Process for producing integral skin polyurethane foam

BACKGROUND OF THE INVENTION
This invention relates to a process for producting an integral skin polyurethane foam.
Integral skin polyurethane foams produced by mixing an isocyanate, a polyether having active hydrogen, a blowing agent, a catalyst and the like, and conducting foaming and curing in a closed mold are excellent in thermal insulation, sound absorption, and strength, so that they are suitable for use as electric machinery and appliances, materials for electronic parts, building materials, etc. With recent development in reaction injection molding technique, applications of these foams are increasing remarkably. But one factor which restricts industrial applications of foamed polyurethane products is that the molding cycle is long, particularly the removal time of a foamed product from a mold (i.e., a time required for injecting the composition into the mold and taking out the foamed product from the mold) is long. That is to say, when a foamed product is taken out of a mold in a short time, there take place peeling of the skin, blister of the foam, generation of small voids on the surface, and the like, so that the molded material should be maintained in the mold for a long time compared with injection molding of thermoplastic resins.
In order to shorten the removal time of the foamed products from the mold, there have been proposed various processes such as increasing the amount of a catalyst, using a catalyst having high activity, raising the liquid temperature, and the like, but these processes also had disadvantages such as the flowability of the foam being lowered, surface properties of the foam becoming worse, and the like.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a process for producing an integral skin polyurethane foam which is excellent in surface properties, and flowability and which can be taken out of the mold in a short time overcoming the disadvantages mentioned above.
This invention provides a process for producing an integral skin polyurethane foam which comprises
impingement mixing at least two solutions one of which (a solution A) comprises polyols containing as an essential component at least one polyol of an alkylene oxide adduct of an aromatic amine having the formula: ##STR1## wherein R is hydrogen or a lower alkyl group; R' is an aromatic residue; and m, n, p and q are independently an integer of 1 or more, a blowing agent and as a catalyst at least one tertiary amine salt having a hetero ring in the molecule, and another of which (a solution B) comprises one or more polyisocyanates,
injecting the resulting impingement mixed solution into a closed mold, and
conducting foaming and curing in the closed mold.

BRIEF DESCRIPTION OF THE DRAWINGS
In the attached drawings,
FIG. 1 is a diagrammatic illustration of a liquid reaction injection apparatus for producing an integral skin polyurethane foam according to this invention,
FIG. 2 is a graph showing rising behavior of foams when foamed freely,
FIG. 3 is a graph showing changes of surface hardness of foams with the lapse of time, and
FIG. 4 is a graph showing a relationship between temperature properties of dynamic modulus and a glass transition temperature.

DESCRIPTION OF THE PREFERRED EMBODIMENTS
In order to shorten the removal time of foamed products from the mold in this invention, there is used the special composition containing the alkylene oxide adducts of aromatic amine having the formula (I) as an essential component in the polyol component together with a tertiary amine salt as a reaction accelerator.
This invention is explained in detail referring to individual components for forming integral skin polyurethane foams.
As the polyols, it is necessary to use (a) the alkylene oxide adduct of aromatic amine having the formula: ##STR2## In the formula (I), a preferable example of R' is ##STR3## R is hydrogen or a lower alkyl group preferably having 1-5 carbon atoms, for example, a methyl group; and p, q, m and n are independently integer of preferably 1 to 10. As the alkylene oxide, there can be used ethylene oxide (EO), propylene oxide (PO), butylene oxide, epichlohydrin, and the like.
Concrete examples of the polyol (a) of alkylene oxide adducts of aromatic amines are ethylene oxide or propylene oxide adduct of diaminodiphenylmethane, ##STR4## R=H, CH.sub.3 m, n, p, q= 1 to 10
ethylene oxide or propylene oxide adduct of tolylenediamine, ethylene oxide or propylene oxide adduct of xylylenediamine, and the like. Among these polyols (a), the ethylene oxide or propylene oxide adducts of diaminodiphenylmethane represented by the formula (II) are preferable. These polyols (a) can be prepared by a conventional process by reacting an alkylene oxide such as ethylene oxide, propylene oxide, etc., with an aromatic amine in the presence of a basic catalyst such as KOH.
As the polyols, there can be used (b) alkylene oxide (e.g. ethylene oxide, propylene oxide, butylene oxide, epichlorohydrin, etc.) adduct of aliphatic amines such as monoethanolamine, triethanolamine, ethylenediamine, triethylenetetramine, ammonia, hexamethylenediamine, diethylenetriamine, etc.
These polyols (b) can be prepared by reacting an aliphatic amine with an alkylene oxide in the presence of a basic catalyst such as KOH according to a conventional process.
As the polyols, there can also be used (c) conventionally used polyether polyols and polyester polyols, e.g., alkylene oxide (e.g. ethylene oxide, propylene oxide, butylene oxide, epichlorohydrin, etc.) adduct of glycerin, trimethylolpropane, pentaerythritol, diglycerin, sorbitol, sucrose, phenol, etc. It is also possible to use other polyols as the polyols (c) described in J. H. Saunders and K. C. Frish "Polymethanes Chemistry and Technology, Part I, Chemistry; Part II Technology," Robert E. Krieger Publishing Company, Huntington, N.Y., 1978; David Staly "Analytical Chemistry of the Polyurethanes, Polymethanes: Part III," Robert E. Krieger Publishing Company, Huntington, N.Y., 1979; and K. Iwata "LECTURES ON PLASTICS MATERIALS II: Polymethane Resins" published by Nikkan Kogyo Shinbun-sha, 1975.
As for the hydroxyl value of the polyols, it is preferable to use the polyols as a whole having an average hydroxyl value of 380 to 760 KOH mg/g. When the average hydroxyl value is too small such as lower than 380 KOH mg/g, the glass transition temperature of the produced foam becomes undesirably lower than 100.degree. C., which easily makes the foam blistered at the time of removing the foam from the mold. On the other hand, when the average hydroxyl value is too large such as larger than 760 KOH mg/g, mold flashes are easily retained on the surface of the mold undesirably.
It is preferable to use the polyol (a) derived from an aromatic amine in an amount of 20 to 80 parts by weight and the polyol (b) derived from an aliphatic amine in an amount of 5 to 70 parts by weight and the polyol (c) in an amount of 0 to 50 parts by weight. By compounding 20 parts by weight or more of the polyol (a) derived from an aromatic amine, the hardness of foamed product at the time of removal from the mold becomes higher, which results in remarkably reducing breakage of molded articles by ejector pin. But when the amount of the polyol (a) is too large, the viscosity of the solution A becomes too high to conduct impingement mixing sufficiently. Since the polyol (b) derived from an aliphatic amine has a catalytic effect by itself, if the amount of the polyol (b) is too small, it cannot be expected a synergistic effect for shortening the removal time from a mold caused by together with a tertiary amine salt having hetero ring in the molecule.
As the isocyanates, there can be used diisocyanates, trifunctional or higher polyfunctional polyisocyanates alone or as a mixture thereof. Examples of the polyisocyanates are 4,4'-diphenylmethane diisocyanate (MDI) obtained by reacting a reaction product of aniline and formaldehyde with phosgene, polyphenylenepolymethylene polyisocyanate, carboxyimidized MDI, xylylene diisocyanate, isophorone diisocyanate, tolylene diisocyanate, and the like. Among these polyisocyanates, those of the formula: ##STR5## wherein l is 0.3 to 0.8, carbodiimidized MDI, and 4,4'-diphenylmethane diisocyanate are preferable.
The mixing ratio of said polyisocyanate to said polyol components is preferably in the range of 0.95-1.30/l in terms of isocyanate index (a molar ratio of NCO groups in the isocyanate compound to OH groups in the polyols and water).
As the catalyst, it is necessary to use at least one tertiary amine salt having a hetero ring in the molecule. Examples of tertiary amines having a hetero ring in the molecule are diaza-bicyclo-alkenes such as 1,4-diazabicyclo[2,2,2]octane (triethylenediamine), 1,8-diazabicyclo[5,4,0]-undecene-7 (DBU), 1,5-diazabicyclo[4,2,0]octene-5, 1,8-diazabicyclo[7,2,0]undecene-8, 1,4-diazabicyclo[3,3,0]octene-4, 3-methyl-1,4-diazabicyclo[3,3,0]octene-4, 3,6,7,7-tetramethyl-1,4-diazabicyclo[3,3,0]octene-4, 7,8,8-trimethyl-1,5-diazabicyclo[4,3,0]nonene-5, 1,8-diazabicyclo[7,3,0]dodecene-8, 1,7-diazabicyclo[4,3,0]nonene-6, 1,5-diazabicyclo-[4,4,0]decene-5, 1,8-diazabicyclo[7,4,0]tridecene-8, 1,8-diazabicyclo[5,3,0]decene-7, 9-methyl-1,8-diazabicyclo[5,3,0]decene-7, 1,6-diazabicyclo[5,5,0]tridecene-6, 1,7-diazabicyclo[6,5,0]tridecene-7, 1,8-diazabicyclo-[7,5,0]tetradecene-8, 1,10-diazabicyclo[7,3,0]dodecene-9, 1,10-diazabicyclo[7,4,0]tridecene-9, 1,14-diazabicyclo[11,3,0]hexadecene-13, 1,14-diazabicyclo[11,4,0]-heptadecene-13; imidazoles such as 1-methylimidazole, 2-methylimidazole, 1,2-dimethylimidazole, 2-ethylimidazole, 2-ethyl-4-methylimidazole, etc. These compounds are characterized by having a nitrogen-containing ring structure in which the direction of unpaired electrons of nitrogen is fixed to some extent. These tertiary amines are used in the form of salts obtained by adding thereto a weak acid such as acid, formic acid, oxalic acid, propionic acid, phosphoric acid, 2-ethylhexoic acid, or the like, a strong acid such as nitric acid, hydrochloric acid, or the like, or a compound having a phenolic hydroxyl group such as phenol, cresol, or the like. The acids which are used in combination with the tertiary amines having a hetero ring in the molecule include Lewis acids and Bte,uml/o/ nsted acids. By masking the lone pair of the tertiary amine with an acid (i.e., in the form of salt of tertiary amine), the catalytic activity can be enhanced with an increase of temperature and the curing properties of the material can be enhanced without lowering flowability of the material.
The above-mentioned diaza-bicyclo-alkene phenol salts are disclosed in e.g., Japanese Patent Appln Kokoku (Post-Exam Publn) No. 40554/70 so as to improve a bad odor of tertiary amines. But in this invention, these tertiary amine salts are used in combination with the polyols (a) derived from aromatic amines and the polyols (b) derived from aliphatic amines in order to shorten the removal time of foamed products from the mold. The above-mentioned tertiary amine salts can be used along or in combination with one or more other conventionary used compounds having catalytic activity.
Examples of the conventional catalysts are triethylenediamine, dimethylethanolamine, morpholines, pyperidines, tin compounds such as dibutyltin dilaurate, dibutyltin acetate, tin octoate, etc.
The above-mentioned tertiary amine salt is used as a catalyst in an amount of 0.2 to 10 parts by weight per 100 parts by weight of the total polyol components. The conventional catalysts can be used in an amount of 0.2 to 10 parts by weight per 100 parts by weight of the total polyol components.
As foam stabilizers, there can be used conventional ones such as silicon compounds, e.g., various alkylene oxide modified polydimethylsiloxanes, fluorine series surface active agents. These foam stabilizers can be used in an amount of 1 to 5 parts by weight per 100 parts by weight of the total polyol components.
As blowing agents, there can be used water, low-boiling organic liquid compounds (halogenated hydrocarbons) such as trichloromonofluoromethane, dichlorodifluoromethane, methylene chloride, trichlorotrifluoroethane, tetrachlorodifluoroethane, etc., compounds which can generate nitrogen by decomposition such as azobisisobutyronitrile, etc. The blowing agent such as low-boiling organic liquid compounds is preferably used in an amount of 5 to 45 parts by weight per 100 parts by weight of the total polyol components. In the case of using water, 0.2 to 5 parts by weight of water can be used based on 100 parts by weight of the total polyol components. The compounds which can generate nitrogen by decomposition can be used in an amount of 5 to 20 parts by weight based on 100 parts by weight of the total polyol components. By changing the compounding amount of the blowing agent, there can be produced various foamed products having different densities. Among these blowing agents, halogenated hydrocarbons having lower boiling points (0.degree. to 60.degree. C.) are more preferable, since they can give strong skin to the foamed products.
Other additives conventionally used such as one or more fillers, pigments, dyes, fire retardants, ultraviolet light absorbers, etc., can be used in this invention. Such additives can be used by mixing them with either the polyol components or the polyisocyanate, or used as separate component (solution C) for impingement mixing.
According to this invention, the solution A containing the polyol components as major components and the solution B containing the polyisocyanate as major component, and if necessary a third solution (C) containing additives should be mixed in a very short time, i.e., should be impingement mixed by using, for example, a reaction injection molding machine, since the time required for from the mixing to gelation is remarkably short. When a known mixing method by using a low-pressure foaming machine is employed, no good integral skin foam cannot be obtained by using the composition used in this invention, since a longer time is necessary for mixing and the mixing efficiency is low.
The composition used in this invention is particularly effective for producing rigid integral skin foam and said composition cannot be thought of from various experiences for producing usual uniform foams, semi-rigid or flexible foams.
The process of this invention will be explained concretely referring to FIG. 1, which is a diagrammatic illustration of a liquid reaction injection apparatus used for practising the process of this invention. When the raw material liquids are not injected, the solution A comprising the polyols, the blowing agent, the catalyst, etc., stored in a raw material liquid tank 1 and the solution B comprising the polyisocyanate as major component stored in a raw material liquid tank 3 are transported to a mixing head 8 by individual high-pressure metering pumps 6, and then returned to the raw material liquid tanks 1 and 3 through individual heat exchangers 5 which are connected to a temperature regulator 11. When the raw material liquids are injected, the mixing head 8 is operated by an oil pressure unit 7 to inject the impingement mixed raw material liquids into a cavity 20 formed by a closed mold 10 placed between a clamping unit 9.
Foaming and curing of the injected raw materials in the cavity can be conducted according to a conventional process.
The raw material composition used in this invention (i.e., the solutions A and B mentioned above and, if necessary the solution C mentioned above) has special properties quite different from those of known compositions. This is clearly shown in the attached FIGS. 2 and 3. FIG. 2 shows foaming behaviors of foams when foamed freely and FIG. 3 shows changes of surface hardness of foams (Shore D) with the lapse of time. In FIGS. 2 and 3, numerals 21 and 23 indicate the cases when the raw material compositions used in this invention are used, and numerals 22 and 24 indicate the case when known raw material compositions are used. There is no difference between densities of foamed products from the composition according to this invention and that according to the known process when foamed freely. But the features when the composition according to this invention is used are that although a time required for beginning foaming (a time required for the composition for beginning rising-hereinafter referred to as "CT (cream time)") is long, a time required for completing foaming (hereinafter referred to as "RT (rise time)") is short, i.e., a ratio of RT/CT is smaller and an increasing rate of surface hardness of the produced foam is remarkably large. This means that when integral skin foams are produced by using the composition according to this invention, the removal time of foamed products from the mold can be shortened and the resulting foams are excellent in surface properties.
Reaction injection molding machines usable in this invention are manufactured, for example, by Maruka Kako-Sha K.K. (Japan), Toho Kikai K.K. (Japan), Cincinnati Milacron Inc. (U.S.), Battenfeld Maschinenfabriken GmbH (West Germany), Elastogran Machinebau (West Germany), Maschinenfabrik Hennecke GmbH (West Germany), Krauss-Maffei AG (West Germany), etc.
As the molds, there can be used those made of metals such as aluminum, iron, or the like; those made from resins such as silicone rubber, epoxy resin, and the like; and those made of wood, etc.
According to this invention, since the special raw material composition, particularly special in the polyol components and the catalyst, is used, the mold temperature can be raised from the conventional mold temperature of about 45.degree. to 50.degree. C. to as high as 55.degree. to 80.degree. C. When foam molded at low temperature such as 45.degree.-50.degree. C., there is a tendency to retain fins in the mold. In order to remove such fins from the mold, a much time is required, which results in making the molding cycle undesirably longer. When the mold temperature is raised higher, there is a tendency that fins are not retained in the mold. But when the known raw material compositions are used, blisters are easily formed on the foam molded products due to the higher mold temperature. Therefore, it was not possible to raise the mold temperature, so long as the known raw material compositions were used. But, it is a surprising thing that the mold temperature can be raised to 55.degree. to 80.degree. C. when the raw material composition according to this invention is used.
If the mold temperature is too high, e.g., higher than 80.degree. C., there is a tendency to lower the density of the skin layer of the resulting foam undesirably and fail to produce tough integral skin foamed articles.
By raising the mold temperature to 55.degree. C. or higher, the glass transition temperature of the skin of the foam produced becomes 100.degree. C. or higher. The glass transition temperature (Tg) of the skin of the foam can be obtained from the temperature at which dynamic modulus of the skin of 1 to 2 mm in thickness (measured at vibration wave: sign wave, vibration frequency: 10 Hz, temperature rise rate: 1.5.degree. C./min) begins to lower rapidly. The dynamic modulus (E) of the skin of a rigid integral skin polyurethane foam changes as shown in FIG. 4 and the glass transition temperature is shown by Tg in FIG. 4.
This invention is illustrated by way of the following Examples, in which all parts and percents are by weight unless otherwise specified. Particularly, the unit of figures in Tables 2, 4 and 6 is parts by weight.
EXAMPLE 1
Using the composition shown in Table 2, rigid integral skin polyurethane foams were produced by using apparatus and conditions as shown in Table 1. The foams having excellent properties as shown in Table 3 were produced in a short time.
More concretely, the solution A obtained by well mixing 30 parts of PO (propylene oxide) adduct of monoethanolamine (OH value 650 KOH mg/g), 40 parts of PO adduct of tolylenediamine (OH value 440 KOH mg/g), 30 parts of PO adduct of glycerin (OH value 513 KOH mg/g), 1.0 part of oxyalkylene adduct of polydimethylsiloxane, 15 parts of trichloromonofluoromethane, 0.25 part of phenol salt of 1,8-diazabicyclo[5,4,0]undecene-7 (DBU) and 0.75 part of triethylenediamine was impingement mixed with the solution B containing 140 parts of crude MDI (NCO content 30.5%) in a mixing ratio of the solution B/the solution A being 1.21 using a reaction injection molding machine (RIM machine) to give rigid integral skin polyurethane foams having an average density of 0.35 g/cm.sup.3. The total polyols in the raw material composition had a OH value of 524.9 KOH mg/g on an average. The reactivity (RT/CT ratio) was 3.4.
When the mold temperature was 48.degree. C., foams having no blister, no crack and no peeling of the skin with high surface gloss were obtained when the mold removal time (the removal time of foams from the mold) was as short as 2 min 45 sec. or more, while when the mold temperature was 55.degree. C., foams were also able to be formed without blister, cracks and peeling of the skin with the mold removal time of 2 min 45 sec. or longer contrary to the case of using known raw material compositions.
The surface hardness (Shore D) of foams measured at 3 min. 15 sec. after the mixing of the solutions A and B was as high as 56. Glass transition temperature, flexural strength and flexural modulus measured after allowed to stand the foams at room temperature for 24 hours were as good as 113.degree. C., 195 kg/cm.sup.2 and 68.times.10.sup.2 kg/cm.sup.2, respectively. When foams were removed from the mold with the mold removal time of 2 min. 30 sec. (mold temperature 55.degree. C.), most of the fins were attached to the molded articles (foams) and scarcely retained on the mold surface, which resulted in making the cleaning of the mold remarkably easy.
EXAMPLES 2 TO 16
Rigid integral skin polyurethane foams were produced in the same manner as described in Example 1 by using the compositions shown in Table 2 and the apparatus and conditions as listed in Table 1. The foams were obtained in a short time and had excellent properties as shown in Table 3.
These compositions used therein were small in the RT/CT ratio and even when the foams were removed from the mold in a short time, no destruction of foams nor blisters were taken place. Further the foams had good surface gloss. The surface hardness measured after 3 min. 15 sec. of the mixing showed high values. Further, the foams had good values in the glass transition temperature, flexural strength and flexural modulus. When foams were removed from the mold with the mold removal time of 2 min. 30 sec. (mold temperature 60.degree.-65.degree. C.), most of the fins were attached to the molded articles (foams) and scarcely retained on the mold surface, which resulted in making the cleaning of the mold remarkably easy.
TABLE 1______________________________________Item Contents______________________________________Appa- Mold Made of steel,ratus Cavity, inside size: 50 cm .times. 80 cm .times. 1.0 cm Reaction injec- RIM machine SH-15 type tion molding manufactured by Battenfeld machine Maschinenfabriken GmbH (West Germany)Mold- Mold temperature 55-80.degree. C., 48.degree. C. ing condi- ##STR6## 25.degree. C. 25.degree. C.tions Impingement mix- 190 kg/cm.sup.2 ing pressure Injection speed 460 g/secMeas- CT, RT Values were measured, whenuring foamed freely. Measuringmeth- temp. 25.degree. C. Open mold,ods 20 cm .times. 20 cm .times. 20 cm, made of wood was used. Surface proper- Observed by the naked eye. ties of a foam Surface hardness Shore D hardness meter Glass transition Dynamic modulus (E): temperature Viscoelastisity spectro- meter, mfd. by Iwamoto Seisakusho. vibration wave: sign wave, vibration frequency: 10 Hz temp. rise rate: 15.degree. C./min. See FIG. 4. Flexural strength ASTM D790 Flexural modulus " State of fin gene- Observed by the naked eye generated at molding______________________________________
TABLE 2__________________________________________________________________________ Example No.Solu-tion Kind Name 1 2 3 4 5 6 7 8__________________________________________________________________________Solu- Polyol PO*.sup.1 adduct of ethylenediamine -- 40 -- -- -- -- -- --tion derived (OH value: 540 KOH mg/g)A from EO**.sup.2 adduct of ethylenediamine -- -- 40 -- -- -- -- -- aliphatic (OH value: 580 KOH mg/g) amine PO adduct of monoethanolamine 30 -- -- 15 40 60 40 40 (OH value: 650 KOH mg/g) PO adduct of triethanolamine -- -- -- -- -- -- -- -- (OH value: 430 KOH mg/g) Polyol PO adduct of 4,4'-diaminodiphenyl- -- 30 30 40 40 30 40 40 derived methane (OH value: 430 KOH mg/g) from PO adduct of tolylenediamine 40 -- -- -- -- -- -- -- aromatic (OH value: 440 KOH mg/g) amine General PO adduct of sorbitol -- -- -- -- -- -- -- -- polyol (OH value: 480 KOH mg/g) PO adduct of glycerin 30 30 30 25 -- -- -- -- (OH value: 513 KOH mg/g) PO.EO adduct of glycerin -- -- -- 20 20 10 20 20 (OH value: 60 KOH mg/g, PO/EO molar ratio: 2/1) Foam Oxyalkylene adduct of polydimethyl- 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 stabilizer siloxane Blowing H.sub.2 O -- -- -- -- -- -- -- -- agent Trichloromonofluoromethane 15 25 25 25 25 25 25 25 Catalyst Phenol salt of DBU*.sup.3 0.25 3.0 1.5 3.5 3.0 2.5 -- -- 2-Ethylhexanoate of DBU -- -- -- -- -- -- 3.0 -- Formate of triethylenediamine -- -- 0.75 -- -- -- -- 3.0 Phenol salt of triethylenediamine -- -- -- -- -- -- -- -- Triethylenediamine 0.75 -- -- -- -- -- -- -- Pentamethyldiethyltriamine -- -- -- -- -- -- -- --Solu- Polyiso- Crude MDI*.sup.4 (NCO content: 30.5 wt %) 140 -- -- -- -- -- -- --tion cyanate Crude MDI*.sup.5 (NCO content: 30.5 wt %) -- 133 137 109 118 140 105 118B Carbodimide modified MDI -- -- -- -- -- -- -- -- (Carbodiimidization: 30 wt %, NCO content: 30 wt %)__________________________________________________________________________ Example No.Solu-tion Kind Name 9 10 11 12 13 14 15 16__________________________________________________________________________Solu- Polyol PO*.sup.1 adduct of ethylenediamine -- -- -- -- -- -- -- --tion derived (OH value: 540 KOH mg/g)A from EO**.sup.2 adduct of ethylenediamine -- -- -- -- -- -- -- -- aliphatic (OH value: 580 KOH mg/g) amine PO adduct of monoethanolamine 40 40 40 40 40 40 40 40 (OH value: 650 KOH mg/g) PO adduct of triethanolamine -- -- -- -- -- -- -- -- (OH value: 430 KOH mg/g) Polyol PO adduct of 4,4'-diaminodiphenyl- 40 40 40 40 40 40 40 40 derived methane (OH value: 430 KOH mg/g) from PO adduct of tolylenediamine -- -- -- -- -- -- -- -- aromatic (OH value: 440 KOH mg/g) amine General PO adduct of sorbitol -- -- -- -- -- -- -- -- polyol (OH value: 480 KOH mg/g) PO adduct of glycerin -- -- -- -- -- -- -- -- (OH value: 513 KOH mg/g) PO.EO adduct of glycerin 20 20 20 20 20 20 20 20 (OH value: 60 KOH mg/g, PO/EO molar ratio: 2/1) Foam Oxyalkylene adduct of polydimethyl- 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 stabilizer siloxane Blowing H.sub.2 O -- -- -- 0.5 0.25 -- -- 1.0 agent Trichloromonofluoromethane 25 25 25 8 15 25 25 -- Catalyst Phenol salt of DBU*.sup.3 -- 1.0 1.0 1.5 1.5 1.5 3.0 1.5 2-Ethylhexanoate of DBU -- -- -- -- -- -- -- -- Formate of triethylenediamine -- -- -- -- -- -- -- -- Phenol salt of triethylenediamine 3.0 -- -- -- -- -- -- -- Triethylenediamine -- 0.75 -- 0.5 0.5 0.5 -- 0.5 Pentamethyldiethyltriamine -- -- 2.0 -- -- -- -- --Solu- Polyiso- Crude MDI*.sup.4 (NCO content: 30.5 wt %) -- -- -- -- -- -- -- --tion cyanate Crude MDI*.sup.5 (NCO content: 30.5 wt %) 118 118 118 127 123 -- -- 135B Carbodimide modified MDI -- -- -- -- -- 122 122 -- (Carbodiimidization: 30 wt %, NCO content: 30 wt %)__________________________________________________________________________ Note to Table 2 *.sup.1 PO = propylene oxide *.sup.2 EO = ethylene oxide *.sup.3 DBU = 1,8diazabicyclo[5.4.0]undecene 7 *.sup.4 MDI = 4,4'-diphenylmethane diisocyanate ##STR7## (l = 0.3 on an average) *.sup.5 MDI = 4,4'-diphenylmethane diisocyanate ##STR8## (l = 0.6 on an average)
TABLE 3 Example No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Mixing ratio (Solution B/Solution A) weight ratio 1.21 1.03 1.07 0.84 0.91 1.08 0.81 0.91 0.91 0.91 0.91 1.12 1.03 0.95 0.95 1.29 Reactivity (RT/CT) 3.4 3.3 3.5 3.2 3.8 3.9 3.2 3.5 3.8 3.3 3.4 3.9 4.0 4.2 3.4 3.9 Average OH value of total polyols (KOH mg/g) 524.9 498.9 514.9 409.8 444 525 444 444 444 444 444 444 444 444 444 444 Average density of foam (g/cm.sup.3) 0.35 0.35 0.35 0.30 0.3 0.30 0.30 0.30 0.30 0.30 0.30 0.35 0.35 0.30 0.30 0.60 Pro- Surface pro- Mold temperature (.degree.C.) 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 perties perties of foam 2 min x x x x x x x x x x x x x x x c of at various 2 min 15 sec x .circle. .circle. .circle. .circle. .circle. .circle. .circle. .circle. .circle. .circle. .circle. .circle. .circle. .circle. .circle. integ- removal time 2 min 30 sec .circle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circle. ral of foam from 2 min 45 sec .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. skin the mold *1 2 min 50 sec .circlein circle. .circleincircle. .circleincircle. .circleincircle. .circleincircl e. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. foam 3 min .circleinc ircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle . .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. Surface pro- Mold temperature (.degree.C.) 55 60 60 65 65 65 65 65 65 65 65 65 65 65 65 65 perties and 2 min x .circle. .circle. .circle. .circle. .circle. .circle. .circle. .circle. .circle. .circle. .circle. .circle. .circle. .circle. .circle. state of fin of 2 min 15 sec .circle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circle. foam at various 2 min 30 sec .circle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. removal time of 2 min 45 sec .circleincircle. .circleincircle. .circleincircle. .circleinci rcle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. foam from the 2 min 50 sec .circleincircle. .circleincircle. .circleincir cle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. mold *1 3 min .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. State of fin when .circle. .circle. .circle. .circle. .circle. .circle. .circle. .circle. .circle. .circle. .circle. .circle. .circle. .circle. .circle. .circle. removed from the mold at 2 min 30 sec *2 Surface hardness (Shore D) 56 60 60 58 55 56 55 54 53 54 54 57 62 52 53 55 Glass transition temperature (.degree.C .) 113 105 110 105 110 115 104 109 110 108 104 108 105 101 100 120 Flexural strength (kg/cm.sup.2) 195 198 200 180 178 168 169 170 170 170 172 210 220 169 165 410 Flexural modulus (10.sup.2 kg/cm.sup.2) 72 75 74 68 65 67 65 64 65 62 58 68 70 62 65 120 Note to Table 3 *1: x: Blisters, cracks, or peeling of the skin took place. .circle.: No blister, crack, nor peeling but relatively poor in surface gloss .circleincircle.: No blister, crack, nor peeling and good in surface glos *2: .circle.: Fins were almost attached to a molded product (foam) and almost no fin was retained in the mold.
EXAMPLES 17 TO 19
Rigid integral skin polyurethane foams were produced in the same manner as described in Example 1 by using the compositions shown in Table 4 and the apparatus and conditions as listed in Table 1. The foams were obtained in a short time and had excellent properties as shown in Table 5.
The compositions used therein were small in the RT/CT ratio. When the mold temperature was raised to 60.degree., 70.degree. and 80.degree. C., the foams having no destruction nor blisters but with good surface gloss could be removed from the mold at the mold removal time of 2 min, 1 min 45 sec and 1 min 45 sec. The surface hardness measured after 3 min 15 sec of the mixing showed high values. The density of the foams was good in uniformity. Further, the foams had good values in the glass transition temperature, flexural strength and flexural modulus. When the foams were removed from the mold in a short time, fins were scarcely retained on the mold surface as shown in Table 5.
EXAMPLES 20 AND 21.
Rigid integral skin polyurethane foams were produced in the same manner as described in Example 1 by using the compositions shown in Table 4 and the apparatus and conditions as listed in Table 1. The foams having excellent properties as shown in Table 5 were obtained in a short time. When the foams were removed from the mold in a short time, fins were scarcely retained on the mold surface as shown in Table 5.
TABLE 4__________________________________________________________________________ Example No.Solu-tion Kind Name 17 18 19 20 21__________________________________________________________________________Solu- Polyol deriv- PO adduct of monoethanol- 40.5 40.5 40.5 50 60tion ed from amineA aliphatic (OH value: 440 KOH mg/g) amine Polyol deriv- PO adduct of 4,4'-diamino- 34.5 34.5 34.5 40 40 ed from diphenylmethane aromatic (OH value: 440 KOH mg/g) amine General PO.EO adduct of glycerin 25.0 25.0 25.0 10 -- polyol (OH value: 58 KOH mg/g) (PO/EO molar ratio = 2/1) Foam Oxyalkylene adduct of poly- 2.0 2.0 2.0 2.0 2.0 stabilizer dimethylsiloxane Blowing H.sub.2 O 0.25 0.25 0.25 0.25 -- agent Trichloromonofluoromethane 8.0 8.0 8.0 8.0 8.0 Catalyst Phenol salt of DBU 0.25 0.25 0.25 0.3 0.3 Dipropylene glycol solution 2.0 2.0 2.0 3.0 3.0 of DABCO *.sup.1 (DABCO content: 33.3 wt %) Black Glycerin PO adduct of 2.0 2.0 2.0 2.0 2.0 pigment carbon black (Carbon black amount: 30 wt %)Solu- Polyiso- Crude MD1 136 136 136 165 184tion cyanate (NCO content: 31 wt %)B (Average functional group number: 2.6)__________________________________________________________________________ Note *.sup.1 DABCO = 1,4diazabicyclo[2,2,2]octane
TABLE 5__________________________________________________________________________Example No. 17 18 19 20 21__________________________________________________________________________Mixing ratio (Solution B/Solution A) 1.18 1.18 1.18 1.46 1.63weight ratioReactivity (RT/CT) 3.5 3.5 3.5 3.9 3.9Average OH value of total polyols 514.6 514.6 514.6 611.8 692(KOH mg/g)Average density of foam (g/cm.sup.3) 0.36 0.36 0.36 0.36 0.36Mold temperature (.degree.C.) 48 60 70 80 70 80Surface properties 1 min 30 sec -- .circle. .circle. .circle. .circle. .circle.of foam at 1 min 45 sec -- .circle. .circleincircle. .circleincircle. .circle. .circle.various removal 2 min .circle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle.time of foam 2 min 15 sec -- .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle.from the mold *1 2 min 30 sec .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle. 3 min .circleincircle. -- -- -- -- -- 3 min 30 sec .circleincircle. -- -- -- -- --State of fin of 1 min 30 sec -- .circle. .circle. .circleincircle. .circle. .circle.foam when removed 2 min 30 sec -- .circleincircle. .circleincircle. .circleincircle. .circleincircle. .circleincircle.from the mold *2Surface hardness (Shore D) 62 68 69 70 72Glass transition temperature (.degree.C.) 125 125 125 130 130Flexural strength (kg/cm.sup.2) 200 200 200 220 220Flexural modulus (10.sup.2 kg/cm.sup.2) 68 68 68 70 72__________________________________________________________________________ Note *1: See Table 3 *2: .circleincircle. No fin was retained in the mold .circle. Fins were almost attached to a molded product and almost no fin was retained in the mold.
EXAMPLE 22
Rigid integral skin polyurethane foams were produced by using the composition of Example 17 shown in Table 4 except for using a PO adduct of tolylenediamine (OH value 440 KOH mg/g) in place of the PO adduct of 4,4'-diaminodiphenylmethane and the mixing ratio of 0.90 in place of 1.18 and by using also the apparatus and conditions as listed in Table 1. The reactivity (RT/CT ratio) was 3.6.
The average density of the foams was 0.36 g/cm.sup.3. When foams were removed from the mold (mold temperature 48.degree. C.) with the mold removal time of 3 min, the foams had no blister, cracks nor peeling of the skin layer but had good surface gloss. When the mold temperature was raised to 60.degree. C., there were obtained foams having good surface gloss without blisters, cracks and the peeling of the skin layer with the mold removal time of 2 min 15 sec. The surface hardness (shore D) of foams measured at 3 min 15 sec after the mixing of the solutions A and B was as high as 60. The density of the foams was good in uniformity. The foams had the glass transition temperature of 120.degree. C., the flexural strength of 180 kg/cm.sup.2 and the flexural modulus of 65.times.10.sup.2 kg/cm.sup.2, these values being good. When the mold temperature was 60.degree. C., foams could be removed from the mold with the mold removal time of 2 min 15 sec or longer scarcely retaining fins on the mold surface. Thus the cleaning of the mold was very easy. Comparative Examples 1 to 5
Integral skin foams were produced in the same manner as described in Example 1 by using the compositions shown in Table 6 and the apparatus and conditions as listed in Table 1. Properties of the resulting foams were as shown in Table 7.
The foams had almost the same values as those obtained in the Examples as to the glass transition temperature, the flexural strength and the flexural modulus, but these foams showed either blisters or poor surface gloss when removed from the mold with the mold removal time of 3 min. In Comparative Example 2, voids were observed on the surface. Further the surface hardness measured after 3 min 15 sec from the mixing of the solutions A and B was almost lower than those of the Examples. As to the reactivity, the value of RT/CT ratio was larger than those of the Examples. When foams were removed from the mold with the mold removal time of 2 min 30 sec, considerable amount of fins were retained in the mold surface, which resulted in making the cleaning of the mold time consuming. When the mold temperature was raised to 55.degree. C., blisters were formed on the surface of the resulting foam.
TABLE 6__________________________________________________________________________Solu- Comparative Example No.tion Kind Name 1 2 3 4 5__________________________________________________________________________Solu- Polyol PO adduct of ethylenediamine 40 -- 40 -- --tion derived (OH value: 540 KOH mg/g)A from PO adduct of triethanolamine -- -- -- 30 -- aliphatic (OH value: 430 KOH mg/g) amine General PO adduct of sorbitol 20 40 20 40 40 polyol (OH value: 480 KOH mg/g) PO adduct of glycerin 40 60 40 30 60 (OH value: 513 KOH mg/g) Foam Oxyalkylene adduct of 1.0 1.0 1.0 1.0 1.0 stabilizer polydimethylsiloxane Blowing H.sub.2 O -- -- -- 0.5 1.0 agent Trichloromonofluoromethane 25 25 25 8 -- Catalyst Triethylenediamine 3.0 -- -- 3.0 -- Pentamethyldiethylenetriamine -- -- 3.0 -- 2.5 Phenol salt of triethylene- -- 3.0 -- -- -- diamineSolu- Polyiso- Crude MDI 138 133 138 135 150tion cyanate (NCO content: 31 wt %)__________________________________________________________________________
TABLE 7__________________________________________________________________________ Comparative Example No. 1 2 3 4 5__________________________________________________________________________Mixing ratio (Solution B/Solution A) 1.07 1.05 1.07 1.21 1.43weight ratioReactivity (RT/CT) 5.6 4.6 5.2 6.2 7.2Average OH value of total polyols (KOH mg/g) 517 499.8 517 474.9 499.8Average density of foam (g/cm.sup.3) 0.35 0.35 0.30 0.30 0.6Mold temperature (.degree.C.) 48 48 48 48 48Surface properties of foam when removed X .DELTA. X X Xfrom the mold at 3 min *1State of fin of form when removed from x x x x xthe mold at 2 min 30 sec *2Surface hardness (Shore D) 48 49 42 43 55Glass transition temperature (.degree.C.) 103 105 104 100 100Flexural strength (kg/cm.sup.2) 170 178 168 168 115Flexural modulus (10.sup.2 kg/cm.sup.2) 73 72 65 64 115__________________________________________________________________________ Note *1: X: Blister(s) was formed or the surface was poor in gloss. .DELTA.: Cracks were formed on the surface. *2: x: Fin was considerably retained on the mold surface.
As mentioned above, according to this invention, the removal time of molded foams from the mold can be reduced remarkably. Further, since the mold temperature can be raised to 55.degree. to 80.degree. C. because of the use of special raw material composition, the molding cycle can be shortened remarkably compared with conventional processes, which results in increasing the producibility effectively and remarkably.
Integral skin polyurethane foams produced by the process of this invention can widely be used in electronic components, electric components, automotive parts, building materials, etc., which are particularly required to have heat insulation, sound absorption and light-weight.

Number	Date	Country	Kind
56-9033	Jan 1981	JPX
56-81016	May 1981	JPX

Number	Name	Date	Kind
4126742	Carleton et al.	Nov 1978
4342842	Hira et al.	Aug 1982

Process for producing integral skin polyurethane foam

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