WO2018199423A1 - Polyurethane foam composition and polyurethane foam prepared therethrough - Google Patents

Abstract

The present invention relates to a polyurethane foam composition and a polyurethane foam prepared therethrough and, specifically, to a polyurethane foam composition comprising a polyol mixture (X) and an isocyanate mixture (Y), wherein the polyol mixture (X) contains polyol (A) and polyol (B), which are different from each other, and the isocyanate mixture (Y) is a mixture of methylene diphenyl diisocyanate (MDI), and to a polyurethane foam prepared therethrough.

Description

Polyurethane Foam Compositions and Polyurethane Foam Made Thereby

The present invention relates to a polyurethane foam composition and a polyurethane foam prepared through the same, and more particularly, to a polyurethane foam composition capable of producing a latex-like foam (Latex like foam) exhibiting properties similar to the latex foam, and the manufacture thereof To a polyurethane foam.

Polyurethane foam is usually obtained by preparing a resin premix containing a polyol, a catalyst for polyurethane foam production, a blowing agent, and the like, and reacting the resin premix with a polyisocyanate.

Polyurethane foam has excellent insulation properties such as electric refrigerators, freezers, freezers, building panels, and excellent cushioning due to its excellent heat insulation performance, formability and self-adhesion, so that seat cushions, seat backs and head rests for automobiles and the like are excellent. It is widely used in office supplies such as arm rests, instrument panels, door trims, interior materials such as ceiling materials, saddles for motorcycles, seats for aircraft and railway vehicles, and other cushions for furniture, bedding and office chairs. It is used.

In general, petroleum-based synthetic polyols are mainly used for producing urethane foams. Efforts have been made to manufacture eco-friendly polyurethane by replacing the existing petroleum-based synthetic polyols with vegetable oil-based natural polyols. However, most of urethane foam manufacturing techniques using vegetable oils are for rigid urethane foams. In the field of soft urethane foams, urethane foam manufacturing using vegetable oils has been poorly studied. Although some studies have been made on the synthesis of flexible foams with only soybean oil-based polyols, large quantities of closed cells have been found.

On the other hand, the flexible polyurethane foam has an open cell structure, excellent elasticity, excellent mechanical strength (elongation, tensile strength, wear resistance), and is being used in various industrial fields such as packaging materials. In particular, it is widely used as a cushion material of bedding, polyurethane foam having a variety of physical properties are produced according to the purpose of using bedding. Therefore, it has been an issue to develop a polyurethane foam composition having an optimum ratio so that the polyurethane foam has a physical property suitable for the purpose.

The problem to be solved by the present invention is to improve the prior art as described above, one aspect of the present invention is to provide a composition for polyurethane foam.

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

One aspect of the present invention to achieve the above object provides a composition for polyurethane foam.

The polyurethane foam composition may include a polyol mixture (X) and an isocyanate mixture (Y).

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

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

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

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

The polyol mixture (X) may further include a silicon foam stabilizer, a urethanization catalyst, and water.

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

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

The polyol (A) has the structure of [Formula 1], and may be a + c + e: b + d + f = 72 ~ 92: 8 ~ 18.

[Formula 1]

The polyol (B) has the structure of [Formula 2], g + i + k: h + j + l = 95 to 99: 1 to 5 may be.

[Formula 2]

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

The MDI (A) may be diphenyl methane diisocyanate.

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

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

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

Based on 100 mass% of the isocyanate mixture (Y), MDI (A) may be 50 to 60 mass%.

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

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

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

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

Another aspect of the present invention to achieve the above object provides a polyurethane foam.

The polyurethane foam may be prepared by the above-described composition for polyurethane foam.

The polyurethane foam can be used in baby bedding.

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

According to the present invention, by preparing a polyurethane foam through a composition for polyurethane foam having an optimum ratio, it is possible to produce a polyurethane foam suitable for use as a bedding for infants.

In addition, by producing a polyurethane foam through a composition for polyurethane foam having an optimum ratio, it is possible to produce a polyurethane foam having a self-extinguishing property.

In addition, by preparing a polyurethane foam through a composition for polyurethane foam having an optimum ratio, it is possible to produce a polyurethane foam having a heavy metal content below the detection limit.

In addition, by preparing a polyurethane foam through a composition for polyurethane foam having an optimum ratio, it is possible to produce a polyurethane foam having a far infrared emissivity of 88% or more.

In addition, by manufacturing a polyurethane foam through a composition for polyurethane foam having an optimum ratio, it is possible to produce a polyurethane foam excellent in antibacterial properties.

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

1 is a view showing a mixing step in the manufacturing process of the preferred polyurethane foam of the present invention.

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

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

Figure 4 is an image showing the antimicrobial measurement results of the preferred polyurethane foam of the present invention.

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

While the invention allows for various modifications and variations, specific embodiments thereof are illustrated by way of example in the drawings and will be described in detail below. However, it is not intended to be exhaustive or to limit the invention to the precise forms disclosed, but rather the invention includes all modifications, equivalents, and alternatives consistent with the spirit of the invention as defined by the claims.

When an element such as a layer, region or substrate is referred to as being on another component "on", it will be understood that it may be directly on another element or there may be an intermediate element in between. .

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

1 is a view showing a mixing step in the manufacturing process of the preferred polyurethane foam of the present invention.

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

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

Polyol (A) according to an embodiment of the present invention is a polyol containing an oxyethylene group in the range of 8 to 18% at the end of the polyol having an average hydroxyl value of 20 to 35 mgKOH / g and a number average molecular weight of 5500 to 7500, It is a structure of following [Formula 1].

[Formula 1]

In Formula 1, a + c + e: b + d + f = 72 to 92: 8 to 18.

Polyol (B) according to an embodiment of the present invention is a polyol containing 5% or less of oxyethylene groups at the terminal of the polyol having an average hydroxyl value of 40 ~ 60 mgKOH / g and a number average molecular weight of 3000 ~ 4000, [Formula 2].

[Formula 2]

In Formula 2, + i + k: h + j + l = 95-99: 1-5.

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

The polyol mixture (X) according to an embodiment of the present invention may include 50 to 90 mass% of polyol (A) and 10 to 50 mass% of polyol (B) based on 100 mass% of polyol mixture (X). . More preferably, 75 to 80 mass% of polyols (A) and 20 to 25 mass% of polyols (B) may be included.

Meanwhile, in the polyol mixture (X) according to an embodiment of the present invention, a silicone foam stabilizer and a urethanization catalyst may be combined with a diisocyanate (Methylene Diphenyl Diisocyanate, hereinafter referred to as 'MDI') to foam and form a foam. And water.

The silicone foam stabilizer, urethane-forming catalyst and water can be used without limitation so long as it does not depart from the object of the present invention.

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

When a polyurethane foam is prepared using a mixture of methylene diphenyl diisocyanate (MDI) as the isocyanate mixture (Y), it can exhibit a smooth surface and elasticity similar to latex foam.

On the other hand, at least one selected from the group consisting of tolylene diisocyanate (TDI), phthalene diisocyanate (NDI), xylylene diisocyanate (XDI), isophorone diisocyanate (IPDI), hexamethylene diisocyanate (HMDI), and these modified substances When foamed by combining the isocyanate of isocyanate with the above-mentioned polyol mixture (X), a rough surface polyurethane foam is produced, which is also economically unsuitable.

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

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

The MDI (A) is Diphenyl methane diisocyanate, the MDI (B) is isocyanic acid polymethylenepolyphenylene ester, the MDI (C) is 1-isocyanato-2-[(4-isocyanatophenyl) methyl) benzene, and the MDI (D Isocyanic acid polymethylenepolyphenylene ester polymer with methyloxirane polymer with oxirane ether with 1,2,3-propanetriol (3: 1).

In addition, in order to produce a polyurethane foam having properties similar to latex foam, the isocyanate mixture (Y) is based on 100% by mass of the isocyanate mixture (Y), MDI (A) 50 to 60% by mass, MDI (B) 20 30 mass%, 10-20 mass% of MDI (C), and 5-10 mass% of MDI (D).

Finally, in order to express properties similar to latex foam and express desired hardness in beddings for infants, a specific range of foaming liquid ratio is specified, and the polyurethane foam composition according to an embodiment of the present invention is a composition for polyurethane foam 100 40 to 80 mass% of isocyanate mixture (Y) is used based on the mass%. When the isocyanate mixture (Y) is used in an amount less than 40% by mass or 80% by mass or more, the foam is not formed due to problems such as polyurethane foam shrinkage or collapsing, or the foam is not suitable for use due to excessive hardness. Is manufactured.

Therefore, by using the composition ratio according to a preferred embodiment of the present invention, it is possible to produce a polyurethane foam suitable for use in the bedding for infants that is the object of the present invention.

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

Referring to Figure 2, after the raw material of the polyurethane foam is injected into the foam mold, it can be seen that the polyurethane foam according to a preferred embodiment of the present invention through the foaming, aging and molding process is produced, the polyurethane The raw material of foam is the composition for polyurethane foam mentioned above.

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

Referring to Figure 3, the polyurethane foam was manufactured through the above-described manufacturing process, the applicant is to perform a variety of experiments with the polyurethane foam prepared, to determine whether the polyurethane foam suitable for use in the beddings for children of the present invention It was.

First, a combustibility test of the prepared polyurethane foam was carried out, the results are shown in the following [Table 1].

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

The combustibility test was carried out after the polyurethane foam was left at least 24 hours at a temperature of 16 to 26 ℃, humidity of 50 to 60%.

Referring to Table 1, a total of five combustibility tests were performed using a polyurethane foam according to an embodiment of the present invention, and as a result, it can be seen that the polyurethane foam has self-extinguishing (SE). Therefore, it can be seen that the polyurethane foam according to an embodiment of the present invention is a polyurethane foam suitable for use in bedding.

In addition, the heavy metal content of the prepared polyurethane foam was measured, and the results are shown in the following [Table 2].

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

(Not detected = below detection limit)

Heavy metal content was measured according to Korean standard KS C IEC 62321: 2009.

Referring to Table 2, the polyurethane foam according to an embodiment of the present invention is not detected because all of the cadmium (Cd), lead (Pb), mercury (Hg) and chromium VI (Cr VI) is measured below the detection limit Did. Therefore, it can be seen that the polyurethane foam according to an embodiment of the present invention is a polyurethane foam suitable for use in bedding.

In addition, the far-infrared emissivity of the prepared polyurethane foam was measured, and the results are shown in the following [Table 3].

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

Far-infrared emissivity was measured at a temperature of 40 ° C. and a wavelength of 5˜20 μm. This result is a result of comparing the black body using the FT-IR spectrum.

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

Figure 4 is an image showing the antimicrobial measurement results of the preferred polyurethane foam of the present invention.

Antibacterial activity was measured by bacterial absorption and plate culture, strain 1 was staphylococcus aureus ATCC 6538 (Staphylococcus aureus), and strain 2 was Klebsiella pneumoniae ATCC 4352 (pneumococcal pneumoniae).

Figure 4 (a) is an image after 18 hours of incubating strain 1 in 100% cotton control specimens, Figure 4 (b) is 18 hours after incubating strain 1 in a polyurethane foam according to an embodiment of the present invention After image.

In addition, Figure 4 (c) is an image after 18 hours of incubating strain 2 in a control specimen of 100% cotton, Figure 4 (d) is cultured strain 2 in a polyurethane foam according to an embodiment of the present invention The image is 18 hours later.

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

		100% cotton	One embodiment
Strain 1	Initial bacterial count	4.0 X 10 4	4.0 X 10 4
	After 18 hours	7.8 X 10 6	<20
	Antibacterial activity	-	5.6
Strain 2	Initial bacterial count	4.0 X 10 4	4.0 X 10 4
	After 18 hours	3.7 X 10 7	<20
	Antibacterial activity	-	6.3

Referring to Figure 4 and Table 4, it can be seen that the polyurethane foam according to an embodiment of the present invention has an antibacterial effect of more than 95%, bacteria caused by wastes such as sweat discharged from the body when used in bedding It can be seen that propagation of is suppressed.

In addition, compressive permanent shrinkage, repeated permanent compression shrinkage and elasticity of the prepared polyurethane foam was measured, the results are shown in Table 5 below.

	The present invention
Compressed permanently reduced rate (KS M 6672: 2016)	5.2%
Repeated permanent compression rate (KS M 6672: 2016)	1.2%
Elasticity (Ball Rebound,%)	50 to 60%

The compression set was measured under 50% compression condition for 22 hours at a temperature of 69 to 71 ° C., and the repeated permanent compression rate was performed under 50% compression and 80000 experiments.

Referring to Table 5, it can be seen that the polyurethane foam according to an embodiment of the present invention has a compressive permanent shrinkage of 5.2% and repeated permanent compression rate of 1.2%. It is understood that the lower the value of the permanent shrinkage, the more elastic the product, and the polyurethane foam having excellent elasticity is manufactured. The elasticity of the polyurethane foam actually produced was expressed in the range of 50-60 (Ball Rebound,%).

In addition, the apparent density of the polyurethane foam according to an embodiment of the present invention was 59.9kg / m2, the hardness was measured to 150N (15.8kgf).

Applicant has prepared a composition for polyurethane foam having an optimal ratio in order to produce a polyurethane foam that can be applied to the 'backflow cushion cushion and the infant bed using the same' of 10-2016-0140430, thereby producing a polyurethane foam Thus, a polyurethane foam suitable for use as a baby bedding was obtained.

However, the application of the polyurethane foam made of the polyurethane foam composition of the present invention is not limited to the beddings for infants, seat cushions, seat backs, head rests, arm rests, instruments, etc. for automobiles, etc. It can be widely applied to office supplies such as panels, door trims, interior materials such as ceiling materials, saddles for motorcycles, seats for aircraft, railway cars, and the like, furniture materials, bedding, cushion materials for office chairs, and the like.

Claims (14)

1. In the polyurethane foam composition for producing a polyurethane foam, comprising a polyol mixture (X) and an isocyanate mixture (Y),

   The polyol mixture (X) contains the following polyol (A) and the following polyol (B),

   The isocyanate mixture (Y) is a polyurethane foam composition, characterized in that the mixture of methylene diphenyl diisocyanate (MDI).

   Polyol (A): A polyol containing an oxyethylene group in the range of 8 to 18% in the terminal of a polyol having an average hydroxyl value of 20 to 35 mgKOH / g and a number average molecular weight of 5500 to 7500.

   Polyol (B): The polyol which contains 5% or less of an oxyethylene group at the terminal among polyols whose average hydroxyl value is 40-60 mgKOH / g, and a number average molecular weight is 3000-4000.
2. The method of claim 1,

   Polyurethane foam composition, characterized in that the polyol mixture (X) further comprises a silicon foam stabilizer, a urethanization catalyst and water.
3. The method of claim 1,

   Based on 100 mass% of said polyol mixture (X), the polyol (A) is 50-90 mass%, The composition for polyurethane foams characterized by the above-mentioned.
4. The method of claim 1,

   Based on 100 mass% of said polyol mixture (X), the polyol (B) is a composition for polyurethane foam, characterized in that 10 to 50 mass%.
5. The method of claim 1,

   The polyol (A) has a structure of the following [Formula 1], a + c + e: b + d + f = 72 ~ 92: 8 ~ 18, characterized in that the polyurethane foam composition.

   [Formula 1]

   
6. The method of claim 1,

   The polyol (B) has a structure of the following [Formula 2], g + i + k: h + j + l = 95 to 99: 1 to 5, characterized in that the polyurethane foam composition.

   [Formula 2]

   
7. The method of claim 1,

   The isocyanate mixture (Y) contains the following MDI (A), the following MDI (B), the following MDI (C) and the composition for polyurethane foam, characterized in that the following MDI (D).

   MDI (A): Diphenyl methane diisocyanate

   MDI (B): isocyanic acid polymethylenepolyphenylene ester

   MDI (C): 1-isocyanato-2-[(4-isocyanatophenyl) methyl) benzene

   MDI (D): isocyanic acid polymethylenepolyphenylene ester polymer with methyloxirane polymer with oxirane ether with 1,2,3-propanetriol (3: 1)
8. The method of claim 7, wherein

   Based on 100 mass% of said isocyanate mixtures (Y), MDI (A) is 50-60 mass%, The composition for polyurethane foams characterized by the above-mentioned.
9. The method of claim 7, wherein

   Based on 100 mass% of said isocyanate mixture (Y), MDI (B) is 20-30 mass%, The composition for polyurethane foams characterized by the above-mentioned.
10. The method of claim 7, wherein

    Based on 100 mass% of said isocyanate mixtures (Y), MDI (C) is 10-20 mass%, The composition for polyurethane foams characterized by the above-mentioned.
11. The method of claim 7, wherein

    Based on 100 mass% of said isocyanate mixture (Y), MDI (D) is 5-10 mass%, The composition for polyurethane foams characterized by the above-mentioned.
12. The method of claim 1,

    The polyurethane foam composition, characterized in that 40 to 80 mass% of the isocyanate mixture (Y) based on 100% by mass of the polyurethane foam composition.
13. In the polyurethane foam made of the composition for polyurethane foam according to any one of claims 1 to 12,

    The polyurethane foam is a polyurethane foam, characterized in that used in bedding for infants.
14. The method of claim 13,

    Elasticity of the polyurethane foam is a polyurethane foam, characterized in that 50 ~ 60 (Ball Rebound,%).

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