WO2024080268A1 - シートパッド - Google Patents

シートパッド Download PDF

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Publication number
WO2024080268A1
WO2024080268A1 PCT/JP2023/036683 JP2023036683W WO2024080268A1 WO 2024080268 A1 WO2024080268 A1 WO 2024080268A1 JP 2023036683 W JP2023036683 W JP 2023036683W WO 2024080268 A1 WO2024080268 A1 WO 2024080268A1
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WO
WIPO (PCT)
Prior art keywords
polyurethane foam
less
seat pad
polyether polyol
content
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/JP2023/036683
Other languages
English (en)
French (fr)
Japanese (ja)
Inventor
景太 今井
哲史 近藤
匠 三國
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Inoac Corp
Original Assignee
Inoue MTP KK
Inoac Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Inoue MTP KK, Inoac Corp filed Critical Inoue MTP KK
Priority to JP2024551684A priority Critical patent/JPWO2024080268A1/ja
Priority to EP23877271.9A priority patent/EP4555902A4/en
Priority to CA3259879A priority patent/CA3259879A1/en
Priority to CN202380062072.6A priority patent/CN119923210A/zh
Publication of WO2024080268A1 publication Critical patent/WO2024080268A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/08—Processes
    • C08G18/16—Catalysts
    • C08G18/18—Catalysts containing secondary or tertiary amines or salts thereof
    • C08G18/20—Heterocyclic amines; Salts thereof
    • C08G18/2045—Heterocyclic amines; Salts thereof containing condensed heterocyclic rings
    • C08G18/2063—Heterocyclic amines; Salts thereof containing condensed heterocyclic rings having two nitrogen atoms in the condensed ring system
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
    • B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
    • B60N2/70—Upholstery springs ; Upholstery
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
    • C08G18/30—Low-molecular-weight compounds
    • C08G18/32—Polyhydroxy compounds; Polyamines; Hydroxyamines
    • C08G18/3203—Polyhydroxy compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
    • C08G18/40—High-molecular-weight compounds
    • C08G18/48—Polyethers
    • C08G18/4804—Two or more polyethers of different physical or chemical nature
    • C08G18/4808—Mixtures of two or more polyetherdiols
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
    • C08G18/40—High-molecular-weight compounds
    • C08G18/48—Polyethers
    • C08G18/4804—Two or more polyethers of different physical or chemical nature
    • C08G18/4812—Mixtures of polyetherdiols with polyetherpolyols having at least three hydroxy groups
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
    • C08G18/40—High-molecular-weight compounds
    • C08G18/48—Polyethers
    • C08G18/4833—Polyethers containing oxyethylene units
    • C08G18/4837—Polyethers containing oxyethylene units and other oxyalkylene units
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
    • C08G18/65—Low-molecular-weight compounds having active hydrogen with high-molecular-weight compounds having active hydrogen
    • C08G18/66—Compounds of groups C08G18/42, C08G18/48, or C08G18/52
    • C08G18/6666—Compounds of group C08G18/48 or C08G18/52
    • C08G18/667—Compounds of group C08G18/48 or C08G18/52 with compounds of group C08G18/32 or polyamines of C08G18/38
    • C08G18/6674—Compounds of group C08G18/48 or C08G18/52 with compounds of group C08G18/32 or polyamines of C08G18/38 with compounds of group C08G18/3203
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/70—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the isocyanates or isothiocyanates used
    • C08G18/72—Polyisocyanates or polyisothiocyanates
    • C08G18/74—Polyisocyanates or polyisothiocyanates cyclic
    • C08G18/76—Polyisocyanates or polyisothiocyanates cyclic aromatic
    • C08G18/7657—Polyisocyanates or polyisothiocyanates cyclic aromatic containing two or more aromatic rings
    • C08G18/7664—Polyisocyanates or polyisothiocyanates cyclic aromatic containing two or more aromatic rings containing alkylene polyphenyl groups
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/70—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the isocyanates or isothiocyanates used
    • C08G18/72—Polyisocyanates or polyisothiocyanates
    • C08G18/77—Polyisocyanates or polyisothiocyanates having heteroatoms in addition to the isocyanate or isothiocyanate nitrogen and oxygen or sulfur
    • C08G18/78—Nitrogen
    • C08G18/79—Nitrogen characterised by the polyisocyanates used, these having groups formed by oligomerisation of isocyanates or isothiocyanates
    • C08G18/797—Nitrogen characterised by the polyisocyanates used, these having groups formed by oligomerisation of isocyanates or isothiocyanates containing carbodiimide and/or uretone-imine groups
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/20—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length
    • B29C44/28—Expanding the moulding material on continuous moving surfaces without restricting the upwards growth of the foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/36—Feeding the material to be shaped
    • B29C44/38—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length
    • B29C44/42—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length using pressure difference, e.g. by injection or by vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/36—Feeding the material to be shaped
    • B29C44/46—Feeding the material to be shaped into an open space or onto moving surfaces, i.e. to make articles of indefinite length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/58—Upholstery or cushions, e.g. vehicle upholstery or interior padding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/771—Seats
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2110/00—Foam properties
    • C08G2110/0008—Foam properties flexible
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2110/00—Foam properties
    • C08G2110/0041—Foam properties having specified density
    • C08G2110/0058—≥50 and <150kg/m3
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2110/00—Foam properties
    • C08G2110/0083—Foam properties prepared using water as the sole blowing agent
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2350/00—Acoustic or vibration damping material

Definitions

  • the present invention relates to a seat pad, and more specifically to a seat pad that is equipped with polyurethane foam that has a small deflection coefficient and a large displacement rate.
  • automobile seats are classified into two types: one in which the seat cushion (seating surface) and the seat back (back surface) are separate, and one in which the two are integrated.
  • automobile seats are generally (a) a seat pad for receiving the weight of an occupant when the occupant is seated; (b) a frame for supporting a seat pad; (c) A trim cover that covers the outer surface of the seat pad.
  • the seat pad is generally made of polyurethane foam.
  • the seat pad When an occupant sits on an automobile seat equipped with a seat pad, the seat pad is compressed in the direction of the load in proportion to the magnitude of the load applied to the seat pad.
  • the magnitude of the load applied to the seat pad varies depending on the shape of the automobile seat, the inclination of the seat back, the part of the human body that comes into contact with the automobile seat, the posture of the occupant, the unevenness of the road surface on which the automobile is traveling, etc. Therefore, if the deflection coefficient or amount of deflection (or displacement rate) of the seat pad is inappropriate, the seat may become uncomfortable to sit on.
  • Patent Document 1 states: (a) 60 parts by mass of polyol A obtained by reacting a compound (initiator 1) having a hydroxyl value of 168 mgKOH/g obtained by adding propylene oxide to glycerin with an ethylene oxide/propylene oxide mixture containing 8% by mass of ethylene oxide; (b) 40 parts by mass of polyol K in which polymer particles are dispersed in polyol G5 obtained by reacting initiator 1 with propylene oxide; (c) TDI-80 (NOC content: 44.8% by mass): an amount equivalent to an isocyanate index of 105.
  • the seat pad is disclosed to be made of a cushion body and a low-breathability foam that is integrally provided on the bottom surface of the cushion body.
  • the document describes that vibrations that deteriorate riding comfort can be absorbed by providing a low-breathability foam integrally with the bottom surface of the cushion body.
  • Patent Document 4 discloses a deformation analysis method for simulating the nonlinear viscoelastic behavior of a compressible material having nonlinear viscoelastic behavior, although this is not a seat pad.
  • the document describes that by using a model that has, in parallel, a linear viscoelastic part based on a generalized Maxwell model and a compressible elastic-plastic part having a yield condition equation dependent on hydrostatic stress, it is possible to analyze with high accuracy the damping behavior of urethane foam when it is slowly compressed.
  • Patent Document 5 A three-dimensional net material is placed in a mold, and polyurethane is foamed in the mold to form a seat back portion in which the three-dimensional net material is incorporated into a polyurethane foam cushion material; (b) An automobile seat is disclosed which is obtained by fixing a net material protruding from both sides of a seat back portion to a frame while applying tension to the net material.
  • a seat back portion can be obtained in which a three-dimensional net material is integrally incorporated into a cushion material made of polyurethane foam; and (B) It is described that the portion of the net material impregnated with polyurethane has high surface rigidity, and therefore can attenuate impact when an impact is applied from behind the occupant.
  • the hardness and elasticity of the seat pad affect the comfort when seated.
  • the displacement rate it is preferable for the displacement rate to be large.
  • seat pads proposed to date that combine a small deflection coefficient and a large displacement rate.
  • the problem that this invention aims to solve is to provide a seat pad made of polyurethane foam that has a small deflection coefficient and a large displacement rate.
  • the seat pad according to the present invention comprises: Equipped with polyurethane foam,
  • the polyurethane foam is
  • the deflection coefficient is 2.8 or less
  • the displacement rate represented by the following formula (1) is 30% or more.
  • Displacement rate t 1 ⁇ 100/t 0 (1) however, t0 is the thickness of a flat sample cut out from the polyurethane foam, t1 is the maximum value of the displacement (sinking amount) of the iron grinding plate when the damping characteristics are measured in accordance with JASO B408 using the flat plate sample.
  • the polyurethane foam is obtained by reacting a raw material mixture containing a polyol component and a polyisocyanate component,
  • the polyol component is (a) the EO content is 50 mol% or more, (b) the number of functional groups is 2.0 or more and 3.0 or less, (c) One or more polyether polyols A having a weight average molecular weight of more than 3,500.
  • the polyisocyanate component preferably contains carbodiimide-modified MDI.
  • polyurethane foam When manufacturing polyurethane foam, using a raw material mixture containing polyether polyol A that satisfies certain conditions and carbodiimide-modified MDI, polyurethane foam with a deflection coefficient of 2.8 or less and a displacement rate of 30% or more can be obtained.
  • the reason why the deflection coefficient is 2.8 or less is believed to be that the use of polyether polyol A with a high EO content results in a relatively small number of side chains in the polymer chain, resulting in less entanglement between the polymer chains, and therefore the molecular chains become more flexible, imparting elasticity to the polyurethane foam.
  • the reason why the displacement rate is 30% or more is believed to be because polyether polyol A having a large weight average molecular weight is used.
  • FIG. 1 is a schematic diagram of a damping test machine.
  • FS curves of the polyurethane foams obtained in Examples 1 to 4 and Comparative Examples 1 and 2. 1 shows the results of a damping test of the polyurethane foams (thickness: 100 mm) obtained in Examples 1 to 4 and Comparative Examples 1 and 2.
  • 1 shows the results of a damping test of the polyurethane foams (thickness: 50 mm) obtained in Examples 1 to 4 and Comparative Examples 1 and 2.
  • the seat pad according to the present invention is made of a polyurethane foam obtained by reacting a raw material mixture containing a polyol component and a polyisocyanate component.
  • the raw material mixture usually further contains a crosslinking agent, a foaming agent, and a catalyst.
  • the polyurethane foam constituting the seat pad is obtained by foaming and reacting a mixture of raw materials that meets certain conditions. The details of the method for producing the polyurethane foam will be described later.
  • the polyurethane foam of the present invention uses polyether polyol A with a high EO content as one of the raw materials.
  • polyether polyol A with a high EO content is used, the deflection coefficient of the polyurethane foam becomes relatively small. This is thought to be because the number of side chains contained in the polymer chain becomes relatively small, resulting in less entanglement between the polymer chains, and because this makes it easier for the molecular chains to stretch and contract, imparting elasticity to the polyurethane foam.
  • the smaller the deflection coefficient the greater the deflection in the high load range, resulting in a greater cushioning feel.
  • the flexure coefficient of the polyurethane foam In order to enhance the cushioning feeling, the flexure coefficient of the polyurethane foam must be 2.8 or less. When the manufacturing conditions are optimized, the flexure coefficient becomes 2.7 or less, 2.6 or less, or 2.5 or less. On the other hand, if the deflection coefficient is too small, the amount of deflection becomes too large, which may result in a strong feeling of bottoming out. Therefore, the deflection coefficient is preferably 2.0 or more. The deflection coefficient is more preferably 2.1 or more, or more preferably 2.2 or more.
  • the displacement rate depends on the thickness t0 of the flat plate sample.
  • the displacement rate In general, the greater the displacement rate, the greater the cushioning effect when sitting. To achieve this effect, the displacement rate must be 30% or more.
  • the displacement rate is preferably 35% or more, 40% or more, 45% or more, 50% or more, or 55% or more.
  • the polyurethane foam that makes up the seat pad is (a) preparing a raw material mixture containing a polyol component and a polyisocyanate component; (b) It is obtained by reacting a mixture of raw materials.
  • the raw material mixture typically further includes a crosslinking agent, a blowing agent, and a catalyst.
  • the polyol component is one of the main raw materials of polyurethane foam.
  • the polyol component is (a) the EO content is 50 mol% or more, (b) the number of functional groups is 2.0 or more and 3.0 or less, (c) Contains polyether polyol A having a weight average molecular weight of more than 3,500.
  • the polyol component may contain one type of polyether polyol A that satisfies these conditions, or may contain two or more types of polyether polyol A that satisfy these conditions.
  • the polyol component is (a) the EO content is 30 mol% or less, (b) It may further contain a polyether polyol B having a functionality of 2.0 or more.
  • the polyol component may contain one type of polyether polyol B that satisfies these conditions, or may contain two or more types of polyether polyol B that satisfy these conditions.
  • polyether polyol A [A. 1. EO content]
  • the "EO content (mol %)" of polyether polyol A refers to the ratio of the number of moles of ethylene oxide (EO) units to the total number of moles of alkylene oxide units contained in polyether polyol A.
  • the polyether polyol A may contain an alkylene oxide unit other than the EO unit. In this case, the type of the alkylene oxide unit other than the EO unit is not particularly limited, but a propylene oxide (PO) unit is preferred.
  • the EO content of polyether polyol A mainly affects the flexibility coefficient. In general, the higher the EO content of polyether polyol A, the smaller the flexibility coefficient. This is thought to be because, as the EO content increases, the number of side chains ( -CH3 ) contained in the polymer chain relatively decreases, resulting in less entanglement between the polymer chains, and because this makes the molecular chains more flexible, imparting elasticity to the polyurethane foam.
  • the EO content of the polyether polyol A is preferably 50.0 mol% or more.
  • the EO content is more preferably 60.0 mol% or more, 70.0 mol% or more, 80.0 mol% or more, or 90.0 mol% or more.
  • the EO content of the polyether polyol A may be 100.0 mol%.
  • the number of functional groups of the polyether polyol A affects the deflection coefficient. In general, the greater the number of functional groups of the polyether polyol A, the higher the rigidity of the polyurethane foam and the smaller the compression set. For this reason, the number of functional groups of the polyether polyol A is preferably 2.0 or more, more preferably 2.1 or more, or even more preferably 2.2 or more.
  • the number of functional groups in polyether polyol A is preferably 3.0 or less.
  • the number of functional groups is more preferably 2.9 or less, or 2.8 or less.
  • the weight average molecular weight of the polyether polyol A As the weight average molecular weight of the polyether polyol A increases, the hardness of the polyurethane foam decreases and the foam becomes more flexible. To obtain such an effect, the weight average molecular weight of the polyether polyol A is preferably more than 3,500. The average molecular weight is more preferably 4,000 or more, or 5,000 or more.
  • the weight average molecular weight of polyether polyol A is preferably 12,000 or less.
  • the weight average molecular weight is more preferably 10,000 or less, or 8,000 or less.
  • the hydroxyl value of the polyether polyol A is preferably 70 mgKOH/g or less.
  • the hydroxyl value is more preferably 60 mgKOH/g or less, or 55 mgKOH/g or less.
  • the hydroxyl value is preferably 10 mgKOH/g or more.
  • the hydroxyl value is more preferably 15 mgKOH/g or more, or 20 mgKOH/g or more.
  • polyether polyol B [B. 1. EO content]
  • the "EO content (mol %)" of polyether polyol B refers to the ratio of the number of moles of ethylene oxide (EO) units to the total number of moles of alkylene oxide units contained in polyether polyol B.
  • the polyether polyol B may contain an alkylene oxide unit other than the EO unit. In this case, the type of the alkylene oxide unit other than the EO unit is not particularly limited, but a propylene oxide (PO) unit is preferred.
  • the EO content of polyether polyol B is preferably 30 mol% or less.
  • the EO content is more preferably 20 mol% or less, 10 mol% or less, or 5 mol% or less.
  • the EO content may be zero.
  • the number of functional groups of the polyether polyol B may be 2.0 or more. However, if the number of functional groups of the polyether polyol B is too large, the elongation of the polyurethane foam may decrease. Therefore, the number of functional groups is preferably 4.0 or less. The number of functional groups is more preferably 3.8 or less. or less, or 3.6 or less.
  • the weight average molecular weight of the polyether polyol B is not particularly limited, and an optimal value can be selected depending on the purpose. In general, if the weight average molecular weight of the polyether polyol B is too small, the polyurethane foam may be deteriorated. Therefore, the weight average molecular weight is preferably 1,000 or more. The weight average molecular weight is more preferably 2,000 or more, or more preferably 3,000 or more.
  • the weight average molecular weight of polyether polyol B is preferably 12,000 or less.
  • the weight average molecular weight is more preferably 10,000 or less, or 8,000 or less.
  • the polyisocyanate component is another of the main raw materials of polyurethane foam.
  • the polyisocyanate component contains at least carbodiimide-modified MDI.
  • the polyisocyanate component may contain only carbodiimide-modified MDI, or may further contain a polyisocyanate other than the carbodiimide-modified MDI (hereinafter, this may also be referred to as "polyisocyanate B").
  • MDI diphenylmethane diisocyanate
  • the polyurethane foam has high elasticity and exhibits a large amount of deflection under high load.
  • polyisocyanate B In the present invention, the type of polyisocyanate B is not particularly limited, and an optimum one can be selected depending on the purpose. Specific examples of the polyisocyanate B include difunctional aromatic isocyanates, difunctional alicyclic isocyanates, difunctional aliphatic isocyanates, and isocyanates having a functionality of more than 2.
  • the raw material mixture may contain any one of these polyisocyanates B, or may contain two or more of them.
  • bifunctional aromatic isocyanates include: 2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate, m-phenylene diisocyanate, p-phenylene diisocyanate, 4,4'-diphenylmethane diisocyanate (4,4'-MDI), 2,4'-diphenylmethane diisocyanate (2,4'-MDI), 2,2'-diphenylmethane diisocyanate (2,2'-MDI), Xylylene diisocyanate, 3,3'-dimethyl-4,4'-biphenylene diisonate, 3,3'-dimethoxy-4,4'-biphenylene diisocyanate, etc., and mixtures of these may also be used.
  • bifunctional alicyclic isocyanate examples include Cyclohexane-1,4-diisocyanate, isophorone diisocyanate, dicyclohexylmethane-4,4'-diisocyanate, Methylcyclohexane diisocyanate.
  • bifunctional aliphatic isocyanates include: Butane-1,4-diisocyanate, hexamethylene diisocyanate, Examples of the isocyanate include isopropylene diisocyanate, methylene diisocyanate, lysine isocyanate, etc. Examples of the di- or higher functional isocyanate include polymeric MDI and tri- or higher functional isocyanate.
  • isocyanates having a functionality of more than two include: 1-methylbenzene-2,4,6-triisocyanate, 1,3,5-trimethylbenzene-2,4,6-triisocyanate, Biphenyl-2,4,4'-triisocyanate, diphenylmethane-2,4,4'-triisocyanate, methyldiphenylmethane-4,6,4'-triisocyanate, 4,4'-dimethyldiphenylmethane-2,2',5,5'tetraisocyanate, Triphenylmethane-4,4',4"-triisocyanate, and so on.
  • NCO group content (NCO%) refers to the ratio of the mass of NCO groups to the total mass of the polyisocyanate component.
  • the NCO % of the polyisocyanate component is preferably less than 35%, more preferably less than 30%, and even more preferably 29.5% or less.
  • the raw material mixture may contain a crosslinking agent.
  • the crosslinking agent is preferably a compound having at least three functional groups and containing a functional group having an active hydrogen atom (e.g., a hydroxyl group, an amino group, etc.).
  • the crosslinking agent may be composed only of a compound having three or more functional groups, or may further contain a compound having two functional groups in addition to a compound having three or more functional groups.
  • the number of functional groups of the crosslinking agent affects the compression set.
  • the number of functional groups of the crosslinking agent is preferably 3 or more.
  • the number of functional groups of the crosslinking agent is preferably 6 or less.
  • the molecular weight of the crosslinking agent is not particularly limited, and an optimal value can be selected depending on the purpose.
  • the molecular weight of the crosslinking agent is preferably 1000 or less, 700 or less, or 500 or less.
  • the molecular weight of the crosslinking agent is preferably 60 or more, 90 or more, or 120 or more.
  • crosslinking agents examples include glycerin, diethanolamine (DEA), and polyfunctional polyols.
  • the raw material mixture may contain any one of these crosslinking agents, or may contain two or more of them.
  • Foaming agent refers to an additive for generating bubbles in the raw material mixture during the process in which the liquid raw material mixture is resinified.
  • the blowing agent is (a) a physical blowing agent that generates gas upon pressure reduction or heating; or (b) It may be either a chemical foaming agent that generates gas by thermal decomposition or chemical reaction.
  • Examples of physical foaming agents include: (a) Hydrocarbons such as cyclopentane, isopentane, and normal pentane; (b) halogen-based compounds such as methylene chloride, trichlorofluoromethane, dichlorodifluoromethane, nonafluorobutyl methyl ether, pentafluoroethyl methyl ether, and pentafluoroisopropyl methyl ether; and so on.
  • Hydrocarbons such as cyclopentane, isopentane, and normal pentane
  • halogen-based compounds such as methylene chloride, trichlorofluoromethane, dichlorodifluoromethane, nonafluorobutyl methyl ether, pentafluoroethyl methyl ether, and pentafluoroisopropyl methyl ether; and so on.
  • Examples of chemical foaming agents include: (a) water, which reacts with isocyanate groups to generate CO2 ; (b) Azodicarbonamide, which generates nitrogen, carbon monoxide, carbon dioxide, or ammonia gas upon thermal decomposition.
  • the raw material mixture may contain any one of these blowing agents, or may contain two or more of them.
  • the foaming agent is preferably water.
  • CO2 gas generated by the reaction of water with isocyanate groups promotes foaming.
  • the reaction heat between water and isocyanate groups promotes the curing of the resin.
  • Catalyst refers to a catalyst that has a strong effect of promoting the resinification reaction and/or a catalyst that has a strong effect of promoting the foaming reaction.
  • a chemical foaming agent water
  • catalysts examples include amine catalysts and metal catalysts.
  • Amine catalysts are catalysts that have a large effect of promoting both the resinification reaction and the foaming reaction.
  • Metal catalysts are catalysts that have a large effect of promoting the resinification reaction.
  • the raw material mixture may contain one of these catalysts, or may contain two or more types.
  • Examples of the amine catalyst include: N,N-dimethylcyclohexylamine, N,N-dimethylbenzylamine, N,N-dimethylaminoethanol, Examples thereof include N,N',N'-trimethylaminoethylpiperazine and triethylenediamine.
  • metal catalysts examples include: (a) tin catalysts such as stannous octoate and dibutyltin dilaurate; (b) mercury catalysts, such as phenylmercury propionate; (c) Lead catalysts such as lead octenate.
  • the raw material mixture may further contain one or more of the following auxiliary materials in addition to the above-mentioned main raw materials.
  • auxiliary materials include the following:
  • foam stabilizer refers to an additive that has the effect of making the size and distribution of bubbles uniform. Adding a foam stabilizer to the raw material mixture makes it possible to obtain polyurethane foam with uniform bubble size and distribution.
  • foam stabilizers include silicone-based foam stabilizers, fluorine-containing compound-based foam stabilizers, and known surfactants.
  • Flame retardant means an additive that has the effect of making polyurethane foam flame retardant.
  • the flame retardant include a halogen-based flame retardant, a phosphorus-based flame retardant, a metal hydroxide-based flame retardant, and an antimony-based flame retardant.
  • the "amount of polyether polyol A blended (parts by mass)" refers to the total mass of polyether polyol A in the polyol component when the total mass of the polyol component is taken as 100.
  • the amount of polyether polyol A is preferably 50 parts by mass or more. More preferably, the amount is 60 parts by mass or more, or 70 parts by mass or more.
  • the amount of polyether polyol A may be 100 parts by mass. However, if the amount of polyether polyol A is excessive, the moldability of the foam may decrease. Therefore, the amount of polyether polyol A is preferably 90 parts by mass or less.
  • the “content (mass %) of carbodiimide-modified MDI” refers to the ratio of the mass of the carbodiimide-modified MDI to the total mass of the polyisocyanate component.
  • the content of carbodiimide-modified MDI is preferably 50% by mass or more. More preferably, the content is 60% by mass or more, or 70% by mass or more.
  • the content of the carbodiimide-modified MDI may be 100% by mass, but is preferably 90% by mass or less, or 80% by mass or less.
  • the NCO content of the carbodiimide-modified MDI is preferably 40% or less, 35% or less, or 32% or less, particularly preferably 30% or less, and more preferably 15% or more, 20% or more, 25% or more, or 27% or more.
  • the “amount of crosslinking agent (parts by mass)” refers to the mass of the crosslinking agent when the total mass of the polyol components is taken as 100.
  • the amount of crosslinking agent used is preferably greater than 0 parts by mass.
  • the amount is more preferably 1 part by mass or more, or 2 parts by mass or more.
  • the amount of crosslinking agent is preferably 10 parts by mass or less.
  • the amount is more preferably 8 parts by mass or less, or 6 parts by mass or less.
  • the "amount (parts by mass) of polyether polyol B” refers to the mass of polyether polyol B in the polyol component when the total mass of the polyol component is taken as 100.
  • the amount of polyether polyol B is preferably less than 50 parts by mass.
  • the amount is more preferably 40 parts by mass or less, or 30 parts by mass or less.
  • isocyanate index refers to the ratio of the equivalent weight of isocyanate groups of the polyisocyanate in the raw material mixture to the equivalent weight of active hydrogen groups in the raw material mixture, multiplied by 100.
  • the isocyanate index is not particularly limited, and an optimal value can be selected depending on the purpose.
  • the larger the isocyanate index the smaller the compression set.
  • the isocyanate index is preferably 90 or more.
  • the isocyanate index is more preferably 95 or more.
  • the isocyanate index is preferably 115 or less.
  • the blending amount of the auxiliary raw material is not particularly limited, and the optimal content can be selected depending on the purpose.
  • slab foaming is a method in which a composition for producing polyurethane foam (raw materials for polyurethane foam) is mixed and discharged onto a belt conveyer, and foamed under atmospheric pressure and at room temperature.
  • mold foaming is a method in which raw materials for producing polyurethane foam (raw materials for polyurethane foam) are mixed and injected into the cavity of a mold (metal mold) and foamed to the shape of the cavity. Mold foaming is preferable because it can produce polyurethane foam having a shape similar to that of the seat pad. In the case of molding, it is preferable to use a polyisocyanate with a low viscosity, and for example, a prepolymer type polyisocyanate is not preferable.
  • the reason why the deflection coefficient is 2.8 or less is believed to be that the use of polyether polyol A with a high EO content results in a relatively small number of side chains in the polymer chain, resulting in less entanglement between the polymer chains, and therefore the molecular chains become more flexible, imparting elasticity to the polyurethane foam.
  • the reason why the displacement rate is 30% or more is believed to be because polyether polyol A having a large weight average molecular weight is used.
  • Examples 1 to 4, Comparative Examples 1 and 2 Preparation of Samples A polyether polyol, a crosslinking agent, a foaming agent, a catalyst, and a foam stabilizer were mixed in a predetermined ratio to obtain a mixed liquid (hereinafter, also referred to as "component A”). Also, polymeric MDI, MDI containing carbodiimide-modified MDI (NCO content: 29%, carbodiimide-modified MDI content: 75% by mass), and MDI prepolymer (NCO content: 28.5%) were blended in a predetermined ratio to obtain a mixed liquid (hereinafter also referred to as "component B"). Furthermore, component A and component B were mixed so that the isocyanate index was a predetermined value, to obtain a raw material mixture. Table 1 shows the compositions of components A and B.
  • Example 1 is an example in which only polyether polyol 2 (molecular weight: 4000, number of functional groups: 2, EO content: 80 mol %) was used as polyether polyol A.
  • the polyether polyol A was: (a) polyether polyol 2 (molecular weight: 4000, number of functional groups: 2, EO content: 80 mol%), (b) This is an example using a mixture with polyether polyol 3 (molecular weight: 5000, number of functional groups: 3, EO content: 80 mol %).
  • Example 4 is an example in which only Polyether polyol 3 was used as Polyether polyol A.
  • the resulting mixture of raw materials was poured into a 400 mm x 400 mm x 100 mm mold, and foamed and cured at a mold temperature of approximately 60°C.
  • the curing time was 5 minutes.
  • Test Method 2.1 Core Density The skin layer was removed from the resulting foam to prepare a sample for measuring the core density. The core density of the resulting sample was measured in accordance with JIS K 7222.
  • the deflection coefficient was measured in accordance with JIS K 6400-2 Method E. The deflection coefficient was calculated by dividing the 65% compression load by the 25% compression load.
  • FIG. 1 A schematic diagram of the damping test machine is shown in Figure 1. An iron grinding plate with a mass of 50 kg was placed 20 mm above the sample. The iron grinding plate was allowed to fall freely from that position toward the sample. The vibration characteristics of the sample were evaluated from the displacement of the iron grinding plate after the drop and the time until the vibration stopped.
  • the seat pad of the present invention can be used as a seat pad for automobiles, aircraft, and railway vehicles, as well as sofas, mattresses, and the cushioning materials for these.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Engineering & Computer Science (AREA)
  • Transportation (AREA)
  • Mechanical Engineering (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Polyurethanes Or Polyureas (AREA)
  • Chair Legs, Seat Parts, And Backrests (AREA)
  • Mattresses And Other Support Structures For Chairs And Beds (AREA)
PCT/JP2023/036683 2022-10-13 2023-10-10 シートパッド Ceased WO2024080268A1 (ja)

Priority Applications (4)

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JP2024551684A JPWO2024080268A1 (https=) 2022-10-13 2023-10-10
EP23877271.9A EP4555902A4 (en) 2022-10-13 2023-10-10 SEAT PADDING
CA3259879A CA3259879A1 (en) 2022-10-13 2023-10-10 Seat pad
CN202380062072.6A CN119923210A (zh) 2022-10-13 2023-10-10 座垫

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Citations (7)

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JP2002102008A (ja) 2000-09-27 2002-04-09 Delta Tooling Co Ltd シート構造及びシートの製造方法
JP2003119240A (ja) 2001-08-06 2003-04-23 Asahi Glass Co Ltd 軟質ポリウレタンフォーム、その製造方法およびその製造用原料システム液
JP2005177171A (ja) 2003-12-19 2005-07-07 Inoac Corp シートパッド
JP2008539314A (ja) * 2005-04-25 2008-11-13 カーギル インコーポレイテッド オリゴマーポリオールを含むポリウレタン発泡体
WO2018111806A1 (en) * 2016-12-15 2018-06-21 Dow Global Technologies Llc Polyurethane product with sulfur-containing polyol
JP2019194321A (ja) 2018-04-27 2019-11-07 株式会社イノアックコーポレーション ポリウレタンフォームとその製造方法
JP2020094980A (ja) 2018-12-14 2020-06-18 株式会社ブリヂストン 圧縮性材料の変形解析手法

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EP1234843A1 (en) * 2001-02-26 2002-08-28 Huntsman International Llc Process for preparing a flexible polyurethane foam
JP4504809B2 (ja) * 2002-08-02 2010-07-14 ハンツマン・インターナショナル・エルエルシー 軟質フォームを製造するためのプレポリマー、ポリオール組成物および方法
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JP2002102008A (ja) 2000-09-27 2002-04-09 Delta Tooling Co Ltd シート構造及びシートの製造方法
JP2003119240A (ja) 2001-08-06 2003-04-23 Asahi Glass Co Ltd 軟質ポリウレタンフォーム、その製造方法およびその製造用原料システム液
JP2005177171A (ja) 2003-12-19 2005-07-07 Inoac Corp シートパッド
JP2008539314A (ja) * 2005-04-25 2008-11-13 カーギル インコーポレイテッド オリゴマーポリオールを含むポリウレタン発泡体
WO2018111806A1 (en) * 2016-12-15 2018-06-21 Dow Global Technologies Llc Polyurethane product with sulfur-containing polyol
JP2019194321A (ja) 2018-04-27 2019-11-07 株式会社イノアックコーポレーション ポリウレタンフォームとその製造方法
JP2020094980A (ja) 2018-12-14 2020-06-18 株式会社ブリヂストン 圧縮性材料の変形解析手法

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EP4555902A1 (en) 2025-05-21

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