U.S. patent application number 11/375012 was filed with the patent office on 2006-07-20 for flexible polyurethane foam and process for its production.
This patent application is currently assigned to Asahi Glass Company, Limited. Invention is credited to Shigeo Hatano, Katsuji Kuribayashi, Takayuki Sasaki, Yoshinori Toyota.
Application Number | 20060160913 11/375012 |
Document ID | / |
Family ID | 34372874 |
Filed Date | 2006-07-20 |
United States Patent
Application |
20060160913 |
Kind Code |
A1 |
Sasaki; Takayuki ; et
al. |
July 20, 2006 |
Flexible polyurethane foam and process for its production
Abstract
To provide a flexible polyurethane foam having improved sound
absorbing properties in a low frequency region. A process for
producing a flexible polyurethane foam which comprises foaming a
starting material composition (E) comprising a high molecular
weight polyoxyalkylene polyol (A), an organic polyisocyanate
compound (B), a blowing agent (C) and a catalyst (D) in a closed
mold, characterized in that at least a part of the high molecular
weight polyoxyalkylene polyol (A) is a polyoxyalkylene polyol (p)
having at least two hydroxyl groups on the average and having a
molecular weight (Mc) per hydroxyl group of from 1,800 to 2,800 and
a total unsaturation value (USV) of at most 0.08 meq/g, and that
the air flowability of a flexible polyurethane foam obtained by
foaming the starting material composition (E) in a thickness of 26
mm, is at most 0.085 m.sup.3/min.
Inventors: |
Sasaki; Takayuki; (Ibaraki,
JP) ; Hatano; Shigeo; (Ibaraki, JP) ; Toyota;
Yoshinori; (Ibaraki, JP) ; Kuribayashi; Katsuji;
(Ibaraki, JP) |
Correspondence
Address: |
OBLON, SPIVAK, MCCLELLAND, MAIER & NEUSTADT, P.C.
1940 DUKE STREET
ALEXANDRIA
VA
22314
US
|
Assignee: |
Asahi Glass Company,
Limited
Tokyo
JP
|
Family ID: |
34372874 |
Appl. No.: |
11/375012 |
Filed: |
March 15, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
PCT/JP04/13668 |
Sep 17, 2004 |
|
|
|
11375012 |
Mar 15, 2006 |
|
|
|
Current U.S.
Class: |
521/174 |
Current CPC
Class: |
C08G 18/4072 20130101;
C08G 18/4866 20130101; C08G 18/632 20130101; B60R 13/08 20130101;
G10K 11/162 20130101; C08G 2110/0008 20210101; C08G 2110/0083
20210101; C08G 2350/00 20130101 |
Class at
Publication: |
521/174 |
International
Class: |
C08G 18/00 20060101
C08G018/00 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 19, 2003 |
JP |
2003-0327588 |
Claims
1. A process for producing a flexible polyurethane foam which
comprises foaming a starting material composition (E) comprising a
high molecular weight polyoxyalkylene polyol (A), an organic
polyisocyanate compound (B), a blowing agent (C) and a catalyst (D)
in a closed mold, characterized in that at least a part of the high
molecular weight polyoxyalkylene polyol (A) is a polyoxyalkylene
polyol (p) having at least two hydroxyl groups on the average and
having a molecular weight (Mc) per hydroxyl group of from 1,800 to
2,800 and a total unsaturation value (USV) of at most 0.08 meq/g,
and that the air flowability of a flexible polyurethane foam
obtained by foaming the starting material composition (E) in a
thickness of 26 mm, is at most 0.085 m.sup.3/min.
2. The process for producing a flexible polyurethane foam according
to claim 1, wherein in a sound absorption measuring method by a
vertical entry method of a flexible polyurethane foam obtained by
foaming the starting material composition (E) in a thickness of 26
mm, the sound absorption characteristic at 500 Hz is at least 0.3,
and the sound absorption characteristic at 2,000 Hz is at least
0.55.
3. The process for producing a flexible polyurethane foam according
to claim 1, wherein the density of the flexible polyurethane foam
is at most 120 kg/m.sup.3.
4. The process for producing a flexible polyurethane foam according
to claim 1, wherein the high molecular weight polyoxyalkylene
polyol (A) has at least two hydroxyl groups on the average and has
a molecular weight (Mc) per hydroxyl group of from 500 to
5,000.
5. The process for producing a flexible polyurethane foam according
to claim 1, wherein the proportion of the polyol (p) in the high
molecular weight polyoxyalkylene polyol (A) is from 5 to 100 mass
%.
6. The process for producing a flexible polyurethane foam according
to claim 1, wherein the polyol (p) is a polyoxyalkylene polyol
obtained by ring opening addition polymerization of an alkylene
oxide in the presence of a composite metal cyanide complex catalyst
or a cesium hydroxide catalyst, and an initiator.
7. The process for producing a flexible polyurethane foam according
to claim 1, wherein the blowing agent is one blowing agent selected
from water and an inert gas.
8. A flexible polyurethane foam for soundproofing material obtained
by the process as defined in claim 1.
9. A flexible polyurethane foam for automobile interior material
obtained by the process as defined in claim 1.
Description
TECHNICAL FIELD
[0001] The present invention relates to a flexible polyurethane
foam having good sound absorbing properties over a wide range of
from low frequency to medium frequency and a process for its
production. Such a polyurethane foam has excellent sound absorbing
properties, and when it is used as a soundproofing material for
automobiles, it is unnecessary to use it in combination with a
thermoplastic base material as required heretofore. Further, it
shows excellent soundproofing performance when used alone, and thus
it is effective for weight reduction of automobiles.
BACKGROUND ART
[0002] Heretofore, it has been common that a soundproofing material
for the purpose of sound absorption or sound insulation is mounted
at a dashboard portion partitioning a vehicle interior from an
engine room of an automobile to take a measure to prevent intrusion
of vibration or noise from the engine room into the vehicle
interior. As such a soundproofing material, one having a sound
insulator such as a rubber, polypropylene sheet or vinyl chloride
sheet integrated on a sound absorbing material made of a porous
material such as polyester fiber or flexible polyurethane foam
(hereinafter referred to also as a flexible foam), has been used.
Especially, a flexible foam has a merit in that it can be produced
inexpensively as compared with a polyester fiber and thus has been
used as a sound absorbing material. For example, Patent Document 1
discloses a flexible foam having specific levels of air flowability
and hardness, and a process for its production. Further, Patent
Document 2 discloses a process for producing a flexible foam which
is light in weight and excellent in the soundproofing
performance.
[0003] However, a conventional flexible foam has been inadequate in
the sound-absorbing performance in a low frequency region by itself
and thus has had a problem that it is necessary to take a measure
to improve the sound insulating property, for example, by bonding
to the flexible foam a thermoplastic material such as a rubber
containing a polyolefin as the main component. This in turn has led
to a further problem that it is required to consider the adhesion
between the flexible foam and the thermoplastic material, or that
the mass will increase. Patent Document 3 proposes a soundproofing
material made of a flexible foam alone, which shows excellent sound
absorbing performance in a range of from a medium frequency to high
frequency (at least 2,000 Hz), but it has had a problem that the
sound absorbing performance is inadequate in a low frequency region
of at most 1,000 Hz, particularly at most 500 Hz.
[0004] Patent Document 1: JP-B-7-59389
[0005] Patent Document 2: JP-A-5-209036
[0006] Patent Document 3: JP-A-10-121597
DISCLOSURE OF THE INVENTION
Object to be Accomplished by the Invention
[0007] Under the circumstances, the present invention provides a
process for producing a flexible polyurethane foam having improved
the low frequency sound absorbing performance which used to be
inadequate. Particularly, it provides a process for producing a
flexible polyurethane foam which is a flexible foam having good
sound absorbing performance over a wide range of from low frequency
to medium frequency and which can be used as a soundproofing
material for automobiles without being used in combination with
another material.
Means to Accomplish the Object
[0008] The present inventors have found that by controlling the air
flowability of a flexible polyurethane foam, the sound absorbing
performance in a region of from low frequency to medium frequency
can be increased, and the present invention has been accomplished.
Namely, the present invention provides the following:
[0009] A process for producing a flexible polyurethane foam which
comprises foaming a starting material composition (E) comprising a
high molecular weight polyoxyalkylene polyol (A), an organic
polyisocyanate compound (B), a blowing agent (C) and a catalyst (D)
in a closed mold, characterized in that at least a part of the high
molecular weight polyoxyalkylene polyol (A) is a polyoxyalkylene
polyol (p) having at least two hydroxyl groups on the average and
having a molecular weight (Mc) per hydroxyl group of from 1,800 to
2,800 and a total unsaturation value (USV) of at most 0.08 meq/g,
and that the air flowability of a flexible polyurethane foam
obtained by foaming the starting material composition (E) in a
thickness of 26 mm, is at most 0.085 m.sup.3/min; a soundproofing
flexible polyurethane foam to be obtained by such a process; and a
flexible polyurethane foam for an interior material for
automobiles.
Effects of the Invention
[0010] The flexible polyurethane foam obtained by the present
invention shows improved sound absorbing performance in a low
frequency region in the vicinity of 500 Hz and thus is suitable as
a soundproofing material for buildings or vehicles. Particularly,
the flexible polyurethane foam according to the present invention
is useful by itself as a soundproofing material for automobiles and
thus is effective also for the weight reduction of automobiles.
BEST MODE FOR CARRYING OUT THE INVENTION
High Molecular Weight Polyoxyalkylene Polyol (A)
[0011] In the present invention, a high molecular weight
polyoxyalkylene polyol (A) (hereinafter referred to simply as the
polyol (A)) is used. The polyol (A) in the present invention is
preferably one obtained by ring opening addition polymerization of
an alkylene oxide in the presence of an initiator and a catalyst,
and it is preferred that the average number of hydroxyl groups is
at least 2, and the molecular weight (Mc) per hydroxyl group is at
least 500.
[0012] The polyol (A) preferably has a molecular weight (Mc) per
hydroxyl group of from 500 to 5,000, more preferably from 800 to
2,800, particularly preferably from 850 to 2,500. Further, the
polyol (A) may be a mixture of high molecular weight
polyoxyalkylene polyols having molecular weights (Mc) per hydroxyl
group of at least 500, and in such a case, the average of the
molecular weights (Mc) per hydroxyl group is preferably from 500 to
5,000, more preferably from 800 to 2,800, particularly preferably
from 850 to 2,500.
[0013] If the average of the molecular weights (Mc) per hydroxyl
group is smaller than 500, curing of the flexible foam tends to be
inadequate, whereby shrinkage is likely to take place, such being
undesirable. If it exceeds 5,000, the elasticity of the foam tends
to be inadequate. In the present invention, a polyoxyalkylene
polyol having a molecular weight per hydroxyl group of less than
500 may be used, but such a polyoxyalkylene polyol is classified in
the after-mentioned crosslinking agent in the present
invention.
[0014] The polyol (A) is a polyol having at least two hydroxyl
groups on the average. The polyol (A) may be a single use of one
type or a mixture of at least two types, or may be a polyol
produced by using such a mixture as an initiator, as will be
described hereinafter. The average number of hydroxyl groups is
preferably from 2 to 8, more preferably from 2 to 4, further
preferably from 2.2 to 3.9, most preferably from 2.4 to 3.7. If the
average number of hydroxyl groups of the polyol is less than 2, the
foam tends to be too soft, and the compression set tends to
deteriorate, and if the average number of hydroxyl groups exceeds
8, the foam tends to be hard, whereby the mechanical properties
such as elongation, of the foam, tend to deteriorate, or the
soundproofing performance tends to be impaired. The number of
hydroxyl groups of the polyol (A) is the same as the number of
hydroxyl groups in the initiator used for its production.
[0015] As the initiator to be used the production of the polyol
(A), a compound having from 2 to 8 active hydrogen atoms, is
preferred. For example, a bi- to octa-hydric alcohol, a polyhydric
phenol or an amine is preferred. Specifically, a polyhydric alcohol
such as ethylene glycol, propylene glycol, 1,4-butanediol,
neopentyl glycol, dipropylene glycol, glycerol, trimethylolpropane,
pentaerythritol, diglycerol, meso-erythritol, methyl glucoside,
glucose, dextrose, sorbitol or sucrose, a polyhydric phenol such as
bisphenol A, pyrogallol or hydroquinone, or an amine, such as a
polyamine such as ethylenediamine, diethylenediamine,
diaminodiphenylmethane, hexamethylenediamine or propylenediamine,
or a condensed compound obtainable by a condensation reaction of
such a polyamine with a phenol resin or a novolak resin, may be
mentioned. Further, a compound which is a polyether polyol having a
low molecular weight obtained by ring opening addition
polymerization of a small amount of an alkylene oxide to the
above-mentioned polyhydric alcohol, polyhydric phenol or amine and
which has a molecular weight per hydroxyl group of from about 200
to 500, preferably from 200 to 350, may also be used. Such a
compound preferably has a molecular weight of at most 1,200.
[0016] As the initiator, a compound having from 2 to 4 active
hydrogen atoms is more preferred, and a bi- to tetra-hydric alcohol
or a bi- to tetra-hydric low molecular weight polyether polyol is
preferred. Among them, a polyol produced by using a tri- or higher
hydric alcohol or low molecular weight polyether polyol as an
initiator is preferred, since it is thereby possible to take a
balance of the soundproofing properties, foaming stability and
physical properties of the flexible foam, and it is preferred to
employ such a polyol as at least a part of the polyol (A). These
initiators may be used in combination as a mixture of two or more
of them.
[0017] The alkylene oxide may, for example, be ethylene oxide,
propylene oxide, butylene oxide or styrene oxide, and a combination
of ethylene oxide and propylene oxide is preferred.
[0018] In a case where ethylene oxide and propylene oxide are to be
combined, it is possible to employ a method wherein after ring
opening addition polymerization of propylene oxide, ethylene oxide
is ring-opening addition polymerized to form oxyethylene block
chains at the terminals, a method (hereinafter referred to as
random addition) wherein a mixture of propylene oxide and ethylene
oxide is ring-opening addition polymerized to form
oxypropylene/oxyethylene random polymerized chains, a method
wherein ethylene oxide is block ring-opening addition polymerized
to the interior of the molecular chain, or a method wherein after
random addition, ethylene oxide is ring-opening addition
polymerized to form oxypropylene/oxyethylene random polymerized
chains in the interior of the molecule and oxyethylene block chains
at the terminals.
[0019] It is particularly preferred to use one having from 5 to 25
wt % of polyoxyethylene block chains at the terminals, as at least
a part of the polyol (A). Particularly preferably, such block
chains may be used for from 50 to 100 mass % of the polyol (A).
[0020] As the catalyst for the ring opening addition polymerization
of an alkylene oxide, an ordinary one may be employed. For example,
potassium hydroxide, sodium hydroxide, cesium hydroxide, a
phosphazenium compound, a boron trifluoride compound or a composite
metal cyanide complex may, for example, be employed. Among them, it
is preferred to use cesium hydroxide or a composite metal cyanide
complex, whereby a polyol having a low unsaturated degree can be
produced, and by using it a flexible foam having proper air
flowability can be produced.
[0021] The polyol (A) may contain fine polymer particles dispersed
in the polyol. Fine polymer particles are ones is having fine
polymer particles stably dispersed in a base polyol as a dispersing
medium, and such fine polymer particles may be an addition
polymerization type polymer or a polycondensation type polymer. For
example, it may be an addition polymerization type polymer such as
a homopolymer or copolymer of acrylonitrile, styrene, an alkyl
methacrylate, an alkyl acrylate or other vinyl monomer, or a
polycondensation type polymer such as a polyester, a polyurea, a
polyurethane or a melamine resin. Among them, acrylonitrile,
styrene or a copolymer thereof is preferred.
[0022] The content of the fine polymer particles is preferably from
0.1 to 10 mass %, more preferably from 1 to 10 mass %, in the
polyol (A). The amount of the fine polymer particles is not
required to be particularly large, and if it is too much, there
will be no trouble other than the economical disadvantage. Further,
the presence of the fine polymer particles in the polyol (A) is not
essential, but the presence is effective for the improvement of the
hardness, air flowability and other physical properties of the
foam. Accordingly, the fine polymer particles are preferably
present in an amount of at least 1 mass %, particularly at least 3
mass %. The method for dispersing the fine polymer particles may be
a method of dispersing the fine polymer particles by using the
polyol (A) as the base polyol, or a method wherein one having the
fine polymer particles dispersed by using a part of the polyol (A)
as the base polyol, is prepared and mixed with another polyol, and
any other method may be employed.
[0023] Further, in the present invention, in a case where the
polyol (A) contains the dispersed polymer particles, the amount of
the polyol (A) or the after-mentioned polyol (p) is calculated
based on the mass excluding the fine polymer particles.
Polyoxyalkylene Polyol (p)
[0024] In the present invention, at least a part of the polyol (A)
is a polyoxyalkylene polyol (p) (hereinafter referred to also as
the polyol (p)). The polyol (p) is a polyoxyalkylene polyol having
at least two hydroxyl groups on the average and having a molecular
weight (Mc) per hydroxyl group of from 1,800 to 2,800 and a total
unsaturation value (USV) of at most 0.08 meq/g, among the
above-mentioned polyols (A).
[0025] The molecular weight (Mc) per hydroxyl group of the polyol
(p) is from 1,800 to 2,800, preferably from 1,850 to 2,500. If the
molecular weight (Mc) per hydroxyl group is smaller than 1,800, the
hardness of the flexible foam tends to be inadequate, and shrinkage
is likely to take place, such being undesirable. If the above
molecular weight exceeds 2,800, the elasticity of the foam tends to
be inadequate.
[0026] The polyoxyalkylene polyol (p) has a total unsaturation
value of at most 0.08 meq/g. If the total unsaturation value
exceeds 0.08 meq/g, the air flowability of the flexible foam is
likely to exceed 0.085 m.sup.3/min, and the sound absorbing
performance tends to be poor, such being undesirable. The total
unsaturation value is more preferably at most 0.06 meq/g, further
preferably at most 0.05 meq/g, most preferably at most 0.04
meq/g.
[0027] In order to obtain the polyol having such a total
unsaturation value, it is preferred to employ cesium hydroxide or a
composite metal cyanide complex, particularly preferably a
composite metal cyanide complex, as the catalyst for ring opening
addition polymerization of an alkylene oxide. As the composite
metal cyanide complex catalyst, a known catalyst may be used. A
complex containing zinc hexacyanocobaltate as the main component,
is preferred, and one having an ether and/or alcohol as an organic
ligand is further preferred. As the organic ligand, monoethylene
glycol mono-tert-butyl ether or tert-butyl alcohol or glyme
(ethylene glycol dimethyl ether) may, for example, be
preferred.
[0028] The average number of hydroxyl groups in the polyol (p) is
at least 2. The polyol (p) is a single use of one type or a mixture
of polyols having molecular weights (Mc) per hydroxyl group of from
1,800 to 2,800 and total unsaturation values (USV) of at most 0.08
meq/g. Otherwise, it may be one produced by using such a mixture as
an initiator. The average number of hydroxyl groups is preferably
from 2 to 8, more preferably from 2 to 4, further preferably from
2.2 to 3.9, most preferably from 2.4 to 3.7. If the average number
of hydroxyl groups of the polyol is less than 2, the foam tends to
be soft, whereby the compression set tends to deteriorate, and if
the number of hydroxyl groups exceeds 8, the foam tends to be hard,
the mechanical properties such as elongation of the foam tend to
deteriorate, or the soundproofing performance tends to be
impaired.
[0029] Further, the polyol (p) is preferably one having
polyoxyethylene block chains at the terminals, particularly
preferably one having from 5 to 25 mass % of such block chains.
[0030] In the present invention, the proportion of the polyol (p)
in the polyol (A) is preferably from 5 to 100 mass %. When from 5
to 100 mass % of the polyol (p) is contained, a flexible foam
having proper hardness and proper air flowability can be obtained,
and the strength of the foam will be improved. The proportion of
the polyol (p) is preferably from 8 to 100 mass %, most preferably
from 8 to 70 mass %. Further, as mentioned above, when the polyol
(A) contains fine polymer particles, the proportion of the polyol
(p) in the polyol (A) is calculated based on the mass excluding the
fine polymer particles.
[0031] In the present invention, in addition to the polyol (A),
other high molecular weight polyol such as a polyester polyol may
be used. However, the amount of such other polyol is preferably at
most 20 parts by mass, more preferably at most 10 parts by mass,
per 100 parts by mass of the polyol (A). It is particularly
preferred that no such other polyol is substantially used.
Organic Polyisocyanate Compound (B)
[0032] The organic polyisocyanate compound (B) to be used in the
present invention is not particularly limited, and it may, for
example, be a polyisocyanate of an aromatic type, an alicyclic type
or an aliphatic type, having at least two isocyanate groups; a
modified polyisocyanate obtainable by modifying such a
polyisocyanate; or a mixture of two or more of such
polyisocyanates. As a specific example, a polyisocyanate such as
tolylene diisocyanate (TDI), diphenylmethane diisocyanate (MDI),
polymethylenepolyphenyl isocyanate (so-called crude MDI), xylylene
diisocyanate (XDI), isophorone diisocyanate (IPDI) or hexamethylene
diisocyanate (HMDI), or a prepolymer modified product, an
isocyanurate modified product, an urea modified product or a
carbodiimide modified product of such a polyisocyanate may be
mentioned. Among them, TDI, MDI, crude MDI or a modified product
thereof is preferred.
[0033] The amount of the organic polyisocyanate compound is usually
represented by an isocyanate index ((isocyanate equivalent)/(total
equivalent of all active hydrogen in the polyol, the crosslinking
agent, water, etc.).times.100), and the amount of the
polyisocyanate compound to be used in the present invention is
preferably from 50 to 110, more preferably from 55 to 95, by the
isocyanate index.
Blowing Agent (C)
[0034] In the present invention, the blowing agent (C) is not
particularly limited, but it is preferred to use at least one
blowing agent selected from water and an inert gas. As the inert
gas, air, nitrogen or carbon dioxide may specifically be mentioned.
As the blowing agent, it is particularly preferred to use water.
The amount of such a blowing agent is not particularly limited, but
in a case where water is to be used, it is preferably at most 10
parts by mass per 100 parts by mass of the polyol (A) (in a case
where high molecular weight polyol is used in addition to the
polyol (A), the total of the polyol (A) and such other high
molecular weight polyol). Other blowing agents may also be used in
proper amounts depending upon the demand for e.g. foaming
magnification.
Catalyst (D)
[0035] When the polyol (A) is reacted with the organic
polyisocyanate compound (B), a catalyst (D) is used. As such a
catalyst (D), an amine compound or an organic metal compound may,
for example, be mentioned.
[0036] With a view to preventing fogging of an automobile glass or
with a view to preventing contamination (whitening) of a
polycarbonate resin to be used in an automobile interior, a
tertiary amine catalyst having a molecular weight of at most 500
and having a hydroxyl group in its molecule, is preferred. If the
molecular weight exceeds 500, the reactivity of the hydroxyl group
in the molecule with the organic polyisocyanate tends to
deteriorate, such being undesirable.
[0037] The tertiary amine catalyst having a molecular weight of at
most 500 and having a hydroxyl group in its molecule may
specifically be N,N-dimethylaminoethoxyethoxyethanol,
N,N-dimethylamino-6-hexanol, N,N-dimethylaminoethoxyethanol, a
compound having 2 mol of ethylene oxide added to
N,N-dimethylaminoethoxyethanol, or
5-(N,N-dimethyl)amino-3-methyl-1-pentanol, but it is not limited
thereto.
[0038] Further, other tertiary amine catalysts may also be used,
such as triethylene diamine, bis(2-dimethylaminoethyl)ether and
N,N,N',N'-tetramethylhexamethylenediamine.
[0039] In the case of the amine catalyst, the amount of the
catalyst to be used is preferably from 0.1 to 5 parts by mass per
100 parts by mass of the polyol (A) (when a high molecular weight
polyol is used in addition to the polyol (A), the total amount of
the polyol (A) and such other high molecular weight polyol). If the
amount is more or less than this range, the reaction for curing of
the isocyanate group with the active hydrogen group tends to be
inadequate. The amount is particularly preferably from 0.5 to 3.0
parts by mass.
[0040] Further, as the catalyst, an organic metal compound may also
be used. As such an organic metal compound, an organic tin
compound, an organic bismuth compound, an organic lead compound or
an organic zinc compound may, for example, be mentioned. For
example, di-n-butyltin oxide, di-n-butyltin dilaurate,
di-n-butyltin diacetate, di-n-octyltin oxide, di-n-octyltin
dilaurate, monobutyltin trichloride, di-n-butyltin dialkylmercaptan
or di-n-octyltin dialkylmercaptan may be mentioned. The amount of
such an organic metal compound to be used is preferably less than
1.0 part by mass, particularly preferably from 0.005 to 1.0 part by
mass, per 100 parts by mass of the polyol (A) (when other high
molecular weight polyol is used in addition to the polyol (A), the
total amount of the polyol (A) and such other high molecular weight
polyol).
Others
[0041] In the present invention, a crosslinking agent may be used.
As the crosslinking agent, a compound having at least two active
hydrogen-containing groups selected from hydroxyl groups, primary
amino groups and secondary amino groups, is preferred. The number
of active hydrogen-containing groups is preferably from 2 to 8.
Further, the molecular weight per active hydrogen-containing group
of the crosslinking agent is preferably from 30 to less than 500,
more preferably from 30 to 200. Two or more crosslinking agents may
be used in combination.
[0042] As such a crosslinking agent, specifically, a compound such
as ethylene glycol, propylene glycol, 1,4-butanediol, neopentyl
glycol, 1,6-hexanediol, diethylene glycol, triethylene glycol,
dipropylene glycol, glycerol, trimethylolpropane, pentaerythritol,
diglycerol, monoethanolamine, diethanolamine, triethanolamine,
bisphenol A, ethylenediamine, 3,5-diethyl-2,4(or
2,6)-diaminotoluene (DETDA), 2-chloro-p-phenylenediamine (CPA),
3,5-bis(methylthio)-2,4(or 2,6)-diaminotoluene,
1-trifluoromethyl-3,5-diaminobenzene,
1-trifluoromethyl-4-chloro-3,5-diaminobenzene, 2,4-toluenediamine,
2,6-toluenediamine, bis(3,5-dimethyl-4-aminophenyl)methane,
4,4'-diaminodiphenylmethane, m-xylylenediamine, 1,4-diaminohexane,
1,3-bis(aminomethyl)cyclohexane or isophoronediamine may, for
example, be mentioned. Further, a low molecular weight
polyoxyalkylene polyol may also be used. The crosslinking agent is
used preferably in an amount of from 0.1 to 20 parts by mass,
particularly preferably from 0.5 to 10 parts by mass, per 100 parts
by mass of the polyol (A).
[0043] Further, a foam stabilizer is used in many cases to form
good foams. As such a foam stabilizer, a silicone foam stabilizer
or a fluorinated compound type foam stabilizer may, for example, be
mentioned. Further, various known additives and adjuvants may be
used as the case requires, such as an emulsifier, an aging
preventive agent such as an antioxidant or an ultraviolet absorber,
a filler such as calcium carbonate or barium sulfate, a
plasticizer, a colorant, a flame retardant, an anti-fungus agent
and a cell opener.
Air Flowability
[0044] The present invention is directed to a process for producing
a flexible polyurethane foam, which comprises foaming a starting
material composition (E) comprising a high molecular weight
polyoxyalkylene polyol (A), an organic polyisocyanate compound (B),
a blowing agent (C) and a catalyst (D) in a closed mold, and is
characterized in that the air flowability of a flexible
polyurethane foam obtained by foaming the starting material
composition (E) in a thickness of 26 mm, is at most 0.085
m.sup.3/min. Hereinafter, the flexible polyurethane foam obtained
by foaming in a thickness of 26 mm will be referred to also as the
26 mm thick test sample. This sample is obtained by foaming by
means of a closed mold having a thickness of 26 mm.
[0045] The air flowability is a numerical value measured by the
method in accordance with JIS K6400 method B (1997). By using the
starting material composition (E) which, when formed into the 26 mm
thick test sample, has an air flowability of at most 0.085
m.sup.3/min, it is possible to obtain a flexible polyurethane foam
which is excellent in the sound absorbing performance in a low
frequency region which used to be inadequate by a conventional
flexible polyurethane foam alone, without impairing the sound
absorbing performance in the medium frequency region which used to
be good. The air flowability when it is formed into the 26 mm thick
test sample, is preferably at most 0.030 m.sup.3/min, more
preferably at most 0.025 m.sup.3/min.
Characteristics
[0046] In the present invention, in a sound absorption measuring
method by a vertical entry method of a flexible polyurethane foam
obtained by foaming the starting material composition (E) in a
thickness of 26 mm, the sound absorption characteristic at 500 Hz
is preferably at least 0.3, and the sound absorption characteristic
at 2,000 Hz is preferably at least 0.55.
[0047] The sound absorption characteristics can be measured by the
method in accordance with JIS A1405 method (1963). If the sound
absorption characteristic at 500 Hz is smaller than 0.3, the sound
absorbing performance in the low frequency region tends to be
inadequate, and as a sound-insulating material for an automobile,
it will be obliged to use it in combination with another material.
If the sound absorption characteristic at 2,000 Hz is smaller than
0.55, the sound absorbing performance in the medium frequency
region tends to be inadequate, whereby it tends to be poor in the
performance as a soundproofing material, particularly as a
soundproofing material for automobiles.
[0048] More preferably, the sound absorption characteristic at 500
Hz is at least 0.35, particularly preferably at least 0.4.
Likewise, the sound absorption characteristic at 2,000 Hz is
preferably at least 0.57, particularly preferably at least 0.6.
[0049] Further, the F-type hardness of the flexible foam of the
present invention is preferably at most 80. When the F-type
hardness is at most 80, a good soundproofing effect can be
obtained, and if the F-type hardness is more than 80, the
soundproofing effect tends to be poor, such being undesirable.
Further, the F-type hardness is preferably at least 40.
[0050] Further, the foam density of the flexible polyurethane foam
of the present invention is preferably at most 120 kg/m.sup.3 and
is preferably from 60 to 120 kg/m.sup.3. If the foam density
exceeds this range, the mass of the flexible foam becomes large,
such being not acceptable for weight reduction of automobiles in
recent years, and if it is less than the range, the soundproofing
effect tends to be low, such being undesirable. The foam density is
particularly preferably from 80 to 100 kg/m.sup.3. Further, the
rebound resilience is preferably from 30 to 50%. If the rebound
resilience exceeds this range, the energy attenuation of the foam
tends to be low, and the acoustic characteristics tend to
deteriorate, such being undesirable.
Molding Method
[0051] Molding of the flexible foam in the process of the present
invention is carried out preferably by a method is wherein using a
low pressure foaming machine or a high pressure foaming machine,
the starting material composition (E) is injected directly into a
closed mold (i.e. a reaction injection molding method) or a method
wherein the starting material composition is injected into a mold,
which is then closed.
[0052] The high pressure foaming machine is preferably one wherein
usually two liquids will be mixed. In such a case, the organic
polyisocyanate compound is used as one of the two liquids, and a
mixture of all starting materials other than the organic
polyisocyanate compound (which is usually called a polyol system
liquid) is used as the other liquid. In some cases, the catalyst or
the foam stabilizer (which is usually employed as dispersed or
dissolved in a part of the high molecular weight polyol) and the
blowing agent may be made to be a separate component, so that the
reactive mixture for injection is constituted by a total of at
least three components.
[0053] The flexible foam of the present invention is produced
usually by a cold curing method, but may be produced by a method
other than the cold curing method, such as a method including a
heating step.
EXAMPLES
[0054] Now, the present invention will be described in detail with
reference to Examples, but it should be understood that the present
invention is by no means restricted thereto.
[0055] The molecular weight (Mc) per hydroxyl group, the number of
hydroxyl groups, the content of oxyethylene (EO) groups (unit: mass
%) and the total unsaturation value (USV) (unit: meq/g), of each of
polyols (p-1) to (p-2) and (A-1) to (A-5) and the polymerization
catalysts used in Examples and Comparative Examples, are shown in
Table 1. For the catalyst in Table 1, KOH represents a potassium
hydroxide catalyst, CsOH a cesium hydroxide catalyst, and DMC a
zinc hexacyano cobaltate/monoethylene glycol mono-t-butyl ether
complex catalyst. Further, the measurement of the unsaturation
value was carried out by the method in accordance with JIS K1557
method (1970). Polyol (p-1) was produced by subjecting PO to ring
opening addition polymerization in the presence of DMC using, as an
initiator a compound having a molecular weight of 1,000 obtained by
ring-opening addition polymerization of propylene oxide (PO) to
glycerol, and then subjecting EO to ring opening addition
polymerization by means of KOH. Polyol (p-2) was produced by
subjecting PO to ring opening addition polymerization in the
presence of CsOH by using glycerol as an initiator, and then
subjecting EO to ring opening addition polymerization. Polyol (A-1)
or (A-5) was produced by subjecting PO to ring opening addition
polymerization in the presence of KOH by using glycerol as an
initiator, and then subjecting EO to ring opening addition
polymerization. Polyol (A-2) was produced by subjecting PO to ring
opening addition polymerization in the presence of KOH by using a
mixture of glycerol and sucrose as an initiator, and then,
subjecting EO to ring opening addition polymerization. Polyol (A-3)
was produced by subjecting a mixture of PO and EO to ring opening
addition polymerization in the presence of KOH by using glycerol as
an initiator. Polyol (A-4) was produced by subjecting PO to ring
opening addition polymerization in the presence of KOH by using
glycerol as an initiator. Further, other starting materials are
shown in Table 2. TABLE-US-00001 TABLE 1 Number Content Identifi-
of of EO Polymeri- cation of hydroxyl groups USV zation polyol Mc
groups (mass %) (meq/g) catalyst (p-1) 2333 3 16 0.015 DMC (p-2)
2000 3 16 0.039 CsOH (A-1) 1633 3 15 0.06 KOH (A-2) 1600 4.75 15
0.06 KOH (A-3) 1170 3 67 0.006 KOH (A-4) 1000 3 0 0.05 KOH (A-5)
2337 3 14 0.10 KOH
[0056] TABLE-US-00002 TABLE 2 Catalyst Dipropylene glycol (DPG)
solution of (D-1) triethylenediamine (tradename: KAOLIZER No. 31,
manufactured by Kao Corporation) Catalyst DPG solution of
bis-[(2-dimethylamino) (D-2) ethyl]ether (tradename: TOYOCAT ET,
manufactured by TOSOH Corporation) Catalyst
1-Isobutyl-2-methylimidazole (tradename: (D-3) NC-IM, manufactured
by Sankyo Air Products) Catalyst Reactive tertiary amine catalyst
(D-4) (tradename: TOYOCAT RX-21 manufactured by TOSOH Corporation)
Foam Silicone foam stabilizer (tradename: SRX- stabilizer 274C,
manufactured by Toray Dow Corning Silicone) Blowing agent Water
Polyol Polymer-dispersed polyol having fine (A-6) particles of
acrylonitrile polymer (20 mass %) dispersed in a dispersant of
polyol (A-1) (80 mass %) Polyol Polymer-dispersed polyol having
fine (A-7) particles of acrylonitrile polymer (20 mass %) dispersed
in a dispersant of polyol (p-2) (80 mass %) Polyisocyanate Mixture
of TDI (mixture of (B-1) 2,4-TDI/2,6-TDI = 80/20 mass %)/crude MDI
= 50/50 mass %. Content of NCO groups: 39.7 mass % (tradename:
Coronate 1025, manufactured by Nippon Polyurethane Industry Co.,
Ltd.) Polyisocyanate Modified MDI. Content of NCO groups: 28.9
(B-2) mass % (tradename: Coronate 1120, manufactured by Nippon
Polyurethane Industry Co., Ltd.) Crosslinking Polyoxypropylene
polyol having an average agent (E-1) number of hydroxyl groups
being 4.7 and a hydroxyl value of 450 mgKOH/g (content of EO
groups: 0 mass %) Crosslinking Glycerol agent (E-2) Crosslinking
Triethanolamine agent (E-3)
Examples 1 to 11
[0057] The upper and lower mold temperature of an aluminum mold of
400 mm.times.400 mm.times.26 mm in height was raised to 60.degree.
C. Among the starting materials in the blend amounts as shown in
Tables 3 and 4, a mixture of all starting materials other than the
organic polyisocyanate compound (the polyol system liquid) and the
organic polyisocyanate compound liquid were, respectively, adjusted
to liquid temperatures of 25.+-.1.degree. C. A prescribed amount of
the organic polyisocyanate compound liquid was added to the polyol
system liquid, and the mixture was stirred and mixed for 5 seconds
by a high speed mixer (3,000 rpm) and injected at room temperature
into a mold and sealed and then foamed and cured to produce a
flexible polyurethane foam. Three minutes later, the flexible foam
was taken out from the mold and left to stand in a room adjusted to
have a room temperature of 23.degree. C. and a humidity of 50% for
at least 24 hours, whereupon measurements of various physical
properties were carried out. The results of such measurements are
shown in Tables 3 and 4. The measurements of the physical
properties of foams were carried out by the following methods, and
the standards used for the measurements of the physical properties
of the flexible foams are shown below. Examples 1 to 8 are Examples
of the present invention, and Examples 9 to 11 are Comparative
Examples. Further, in Tables 3 and 4, the numerical values in the
columns for formulations show mass %.
[0058] The foam density (unit: kg/m.sup.3) and the air flowability
(unit: m.sup.3/min) were measured by the methods in accordance with
JIS K6400 Method B (1997), and the vertical entry sound absorption
characteristic was measured by the method in accordance with JIS
A1405 method (1963) by means of an apparatus: vertical entry sound
absorption measuring tube model No. 4206, manufactured by Bruel
& Kjaer, an analysis software: Winzac, manufactured by Nittobo
Acoustic Engineering Co., Ltd., a power amplifier: A100a,
manufactured by YAMAHA CORPORATION, and a microphone amplifier:
Model No. 2691, manufactured by Bruel & Kjaer. TABLE-US-00003
TABLE 3 Examples 1 2 3 4 5 6 7 8 Polyol (p-1) 8 24 40 24 24 14
Polyol (p-2) -- -- -- -- -- 59.2 59.2 Polyol (A-2) 12 Polyol (A-3)
3 3 3 3 3 3 3 2 Polyol (A-4) 18 18 Polyol (A-5) 72 56 40 56 56 44
Polyol (A-6) 20 20 20 20 20 30 Polyol (A-7) 14.8 14.8 Crosslinking
agent 8 8 (E-1) Crosslinking agent 1 (E-2) Crosslinking agent 0.7
(E-3) Blowing agent 2.35 2.35 2.35 2.35 2.35 2.35 2.35 3.5 Catalyst
(D-1) 0.6 0.6 0.6 0.6 0.6 0.6 0.6 Catalyst (D-2) 0.3 0.3 0.3 0.3
0.3 0.3 0.3 0.05 Catalyst (D-3) 0.3 0.3 0.3 0.3 0.3 0.3 0.3
Catalyst (D-4) 0.5 Foam stabilizer 0.4 0.4 0.4 0.4 0.4 0.4 0.4 1.0
Isocyanate (B-1) (Index) 83 83 83 90 100 83 90 Isocyanate (B-2)
(Index) 85 Thickness of sample (mm) 26 26 26 26 26 26 26 26 Foam
density (kg/m.sup.3) 98.0 95.7 94.6 92.9 91.7 89.0 85.0 81.1
Surface density (kg/m.sup.2) 2.58 2.49 2.45 2.42 2.48 2.23 2.08
1.98 Mold temperature (.degree. C.) 60 60 60 60 60 60 60 56 F-type
hardness 45 43 46 51 56 60 70 77 Air flowability (m.sup.3/min)
0.0218 0.0164 0.0113 0.0139 0.0100 0.0270 0.0290 0.0240 Vertical
entry sound absorbing characteristic 500 Hz 0.45 0.51 0.56 0.53
0.59 0.58 0.43 0.52 1000 Hz 0.83 0.74 0.63 0.67 0.57 0.74 0.84 0.78
2000 Hz 0.85 0.83 0.70 0.68 0.58 0.86 0.81 0.79 4000 Hz 0.77 0.82
0.78 0.72 0.62 0.78 0.78 0.80
[0059] TABLE-US-00004 TABLE 4 Examples 9 10 11 Polyol (A-3) 3 3 3
Polyol (A-5) 80 80 80 Polyol (A-6) 20 20 20 Blowing agent 2.35 2.35
2.35 Catalyst (D-1) 0.6 0.6 0.6 Catalyst (D-2) 0.3 0.3 0.3 Catalyst
(D-3) 0.3 0.3 0.3 Foam stabilizer 0.4 0.4 0.4 Isocyanate (B-1)
(Index) 80 90 100 Thickness of sample (mm) 26 26 26 Foam density
(kg/m.sup.3) 104 95.6 97.1 Surface density (kg/m.sup.2) 2.69 2.49
2.58 Mold temperature (.degree. C.) 60 60 60 F-type hardness 40 44
50 Air flowability (m.sup.3/min) 0.0289 0.0229 0.0178 Vertical
entry sound absorbing characteristic 500 Hz 0.25 0.26 0.28 1000 Hz
0.65 0.68 0.71 2000 Hz 0.99 0.99 0.97 4000 Hz 0.78 0.77 0.84
[0060] The flexible foams obtained in Examples 1 to 8 show good
sound absorbing performance, and particularly, the sound absorbing
performance at 500 Hz (in a low frequency region) is good. Further,
they show proper values with respect to the foam density and the
F-type hardness. Whereas, Examples 9 to 11 tend to be inferior in
the sound absorbing performance in the low frequency region.
INDUSTRIAL APPLICABILITY
[0061] The flexible polyurethane foam obtained by the present
invention has improved sound absorbing properties in the low
frequency region in the vicinity of 500 Hz and thus is suitable as
a soundproofing material for buildings or vehicles. It is
particularly useful as a soundproofing material for vehicles such
as automobiles.
[0062] The entire disclosure of Japanese Patent Application No.
2003-327588 filed on Sep. 19, 2003 including specification, claims
and summary is incorporated herein by reference in its
entirety.
* * * * *