exceeding it is not preferable because the amount of by-product monool increases.
- alkylene oxide compound that undergoes addition polymerization to the active hydrogen compound examples include propylene oxide, ethylene oxide, 1,2-butylene oxide, 2,3-butylene oxide, styrene oxide, cyclohexene oxide, epichlorohydrin, epibromohydrin, Examples include methyl glycidyl ether, allyl glycidyl ether, and glycidol. These may be used alone or in combination of two or more.
- propylene oxide ethylene oxide, 1,2-butylene oxide, 2,3-butylene oxide, and styrene oxide are preferable. More preferred are propylene oxide and ethylene oxide.
- the temperature for addition polymerization of the alkylene oxide compound to the active hydrogen compound is preferably 15 to 150 ° C, more preferably 40 to 130 ° C, and still more preferably 50 to 125 ° C.
- the maximum pressure of the addition polymerization reaction of the alkylene oxide compound is preferably 882 kPa or less.
- addition polymerization of an alkylene oxide compound is performed in a pressure resistant reactor.
- the reaction of the alkylene oxide compound may be started from a reduced pressure state or an atmospheric pressure state. When starting from an atmospheric pressure state, it is desirable to carry out in the presence of an inert gas such as nitrogen or helium. If the maximum reaction pressure of the alkylene oxide compound exceeds 882 kPa, the amount of by-product monool may increase.
- the method of supplying the epoxide compound to the polymerization system is a method of supplying a part of the required amount of the alkylene oxide compound at a time and supplying the remainder continuously, or a method of supplying all the alkylene oxide compounds continuously. Etc. are used.
- the reaction temperature at the initial stage of the polymerization reaction of the alkylene oxide compound is set to a lower temperature within the above temperature range, and the reaction is gradually performed after the alkylene oxide compound is charged. A method of increasing the temperature is preferred.
- a solvent can be used if necessary.
- the solvent include aliphatic hydrocarbons such as pentane, hexane and heptane, ethers such as diethyl ether, tetrahydrofuran and dioxane, and aprotic polar solvents such as dimethyl sulfoxide and N, N-dimethylformamide.
- a solvent When a solvent is used, a method of recovering and reusing the solvent after production is desirable in order not to increase the production cost of the polyoxyalkylene polyol.
- the polymer polyol according to the present invention (also referred to as a polymer-dispersed polyol) is obtained by dispersing and polymerizing a compound having an unsaturated bond in a polyoxyalkylene polyol using a radical initiator such as an azo compound or a peroxide. It can be obtained as a dispersion in which vinyl polymer particles are dispersed in an oxyalkylene polyol.
- This vinyl polymer particle may be a vinyl polymer particle made of a polymer of a compound having an unsaturated bond, but at the time of dispersion polymerization, at least a part of the compound having an unsaturated bond was grafted to a specific polyol as a dispersion medium. Polymer particles are preferred.
- azo compound examples include 2,2′-azobis (4-methoxy2,4-dimethylvaleronitrile), 2,2′-azobis (2-methylbutylnitrile), 2,2′-azobis (isobutyro). Nitrile) and dimethyl 2,2′-azobis (2-methylpropionate).
- peroxide examples include benzoyl peroxide, t-butyl peroxide, di-t-butyl peroxide and the like. Of these, azo compounds are preferable, and 2,2′-azobis (isobutyronitrile) and dimethyl 2,2′-azobis (2-methylpropionate) are more preferable.
- the compound having an unsaturated bond is a compound having an unsaturated bond in the molecule, for example, a cyano group-containing monomer such as acrylonitrile and methacrylonitrile, Methacrylic acid ester monomers such as methyl acrylate, butyl acrylate, stearyl acrylate, hydroxyethyl acrylate, hydroxymethyl methacrylate, hydroxyethyl methacrylate, hydroxypropyl methacrylate, dimethylaminoethyl acrylate and dimethylaminopropyl methacrylate, Carboxyl group-containing monomers such as acrylic acid, methacrylic acid, itaconic acid, maleic acid and fumaric acid, Acid anhydride group-containing monomers such as maleic anhydride and itaconic anhydride, Hydrocarbon monomers such as butadiene, isoprene and 1,4-pentadiene, Aromatic hydrocarbon monomers such as styrene, ⁇ -methyls
- acrylonitrile styrene
- methyl acrylate styrene
- hydroxyethyl methacrylate is preferred.
- a dispersion stabilizer or a chain transfer agent may be added.
- the hydroxyl value of the polymer polyol is not particularly limited, but is preferably 10 to 80 mgKOH / g, more preferably 15 to 60 mgKOH / g, and most preferably 18 to 40 mgKOH / g. It is preferable that the hydroxyl value is in the above range from the viewpoint of obtaining good flexibility and resilience as a polyurethane foam.
- the total amount of the polymer polyol is usually 2 to 100% by mass, preferably 2 to 95% by mass, more preferably 5 to 80% with respect to 100% by mass of the total amount of all polyol components. % By mass.
- the content of the vinyl polymer particles in the polymer polyol is not particularly limited with respect to 100% by mass of the total amount of the polymer polyol, but is preferably 3 to 60% by mass, more preferably 5 to 50% by mass, and still more preferably. 8 to 45% by mass.
- the polymer polyol is obtained by dispersing a polymer fine particle by directly polymerizing a compound having an unsaturated bond in the preparation using the polyoxyalkylene polyol (p) contained in the preparation (c) of the present invention. And can be prepared.
- the preparation (c) contains at least the compound (ii), antioxidant (iii) and acid or salt (iv) used in the production of the polyol (p).
- the prepared preparation (pc) can also suppress coloring and discoloration during storage for a long period of time.
- a polymerization reaction is performed using the above-described polyoxyalkylene polyol, a compound having an unsaturated bond, a radical initiator, and, if necessary, a chain transfer agent and a dispersion stabilizer.
- the polymerization reaction can be carried out either batchwise or continuously.
- the polymerization temperature is determined according to the kind of the polymerization initiator, but it is higher than the decomposition temperature of the polymerization initiator, preferably 60 to 200 ° C., more preferably 90 to 150 ° C.
- the polymerization reaction can be carried out under pressure or at atmospheric pressure.
- the polymerization reaction can be performed without a solvent, but can also be performed in the presence of at least one solvent selected from water and an organic solvent, or a mixture of water and the organic solvent.
- the organic solvent include toluene, xylene, acetonitrile, hexane, heptane, dioxane, ethylene glycol dimethyl ether, N, N-dimethylformamide, methanol, butanol, isopropanol and the like.
- the obtained polymer polyol can be used as a raw material for polyurethane as it is, but it is used after distilling off a compound having an unsaturated bond, a decomposition product of a radical initiator, a chain transfer agent, a solvent, etc. under reduced pressure. It is preferable to do.
- the average particle size of the polymer contained in the polymer polyol of the present invention is preferably 0.01 to 10 ⁇ m from the viewpoint of the influence on the dispersion stability of the polymer and the physical properties of the polyurethane.
- the chain transfer agent, the dispersion stabilizer, the type and amount of the solvent used, the weight composition ratio of the ethylenically unsaturated monomer, and the like can be appropriately adjusted. .
- the polyurethane foam composition of the present invention may contain, in addition to the polyoxyalkylene polyol and / or polymer polyol, other polyols generally used for the production of polyurethane foam, if necessary.
- other polyols include polyester polyols, polyether ester polyols, and polycarbonate polyols.
- Polyester polyols include, for example, condensates of low molecular weight polyols and carboxylic acids; lactone-based polyols such as ⁇ -caprolactone ring-opening polymer, ⁇ -methyl- ⁇ -valerolactone ring-opening polymer, polylactic acid, and polyricinoleic acid And other hydroxycarboxylic acid-based polyols.
- Low molecular polyols include dihydric alcohols having 2 to 10 carbon atoms such as ethylene glycol and propylene glycol, trihydric alcohols having 2 to 10 carbon atoms such as glycerin, trimethylolpropane and trimethylolethane, pentaerythritol, diglycerin and the like. And saccharides such as tetrahydric alcohol, sorbitol and sucrose.
- carboxylic acid examples include dicarboxylic acids having 2 to 10 carbon atoms such as succinic acid, adipic acid, maleic acid, fumaric acid, phthalic acid and isophthalic acid, and 2 to 2 carbon atoms such as succinic anhydride, maleic anhydride and phthalic anhydride. 10 acid anhydrides and the like.
- the content thereof is preferably less than 80% by mass, more preferably 50% by mass or less, and particularly preferably 30% by mass or less, with respect to 100% by mass of all the polyol components. .
- the compound having a P ⁇ N bond according to the present invention (also referred to as compound (ii)) is not particularly limited as long as it can be used as a catalyst for producing a polyoxyalkylene polyol contained in the polyol.
- a phosphazenium compound examples include phosphine oxide compounds and phosphazene compounds.
- the content of the compound (ii) contained in the polyol (p) is not particularly limited as long as the effects of the present invention are exhibited, but when calculated from the charged amounts of each component, the lower limit is preferably 150 ppm, more preferably 200 ppm, still more preferably 300 ppm, and the upper limit is preferably 5000 ppm, more preferably 3000 ppm, still more preferably 2000 ppm.
- the content of the compound (ii) contained in the polyurethane foam preparation (c) is not particularly limited as long as the effects of the present invention are exhibited, but when calculated from the charged amounts of each component, Is preferably 50 ppm, more preferably 100 ppm, still more preferably 200 ppm, and the upper limit is preferably 3000 ppm, more preferably 2500 ppm, and still more preferably 2000 ppm.
- the content of the compound (ii) contained in the composition for polyurethane foam is not particularly limited as long as the effect of the present invention is exhibited, but when calculated from the charged amount of each component,
- the upper limit is preferably 50 ppm, more preferably 100 ppm, still more preferably 200 ppm, and the upper limit is preferably 3000 ppm, more preferably 2500 ppm, still more preferably 2000 ppm.
- the amount of the compound (ii) contained in the polyol (p), the polyurethane foam preparation (c), or the polyurethane foam composition is determined by capillary electrophoresis, a method using a trace total nitrogen analyzer, or 1H-NMR. It can also be quantified by methods.
- the upper limit value is preferably 25, more preferably 15, more preferably 10, most preferably 8, and the lower limit value in terms of good coloration and discoloration suppression properties and stability of the urethanization reaction. Is preferably 0.3, more preferably 0.5, and still more preferably 0.8. It is preferable that it is contained in the composition for polyurethane foam and the preparation (c or pc) so that it may become the said ratio.
- the molar ratio (a / b) is preferably 5 to 25, more preferably 8 to 23, and still more preferably 10 to 22.
- the molar ratio (a / b) is preferably 0.3 to 13, more preferably 0.5 to 11, and still more preferably 0.8 to 8.
- the compound (ii) used in the production of the polyoxyalkylene polyol (p) is not removed, and the polyol (i) containing the polyol (p) and the compound (ii) is used as it is as a polyurethane foam preparation (c ) Can also be used.
- the molar ratio (a / b) is the molar ratio of the number of moles of compound (ii) used in the production of polyol (p) and the acid added to preparation (c) or salt (iv) thereof. The above range is preferable.
- Examples of the phosphazenium compound include a compound represented by the following chemical formula (2) and a compound represented by the following chemical formula (3).
- a, b, c and d are each a positive integer of 0 to 3, but all of a, b, c and d are not 0 at the same time.
- R is the same or different hydrocarbon group having 1 to 10 carbon atoms, and two Rs on the same nitrogen atom may be bonded to each other to form a ring structure.
- Q ⁇ represents a hydroxy anion, an alkoxy anion, an aryloxy anion or a carboxy anion.
- a, b, c and d are each a positive integer of 0 to 3, but all of a, b, c and d are not 0 at the same time.
- R is the same or different hydrocarbon group having 1 to 10 carbon atoms, and two Rs on the same nitrogen atom may be bonded to each other to form a ring structure.
- r is an integer of 1 to 3 and represents the number of phosphazenium cations, and T r ⁇ represents an inorganic anion having a valence of r].
- the compound represented by the chemical formula (2) is preferable.
- A, b, c and d in the phosphazenium cation represented by the chemical formula (2) or the chemical formula (3) are each a positive integer of 0 to 3. However, all are not 0 at the same time. Preferably it is an integer of 0-2. More preferably, regardless of the order of a, b, c and d, (2, 1, 1, 1), (1, 1, 1, 1), (0, 1, 1, 1), (0, 0 , 1, 1) or (0, 0, 0, 1) in combination. More preferably, it is a number in a combination of (1, 1, 1, 1), (0, 1, 1, 1), (0, 0, 1, 1) or (0, 0, 0, 1). .
- R in the phosphazenium cation represented by chemical formula (2) or chemical formula (3) is the same or different hydrocarbon group having 1 to 10 carbon atoms.
- R is, for example, methyl, ethyl, n-propyl, isopropyl, allyl, n-butyl, sec-butyl, tert-butyl, 2-butenyl, 1-pentyl, 2-pentyl, 3-pentyl, 2-methyl-1 -Butyl, isopentyl, tert-pentyl, 3-methyl-2-butyl, neopentyl, n-hexyl, 4-methyl-2-pentyl, cyclopentyl, cyclohexyl, 1-heptyl, 3-heptyl, 1-octyl, 2-octyl 2-ethyl-1-hexyl, 1,1-dimethyl-3,3-dimethylbutyl (tert-octyl), nony
- aliphatic or aromatic hydrocarbon group is mentioned.
- aliphatic hydrocarbon groups having 1 to 10 carbon atoms such as methyl, ethyl, n-propyl, isopropyl, tert-butyl, tert-pentyl, and tert-octyl are preferable. More preferably, it is a methyl group or an ethyl group.
- the divalent hydrocarbon group on the nitrogen atom is from 4 to 6 carbon atoms.
- a divalent hydrocarbon group having a main chain (the ring is a 5- to 7-membered ring containing a nitrogen atom).
- Preferable examples include tetramethylene, pentamethylene and hexamethylene. More preferably, it is a tetramethylene or pentamethylene group.
- the main chain may be substituted with an alkyl group such as methyl or ethyl.
- Such a ring structure may be taken for all possible nitrogen atoms in the phosphazenium cation, or a part thereof.
- T r ⁇ in the chemical formula (3) represents an inorganic anion having a valence of r.
- r is an integer of 1 to 3.
- inorganic anions include boric acid, tetrafluoro acid, hydrocyanic acid, thiocyanic acid, hydrofluoric acid, hydrochloric acid or hydrohalic acid, nitric acid, sulfuric acid, phosphoric acid, phosphorous acid, and the like.
- Inorganic anions such as acid, hexafluorophosphoric acid, carbonic acid, hexafluoroantimonic acid, hexafluorothalamic acid, perchloric acid, HSO 4 ⁇ and HCO 3 ⁇ can be mentioned.
- inorganic anions can be exchanged with each other by an ion exchange reaction.
- inorganic anions anions of inorganic acids such as boric acid, tetrafluoroboric acid, hydrohalic acid, phosphoric acid, hexafluorophosphoric acid and perchloric acid are preferable, and a chlorine anion is more preferable.
- the alkali metal or alkaline earth metal salt of the active hydrogen compound that coexists with the compound represented by the chemical formula (3) is an alkali metal or alkaline earth metal obtained by dissociating the active hydrogen of the active hydrogen compound as a hydrogen ion. It is a salt that replaces ions.
- tetrakis [tris (dimethylamino) phosphoranylideneamino] phosphonium hydroxide tetrakis [tris (dimethylamino) phosphoranylideneamino] phosphine Examples include phonium methoxide, tetrakis [tris (dimethylamino) phosphoranylideneamino] phosphonium ethoxide, tetrakis [tri (pyrrolidin-1-yl) phosphoranylideneamino] phosphonium tert-butoxide, and the like.
- Examples of the phosphine oxide compound include compounds represented by the following chemical formula (4).
- R is the same or different hydrocarbon group having 1 to 10 carbon atoms.
- R is, for example, methyl, ethyl, n-propyl, isopropyl, allyl, n-butyl, sec-butyl, tert-butyl, 2-butenyl, 1-pentyl, 2-pentyl, 3-pentyl, 2-methyl-1 -Butyl, isopentyl, tert-pentyl, 3-methyl-2-butyl, neopentyl, n-hexyl, 4-methyl-2-pentyl, cyclopentyl, cyclohexyl, 1-heptyl, 3-heptyl, 1-octyl, 2-octyl 2-ethyl-1-hexyl, 1,1-dimethyl-3,3-dimethylbutyl (common name: tert-octyl), nonyl, decyl, phenyl
- R may be in the form of a pyrrolidino group or a piperidino group.
- the same or different 1 to 8 carbon atoms such as methyl, ethyl, n-propyl, isopropyl, tert-butyl, tert-pentyl, 1,1-dimethyl-3,3-dimethylbutyl, etc.
- the aliphatic hydrocarbon group is preferable.
- a methyl group or an ethyl group is more preferable.
- the phosphine oxide compound represented by the chemical formula (4) can be synthesized by a method described in Journal of general chemistry of the USSR, 55, 1453 (1985), or a method similar thereto. Usually, the phosphine oxide compound represented by the chemical formula (4) has a hygroscopic property and tends to be a hydrate or hydrate.
- X representing the amount of water molecules contained in the phosphine oxide compound is shown as a molar ratio with respect to the phosphine oxide compound, and x is 0 to 5, preferably 0 to 2.
- Preferable forms of the phosphine oxide compound include tris [tris (dimethylamino) phosphoranylideneamino] phosphine oxide or tris [tris (diethylamino) phosphoranylideneamino] phosphine oxide.
- Examples of the phosphazene compound include compounds shown in JP-A No. 10-36499, and specifically include compounds represented by the following chemical formula (5).
- l, m and n each represents a positive integer of 0 to 3.
- Q represents a hydrocarbon group having 1 to 20 carbon atoms.
- D is the same or different hydrocarbon group having 1 to 20 carbon atoms, alkoxy group, phenoxy group, thiol residue, thiophenol residue, monosubstituted amino group, disubstituted amino group, or 5 It is a 6-membered cyclic amino group.
- hydrocarbon group having 1 to 20 carbon atoms of D examples include, for example, methyl, ethyl, propyl, isopropyl, n-butyl, isobutyl, sec-butyl, tert-butyl, pentyl, neopentyl, hexyl, heptyl, octyl, tert -Alkyl groups such as octyl, nonyl and decyl, An alkyl group having an unsaturated bond or an aromatic group such as allyl, 2-methylallyl, benzyl, phenethyl, o-anisyl, 1-phenylethyl, diphenylmethyl, triphenylmethyl or cinnamyl; Cycloaliphatic groups such as cyclopentyl, cyclohexyl, 4-methylcyclohexyl, 3-propylcyclohexyl, 4-phenylcyclohexyl, cycl
- alkoxy group for D for example, an alkoxy group containing 1 to 20 carbon atoms such as methoxy, ethoxy, propoxy, isopropoxy, butoxy, pentyloxy, allyloxy, cyclohexyloxy and benzyloxy
- phenoxy group for D include, for example, phenoxy groups containing 6 to 20 carbon atoms such as phenoxy, 4-methylphenoxy, 3-propylphenoxy and 1-naphthyloxy
- Examples of the thiol residue of D include 1 to 20 carbon atoms such as methylthio, ethylthio, propylthio, isopropylthio, butylthio, isobutylthio, tert-butylthio, pentylthio, hexylthio, heptylthio, octylthio, tert-octylthio, nonylthio and decylthi
- Examples of the thiophenol residue of D include phenylthio, o-toluylthio, m-toluylthio, p-toluylthio, 2,3-xylylthio, 2,4-xylylthio, 3,4-xylylthio, 4-ethylphenylthio and 2 A thiophenol residue containing 6 to 20 carbon atoms such as naphthylthio,
- Examples of the monosubstituted amino group of D include methylamino, ethylamino, propylamino, isopropylamino, butylamino, isobutylamino, tert-butylamino, pentylamino, hexylamino, heptylamino, octylamino, tert-octylamino , Nonylamino, decylamino, 1-ethylpropylamino
- disubstituted amino group for D examples include dimethylamino, diethylamino, methylethylamino, dipropylamino, methylpropylamino, diisopropylamino, dibutylamino, methylbutylamino, diisobutylamino, di-sec-butylamino, dipentylamino.
- DD divalent group
- the divalent group (DD) include ethylene, vinylene, propylene, 1,2-cyclohexanylene, 1,2-phenylene, trimethylene, propenylene, tetramethylene, 2,2′-biphenylene, 1-butenylene, And saturated or unsaturated aliphatic divalent hydrocarbon groups such as 2-butenylene and pentamethylene.
- an oxygen atom, a sulfur atom, a hydrogen atom or a methyl group, an ethyl group, a butyl group, a cyclohexyl group, a benzyl group or a phenyl group is attached to one or both of the bonds between both ends of the divalent group and the phosphorus atom.
- a divalent group in which any one or two of a group consisting of nitrogen atoms to which an aliphatic or aromatic hydrocarbon group is bonded are inserted.
- divalent group examples include, for example, methyleneoxy, ethylene-2-oxy, trimethylene-3-oxy, methylenedioxy, ethylenedioxy, trimethylene-1,3-dioxy, cyclohexane-1,2-dioxy , Benzene-1,2-dioxy, methylenethio, ethylene-2-thio, trimethylene-3-thio, tetramethylene-4-thio, methylenedithio, ethylenedithio, trimethylene-1,3-dithio, iminomethylene, 2-imino Ethylene, 3-iminotrimethylene, 4-iminotetramethylene, N-ethyliminomethylene, N-cyclohexyl-2-iminoethylene, N-methyl-3-iminotrimethylene, N-benzyl-4-iminotetramethylene, di Iminomethylene, 1,2-diiminoethylene, 1,2-diiminobini 1,3-diiminotrimethylene, N, N′-dimethyldiiminomethylene,
- D and Q that are possible by bonding to each other may form a ring structure, and in this case, as a divalent group (DQ) that connects a nitrogen atom and a phosphorus atom Is a saturated or unsaturated aliphatic divalent hydrocarbon group identical to the divalent group on the phosphorus atom shown above, and an oxygen atom in the bond between the divalent hydrocarbon group and the phosphorus atom.
- DQ divalent group that connects a nitrogen atom and a phosphorus atom
- Examples include a divalent group in an inserted form.
- Specific examples of the divalent group include, for example, methyleneoxy, ethylene-2-oxy, methylenethio, ethylene-2-thio, iminomethylene, 2-iminoethylene, N-methyliminomethylene, N-ethyl-2-imino.
- groups such as ethylene, N-methyl-3-iminotrimethylene or N-phenyl-2-iminoethylene.
- phosphazene compound having a structure represented by the chemical formula (5) include, for example, when D is the same or different alkyl group, such as 1-tert-butyl-2,2,2-trimethylphosphazene or 1 -(1,1,3,3-tetramethylbutyl) -2,2,4,4,4-pentaisopropyl-2 ⁇ 5 , 4 ⁇ 5 -catenadi (phosphazene) and the like.
- D is an unsaturated bond or an alkyl group having an aromatic group
- D examples include, for example, 1-tert-butyl-2,2,2-triallylphosphazene, 1-cyclohexyl-2,2,4,4, 4-pentaallyl-2 ⁇ 5 , 4 ⁇ 5 -catenadi (phosphazene) or 1-ethyl-2,4,4,4-tribenzyl-2-tribenzylphosphoranylideneamino-2 ⁇ 5 , 4 ⁇ 5 -catenadi (phosphazene), etc. Is mentioned.
- D is an alicyclic group
- D examples include 1-methyl-2,2,2-tricyclopentylphosphazene or 1-propyl-2,2,4,4,4-cyclohexyl-2 ⁇ 5 , 4 ⁇ 5- Catenaji (phosphazene) etc. are mentioned.
- D is an alkenyl group
- examples of the case where D is an alkenyl group include 1-butyl-2,2,2-trivinylphosphazene or 1-tert-butyl-2,2,4,4,4-pentastyryl-2 ⁇ 5 , 4 ⁇ 5 -Catenadi (phosphazene) and the like.
- Examples of the case where D is an alkynyl group include 1-tert-butyl-2,2,2-tri (2-phenylethynyl) phosphazene, and the case where D is an aromatic group include, for example, Examples thereof include 1-isopropyl-2,4,4,4-tetraphenyl-2-triphenylphosphoranylideneamino-2 ⁇ 5 , 4 ⁇ 5 -catenadi (phosphazene).
- D is an alkoxy group
- D is an alkoxy group
- D is an alkoxy group
- D is an alkoxy group
- Examples of the case where D is an alkoxy group include 1-tert-butyl-2,2,2-trimethoxyphosphazene, 1- (1,1,3,3-tetramethylbutyl) -2,2,4, 4,4-pentaisopropoxy-2 ⁇ 5 , 4 ⁇ 5 -catenadi (phosphazene) or 1-phenyl-2,2,4,4,4-pentabenzyloxy-2 ⁇ 5 , 4 ⁇ 5 -catenadi (phosphazene) It is done.
- D is a phenoxy group
- D is a phenoxy group
- examples of the case where D is a phenoxy group include 1-methyl-2,2,2-triphenoxyphosphazene or 1-tert-butyl-2,2,4,4,4-penta (1-naphthyloxy)- 2 ⁇ 5 , 4 ⁇ 5 -catenadi (phosphazene) and the like.
- D is a disubstituted amino group
- D is a disubstituted amino group
- Examples of the case where D is a disubstituted amino group include 1-tert-butyl-2,2,2-tris (dimethylamino) phosphazene, 1- (1,1,3,3-tetramethylbutyl) -2 , 2,2-Tris (dimethylamino) phosphazene, 1-ethyl-2,2,4,4,4-pentakis (dimethylamino) -2 ⁇ 5 , 4 ⁇ 5 -catenadi (phosphazene), 1-tert-butyl-2 , 4,4,4-tetrakis (dimethylamino) -2-tris (dimethylamino) phosphoranylideneamino-2 ⁇ 5 , 4 ⁇ 5 -catenadi (phosphazene), 1-tert-butyl-2,4,4,4 - tetrakis (di
- examples of the case where D on the same phosphorus atom or two different phosphorus atoms are bonded to each other to form a ring structure include, for example, 2- (tert-butylimino) -2-dimethylamino -1,3-dimethyl-1,3-diaza-2 ⁇ 5 -phosphinan and the like.
- Preferred forms of the phosphazene compound include, for example, 1-tert-butyl-2,2,2-tris (dimethylamino) phosphazene, 1- (1,1,3,3-tetramethylbutyl) -2,2,2 Tris (dimethylamino) phosphazene, 1-ethyl-2,2,4,4,4-pentakis (dimethylamino) -2 ⁇ 5 , 4 ⁇ 5 -catenadi (phosphazene), 1-tert-butyl-4,4,4 Tris (dimethylamino) -2,2-bis [tris (dimethylamino) phosphoranylideneamino] -2 ⁇ 5 , 4 ⁇ 5 -catenadi (phosphazene), 1- (1,1,3,3-tetramethylbutyl ) -4,4,4-tris (dimethylamino) -2,2-bis [tris (dimethylamino) phosphoranyliden
- a phosphazenium compound is preferred, more preferably, from the viewpoint of long-term storage stability of the resin premix, coloration and discoloration suppression during storage, and industrially effective use of the catalyst.
- the composition of the present invention contains an antioxidant having a hydroxyphenyl group for the purpose of preventing deterioration of polyols such as polyoxyalkylene polyol and polymer polyol. In the present invention, it may be referred to as an antioxidant (iii).
- the content of the antioxidant (iii) contained in the polyol (p) of the present invention is not particularly limited as long as the effects of the present invention are exhibited, but when calculated from the charged amounts of the respective components, the lower limit is 100 ppm, Preferably, it is 200 ppm, and the upper limit is 20000 ppm, preferably 15000 ppm.
- the content of the antioxidant (iii) contained in the preparation (c) of the present invention is not particularly limited as long as the effects of the present invention are exhibited, but when calculated from the charged amounts of each component, preferably 100 to 15000 ppm, more preferably 200 to 10000 ppm, still more preferably 250 to 6000 ppm.
- the content of the antioxidant (iii) contained in the composition of the present invention is not particularly limited as long as the effect of the present invention is exhibited, but preferably 100 to 15000 ppm when calculated from the charged amount of each component, More preferably, it is 200 to 10000 ppm, and further preferably 250 to 6000 ppm.
- the content of the antioxidant (iii) contained in the polyol (p), the preparation (c) or the composition according to the present invention is appropriately combined with NMR, gas chromatography, liquid chromatography, and mass spectrometry. It is also possible to quantify with.
- antioxidants examples include BHT (3,5-di-tert-butyl-4-hydroxytoluene), pentaerythrityl-tetrakis-3- (3,5-di-tert-butyl-4-hydroxyphenyl).
- Propionate also referred to as Irganox 1010
- octadecyl-3- (3,5-di-tert-butyl-4-hydroxyphenyl) -propionate also referred to as Irganox 1076
- 2-tert-butyl-4-ethylphenol 2,6- Di-tert-butyl-4-ethylphenol
- stearyl-3- (3,5-di-t -Butyl-4-hydroxyphenyl) propionate 2,2-thio-diethyl Bis [3- (3,5-di-tert-butyl-4-hydroxyphenyl) propionate]
- isooctyl-3- (3,5-di-tert-butyl-4-hydroxyphenyl) propionate also referred to as Irganox 1135
- antioxidants having a t-butyl group-substituted hydroxyphenyl group are preferred, and BHT, Irganox 1010, Irganox 1076, and Irganox 1135 are more preferred for reasons such as solubility in polyurethane foam compositions and antioxidant performance.
- antioxidants may be used alone or in combination of two or more.
- the composition of the present invention includes an acyclic aliphatic monocarboxylic acid having 2 to 25 carbon atoms, a hydroxycarboxylic acid having 2 to 25 carbon atoms, a polyvalent carboxylic acid having 20 to 60 carbon atoms, the above formula (1) And at least one acid selected from the group consisting of an aromatic monocarboxylic acid, a sulfonic acid, and an acid having a sulfate ester group, or a salt thereof. In the present invention, these may be referred to as acids or salts (iv) thereof.
- the polyurethane foam composition of the present invention crystals do not precipitate, and further, the resin premix can be stored for a long time without causing separation of the aqueous layer and the organic layer. be able to. Further, as described above, it has been found that the reactivity of the polyurethane foam composition does not change even when stored for a long period of time, and the storage stability is improved by using it together with the antioxidant according to the present invention. Although these reasons are not clear, it is presumed that the compounds in the polyurethane foam composition exist stably in a specific acid / antioxidant combination and have succeeded in maintaining the reactivity for a long time. ing.
- the acid or salt (iv) of the present invention preferably satisfies the ratio (a / b) to the number of moles of the compound (ii) having a P ⁇ N bond.
- Examples of the acyclic aliphatic monocarboxylic acid having 2 to 25 carbon atoms, preferably 2 to 20 carbon atoms or a salt thereof include acetic acid, propionic acid, butyric acid, valeric acid, caproic acid, heptanoic acid, caprylic acid, Examples include pelargonic acid, capric acid, lauric acid, myristic acid, palmitic acid, stearic acid, and the like, and salts thereof.
- hydroxycarboxylic acid having 2 to 25 carbon atoms, preferably 2 to 20 carbon atoms or a salt thereof examples include lactic acid, malic acid, tartaric acid, citric acid, ricinoleic acid, and salts thereof.
- Examples of the polyvalent carboxylic acid having 20 to 60 carbon atoms, preferably 25 to 55 carbon atoms or a salt thereof include dimer acid (a dimer of carboxylic acid having 18 carbon atoms) (Pripol 1009, Pripol 1006 manufactured by Croda Japan Co., Ltd.). , Pripol 1013), and the like, and salts thereof. Dimer acid can be produced, for example, based on the description in JP-A-2005-2085.
- aromatic monocarboxylic acid represented by the above formula (1) or a salt thereof examples include benzoic acid, decylbenzoic acid, dodecylbenzoic acid, and the like, and salts thereof.
- R 1 represents a hydrocarbon group.
- Hydrocarbon groups include methyl, ethyl, propyl, isopropyl, n-butyl, isobutyl, sec-butyl, t-butyl, n-pentyl, isopentyl, t-pentyl, neopentyl Group, hexyl group, isohexyl group, heptyl group, octyl group, nonyl group, decyl group, dodecyl group and the like.
- R 1 is preferably a decyl group or a dodecyl group.
- M represents the number of hydrogen atoms in the benzene ring substituted by R 1 , and is 0 to 5, preferably 0 to 2.
- sulfonic acid or a salt thereof examples include alkylbenzenesulfonic acids such as p-toluenesulfonic acid and dodecylbenzenesulfonic acid (including linear and branched types), benzenesulfonic acid, methanesulfonic acid, camphorsulfonic acid, and the like. These salts are mentioned.
- Examples of the acid having a sulfate group or a salt thereof include polyoxyalkylene alkenyl ether ammonium sulfate (Latemul PD-105 manufactured by Kao Corporation), polyoxyethylene styrenated phenyl ether ammonium sulfate (Latemul E manufactured by Kao Corporation) -1000A).
- the salt can be neutralized with an acid and is not particularly limited as long as the effect of the present invention is achieved.
- an alkali metal salt such as a lithium salt, a sodium salt, or a potassium salt, an alkaline earth such as a calcium salt, a magnesium salt, or a barium salt.
- a salt of a weak base such as a metal salt, ammonium salt, amine salt or pyridinium salt, a salt with a metal such as a copper salt or a silver salt, or a complex salt with copper.
- a weak base salt such as an ammonium salt, an amine salt, or a pyridinium salt is used.
- These acids may be acid anhydrides or hydrates as long as the effects of the present invention are exhibited.
- the ratio (a / b) of the number of moles (b) of the compound having a P N bond necessary for obtaining coloring and discoloration inhibiting properties and the total number of moles (a) of the acid or its salt. ), I.e., because it can efficiently suppress coloring and discoloration with a small amount of acid addition, and there is no acid odor, lactic acid, malic acid, tartaric acid, citric acid, dimer acid, benzoic acid, Alkylbenzenesulfonic acids such as decylbenzoic acid, dodecylbenzoic acid, p-toluenesulfonic acid and dodecylbenzenesulfonic acid (including linear and branched types), benzenesulfonic acid, methanesulfonic acid, camphorsulfonic acid, polyoxyalkylenealkenyl Ether ammonium sulfate, polyoxyethylene styrenated phenyl ether ammonium
- acids or salts thereof may be used alone or in combination of two or more.
- the polyurethane foam production catalyst (also referred to as production catalyst (v)) according to the present invention is not particularly limited as long as it can be used for the reaction between a polyol and a polyisocyanate, and a conventionally known catalyst can be used.
- the amount of the production catalyst (v) is not particularly limited, but is preferably 0.1 to 10 parts by mass, more preferably 0.2 to 5 parts by mass with respect to 100 parts by mass of all the polyol components.
- Examples of the production catalyst (v) include aliphatic amines such as triethylenediamine, bis (2-dimethylaminoethyl) ether, 1-isobutyl-2-methylimidazole, morpholines; tin octoate, dibutyltin dilaurate An organic tin compound such as can be preferably used.
- These catalysts can be used singly or in combination of two or more.
- foaming agent physical foaming agents such as water, hydroxyfluorocarbons (HFC-245fa, etc.), hydrocarbons (cyclopentane, etc.), carbon dioxide, liquefied carbon dioxide, etc., developed for the purpose of protecting the global environment can be used. .
- water, carbon dioxide gas, and liquefied carbon dioxide gas are preferable from the viewpoint of reducing environmental burden.
- a physical foaming agent such as liquefied carbon dioxide can be used, but it is desirable to use water.
- water When water is used as the blowing agent, it is preferably 1.3 to 6.5 parts by weight, more preferably 1.8 to 6.0 parts by weight, and still more preferably 2 parts per 100 parts by weight of all polyol components. 0.0 to 5.5 parts, particularly preferably 2.0 to 5.0 parts by weight. When the amount of water as the foaming agent is in the above range, foaming is stabilized and effectively performed.
- a foaming agent a physical foaming agent can be used in combination with water.
- carbon dioxide gas and liquefied carbon dioxide gas are preferable from the viewpoint of reducing environmental burden.
- the polyurethane foam composition, polyurethane foam preparation, and polyurethane foam polymer polyol preparation of the present invention include a foam stabilizer, a chain extender, a crosslinking agent, a communicating agent, an antifoaming agent, Furthermore, additives generally used in producing a polyurethane foam or polyurethane resin as a flame retardant, a pigment, an ultraviolet absorber as an auxiliary agent can be used as long as the object of the present invention is not impaired.
- foam stabilizer a conventionally known foam stabilizer can be used, and is not particularly limited, but it is usually preferable to use an organosilicon surfactant.
- the amount of the foam stabilizer used is preferably 0.1 to 10 parts by mass, more preferably 0.5 to 5 parts by mass with respect to 100 parts by mass of all the polyol components.
- Additives include Nobutaka Matsudaira and Tetsuro Maeda, "Polyurethane” 8th Printing Bookstore (1964), 134-137, Hitoshi Matsuo, Nobuaki Kunii, Kiyoshi Tanabe "Functional Polyurethane” 1st Printing Co. Additives described in, for example, pages 54 to 68 of CMMC (1989).
- a crosslinking agent can also be used.
- a crosslinking agent a compound having a hydroxyl value of 200 to 1800 mgKOH / g is preferably used as the crosslinking agent.
- crosslinking agents examples include aliphatic polyhydric alcohols such as glycerin; alkanolamines such as diethanolamine and triethanolamine.
- a polyoxyalkylene polyol having a hydroxyl value of 200 to 1800 mgKOH / g can also be used as a crosslinking agent, and a conventionally known crosslinking agent can also be used.
- crosslinking agent When such a crosslinking agent is used, it is preferable to use an amount of 10 parts by mass or less with respect to 100 parts by mass of all polyol components.
- the polyisocyanate used in the present invention is not particularly limited.
- conventionally known polyisocyanates shown in “Polyurethane resin handbook” edited by Keiji Iwata, 1st Nikkan Kogyo Shimbun (1987), pages 71 to 98, and the like are used. Can be mentioned.
- toluylene diisocyanate (the ratio of isomers such as 2,4-isomer and 2,6-isomer is not particularly limited, but 2,4-isomer / 2,6-isomer is 80/20 ratio is preferable) (for example, Cosmonate (trademark) T-80 manufactured by Mitsui Chemicals, Inc.), polymethylene polyphenyl polyisocyanate (for example, Cosmonate (trademark) M manufactured by Mitsui Chemicals, Inc.) -200) or a modified urethane thereof, or a mixture thereof can be preferably used.
- toluylene diisocyanate for example, Cosmonate (trademark) T-80 manufactured by Mitsui Chemicals, Inc.
- polymethylene polyphenyl polyisocyanate for example, Cosmonate (trademark) M manufactured by Mitsui Chemicals, Inc.
- a modified urethane thereof or a mixture thereof
- toluylene diisocyanate is preferably used in an amount of 50 to 99% by mass with respect to the total amount of polyisocyanate from the viewpoint of balance between durability of the foam and mechanical strength. More preferably, it is contained in an amount of 70 to 90% by mass, particularly preferably 75 to 85% by mass.
- an isocyanate-terminated prepolymer obtained by reacting a polyol and a polyisocyanate by a conventionally known method may be used instead of the above polyisocyanate.
- polyisocyanate used in the present invention a polyisocyanate and an isocyanate-terminated prepolymer may be used in combination.
- the NCO index is preferably 0.70 to 1.30, more preferably 0.80 to 1.20.
- the NCO index means a value obtained by dividing the total number of isocyanate groups in the polyisocyanate by the total number of active hydrogens reacting with an isocyanate group such as an amino group such as a hydroxyl group and a crosslinking agent of polyol and water, and water. . That is, when the number of active hydrogens reacting with an isocyanate group and the isocyanate group in the polyisocyanate are stoichiometrically equal, the NCO index is 1.0.
- the method for producing the polyurethane foam composition of the present invention is not particularly limited, and can be produced by a known method in the polyurethane field as long as the effects of the present invention are exhibited.
- a predetermined amount of raw material is charged into a mixing tank equipped with a stirrer and mixed with the stirrer.
- a mixing tank that can be sealed so that the water content of the polyurethane foam composition does not change, and it is preferable to mix in dry air or nitrogen.
- the temperature during mixing may be room temperature, but may be heated in a range that does not adversely affect the production of the polyurethane foam in order to improve the mixing stirrability.
- the raw material charged in the tank can be guided to the pipe by a pump or the like, and can be manufactured by a mixer installed in the pipe.
- a polyurethane foam containing an acid or a salt thereof in an amount satisfying a predetermined molar ratio (a / b), and containing the polyol, the compound having a P N bond, the antioxidant, the acid or a salt thereof, and the like
- the preparation (c) After the preparation (c) is obtained, it can be produced by adding a polyol (i), a catalyst for producing polyurethane foam, a foaming agent, and, if necessary, other auxiliary agents.
- the preparation (pc) can also be used in a polyurethane foam composition.
- the preparation (c) may contain a polymer polyol in advance, but considering efficiency, it is better that the preparation (c) does not contain a polymer polyol.
- the antioxidant according to the present invention and a predetermined molar ratio (a) are added to the polymer polyol in which polymer fine particles obtained by polymerizing a compound having an unsaturated bond are dispersed in the crude polyoxyalkylene polyol (p) obtained as described above. It is also possible to obtain a polymer foam preparation (pc2) for polyurethane foam to which an acid or a salt thereof is added in an amount satisfying / b), and to use the preparation (pc2) in the composition for polyurethane foam.
- an acid or a salt thereof (iv) and an antioxidant (iii) are usually added in a predetermined amount at 50 to 130 ° C.
- water or an inert organic solvent may be added in order to improve solubility, dispersibility, handleability and the like. You may apply the added water as it is as a foaming agent contained in a resin premix.
- an organic solvent it may be removed by heat treatment, reduced pressure treatment or heated reduced pressure treatment to the extent that it does not affect polyurethane foam production.
- the acid or salt thereof and the antioxidant may be added simultaneously, but it is preferable to add the antioxidant after adding the acid or salt thereof, and the antioxidant may be added immediately.
- the ratio (a / b) of the number of moles (b) of the compound having a P ⁇ N bond and the total number of moles (a) of the acid or salt thereof may be added in an amount that falls within the above range. Is preferred in that it has high coloration and discoloration inhibiting properties and high storage stability.
- the acid or a salt thereof and the antioxidant may be added at the same time, but the antioxidant (iii) is added after the acid or the salt (iv) is added. It is preferable to add.
- the addition of the acid or its salt (iv) to the crude polyol (i) containing the polyol (p) may be at room temperature, but may be heated to about 120 ° C. in consideration of stirring properties.
- the antioxidant when the antioxidant is solid, when adding the antioxidant, it is preferable to heat at 60 ° C. or higher in consideration of solubility.
- the pressure at the time of addition is preferably from normal pressure to under pressure, and is preferably performed in a nitrogen atmosphere.
- polyurethane foam and method for producing the same The polyurethane foam composition, polyurethane foam preparation, and polyurethane foam polymer polyol preparation of the present invention can be used as a raw material for polyurethane foam, particularly flexible polyurethane foam.
- the method for producing the polyurethane foam according to the present invention is not particularly limited, and a conventionally known production method can be appropriately employed. Specifically, any of a slab foam method, a hot cure mold foam method, and a cold cure mold foam method can be adopted.
- a known cold cure mold foam method can be adopted as a method of producing a polyurethane foam by the cold cure mold foam method.
- the resin premix obtained from the polyurethane foam composition of the present invention and the polyisocyanate are usually mixed using a high-pressure foaming machine or a low-pressure foaming machine so as to have a predetermined NCO index, and this mixture is mixed into a mold. It can be injected, reacted, foamed, and cured to obtain a polyurethane foam having a fixed shape.
- the curing time is usually from 30 seconds to 30 minutes
- the mold temperature is usually from about room temperature to about 80 ° C.
- the curing temperature is preferably from about room temperature to about 150 ° C.
- the cured product may be heated in the range of 80 to 180 ° C. so long as it does not impair the temperature.
- the resin premix is usually mixed with polyisocyanate in a high-pressure foaming machine or a low-pressure foaming machine.
- a hydrolyzable compound such as an organotin catalyst
- the foaming agent is water.
- the viscosity of the resin premix used is 4000 mPa ⁇ s at 25 ° C. from a viewpoint of mixing property in a foaming machine and foam formability (using a Brookfield type B viscometer at JIS-K1557-5 (2007)). Or less).
- the physical properties (for example, impact resilience, hardness, durability, etc.) of the foam can be set as appropriate according to the use.
- automobiles such as automobile seat cushions and seat backs such as automobiles.
- Interior materials, furniture, bedding, office supplies, etc. can be suitably manufactured.
- Part and “%” in the examples represent “part by mass” and “% by mass”, respectively.
- Terminal oxyethylene group content (mass%) The content (mass%) of the terminal oxyethylene group in the polyol was calculated using the following formula from the preparation of each component.
- the content of the phosphazenium cation was calculated by quantifying the nitrogen atoms remaining in the polyol.
- the nitrogen content in the polyol was analyzed using a trace total nitrogen analyzer (model: TN-100) manufactured by Mitsubishi Chemical Corporation and an element analyzer (model: PE2400) manufactured by PerkinElmer Co., Ltd.
- a compound having a P ⁇ N bond with reference to the method of JP-A-2000-344881 can be obtained by performing 1 H-NMR measurement with a nuclear magnetic resonance apparatus AL-400 manufactured by JEOL Data Co., Ltd. .
- the chemical shift of the proton of the methyl group of tetrakis [tris (dimethylamino) phosphoranylideneamino] phosphonium is around 2.7 ppm, and tetrakis [tris (dimethylamino) phosphoranylideneamino] phosphonium at known concentrations. It can also be calculated by comparison with.
- the mole was calculated from the molecular weight and the molar ratio was calculated.
- the rise time represents the time from the start of mixing the resin premix and the polyisocyanate until the reaction mixture is foamed and reaches the maximum height.
- a smaller difference (RT b ⁇ RT a ) indicates that the urethanization reaction is more stable without change over time, and the reactivity can be appropriately adjusted to obtain a urethane foam stably. I can.
- the total unsaturation degree of this polyol was 0.018 meq / g, the hydroxyl value was 34 mgKOH / g, and the terminal oxyethylene group content was 15% by mass.
- the total unsaturation of this polyol was 0.025 meq / g, the hydroxyl value was 24 mgKOH / g, and the terminal oxyethylene group content was 14.5% by mass.
- the total unsaturation of this polyol was 0.025 meq / g, the hydroxyl value was 34 mgKOH / g, and the terminal oxyethylene group content was 15% by mass.
- the hydroxyl value of polyol d after the purification operation is 34 mg KOH / g, and the total unsaturation is 0.018 meq. / G.
- the content of the compound having a P ⁇ N bond with respect to polyol d was measured to be 17 ppm using 1 H-NMR.
- the total unsaturation degree of this polyol was 0.018 meq / g, the hydroxyl value was 34 mgKOH / g, and the terminal oxyethylene group content was 15% by mass.
- the content of the compound having a P ⁇ N bond relative to polyol e was calculated as 612 ppm from the charged amount. The appearance was slightly cloudy.
- polyol f 1 equivalent of phosphoric acid is added to polyol f with respect to water and KOH at 80 ° C. and stirred for 30 minutes. Further, an adsorbent (trade name: AD-600, manufactured by Tomita Pharmaceutical Co., Ltd.) and BHT are added. 300 ppm was added, and dehydration drying was performed for 3 hours under the conditions of 100 ° C. and 1330 Pa. Then, the solid substance was removed by filtration to obtain polyol g.
- the polyol g had a hydroxyl value of 34 mgKOH / g and a terminal oxyethylene group content of 15% by mass.
- the polyol g was charged in an autoclave equipped with a stirrer, a thermometer, a pressure gauge, and a liquid feeding device until the liquid became full, and the temperature was raised to 120 ° C. while stirring.
- a mixture of polyol g, 2,2′-azobis (isobutyronitrile), acrylonitrile and styrene was continuously charged into the autoclave.
- the initial reaction solution obtained continuously from the outlet was discarded, and the subsequent reaction solution was used in the next step.
- the reaction conditions were a reaction temperature of 120 ° C. and a reaction pressure of 440 kPa, and the residence time was 50 minutes.
- reaction solution After adding BHT in an amount of 300 ppm with respect to the reaction solution obtained, the reaction solution was heated under reduced pressure for 3 hours under the conditions of 120 ° C. and 655 Pa or less, unreacted ethylenically unsaturated monomer, polymerization initiation The decomposition product of the agent was removed to obtain a polymer polyol a.
- the hydroxyl value of this polymer polyol a is 21 mgKOH / g
- the content of the component derived from polyol g is 61.5% by mass
- the content of the polymer component derived from acrylonitrile is 30.8% by mass
- the content of the polymer component derived from styrene is 7.7. It was mass%.
- Polymer polyol b To a polyol b in a four-necked flask equipped with a stirrer, a nitrogen inlet tube and a thermometer, DBSA-L was added in an amount such that the molar ratio (acid (a) / compound (b)) was 4.0, Heated at 100 ° C. for 2 hours. Then, 300 ppm of antioxidant (BHT) was added to polyol b, and polyol h was obtained by heating at 100 ° C. for 1 hour. All mixing was performed in a sealed state.
- BHT antioxidant
- the content of the compound having a P ⁇ N bond with respect to polyol h was set to 580 ppm. Also, assuming that DBSA-L and BHT do not disappear during the preparation, they were calculated to be 1000 ppm and 300 ppm with respect to polyol h, respectively.
- polymer polyol b Using this polyol h solution in place of polyol g, and changing the amounts of acrylonitrile and styrene and using acrylonitrile, the same operation as in the production of polymer polyol a was carried out to obtain polymer polyol b. .
- the hydroxyl value of this polymer polyol b was 19 mg KOH / g, the content of the component derived from polyol h was 80% by mass, and the content of the polymer component derived from acrylonitrile was 20% by mass.
- the compound having a P ⁇ N bond was calculated to be 464 ppm, assuming that the compound having a P ⁇ N bond is derived from the polyol h and does not disappear in the polymer dispersion step.
- Polymer polyol d Except for changing the amounts of acrylonitrile and styrene and changing the polyol g to the polyol c, the same operation as in the production of the polymer polyol a was performed to obtain a polymer polyol c.
- the hydroxyl value of this polymer polyol c is 22.3 mgKOH / g
- the content of the component derived from polyol c is 60% by mass
- the content of the polymer component derived from acrylonitrile is 12.3% by mass
- the content of the polymer component derived from styrene is It was 27.7 mass%.
- DBSA-L was added to polymer polyol c in such an amount that the molar ratio (acid (a) / compound (b)) was 4.0. And heated at 100 ° C. for 2 hours. Then, 300 ppm of antioxidant (BHT) was added to the polymer polyol c, and the polymer polyol d was obtained by heating at 100 ° C. for 1 hour. All mixing was performed in a sealed state.
- the content of the compound having P ⁇ N bond with respect to polymer polyol d was set to 180 ppm.
- DBSA-L and BHT were calculated to be 310 ppm and 300 ppm with respect to polymer polyol d, respectively, assuming that they were not lost during the preparation.
- the content of the compound having P ⁇ N bond with respect to polyol i was set to 800 ppm. Also, assuming that DBSA-L and BHT do not disappear during the preparation, they were calculated as 800 ppm and 300 ppm with respect to polyol i, respectively.
- the hydroxyl value of this polymer polyol e is 19.9 mgKOH / g
- the content of the component derived from polyol i is 61% by mass
- the content of the polymer component derived from acrylonitrile is 15.6% by mass
- the content of the polymer component derived from styrene is It was 23.4% by mass.
- the content of the compound having P ⁇ N bond relative to polymer polyol e was calculated as 488 ppm.
- Polymer polyol f Except not adding BHT, operation similar to preparation of the polyol g was performed, and the polyol j was obtained. Thereafter, the same operation as in the production of the polymer polyol a was carried out except that this polyol j was used and BHT was not used to obtain a polymer polyol f.
- Antioxidant a ⁇ BHT (Pure Chemical Co., Ltd.)
- Antioxidant b ⁇ Irganox 1010 (manufactured by BASF Japan Ltd.)
- Antioxidant c ⁇ Irganox 1076 (manufactured by BASF Japan Ltd.)
- Antioxidant d ⁇ Irganox 1135 (manufactured by BASF Japan Ltd.)
- Antioxidant having no hydroxyl group> Antioxidant e) ⁇ Tris (2-ethylhexyl phosphite) (JP-308E manufactured by Johoku Chemical Industry Co., Ltd.)
- Antioxidant f Bis (tridecyl) pentaerythritol diphosphite (JPP-13R, manufactured by Johoku Chemical Industry Co., Ltd.)
- ⁇ Polyurethane foam catalyst> (Catalyst a) ⁇ Minico L-1020 amine catalyst (trade name, 33% diethylene glycol solution of triethylenediamine) manufactured by Active Materials Chemical Co., Ltd. (Catalyst b) ⁇ Amine catalyst of Bis (2-dimethylaminoethyl) ether (trade name: Minico TMDA) manufactured by Active Materials Chemical Co., Ltd. ⁇ Blowing agent> ⁇ Water ⁇ Other additives> (Communicating agent a) -Polyol polyol of Actol EP-505S (trade name, hydroxyl value: 52 mgKOH / g) manufactured by Mitsui Chemicals, Inc.
- crosslinking agent a -Amine-based crosslinking agent (Crosslinking agent b) of Actol KL-210 (trade name, hydroxyl value: 840 mgKOH / g) manufactured by Mitsui Chemicals, Inc. ⁇ Purified glycerin (hydroxyl value 1830 mgKOH / g) (Foam stabilizer a) ⁇ Silicone foam stabilizer (air stabilizer b) of DC-6070 (trade name) manufactured by Air Products Japan Co., Ltd. ⁇ Silicone foam stabilizer from Air Products Japan Co., Ltd. DC-2525 (trade name)
- Example 1 Acetic acid was added to a polyol a in a molar ratio (a / b) of 20.5 to a four-necked flask equipped with a stirrer, a nitrogen inlet tube and a thermometer, and heated at 100 ° C. for 2 hours. Then, 300 ppm of antioxidant (BHT) was added with respect to polyol a, and the preparation for polyurethane foams was prepared by heating at 100 degreeC for 1 hour. All mixing was performed in a sealed state.
- BHT antioxidant
- the content of the compound having a P ⁇ N bond with respect to polyol a was set to 800 ppm.
- acetic acid and BHT were calculated to be 1300 ppm and 300 ppm with respect to polyol a, assuming that they would not disappear during the preparation.
- polyurethane foam composition 60 parts of the above polyurethane foam preparation, 40 parts of polymer polyol (a), 0.4 part of catalyst (a), 0.1 part of catalyst (b), 4.0 parts of water, communicator (a) 5 parts, 2.5 parts of crosslinking agent (a), 0.2 part of crosslinking agent (b), 0.3 part of foam stabilizer (a) and 0.7 part of foam stabilizer (b) are mixed to form polyurethane foam Composition (resin premix) was prepared.
- the acetic acid and BHT contents were calculated to be 711 ppm and 273 ppm in the resin premix, respectively.
- a colorability test was evaluated using the obtained resin premix. The results are shown in Table 1. The resin premix did not change color after storage for 7 days.
- Examples 2 to 24 and 27, Comparative Examples 1 to 5 Polyol (a to e), polymer polyol (a, b, e and f), antioxidant (a to f), acid or salt thereof, catalyst (a and b), water, communication agent (a), crosslinking Resin premix and polyurethane foam (Examples 2 to 4) were prepared in the same manner as in Example 1 except that the amounts of the agents (a and b) and foam stabilizers (a and b) were changed according to Tables 1 to 4. 24, 27 and Comparative Examples 1 to 5) were obtained. The results are shown in Tables 1 to 4.
- Example 3 Further, the same operation as in Example 1 was performed to obtain a polyurethane foam, and the storage stability of the resin premix was evaluated. The results are shown in Table 3.
- Example 26 A resin premix and a polyurethane foam were obtained in the same manner as in Example 25 except that the amount of the polyol (d) and the polymer polyol (b) were changed to the polymer polyol (e). The results are shown in Table 3.
- Example 1 60 parts of the above polyurethane foam preparation, 40 parts of polymer polyol (a), 0.4 part of catalyst (a), 0.1 part of catalyst (b), 3.9 parts of water, communicator (a) 1.
- the same operation as in Example 1 was performed using 0 part, 1.5 parts of the crosslinking agent (a), 0.2 part of the crosslinking agent (b), and 1.0 part of the foam stabilizer (b).
- Mixed and polyurethane foams were obtained and evaluated.
- Example 100 To a four-necked flask equipped with a stirrer, a nitrogen inlet tube and a thermometer, PTSA was added to 100 parts by weight of polyol a in an amount such that the molar ratio (a / b) was 1.2, and then at 100 ° C. for 2 hours. Heated. Then, 300 ppm of antioxidant (BHT) was added with respect to polyol a, and the preparation for polyurethane foams was prepared by heating at 100 degreeC for 1 hour. All mixing was performed in a sealed state.
- BHT antioxidant
- the content of the compound having a P ⁇ N bond with respect to polyol a was set to 800 ppm. Also, assuming that PTSA and BHT do not disappear during the preparation, they were calculated as 250 ppm and 300 ppm, respectively, with respect to polyol a.
- the obtained preparation was subjected to a coloring test.
- the results are shown in Table 7.
- the polyurethane foam preparation was not discolored after 24 hours at 100 ° C. and after 28 days storage at 50 ° C.
- Examples 101 to 106, Comparative Examples 100 and 101, Reference Examples 100 and 101 Preparation for polyurethane foam in the same manner as in Example 100 except that the amount of the polyol (a, c, d), antioxidant (ac), acid or salt thereof was changed according to Table 7 or 8.
- Examples 101 to 106, Comparative Examples 100 and 101, Reference Examples 100 and 101 were obtained.
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Abstract
Description
(i)ポリオキシアルキレンポリオールおよび不飽和結合を有する化合物を重合させてなるポリマー微粒子が該ポリオキアルキレンポリオール中に分散したポリマーポリオールから選ばれる少なくとも1種のポリオール、
(ii)P=N結合を有する化合物、
(iii)ヒドロキシフェニル基を有する酸化防止剤、
(iv)炭素数2~25の非環式の脂肪族モノカルボン酸、炭素数2~25のヒドロキシカルボン酸、炭素数20~60の多価カルボン酸、下記式(1)で表される芳香族モノカルボン酸、スルホン酸および硫酸エステル基を有する酸からなる群から選ばれる少なくとも1種の酸またはその塩、
(v)ポリウレタンフォーム製造用触媒および
(vi)発泡剤を含むことを特徴とする。
前記化合物(ii)を触媒として、活性水素化合物にアルキレンオキサイド化合物を付加重合して得られたポリオキシアルキレンポリオール(p)と、該ポリオール(p)の製造に用いられた化合物(ii)を含むポリオール(i)に、
前記酸化防止剤(iii)および、前記酸またはその塩(iv)を、該ポリオール(p)の製造に用いられたP=N結合を有する化合物(ii)(b)と該酸またはその塩(iv)(a)とのモル比(a/b)が、0.3以上25以下となる量で添加してポリウレタンフォーム用調製物(c)を得た後、該調製物(c)に、前記製造用触媒(v)および前記発泡剤(vi)を添加する工程を含むことを特徴とする。
本発明のポリウレタンフォーム用組成物は、少なくとも、(i)特定のポリオール、(ii)P=N結合を有する化合物、(iii)ヒドロキシフェニル基を有する酸化防止剤、(iv)特定の酸またはその塩、(v)ポリウレタンフォーム製造用触媒および(vi)発泡剤と、必要に応じて、その他の助剤を含む。該組成物は、ポリウレタンフォームの製造において調製されるレジンプレミックスとして好適である。
本発明のポリウレタンフォーム用組成物には、後述する、ポリオキシアルキレンポリオールおよびポリマー分散ポリオールから選ばれる少なくとも1種のポリオールを含み、必要に応じて、その他のポリオールを含んでもよい。
本発明に係るポリオキシアルキレンポリオールは、たとえば、後述する、P=N結合を有する化合物、水酸化カリウム、水酸化セシウムおよび水酸化ルビジウムを触媒とし、活性水素化合物にアルキレンオキサイド化合物を付加重合して得られる。触媒としては、付加重合終了時の総不飽和度をより低減出来、効率的にポリオキシアルキレンポリオールの製造ができるという点、1モルあたりの活性が高いために重合に必要な触媒量が少なくてすみ、添加する酸の量を少なくできるという点で、P=N結合を有する化合物が好ましい。
モノエタノールアミン、ジエタノールアミン、トリエタノールアミン等のアルカノールアミン類、
グリセリン、ジグリセリン、トリグリセリン、テトラグリセリン、トリメチロールプロパン、トリメチロールエタン、トリメチロールブタン、ジトリメチロールプロパン、ペンタエリスリトール、ジペンタエリスリトール、トリペンタエリスリトール等の多価アルコール類、
グルコース、ソルビトール、デキストロース、フラクトース、蔗糖、メチルグルコシド等の糖類又はその誘導体、
エチレンジアミン、ジ(2-アミノエチル)アミン、ヘキサメチレンジアミン等の脂肪酸アミン類、トルイレンジアミン、ジフェニルメタンジアミン等の芳香族アミン類、
ビスフェノールA、ビスフェノールF、ビスフェノールS、ノボラック、レゾール、レゾルシン等のフェノール化合物、
エチレンチオグリコール、プロピレンチオグリコール、トリメチレンチオグリコール、ブタンジチオール等の2価のチオアルコール類、
ジエチレンチオグリコール、トリエチレンチオグリコール等のアルキレンチオグリコール類が挙げられる。
本発明に係るポリマーポリオール(ポリマー分散ポリオールとも称す)は、アゾ化合物あるいは過酸化物等のラジカル開始剤を用いて、ポリオキシアルキレンポリオール中で不飽和結合を有する化合物を分散重合させることにより、ポリオキシアルキレンポリオール中にビニルポリマー粒子が分散した分散体として得ることができる。このビニルポリマー粒子は、不飽和結合を有する化合物の重合体からなるビニルポリマー粒子でもよいが、分散重合時に、不飽和結合を有する化合物の少なくとも一部が分散媒である特定ポリオールにグラフト化されたポリマー粒子が好ましい。
メチルアクリレート、ブチルアクリレート、ステアリルアクリレート、ヒドロキシエチルアクリレート、ヒドロキシメチルメタクリレート、ヒドロキシエチルメタクリレート、ヒドロキシプロピルメタクリレート、ジメチルアミノエチルアクリレートおよびジメチルアミノプロピルメタクリレート等のメタクリル酸エステル系モノマー、
アクリル酸、メタクリル酸、イタコン酸、マレイン酸およびフマル酸等のカルボキシル基含有モノマー、
無水マレイン酸および無水イタコン酸等の酸無水物基含有モノマー、
ブタジエン、イソプレンおよび1,4-ペンタジエン等の炭化水素系モノマー、
スチレン、α-メチルスチレン、フェニルスチレンおよびクロルスチレン等の芳香族炭化水素系モノマー、
塩化ビニルおよび塩化ビニリデン等のハロゲン含有モノマー、
ビニルエチルエーテルおよびビニルブチルエーテル等のビニルエーテル類、
ビニルエチルケトン等のビニルケトン類、
酢酸ビニル等のビニルエステル類、
アクリルアミド、N,N-ジメチルアクリルアミド、N-イソプロピルアクリルアミド、N,N-ジメチルアミノプロピルアクリルアミド、メチレンビスアクリルアミド等のアクリルアミド類およびN,N-ジメチルメタクロイルアミド等のメタクリルアミド類が挙げられる。
本発明のポリウレタンフォーム用組成物には、上記ポリオキシアルキレンポリオールおよび/またはポリマーポリオールに加えて、必要に応じて、ポリウレタンフォームの製造用に一般に使用されるその他のポリオールが含まれていてもよい。その他のポリオールとしては、たとえば、ポリエステルポリオール、ポリエーテルエステルポリオール、ポリカーボネートポリオールなどが挙げられる。
本発明に係るP=N結合を有する化合物(化合物(ii)とも称す)は、上記ポリオール中に含まれるポリオキシアルキレンポリオールの製造用触媒として用いることができれば特に限定されないが、たとえば、ホスファゼニウム化合物、ホスフィンオキシド化合物およびホスファゼン化合物が挙げられる。
アリル、2-メチルアリル、ベンジル、フェネチル、o-アニシル、1-フェニルエチル、ジフェニルメチル、トリフェニルメチルおよびシンナミル等の不飽和結合もしくは芳香族基を有するアルキル基、
シクロペンチル、シクロヘキシル、4-メチルシクロヘキシル、3-プロピルシクロヘキシル、4-フェニルシクロヘキシル、シクロヘプチルおよび1-シクロヘキセニル等の脂環族基、
ビニル、スチリル、プロペニル、イソプロペニル、2-メチル-1-プロペニルおよび1,3-ブタジエニル等のアルケニル基、
エチニルおよび2-プロピニル等のアルキニル基、
フェニル、o-トリル、m-トリル、p-トリル、2,3-キシリル、2,4-キシリル、3,4-キシリル、メシチル、o-クメニル、m-クメニル、p-クメニル、1-ナフチル、2-ナフチルおよびp-メトキシフェニル等の芳香族基が挙げられる。
アリル、2-メチルアリル、ベンジル、フェネチル、o-アニシル、1-フェニルエチル、ジフェニルメチル、トリフェニルメチルまたはシンナミル等の不飽和結合もしくは芳香族基を有するアルキル基、
シクロペンチル、シクロヘキシル、4-メチルシクロヘキシル、3-プロピルシクロヘキシル、4-フェニルシクロヘキシル、シクロヘプチルおよび1-シクロヘキセニル等の脂環族基、
ビニル、スチリル、プロペニル、イソプロペニル、2-メチル-1-プロペニルおよび1,3-ブタジエニル等のアルケニル基、
エチニルおよび2-プロピニル等のアルキニル基、
フェニル、o-トリル、m-トリル、p-トリル、2,3-キシリル、2,4-キシリル、3,4-キシリル、メシチル、o-クメニル、m-クメニル、p-クメニル、1-ナフチル、2-ナフチルおよびp-メトキシフェニル等の芳香族基が挙げられる。
Dのフェノキシ基としては、例えば、フェノキシ、4-メチルフェノキシ、3-プロピルフェノキシおよび1-ナフチルオキシ等の炭素数6~20を含むフェノキシ基、
Dのチオール残基としては、例えば、メチルチオ、エチルチオ、プロピルチオ、イソプロピルチオ、ブチルチオ、イソブチルチオ、tert-ブチルチオ、ペンチルチオ、ヘキシルチオ、ヘプチルチオ、オクチルチオ、tert-オクチルチオ、ノニルチオおよびデシルチオ等の炭素数1~20を含むチオール残基が挙げられる。
Dの一置換アミノ基としては、例えば、メチルアミノ、エチルアミノ、プロピルアミノ、イソプロピルアミノ、ブチルアミノ、イソブチルアミノ、tert-ブチルアミノ、ペンチルアミノ、ヘキシルアミノ、ヘプチルアミノ、オクチルアミノ、tert-オクチルアミノ、ノニルアミノ、デシルアミノ、1-エチルプロピルアミノ、1-エチルブチルアミノ、アニリノ、o-トルイルアミノ、m-トルイルアミノ、p-トルイルアミノ、2,3-キシリノアミノ、2,4-キシリノアミノおよび3,4-キシリノアミノ等の炭素数1~20を含む一置換アミノ基が挙げられる。
Dの5ないし6員環の環状アミノ基としては、1-ピロリジニル、3-メチル-1-ピロリジニル、1-ピロリル、3-エチル-1-ピロリル、1-インドリル、1-ピペリジル、3-メチル-1-ピペリジル、1-ピペラジニル、4-メチル-1-ピペラジニル、1-イミダゾリジニルおよび4-モルホリニル等が挙げられる。
本発明の組成物には、ポリオキシアルキレンポリオールおよびポリマーポリオールなどのポリオールの劣化を防止する目的で、ヒドロキシフェニル基を有する酸化防止剤が含まれる。なお、本発明では、酸化防止剤(iii)と称すこともある。
本発明の組成物には、炭素数2~25の非環式の脂肪族モノカルボン酸、炭素数2~25のヒドロキシカルボン酸、炭素数20~60の多価カルボン酸、上記式(1)で表される芳香族モノカルボン酸、スルホン酸および硫酸エステル基を有する酸からなる群から選ばれる少なくとも1種の酸またはその塩が含まれる。なお、本発明では、これらを酸またはその塩(iv)と称すこともある。
本発明に係るポリウレタンフォーム製造用触媒(製造用触媒(v)とも称す)は、ポリオールとポリイソシアネートとの反応に用いることができれば特に限定されず、従来公知の触媒が使用できる。
発泡剤として、水、地球環境保護の目的で開発されたヒドロキシフルオロカーボン類(HFC-245fa等)、炭化水素類(シクロペンタン等)、炭酸ガス、液化炭酸ガスなどの物理発泡剤を用いることができる。これらのうち、環境への負荷低減の面から、水、炭酸ガス、液化炭酸ガスが好ましい。
本発明のポリウレタンフォーム用組成物、ポリウレタンフォーム用調製物およびポリウレタンフォーム用ポリマーポリオール調製物には、上記成分に加えて、整泡剤、鎖延長剤、架橋剤、連通化剤、消泡剤、さらにその他助剤として難燃剤、顔料、紫外線吸収剤のポリウレタンフォームまたはポリウレタン樹脂を製造する際に一般的に用いられる添加剤を、本発明の目的を損なわない範囲で用いることができる。
本発明で用いられるポリイソシアネートは、特に限定されず、たとえば、岩田敬治編「ポリウレタン樹脂ハンドブック」第1刷日刊工業新聞社(1987)71~98頁等に示されている従来公知のポリイソシアネートが挙げられる。この中で、発泡体を得るためには、トルイレンジイソシアネート(2,4-体や2,6-体等の異性体比率は特に限定されないが、2,4-体/2,6-体が80/20の比率のものが好ましい)(たとえば、三井化学(株)製コスモネート(商標)T-80)、ポリメチレンポリフェニルポリイソシアネート(たとえば、三井化学(株)製コスモネート(商標)M-200)もしくはそのウレタン変性体、またはこれらの混合物が好ましく使用できる。
本発明のポリウレタンフォーム用組成物の製造方法は、特に限定されず、本発明の効果を奏する限り、ポリウレタン分野における公知の方法で製造できる。
本発明のポリウレタンフォーム用組成物、ポリウレタンフォーム用調製物およびポリウレタンフォーム用ポリマーポリオール調製物は、ポリウレタンフォーム、特に、軟質ポリウレタンフォームの原料として使用できる。
(1)水酸基価(OHV)
JIS K-1557-1(2007)のB法記載の方法により測定を実施した。
JIS K-1557-3(2007)記載の方法により測定を実施した。
ポリオール中の末端オキシエチレン基の含有率(質量%)は、各成分の仕込みより、以下の計算式を用いて算出した。
なお、該含有率(質量%)は、1H-NMRを用いても測定できる。
本実施例においては、各成分の仕込みより、ポリオール中のP=N結合を有する化合物の含有率を算出した。以下、計算式を示す。
また、ポリオール中のP=N結合を有する化合物の含有率は、Waters社製全自動CIAシステムを用いたキャピラリー電気泳動法により行った。ポリオールに塩酸水溶液を添加し、シェーカーにて塩酸水溶液中にP=N結合を有する化合物の抽出を行う。その後、静置分液を行い、水層を分離し、キャピラリー電気泳動分析装置を用いて、ホスファゼニウムカチオンの定量を行った。
硫酸エステル基を有する酸は、水酸化ナトリウムを用いて滴定を行い、得られた滴定値からモル比を算出した。
ポリウレタンフォーム用組成物を、窒素封入したガラス瓶に取分け、室温にて7日間保管した。保管後の組成物を、光路長2cmの無色透明のセルに入れ、外観(変色の程度)を目視にて観察した。
ポリウレタンフォーム用組成物の調製直後と、調製してから室温にて7日間保存後の組成物を用いて、ポリウレタンフォームを作製するに際し、ライズタイム(RT、秒)を測定した。7日後のライズタイム(RTb)と調製直後のライズタイム(RTa)の差(RTb-RTa)を算出して、酸を添加していない参考例1で得られた値(RTb-RTa:40秒)と比較することで、得られたポリウレタンフォーム用組成物の貯蔵安定性を評価した。
得られた調製物を窒素封入したガラス瓶に取分け、50℃にて28日間、または100℃にて24時間保管した。調製後または保管後の組成物を、光路長2cmの無色透明のセルに入れ、それぞれの外観(変色の程度)を目視で観察した。
<ポリオール>
(ポリオールa)
攪拌装置、温度計、圧力計を装備したオートクレーブに、グリセリンとグリセリンの水酸基に対して、P=N結合を有する化合物として0.18mol%/molOHとなる量のテトラキス[トリス(ジメチルアミノ)ホスフォラニリデンアミノ]ホスフォニウムヒドロキシド(PZN)を加え、100℃で6時間減圧脱水した後、プロピレンオキシドを反応温度80℃、最大反応圧力3.8kg/cm2で連続的に導入し付加重合させた。次いで、エチレンオキシドを反応温度100℃、最大反応圧力3.8kg/cm2で連続的に導入し付加重合させてポリオールaを得た。
攪拌装置、温度計、圧力計を装備したオートクレーブに、グリセリンとグリセリンの水酸基に対して、P=N結合を有する化合物として0.18mol%/molOHとなる量のテトラキス[トリス(ジメチルアミノ)ホスフォラニリデンアミノ]ホスフォニウムヒドロキシドを加え、100℃で6時間減圧脱水した後、プロピレンオキシドを反応温度80℃、最大反応圧力3.8kg/cm2で連続的に導入し付加重合させた。次いで、エチレンオキシドを反応温度100℃、最大反応圧力3.8kg/cm2で連続的に導入し付加重合させてポリオールbを得た。
攪拌装置、温度計、圧力計を装備したオートクレーブに、ペンタエリスリトール1モルおよびグリセリン0.03モルと、ペンタエリスリトールとグリセリンの水酸基の合計に対して、P=N結合を有する化合物として0.07mol%/molOHとなる量のテトラキス[トリス(ジメチルアミノ)ホスフォラニリデンアミノ]ホスフォニウムヒドロキシドを加え、プロピレンオキシドを反応温度107℃、最大反応圧力2.9kg/cm2で連続的に導入し付加重合させた。次いで、エチレンオキシドを反応温度120℃、最大反応圧力2.9kg/cm2で連続的に導入し付加重合させてポリオールcを得た。
ポリオールaをオートクレーブに仕込み、窒素雰囲気下とした後、80℃に昇温した。次に、ポリオールa100重量部に対して、4重量部のイオン交換水を加え、ポリオールaに対して、300ppmのBHTを装入後、0.5重量部の吸着剤KW-700〔協和化学工業(株)製〕を装入した。100℃で3時間攪拌後、減圧下で脱水を行い、最終的に、液相中に窒素を通気しながら、110℃、30mmHgabs.(3990Pa)の条件で4時間、減圧窒素バブリングを行った。窒素により減圧から大気圧状態にした後、アドバンテック東洋株式会社製の5Cろ紙(保持粒径1μm)により減圧ろ過を行い、ポリオールの精製を行った。
攪拌装置、温度計、圧力計を装備したオートクレーブに、グリセリンとグリセリンの水酸基に対して、P=N結合を有する化合物として0.18mol%/molOHとなる量のトリス[トリス(ジメチルアミノ)ホスフォラニリデンアミノ]ホスフィンオキシド(PZO)を加え、100℃で6時間減圧脱水した後、プロピレンオキシドを反応温度80℃、最大反応圧力3.8kg/cm2で連続的に導入し付加重合させた。次いで、エチレンオキシドを反応温度100℃、最大反応圧力3.8kg/cm2で連続的に導入し付加重合させてポリオールeを得た。
攪拌装置、温度計、圧力計を装備したオートクレーブに、グリセリンと水酸化カリウムを加え、100℃で6時間減圧脱水した後、プロピレンオキシドを反応温度120℃、最大反応圧力3.8kg/cm2で連続的に導入し付加重合させた。次いで、エチレンオキシドを反応温度110℃、最大反応圧力3.8kg/cm2で連続的に導入し付加重合させてポリオールfを得た。
撹拌装置、窒素導入管および温度計を装備した4つ口フラスコにポリオールbに、モル比(酸(a)/化合物(b))が4.0になる量でDBSA-Lを添加して、100℃にて2時間加熱した。その後、酸化防止剤(BHT)をポリオールbに対して300ppm添加し、100℃にて1時間加熱させることで、ポリオールhを得た。なお、混合は、全て密閉状態で行った。また、P=N結合を有する化合物は、ポリオールbに由来し、調製中では消失しないと仮定して、ポリオールhに対するP=N結合を有する化合物の含有率を580ppmとした。また、DBSA-LおよびBHTも調製中では消失しないと仮定して、それぞれ、ポリオールhに対して1000ppmおよび300ppmと算出した。
アクリロニトリルとスチレンの量の変更、及びポリオールgをポリオールcに変更した以外は、ポリマーポリオールaの製造と同様の操作を行い、ポリマーポリオールcを得た。
撹拌装置、窒素導入管および温度計を装備した4つ口フラスコにポリオールaに、モル比(酸(a)/化合物(b))が2.3になる量でDBSA-Lを添加して、100℃にて2時間加熱した。その後、酸化防止剤(BHT)をポリオールaに対して300ppm添加し、100℃にて1時間加熱させることで、ポリオールiを得た。なお、混合は、全て密閉状態で行った。また、P=N結合を有する化合物は、ポリオールaに由来し、調製中では消失しないと仮定して、ポリオールiに対するP=N結合を有する化合物の含有率を800ppmとした。また、DBSA-LおよびBHTも調製中では消失しないと仮定して、それぞれ、ポリオールiに対して800ppmおよび300ppmと算出した。
BHTを添加しないこと以外はポリオールgの調製と同様の操作を行い、ポリオールjを得た。その後、このポリオールjを用いて、かつ、BHTを使用しなかった以外はポリマーポリオールaの製造と同様の操作を行い、ポリマーポリオールfを得た。
(酸化防止剤a)
・BHT(純正化学(株)社製)
(酸化防止剤b)
・Irganox1010(BASFジャパン(株)社製)
(酸化防止剤c)
・Irganox1076(BASFジャパン(株)社製)
(酸化防止剤d)
・Irganox1135(BASFジャパン(株)社製)
<ヒドロキシル基を有しない酸化防止剤>
(酸化防止剤e)
・トリス(2-エチルヘキシルホスファイト)(城北化学工業(株)社製JP-308E)
(酸化防止剤f)
・ビス(トリデシル)ペンタエリスリトールジホスファイト(城北化学工業(株)社製JPP-13R)
(炭素数2~25の非環式の脂肪族モノカルボン酸またはその塩)
・酢酸(和光純薬工業(株)社製)
・ヘプタン酸(和光純薬工業(株)社製)
・パルミチン酸(和光純薬工業(株)社製)
(炭素数2~25のヒドロキシカルボン酸またはその塩)
・乳酸(和光純薬工業(株)社製)
(炭素数20~60の多価カルボン酸またはその塩)
・ダイマー酸(クローダジャパン(株)社製Pripol1009)
(式(1)で表される芳香族モノカルボン酸またはその塩またはその塩)
・デシル安息香酸(DCA、和光純薬工業(株)社製)
・安息香酸(和光純薬工業(株)社製)
(スルホン酸またはその塩)
・p-トルエンスルホン酸(PTSA、和光純薬工業(株)社製)
・カンファースルホン酸(CSA、和光純薬工業(株)社製)
・ドデシルベンゼンスルホン酸(DBSA-L(直鎖型):花王(株)社製ネオペレックスGS)
・ドデシルベンゼンスルホン酸(DBSA-B(分岐型):ライオン(株)社製ライポンLH-900)
(硫酸エステル基を有する酸またはその塩)
・ポリオキシエチレンスチレン化フェニルエーテルアンモニウムサルファート(花王(株)社製ラテムルE-1000A)
・ポリオキシアルキレンアルケニルエーテル硫酸アンモニウム、(花王(株)社製ラテムルPD-105)
(その他)
・シュウ酸(和光純薬工業(株)社製)
・スベリン酸(和光純薬工業(株)社製)
・リン酸(和光純薬工業(株)社製)
(触媒a)
・活材ケミカル(株)社製Minico L-1020のアミン触媒(商品名、トリエチレンジアミンの33%ジエチレングリコール溶液)
(触媒b)
・活材ケミカル(株)社製ビス(2-ジメチルアミノエチル)エーテル(商品名Minico TMDA)のアミン触媒
<発泡剤>
・水
<その他添加剤>
(連通化剤a)
・三井化学(株)社製アクトコールEP-505S(商品名、水酸基価:52mgKOH/g)のポリエーテルポリオール
(架橋剤a)
・三井化学(株)社製アクトコールKL-210(商品名、水酸基価:840mgKOH/g)のアミン系架橋剤
(架橋剤b)
・精製グリセリン(水酸基価1830mgKOH/g)
(整泡剤a)
・エアープロダクツジャパン(株)社製DC-6070(商品名)のシリコーン整泡剤
(整泡剤b)
・エアープロダクツジャパン(株)社DC-2525(商品名)のシリコーン整泡剤
(実施例1)
撹拌装置、窒素導入管および温度計を装備した4つ口フラスコにポリオールaに、モル比(a/b)が20.5になる量で酢酸を添加して、100℃で2時間加熱した。その後、酸化防止剤(BHT)をポリオールaに対して300ppm添加し、100℃にて1時間加熱させることで、ポリウレタンフォーム用調製物を調製した。なお、混合は、全て密閉状態で行った。また、P=N結合を有する化合物は、ポリオールaに由来し、調製中では消失しないと仮定して、ポリオールaに対するP=N結合を有する化合物の含有率を800ppmとした。また、酢酸およびBHTも調製中では消失しないと仮定して、それぞれ、ポリオールaに対して1300ppmおよび300ppmと算出した。
ポリオール(a~e)、ポリマーポリオール(a、b、eおよびf)、酸化防止剤(a~f)、酸またはその塩、触媒(aおよびb)、水、連通化剤(a)、架橋剤(aおよびb)、整泡剤(aおよびb)の仕込み量を、表1~4に従って変更した以外は、実施例1と同様に行って、レジンプレミックスおよびポリウレタンフォーム(実施例2~24、27、比較例1~5)を得た。結果を表1~4に示す。
ポリウレタンフォーム用調製物(c)としてポリマーポリオール(b)40部に、ポリオール(d)60部、触媒(a)0.4部、触媒(b)0.1部、水3.9部、連通化剤(a)1.0部、架橋剤(a)1.5部、架橋剤(b)0.2部、および整泡剤(b)1.0部を混合し、ポリウレタンフォーム用組成物(レジンプレミックス)を調製した。なお、P=N結合を有する化合物(触媒)は、ポリオール(d)とポリマーポリオール(b)に含まれているので、レジンプレミックス中のP=N結合を有する化合物の含有率は、222ppmと算出された。また、DBSA-LおよびBHTの含有率は、それぞれレジンプレミックス中に、370ppmおよび278ppmと算出した。得られたレジンプレミックスを用いて、着色性試験を評価した。
ポリオール(d)の配合量、ポリマーポリオール(b)をポリマーポリオール(e)に変更した以外は、実施例25と同様の操作を行い、レジンプレミックスおよびポリウレタンフォームを得た。結果を表3に示す。
撹拌装置、窒素導入管および温度計を装備した4つ口フラスコにポリオールaに、酸化防止剤(BHT)をポリオールaに対して300ppm添加し、100℃にて1時間加熱させた。なお、混合は、全て密閉状態で行った。また、P=N結合を有する化合物は、ポリオールaに由来し、調製中では消失しないと仮定して、ポリオールaに対するP=N結合を有する化合物の含有率を800ppmとした。また、BHTも調製中では消失しないと仮定して、ポリオールaに対して300ppmと算出した。
ポリオール(aまたはd)、水、連通化剤(a)、架橋剤(a)、整泡剤(aおよびb)を表4に従って変更した以外は、参考例1と同様に行って、レジンプレミックスおよびポリウレタンフォーム(参考例2、3)を得て、評価した。
実施例10、11、17、22~27で得られたポリウレタンフォームの外観を目視で観察し、発泡後5分経過の時点と、発泡後10分経過の時点を比較して、外観の収縮が認められたものを『×』、同様に、発泡後1時間経過の時点で外観の収縮が認められたものを『△』、発泡後1時間経過の時点でも外観の収縮が認められなかったものを『○』とした。
実施例10、11で得られたレジンプレミックスを22±1℃に温調しておき、そこに22±1℃に温調したポリイソシアネート(三井化学(株)製コスモネート(商標)TM-20)(NCOインデックス1.00)を加え、すぐにホモジナイザーを用いて5000rpmにて5秒間激しく撹拌し、あらかじめ市販の離型剤を塗布した65℃のアルミ製テストモールド(内寸:300×300×100mm)に注入後、蓋を閉めクランプにより密閉し、発泡硬化させた。攪拌開始から5分後にテストモールドのクランプを外し、硬化した軟質ポリウレタンフォームを脱型、続いて、ローラーを使って厚みを80%圧縮して気泡を完全に連通化させた(クラッシング操作)。発泡して24時間後に得られた軟質ポリウレタンフォームの諸物性を、JIS K-6400記載の方法により測定した。結果を表6に示す。
(実施例100)
撹拌装置、窒素導入管および温度計を装備した4つ口フラスコにポリオールa100重量部に、モル比(a/b)が1.2になる量でPTSAを添加して、100℃にて2時間加熱した。その後、酸化防止剤(BHT)をポリオールaに対して300ppm添加し、100℃にて1時間加熱させることで、ポリウレタンフォーム用調製物を調製した。なお、混合は、全て密閉状態で行った。また、P=N結合を有する化合物は、ポリオールaに由来し、調製中では消失しないと仮定して、ポリオールaに対するP=N結合を有する化合物の含有率を800ppmとした。また、PTSAおよびBHTも調製中では消失しないと仮定して、それぞれ、ポリオールaに対して250ppmおよび300ppmと算出した。
ポリオール(a、c、d)、酸化防止剤(a~c)、酸またはその塩の仕込み量を、表7または8に従って変更した以外は、実施例100と同様にして、ポリウレタンフォーム用調製物(実施例101~106、比較例100および101、参考例100および101)を得た。
ポリマーポリオールbまたはdを、ポリウレタンフォーム用調製物(c)として用いて評価した。結果を表7に示す。
Claims (17)
- (i)ポリオキシアルキレンポリオールおよび不飽和結合を有する化合物を重合させてなるポリマー微粒子が該ポリオキシアルキレンポリオール中に分散したポリマーポリオールから選ばれる少なくとも1種のポリオール、
(ii)P=N結合を有する化合物、
(iii)ヒドロキシフェニル基を有する酸化防止剤、
(iv)炭素数2~25の非環式の脂肪族モノカルボン酸、炭素数2~25のヒドロキシカルボン酸、炭素数20~60の多価カルボン酸、下記式(1)で表される芳香族モノカルボン酸、スルホン酸および硫酸エステル基を有する酸からなる群から選ばれる少なくとも1種の酸またはその塩、
(v)ポリウレタンフォーム製造用触媒および
(vi)発泡剤を含む
ことを特徴とするポリウレタンフォーム用組成物。
- 前記(ii)化合物(b)と、前記(iv)酸またはその塩(a)とのモル比(a/b)が、0.3以上25以下であることを特徴とする請求項1に記載のポリウレタンフォーム用組成物。
- 前記ポリオール(i)が、
前記化合物(ii)を触媒として、活性水素化合物にアルキレンオキサイド化合物を付加重合して得られたポリオキシアルキレンポリオール(p)および該ポリオキシアルキレンポリオール(p)に、不飽和結合を有する化合物を重合させてなるポリマー微粒子が分散したポリマーポリオールから選ばれる少なくとも1種のポリオールを含むことを特徴とする請求項1に記載のポリウレタンフォーム用組成物。 - 前記ポリウレタンフォーム用組成物が、ポリウレタンフォーム用調製物(c)、前記触媒(v)および前記発泡剤(vi)を含み、
該調製物(c)が、前記ポリオール(i)、前記ポリオール(p)の製造に用いたP=N結合を有する化合物(ii)、前記酸化防止剤(iii)および前記酸またはその塩(iv)を含み、かつ、
該調製物(c)が、ポリオール(i)に、化合物(ii)(b)と酸またはその塩(iv)(a)とのモル比(a/b)が、0.3以上25以下となる量で酸またはその塩(iv)、および酸化防止剤(iii)を添加して得られる
ことを特徴とする請求項4に記載のポリウレタンフォーム用組成物。 - 得られた前記調製物(c)を用いて、
不飽和結合を有する化合物を重合させてなるポリマー微粒子を前記調製物(c)中に分散させた、ポリマーポリオールを含むことを特徴とする請求項5に記載のポリウレタンフォーム用組成物。 - 前記ポリオール(p)に対する前記化合物(ii)の含有率が、150~5000ppmであることを特徴とする請求項4に記載のポリウレタンフォーム用組成物。
- 前記ポリウレタンフォーム用組成物中の酸化防止剤(iii)の含有率が、100~15000ppmであることを特徴とする請求項1に記載のポリウレタンフォーム用組成物。
- 前記ポリオキシアルキレンポリオールの水酸基価が、10~80mgKOH/gであることを特徴とする請求項1に記載のポリウレタンフォーム用組成物。
- P=N結合を有する化合物(ii)を触媒として、活性水素化合物にアルキレンオキサイド化合物を付加重合して得られたポリオキシアルキレンポリオール(p)と、該ポリオール(p)の製造に用いられた化合物(ii)を含むポリオール(i)に、
ヒドロキシフェニル基を有する酸化防止剤(iii)および、
酸またはその塩(iv)を、該ポリオール(p)の製造に用いられたP=N結合を有する化合物(ii)(b)と該酸またはその塩(iv)(a)とのモル比(a/b)が、0.3以上25以下となる量で添加してポリウレタンフォーム用調製物(c)を得た後、該調製物(c)に、ポリウレタンフォーム製造用触媒(v)および発泡剤(vi)を添加する工程を含み、かつ、
該酸またはその塩(iv)が、炭素数2~25の非環式の脂肪族モノカルボン酸、炭素数2~25のヒドロキシカルボン酸、炭素数20~60の多価カルボン酸、下記式(1)で表される芳香族モノカルボン酸、スルホン酸および硫酸エステル基を有する酸からなる群から選ばれる少なくとも1種である
ことを特徴とするポリウレタンフォーム用組成物の製造方法。
- さらに、前記調製物(c)中でポリマーポリオールを調製する工程を含み、
該ポリマーポリオールが、該調製物(c)中に、不飽和結合を有する化合物を重合させてなるポリマー微粒子を分散させて得られることを特徴とする請求項10に記載のポリウレタンフォーム用組成物の製造方法。 - ポリオール(i)、P=N結合を有する化合物(ii)、ヒドロキシフェニル基を有する酸化防止剤(iii)および酸またはその塩(iv)を含むポリウレタンフォーム用調製物(c)であり、
該ポリオール(i)が、該化合物(ii)を触媒として、活性水素化合物にアルキレンオキサイド化合物を付加重合して得られたポリオキシアルキレンポリオール(p)と、該ポリオール(p)の製造に用いられた化合物(ii)を含み、
該酸またはその塩(iv)が、炭素数2~25の非環式の脂肪族モノカルボン酸、炭素数2~25のヒドロキシカルボン酸、炭素数20~60の多価カルボン酸、下記式(1)で表される芳香族モノカルボン酸、スルホン酸および硫酸エステル基を有する酸からなる群から選ばれる少なくとも1種であり、
該調製物(c)が、ポリオール(i)に、該ポリオール(p)の製造に用いられた化合物(ii)(b)と酸またはその塩(iv)(a)とのモル比(a/b)が、0.3以上25以下となる量で酸またはその塩(iv)、および酸化防止剤(iii)を添加して得られ、かつ、
該ポリオール(p)に対する該ポリオール(p)の製造に用いられた化合物(ii)の含有率が150~5000ppmである、ポリウレタンフォーム用調製物。
- 請求項12または13に記載のポリウレタンフォーム用調製物(c)中に、不飽和結合を有する化合物を重合させてなるポリマー微粒子を分散させた、ポリマーポリオールを含み、かつ、
該ポリマーポリオール中のビニルポリマー粒子の含有量が、ポリオール成分100重量%に対して3~60重量%である、ポリウレタンフォーム用ポリマーポリオール調製物。 - P=N結合を有する化合物(ii)を触媒として、活性水素化合物にアルキレンオキサイド化合物を付加重合して得られたポリオキシアルキレンポリオール(p)と、該ポリオール(p)の製造に用いられた化合物(ii)を含むポリオール(i)に、
ヒドロキシフェニル基を有する酸化防止剤(iii)および、
酸またはその塩(iv)を、該ポリオール(p)の製造に用いられたP=N結合を有する化合物(ii)(b)と該酸またはその塩(iv)(a)とのモル比(a/b)が、0.3以上25以下となる量で添加し、かつ、
該ポリオール(p)に対する該ポリオール(p)の製造に用いられた化合物(ii)の含有率が150~5000ppmとなる工程を含み、かつ、
該酸またはその塩(iv)が、炭素数2~25の非環式の脂肪族モノカルボン酸、炭素数2~25のヒドロキシカルボン酸、炭素数20~60の多価カルボン酸、下記式(1)で表される芳香族モノカルボン酸、スルホン酸および硫酸エステル基を有する酸からなる群から選ばれる少なくとも1種である
ことを特徴とするポリウレタンフォーム用調製物の製造方法。
- 請求項15に記載の製造方法で得られたポリウレタンフォーム用調製物(c)を用いて、ポリマーポリオールを調製する工程を含み、
該ポリマーポリオールが、該調製物(c)中に、不飽和結合を有する化合物を重合させてなるポリマー微粒子を、ポリマーポリオール中のビニルポリマー粒子の含有量が、ポリオール成分100重量%に対して3~60重量%なる量で分散させて得られる、ことを特徴とするポリウレタンフォーム用ポリマーポリオール調製物の製造方法。 - 請求項1~9のいずれか一項に記載のポリウレタンフォーム用組成物を用いて得られたポリウレタンフォーム。
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EP12817644.3A EP2738220B1 (en) | 2011-07-26 | 2012-07-23 | Composition for polyurethane foam, preparation for polyurethane foam, polymer polyol preparation for polyurethane foam, methods for producing these, and polyurethane foam |
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