Foam polyurethane material, molded article, and method for producing foam polyurethane material

Patent metadata

Field	Value
Publication number	US-10513575-B2
Application number	US-201615752762-A
Country	US
Kind code	B2
Filing date	Aug 10, 2016
Priority date	Aug 18, 2015
Publication date	Dec 24, 2019
Grant date	Dec 24, 2019

Abstract

A foam polyurethane material is a reaction-foaming-product of a composition containing a polyisocyanate (a), an isocyanate-terminated prepolymer (b) containing 0.3 mass % or more and less than 5 mass % of an isocyanate group, a polyol (c), and a catalyst.

First claim

The invention claimed is:

1. A foam polyurethane material, wherein the foam polyurethane material is a reaction-foaming-product of a composition containing a polyisocyanate (a), an isocyanate-terminated prepolymer (b) containing 0.3 mass % or more and less than 5 mass % of an isocyanate group, a polyol (c), and a catalyst,
the isocyanate-terminated prepolymer (b) is a reaction product of a polyisocyanate (b-1) and a polyol (b-2) which is different from the polyol (c),
the polyisocyanate (b-1) is bis(isocyanatomethyl) cyclohexane, isophoronediisocyanate, or xylylene diisocyanate,
0.5 mass % or more and 27 mass % or less of the isocyanate-terminated prepolymer (b) is contained in a total amount of the polyisocyanate (a) and the isocyanate-terminated prepolymer (b), and
wherein the foam polyurethane material has an impact resilience measured in accordance with JIS K6400-3 (2012) of 65% or more.

2. The foam polyurethane material according to claim 1 , wherein the isocyanate-terminated prepolymer (b) contains 0.4 mass % or more and 3.5 mass % or less of the isocyanate group.

3. The foam polyurethane material according to claim 1 , wherein 1 mass % or more and 25 mass % or less of the isocyanate-terminated prepolymer (b) is contained in a total amount of the polyisocyanate (a) and the isocyanate-terminated prepolymer (b).

4. The foam polyurethane material according to claim 1 , wherein
the polyol (b-2) has a number average molecular weight of 1000 or more and 9000 or less.

5. The foam polyurethane material according to claim 1 , wherein
the polyisocyanate (b-1) is bis(isocyanatomethyl) cyclohexane.

6. The foam polyurethane material according to claim 1 , wherein
the polyisocyanate (a) is at least one selected from the group consisting of aliphatic polyisocyanate, alicyclic polyisocyanate, and araliphatic polyisocyanate.

7. The foam polyurethane material according to claim 1 , wherein the foam polyurethane material has an apparent core density measured in conformity with JIS K 7222 (2005) of 0.5 g/cm 3 or less.

8. The foam polyurethane material according to claim 1 , wherein
the polyol (b-2) has an average functionality of 2, and
the polyol (c) includes a polyol having an average functionality of 3.0.

9. A molded article made of the foam polyurethane material according to claim 1 .

10. The molded article according to claim 9 , wherein the molded article is a shoe midsole.

11. A method for producing the foam polyurethane material according to claim 1 , the method including
reacting and foaming, the composition containing the polyisocyanate (a), the isocyanate-terminated prepolymer (b), the polyol (c), and the catalyst.

Assignees

• Mitsui Chemicals Inc

Inventors

• Hasegawa Daisuke
• Kageoka Masakazu
• Kuwamura Goro
• Yamasaki Satoshi

Classifications

• C08J9/00

  Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof (mechanical aspects of shaping of plastics or substances in a plastic state for the production of porous or cellular articles B29C) · CPC title

• C08G18/7642

  containing at least two isocyanate or isothiocyanate groups linked to the aromatic ring by means of an aliphatic group having a primary carbon atom next to the isocyanate or isothiocyanate groups, e.g. xylylene diisocyanate or homologues substituted on the aromatic ring · CPC title

• C08G18/757

  containing at least two isocyanate or isothiocyanate groups linked to the cycloaliphatic ring by means of an aliphatic group · CPC title

• C08G18/4837

  and other oxyalkylene units · CPC title

• C08G18/3275

  containing two hydroxy groups · CPC title