Patent Application
20240010781
The present disclosure relates to a polyurethane foam and a seat pad.
This application is based on and claims the benefit of priority of Japanese Patent Application No. 2021-20786 filed on Feb. 12, 2021 and Japanese Patent Application No. 2021-72390 filed on Apr. 22, 2021, the entire contents of which are incorporated herein by reference.
Patent Literature 1 discloses a polyurethane foam used as a vehicle seat cushion material.
In a polyurethane foam used for a seat pad for a vehicle and the like, reduction in rebound elasticity and reduction in a stress relaxation rate and a hysteresis loss rate are required in order to improve ride comfort.
However, the reduction in the rebound elasticity and the reduction in the stress relaxation rate and the hysteresis loss rate are contradictory performances, and it is difficult to achieve both of them.
The present disclosure has been made in view of the above circumstances, and an object of the present disclosure is to provide a polyurethane foam having a reduced stress relaxation rate and a reduced hysteresis loss rate while having moderate rebound elasticity.
The present disclosure can be implemented in the following forms.
[1] A polyurethane foam obtained from a composition containing a polyol and an isocyanate,
The polyurethane foam of the present disclosure has a reduced stress relaxation rate and a reduced hysteresis loss rate while having moderate rebound elasticity.
Desirable examples of the present disclosure will now be described.
[2] A polyurethane foam in which the number of functional groups of the polyol (a) is less than 3, and the polyol (a) has a number average molecular weight of 2000 or more and 20000 or less.
[3] A polyurethane foam having a hysteresis loss rate according to JIS K 6400-2 B method of 20% or less.
[4] A polyurethane foam having a stress relaxation rate of 15% or less.
[5] A seat pad including a polyurethane foam.
Hereinafter, the present disclosure will be described in detail. In the present specification, unless otherwise specified, the numerical value range expressed by “(value) to (value)” includes the lower limit and the upper limit of the range. For example, the expression “10 to 20” includes both a lower limit of “10” and an upper limit of “20.” That is, “10 to 20” is equivalent to “10 or more and 20 or less.”
The polyurethane foam is obtained from a composition containing a polyol and an isocyanate. As the polyol, a polyol (a) in which the content of an ethylene oxide unit (hereinafter, abbreviated as an “EO unit”) is 60 mol % or more is contained when a total amount of alkylene oxide units is 100 mol %. The content of the polyol (a) is 60 parts by mass or more and 95 parts by mass or less when a total amount of the polyol is 100 parts by mass.
The composition contains a polyol and an isocyanate. The composition may contain at least one selected from a foaming agent, a catalyst, a foam stabilizer, and a crosslinking agent as an optional component. Each component of the composition will be described.
The polyol includes a polyol (a) having a content of the EO unit of 60 mol % or more when the total amount of the alkylene oxide units is 100 mol %. Hereinafter, the content of the EO unit refers to a content when the total amount of the alkylene oxide units is 100 mol %. As the polyol, another polyol (b) having a content of the EO unit of less than 60 mol % (which need not contain the EO unit) is used in combination.
The polyol (a) is a polyether polyol having a content of the EO unit of 60 mol % or more. The content of the EO unit is preferably 70 mol % or more, and more preferably 80 mol % or more from the viewpoint of reducing a stress relaxation rate and a hysteresis loss rate. An upper limit of the content of the EO unit is not particularly limited, and may be 100 mol %.
Examples of the alkylene oxide other than ethylene oxide used for the production of the polyol (a) include propylene oxide and butylene oxide, and propylene oxide is often used. As the polyol (a), a polyol whose total amount excluding the EO unit is a propylene oxide unit (hereinafter, abbreviated as “PO unit”) can be suitably used.
The content of the polyol (a) is 60 parts by mass or more and 95 parts by mass or less when a total amount of the polyol is 100 parts by mass. A lower limit of the content of the polyol (a) is preferably 70 parts by mass or more, and more preferably 80 parts by mass or more from the viewpoint of reducing the stress relaxation rate and the hysteresis loss rate. An upper limit of the content of the polyol (a) is preferably 93 parts by mass or less, and more preferably 90 parts by mass or less from the viewpoint of formability. From these viewpoints, the content of the polyol (a) is preferably 70 parts by mass or more and 93 parts by mass or less, and more preferably 80 parts by mass or more and 90 parts by mass or less.
A number average molecular weight of the polyol (a) is not particularly limited. The number average molecular weight of the polyol (a) is preferably 20000 or less, more preferably 15000 or less, still more preferably 10000 or less, even more preferably 7000 or less, and further more preferably 5000 or less from the viewpoint of achieving low repulsion. A lower limit of the number average molecular weight of the polyol (a) is usually 2000 or more.
The number average molecular weight of the polyol (a) can be measured by gel permeation chromatography (GPC). When the polyol (a) is a commercially available product, a catalog value may be employed as the number average molecular weight of the polyol (a).
The number of functional groups of the polyol (a) is not particularly limited. The number of functional groups of the polyol (a) is preferably less than 3, more preferably 2.5 or less, and still more preferably 2 from the viewpoint of reducing the stress relaxation rate and the hysteresis loss rate. The number of functional groups of the polyol (a) is usually 2 or more. The polyol (a) is preferably a polyoxyethylene/propylene glycol copolymer having a content of the EO unit of 60 mol % or more.
When the number of functional groups of the polyol (a) is the above value, formation of a network structure can be suppressed when the polyol and the isocyanate react with each other. It is presumed that in the polyurethane foam formed in this way, entanglement of polyurethane molecules during compression is suppressed, and the stress relaxation rate and the hysteresis loss rate are reduced.
In the present disclosure, the number of functional groups means an average of the number of active hydrogen groups of each component contained in the polyol. When the polyol is a commercially available product, a catalog value may be employed as the number of functional groups of the polyol (a).
The polyol (b) is not particularly limited as long as it is a polyol having a content of the EO unit of less than 60 mol % (which need not contain the EO unit). Only one kind of polyol (b) may be used, or two or more kinds thereof may be used in combination.
Examples of the polyol (b) include polyether polyols containing PO units, butylene oxide units, and the like as other alkylene oxide units excluding the EO unit. Hereinafter, this polyol is referred to as a polyol (b1). As the polyol (b1), a polyol whose total amount excluding the EO unit is the PO unit can be suitably used.
When the polyol (a) and the polyol (b1) are used in combination, cushioning properties of the polyurethane foam can be improved. The reason is not clear, but is presumed as follows.
When only the polyol (a) is used as the polyol, a rough foam having low cushioning properties is obtained. One reason for this is considered to be that the components of the polyol are homogenized and the reaction proceeds quickly when only the polyol (a) is used as the polyol. It is presumed that when the polyol (a) and the polyol (b1), which is a polyether polyol having a property different from that of the polyol (a), are used in combination as the polyol, the reaction can be made gentle, and the cushioning properties can be improved.
The content of the EO unit in the polyol (b1) is not particularly limited. For example, the content of the EO unit in the polyol (b1) is preferably more than 0 mol %, more preferably 10 mol % or more, and still more preferably 15 mol % or more, from the viewpoint of reducing the stress relaxation rate and the hysteresis loss rate. The upper limit of the content of the EO unit in the polyol (b1) is not particularly limited, and only need be less than 60 mol %.
The number of functional groups of the polyol (b1) is not particularly limited. The number of functional groups of the polyol (b1) is preferably less than 3, more preferably 2.5 or less, and still more preferably 2. The number of functional groups of the polyol (b1) is usually 2 or more. As the polyol (b1), a polyoxyethylene/propylene glycol copolymer or polypropylene glycol having a content of the EO unit of less than 60 mol % is preferable, and the polyoxyethylene/propylene glycol copolymer having a content of the EO unit of less than 60 mol % is more preferable.
When the number of functional groups of the polyol (b1) is the above value, formation of a network structure can be suppressed when the polyol and the isocyanate react with each other. It is presumed that in the polyurethane foam formed in this way, entanglement of polyurethane molecules during compression is suppressed, and the stress relaxation rate and the hysteresis loss rate are reduced.
A number average molecular weight of the polyol (b1) is not particularly limited. The number average molecular weight of the polyol (b1) is preferably 2000 or more and 20000 or less, more preferably 2500 or more and 15000 or less, and still more preferably 3000 or more and 10000 or less.
Examples of the polyol (b) include aliphatic polyether polyols having 3 to 20 carbon atoms such as polyoxytetramethylene glycol (PTMG). Hereinafter, this polyol is referred to as a polyol (b2). When the polyol (a) and the polyol (b2) are used in combination, the tensile strength and tear strength of the polyurethane foam can be improved. As the polyol (b2), polyoxytetramethylene glycol (having two functional groups) can be suitably used.
When the number of functional groups of the polyol (b2) is two, formation of a network structure can be suppressed when the polyol and the isocyanate react with each other. It is presumed that in the polyurethane foam formed in this way, entanglement of polyurethane molecules during compression is suppressed, and the stress relaxation rate and the hysteresis loss rate are reduced.
A number average molecular weight of the polyol (b2) is not particularly limited. The number average molecular weight of the polyol (b2) is preferably 1500 or more and 15000 or less, more preferably 2000 or more and 10000 or less, and still more preferably 2500 or more and 8000 or less.
As the polyol (b), the polyol (b2) is preferably used from the viewpoint of improving the tensile strength and tear strength of the polyurethane foam. When the polyol (a) and the polyol (b2) are used in combination as the polyol, the stress relaxation rate and the hysteresis loss rate can be suitably reduced while ensuring basic physical properties of the polyurethane foam.
As the polyol (b), a polyol other than the polyol (b1) and the polyol (b2) may be used as long as characteristics of the polyurethane foam, such as rebound elasticity, the stress relaxation rate, and the hysteresis loss rate, are not impaired. Only one kind of polyol other than the polyol (b1) and the polyol (b2) may be used, or two or more kinds thereof may be used in combination.
As the foaming agent, a hydrocarbon such as water, alternative fluorocarbon, or pentane can be used alone or in combination. As the foaming agent, water is particularly preferable. In the case of water, carbon dioxide gas is generated during the reaction between the polyol and the isocyanate, and foaming is performed by the carbon dioxide gas. The amount of water as the foaming agent is preferably 1.0 part by mass or more and 4.0 parts by mass or less with respect to 100 parts by mass of the polyol.
As the catalyst, a known catalyst for a polyurethane foam can be used. In the present disclosure, it is preferable to use a foaming catalyst and a resinification catalyst in combination. The foaming catalyst is a catalyst that promotes the reaction between polyisocyanate and water to generate carbon dioxide gas. The foaming catalyst is not limited, and examples thereof include amine-based catalysts such as bis(2-dimethylaminoethyl)ether, triethylamine, dimethylaminoethoxyethanol, N,N,N′-trimethylaminoethyl-ethanolamine, and N,N,N′,N″,N″-entamethyldiethylenetriamine.
The resinification catalyst is a catalyst that promotes a urethanization reaction (resinification reaction) between polyol and isocyanate. The resinification catalyst is not limited, and examples thereof include amine-based catalysts such as triethylenediamine, 1,2-dimethylimidazole, N⋅(N′,N′-dimethylaminoethyl)-morpholine, tetramethylguanidine, dimethylaminoethanol, N-methyl-N′-(2hydroxyethyl)-piperazine, N,N,N′,N′-tetramethylpropane 1,3-diamine, N,N′-dimethylpiperazine, N,N,N′,N′-tetramethylhexane-1,6-diamine, N,N,N′,N″,N″-pentamethyldipropylene-triamine, N-(2-hydroxyethyl)morpholine, ethylene glycol bis(3-dimethyl)-aminopropyl ether, N,N-dimethylcyclohexylamine, and N-methyl-N′-(2dimethylamino)ethylpiperazine.
By using the foaming catalyst and the resinification catalyst in combination, the formability of the polyurethane foam can be made excellent. A total amount of the catalysts is preferably 0.3 parts by mass or more and 3.0 parts by mass or less with respect to 100 parts by mass of the polyol.
The foam stabilizer may be any one that is usually employed as a urethane foam raw material, and examples thereof include silicone-based compounds and nonionic surfactants. The amount of the foam stabilizer is preferably 0.2 parts by mass or more and 2.0 parts by mass or less with respect to 100 parts by mass of the polyol.
The crosslinking agent is blended to improve the hardness and tear strength of the polyurethane foam, and is particularly effective for increasing the hardness. The crosslinking agent is an optional component, and the stress relaxation rate and the hysteresis loss rate can be reduced without adding the crosslinking agent.
Examples of the crosslinking agent include polyhydric alcohols such as trimethylolpropane, glycerin, 1,4-butanediol, and diethylene glycol; and amines such as ethanolamines and polyethylene polyamines. Two or more crosslinking agents may be used. A total amount of the crosslinking agent is preferably 0.1 parts by mass or more and 6.0 parts by mass or less with respect to 100 parts by mass of the polyol.
The isocyanate is not particularly limited. As the isocyanate, MDI-based isocyanate (diphenylmethane diisocyanate-based isocyanate) is preferable. When the MDI-based isocyanate is used, the surface of the polyurethane foam can have a softer touch than when TDI (toluene diisocyanate) is used, for example.
Specific examples of the MDI-based isocyanate include: monomeric MDI such as 2,2′-diphenylmethane diisocyanate (2,2′-MDI), 2,4′-diphenylmethane diisocyanate (2,4′-MDI), and 4,4′-diphenylmethane diisocyanate (4,4′-MDI); polymeric MDI which is a mixture of diphenylmethane diisocyanate and polymethylene polyphenylene polyisocyanate; carbodiimide-modified products, urethane-modified products, urea-modified products, allophanate-modified products, biuret-modified products, and isocyanurate-modified products thereof; and MDI prepolymers obtained by reacting these isocyanates with polyols. A plurality of kinds of MDI-based isocyanates may be used in combination.
Among them, the isocyanate preferably contains carbodiimide-modified MDI, more preferably contains carbodiimide-modified MDI and polymeric MDI, and still more preferably contains carbodiimide-modified MDI, monomeric MDI, and polymeric MDI.
An isocyanate index (INDEX) is preferably 80 or more and 120 or less, and more preferably 90 or more and 110 or less.
The isocyanate index is a value obtained by multiplying a value, obtained by dividing the number of moles of isocyanate groups in isocyanate by a total number of moles of active hydrogen groups such as hydroxyl groups of polyol and water or the like as a foaming agent, by 100, and is calculated by [NCO equivalent of isocyanate/active hydrogen equivalent×100].
In addition, examples of additives to be appropriately blended include a flame retardant and a colorant.
The flame retardant is blended to reduce flammability of the polyurethane foam. Examples of the flame retardant include known liquid flame retardants and solid flame retardants. Examples thereof include: halogenated polymers such as polyvinyl chloride, chloroprene rubber, and chlorinated polyethylene; phosphoric acid esters and halogenated phosphoric acid ester compounds; organic flame retardants such as melamine resins and urea resins; and inorganic flame retardants such as antimony oxide and aluminum hydroxide. The flame retardant is not limited to one type, and two or more types may be used in combination. A total amount of the flame retardant is preferably 0.1 parts by mass or more and 6.0 parts by mass or less with respect to 100 parts by mass of the polyol.
The colorant is blended in order to make the polyurethane foam have an appropriate color, and a colorant corresponding to the desired color is used. Examples of the colorant include a pigment and graphite.
The physical properties of the polyurethane foam can be appropriately set according to the application and the like. The polyurethane foam is preferably a flexible polyurethane foam.
The polyurethane foam preferably has the following physical properties.
The hysteresis loss rate (JIS K 6400-2 B method) is preferably 20% or less, more preferably 15% or less, and still more preferably 10% or less. The lower limit of the hysteresis loss rate is not particularly limited, and is usually 5.0% or more.
The stress relaxation rate is preferably 15% or less, more preferably 10% or less, and still more preferably 5.0% or less. The lower limit of the stress relaxation rate is not particularly limited, and is usually 1.0% or more.
The stress relaxation rate (%) can be measured as follows.
A circular pressure plate with a diameter of 200 mm was used to compress a distance of 75% of an initial thickness of the polyurethane foam at a rate of 50 mm/min. Thereafter, a load was removed, and the polyurethane foam was left for 1 minute. The load was applied again at the same rate, the pressure plate was stopped at the time when a load of 196 N (20 kgf) was applied, and the load after leaving for 5 minutes was read. Then, the stress relaxation rate was calculated by the following formula.
Stress relaxation rate (%)=100−[load when pressure plate is stopped (196 N)−load after leaving for 5 minutes]/load when pressure plate is stopped (196 N)
The rebound elasticity (JIS K 6400-3) is preferably 5% or more and 80% or less, more preferably 10% or more and 50% or less, and still more preferably 15% or more and 30% or less.
25% hardness (JIS K 6400-2 D method) is preferably 10 N to 600 N, and more preferably 100 N to 400 N. When the 25% hardness is 600 N or less, flexibility is excellent, and it is preferable as the polyurethane foam.
An apparent core density (JIS K 7222) is preferably 10 kg/m3 to 150 kg/m3, and more preferably 30 kg/m3 to 80 kg/m3.
The tensile strength (JIS K 6400-5) is preferably 45 kPa or more, more preferably 70 kPa or more, and still more preferably 95 kPa or more.
The tear strength (JIS K 6400-5) is preferably 2.0 N/cm or more, more preferably 3.5 N/cm or more, and still more preferably 5.0 N/cm or more.
The elongation (JIS K 6400-5) is preferably 50% to 500%, more preferably 60% to 300%, and preferably 70% to 150%. When the elongation is 50% or more, flexibility is excellent, and it is preferable as the polyurethane foam.
A reason why the stress relaxation rate and the hysteresis loss rate are reduced in the polyurethane foam of the present disclosure is not clear, but is presumed as follows. However, the present disclosure is not to be construed as being limited by the presumed reason.
By using the polyol (a) having a content of the EO unit of 60 mol % or more, side chains in polyurethane molecules can be reduced, and entanglement of polyurethane molecules when a polyurethane foam is compressed is suppressed. Then, it is presumed that distortion due to the entanglement of polyurethane molecules is less likely to occur when the polyurethane foam is compressed, and the stress relaxation rate and the hysteresis loss rate are reduced.
The polyurethane foam can be produced by a known foaming method in which a polyurethane resin composition is stirred and mixed to react polyol with isocyanate. The foaming method includes slab foaming and mold foaming, and any molding method may be used.
The slab foaming is a method in which the mixed polyurethane resin composition is discharged onto a belt conveyor and foamed at normal temperature under atmospheric pressure.
On the other hand, the mold foaming is a method in which the mixed polyurethane resin composition is filled in a mold (molding die) and foamed in the mold. The molding method by the mold foaming is suitable for a molded article having a complicated three-dimensional shape. For example, this method is suitable for molding a cushion material such as a seat pad, bedding such as a pillow and a mattress, a cushion, a pad for a chair, and a pad for clothing.
An article in which the polyurethane foam of the present disclosure is used is not limited. The polyurethane foam is suitable for a seat pad, and is particularly suitable for a seat pad for a vehicle (automobile).
As performance of the seat pad for a vehicle, improvement of ride comfort associated with thinning is required. In order to improve ride comfort, it is important to suppress wobbling at the time of boarding and traveling. In order to suppress wobbling at the time of boarding and traveling, improvement of vibration absorption characteristics of the seat pad and improvement of posture stability at the time of seating are required. Reduction of the rebound elasticity is effective for improvement of the vibration absorption characteristics. In addition, reduction in the stress relaxation rate and the hysteresis loss rate is effective for improving the posture stability at the time of seating. The polyurethane foam of the present disclosure has characteristics of low stress relaxation rate and low hysteresis loss rate while having moderate rebound elasticity. Thus, the seat pad 10 including the polyurethane foam of the present disclosure can suppress wobbling at the time of boarding and traveling, and the ride comfort is good even when the thickness is reduced.
Hereinafter, the present disclosure will be specifically described with reference to examples. In Tables 1 and 2, when “*” is affixed as in “Experimental Example 1*”, it indicates that it is a comparative example. Experimental Examples 3, 4, 6 to 8, 10, and 11 are examples, and Experimental Examples 1, 2, 5, and 9 are comparative examples.
Compositions blended in the proportions shown in Tables 1 and 2 were prepared, and polyurethane foams of Examples and Comparative Examples were produced by mold foaming.
Details of each raw material are as follows. An EO unit content (mol %) of the polyol is shown as “EO rate” in the tables.
A test piece was cut out from the polyurethane foam produced using the above raw materials, and the hysteresis loss rate, the stress relaxation rate, the rebound elasticity, and the like were measured by the following methods. In Experimental Example 2, since demolding was not possible, physical properties were not evaluated.
The hysteresis loss rate (%) was measured according to JIS K 6400-2 B method. The smaller the numerical value, the better the posture stability at the time of seating.
The stress relaxation rate (%) was measured by the method described in the embodiment. The smaller the numerical value, the better the posture stability at the time of seating.
The rebound elasticity (%) was measured according to JIS K 6400-3.
The 25% hardness (N) was measured according to JIS K 6400-2 D method.
The apparent core density (kg/m3) was measured according to JIS K 7222.
The tensile strength (kPa), the tear strength (N/cm), and the elongation (%) were measured according to JIS K 6400-5.
The results are shown in Tables 1 and 2. The comprehensive evaluation was made as follows. In the comprehensive evaluation, the rebound elasticity of each of Experimental Examples 2 to 11 was evaluated based on the rebound elasticity (71.8%) of Experimental Example 1; however, a preferable value of the rebound elasticity is not limited thereto. The rebound elasticity of the polyurethane foam can be appropriately set according to the use or the like of the polyurethane foam.
In the polyurethane foams of Experimental Examples 3, 4, 6 to 8, 10, and 11, results by comprehensive determination were good. It was confirmed that by using 60 parts by mass or more and 95 parts by mass or less of the polyol (a) having an EO unit content of 60 mol % or more, the rebound elasticity was reduced, and the stress relaxation rate and the hysteresis loss rate were also reduced.
According to the above Examples, it is possible to provide a polyurethane foam having a reduced stress relaxation rate and a reduced hysteresis loss rate while having moderate rebound elasticity.
The present disclosure is not limited to Examples described in detail above, and can be modified or changed in various manners within the scope of the present disclosure.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2021-020786 | Feb 2021 | JP | national |
| 2021-072390 | Apr 2021 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2022/004708 | 2/7/2022 | WO |
