CN105683236B - 低密度聚氨酯微孔弹性体 - Google Patents
低密度聚氨酯微孔弹性体 Download PDFInfo
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- CN105683236B CN105683236B CN201480057714.4A CN201480057714A CN105683236B CN 105683236 B CN105683236 B CN 105683236B CN 201480057714 A CN201480057714 A CN 201480057714A CN 105683236 B CN105683236 B CN 105683236B
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- polyesterols
- aethoxy sklerol
- polyurethane foam
- reaction
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Classifications
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Abstract
本发明涉及用于制备密度为200至500g/dm3的聚氨酯泡沫模制品的方法,其中将(a)多异氰酸酯预聚物与(b)至少一种第二聚酯醇、(c)发泡剂以及任选地(d)扩链剂和/或交联剂、(e)催化剂和(f)其他助剂和/或添加剂混合以形成反应混合物,然后将该反应混合物引入至模具中并使其反应以形成聚氨酯泡沫模制品,其中所述(a)多异氰酸酯预聚物可通过使下列物质反应而获得:至少一种有机多异氰酸酯(a1)、至少一种第一聚酯醇(a2)和至少一种聚醚醇(a3),所述聚醚醇(a3)由包含环氧乙烷的环氧烷使起始分子烷氧基化获得,其中聚醚醇(a3)的羟基数在20至65mgKOH/g范围内、数均分子量为2000至6000、官能度为1.7至3.0以及环氧乙烷单元的含量在13至30重量%范围内,基于聚醚醇(a3)的总重量计;并且其中聚醚醇(a3)的含量基于有机多异氰酸酯预聚物(a)的总重量计在3至15重量%范围内。本发明还涉及由本发明的方法获得的聚氨酯泡沫模制品,以及本发明的聚氨酯泡沫模制品作为鞋底的用途。
Description
本发明涉及用于制备密度为200至500g/dm3的聚氨酯泡沫模制品的方法,其中将(a)多异氰酸酯预聚物与(b)至少一种第二聚酯醇、(c)发泡剂以及任选地(d)扩链剂和/或交联剂、(e)催化剂和(f)其他助剂和/或添加剂混合以形成反应混合物,然后将该反应混合物引入至模具中并使其反应以形成聚氨酯泡沫模制品,其中所述(a)多异氰酸酯预聚物可通过使下列物质反应而获得:至少一种有机多异氰酸酯(a1)、至少一种第一聚酯醇(a2)和至少一种聚醚醇(a3),所述聚醚醇(a3)由包含环氧乙烷的环氧烷使起始分子烷氧基化获得,其中聚醚醇(a3)的羟基数在20至65mg KOH/g范围内、数均分子量为2000至6000、官能度为1.7至3.0以及环氧乙烷单元的含量在13至30重量%范围内,基于该聚醚醇(a3)的总重量计;并且其中聚醚醇(a3)的含量基于有机多异氰酸酯预聚物(a)的总重量计在3至15重量%的范围内。本发明还涉及由本发明的方法获得的聚氨酯泡沫模制品,以及本发明的聚氨酯泡沫模制品作为鞋底的用途。
显然近年来呈现出鞋底变轻的趋势。然而,聚氨酯鞋底密度的下降产生了模制品的尺寸稳定性问题。这意味着整个底部变得更小,或者鞋底的表面质量会由于空间收缩而受到影响。
为了改善聚氨酯的尺寸稳定性,文献中已经讨论了多种可能性。例如,DE 2402734记载了整体聚氨酯泡沫的制备,其中将基于聚酯醇的预聚物与基于聚醚醇的多元醇组分混合。以这种方式制备的聚氨酯体系的缺点为,聚酯醇与聚醚醇尤其在低密度下的不相容性对于机械性能具有不利的影响,并且无法防止整体聚氨酯泡沫的收缩。
文献中记载的另一可能性为使用接枝或聚合物多元醇。因此,EP 1042384记载了通过使用大量的接枝聚醚多元醇来制备基于聚醚醇的低密度、尺寸稳定的鞋底。这种方法的缺点是与基于聚酯醇的鞋底相比机械性能明显较差。此外,聚合物聚醚醇的高比例对于多元醇组分的粘度具有不利的影响。
EP 1790675和EP 1756187中记载了在聚酯聚氨酯中使用基于聚酯醇的聚合物多元醇。由于大量的聚酯聚合物多元醇的较高粘度,因此这些体系明显地更加难以处理。此外,EP 1790675和EP 1756187公开了在聚酯醇聚氨酯体系中使用基于聚醚醇的聚合物多元醇。该文件在对比实施例中显示,聚合物聚醚醇的使用导致整体泡沫具有不能令人满意的表面和粗糙的孔结构。此外,聚合物多元醇的应用增加了组分的粘度,并使得混合组分以及将反应混合物注入模具中更加困难。另外,聚合物多元醇通常比聚醚醇或聚酯醇更加昂贵。
EP 0582385记载了包含下列物质的反应体系:1)游离NCO值为15-25重量%的多异氰酸酯组合物,其为过量的有机多异氰酸酯与具有官能度为2-6、分子量为2000-6000和EO含量为20-35重量%的聚醚多元醇的反应产物;2)多元醇,其为具有官能度为2-3和分子量为750-4000的聚酯多元醇;以及3)水。EP 582385的聚氨酯模制品在特别是较大部分的例如高跟女鞋的机械性能以及尺寸稳定性和表面质量方面仍然有待改善。
EP 358328公开了包含下列物质的异氰酸酯组合物:10-90重量份的基于聚酯的官能度为2-2.3的异氰酸酯预聚物(所述异氰酸酯预聚物由分子量为1000-10000的聚酯多元醇制成),以及10-90重量份的基于聚醚的官能度为2-2.3的异氰酸酯预聚物(所述异氰酸酯预聚物由分子量为1000-10000且环氧乙烷含量为3-50重量%的聚醚多元醇制成),该预聚物组合物的游离NCO值为8-25%。EP 358328的聚氨酯模制品在特别是较大部分的例如高跟女鞋的机械性能以及尺寸稳定性方面仍然有待改善。
CN 101486788记载了用于制备密度为0.2至0.5g/cm3的聚氨酯泡沫的方法,包括使含有聚酯多元醇的多元醇组分与含有65-75重量%的多异氰酸酯、15-30重量%的聚酯以及0-15重量%的聚醚多元醇(优选官能度为2-4和Mw为500-6000的PO/EO多元醇)的多异氰酸酯预聚物进行反应的步骤。CN 101486788的聚氨酯模制品在特别是较大部分的例如高跟女鞋的机械性能以及尺寸稳定性方面仍然有待改善。
本发明的目的是提供一种聚氨酯泡沫模制品,其具有低于500g/l的密度和无收缩的优异尺寸稳定性以及优异的表面质量。本发明的另一个目的是提供一种反应混合物以获得这样的聚氨酯模制品,其中原料廉价并显示出低粘度且易于混合。
此目的通过密度为200至500g/dm3的聚氨酯泡沫模制品实现,所述聚氨酯泡沫模制品通过下述方法获得:其中将(a)有机多异氰酸酯预聚物与(b)至少一种第二聚酯醇、(c)发泡剂以及任选地(d)扩链剂和/或交联剂、(e)催化剂和(f)其他助剂和/或添加剂混合以形成反应混合物,然后将该反应混合物引入至模具中并使其反应以形成聚氨酯泡沫模制品,其中所述(a)有机多异氰酸酯预聚物可通过使下列物质反应而获得:至少一种多异氰酸酯(a1)、至少一种第一聚酯醇(a2)和至少一种聚醚醇(a3),所述聚醚醇(a3)由包含环氧乙烷的环氧烷使起始分子烷氧基化获得,其中聚醚醇(a3)的羟基数在20至65mg KOH/g范围内、数均分子量为2000至6000、官能度为1.7至3.0以及环氧乙烷单元的含量在13至30重量%范围内,基于该聚醚醇(a3)的总重量计;并且其中聚醚醇(a3)的含量基于有机多异氰酸酯预聚物(a)的总重量计在3至15重量%范围内。本发明还涉及由本发明的方法获得的聚氨酯泡沫模制品,以及本发明的聚氨酯泡沫模制品作为鞋底的用途。
为了本发明的目的,聚氨酯泡沫模制品为在模具中制备的聚氨酯泡沫。核心和外部区域的总泡沫密度的平均值优选为>80g/l至500g/l,更优选150g/l至450g/l,更优选200g/l至350g/l,并且最优选250g/l至300g/l。
有机异氰酸酯预聚物(a)由有机异氰酸酯(a1)、至少一种第一聚酯醇(a2)和至少一种聚醚醇(a3)的反应获得。用于制备本发明的聚氨酯泡沫模制品的有机异氰酸酯(a1)包含聚氨酯领域中已知的脂族、脂环族和芳族双官能或多官能的异氰酸酯及其任意混合物。实例为4,4′-甲烷二(苯基二异氰酸酯)、2,4′-甲烷二(苯基二异氰酸酯)、单体甲烷二(苯基二异氰酸酯)与更大环数的甲烷二(苯基二异氰酸酯)同系物(聚合MDI)的混合物、四亚甲基二异氰酸酯、六亚甲基二异氰酸酯(HDI)、异佛尔酮二异氰酸酯(IPDI)、甲代亚苯基2,4-或2,6-二异氰酸酯(TDI),或者所提及的异氰酸酯的混合物。
优选使用4,4′-MDI。优选使用的4,4′-MDI可包含0至20重量%的2,4′-MDI和少量的,最高达约10重量%的脲基甲酸酯或脲酮亚胺改性的多异氰酸酯。也可使用少量的聚亚苯基聚亚甲基多异氰酸酯(聚合MDI)。这些高官能度多异氰酸酯的总量不应超过所用的异氰酸酯的5重量%。
作为第一聚酯醇(a2),可使用在聚氨酯化学中通常使用的聚酯醇。第一聚酯醇(a2)可以例如由具有2至12个碳原子的有机二羧酸(优选具有4至6个碳原子的脂族二羧酸)与具有2至12个碳原子,优选2至6个碳原子的多元醇(优选二醇)来制备。可用的二羧酸为,例如:琥珀酸、戊二酸、己二酸、辛二酸、壬二酸、癸二酸、癸烷二羧酸、马来酸、富马酸、邻苯二甲酸、间苯二甲酸和对苯二甲酸。所述二羧酸可以单独地或以彼此的混合物来使用。也可使用相应的羧酸衍生物,例如具有1至4个碳原子的醇的二羧酸酯或二羧酸酐,来代替游离的二羧酸。优选使用琥珀酸、戊二酸和己二酸以例如20-35:35-50:20-32的重量比的二羧酸混合物,并且特别是己二酸。二元醇和多元醇,特别是二醇的实例为:乙二醇、二乙二醇、1,2-或1,3-丙二醇、二丙二醇、1,4-丁二醇、1,5-戊二醇、1,6-己二醇、1,10-癸二醇、丙三醇和三羟甲基丙烷。优选使用乙二醇、二乙二醇、1,4-丁二醇、丙三醇、1,5-戊二醇和1,6-己二醇。也可使用衍生自内酯例如ε-己内酯或羟基羧酸例如ω-羟基己酸的聚酯多元醇。
为制备聚酯多元醇,在不存在催化剂或优选在酯化催化剂的存在下,有利地在惰性气体例如氮气、一氧化碳、氦气、氩气等的气氛中,在150至250℃,优选180至220℃温度下的熔体中,任选地在减压下,可将有机(例如芳族且优选脂族)多元羧酸和/或多元羧酸衍生物与多元醇缩聚至所需的酸值,所述酸值优选小于10,特别优选小于2。在一个优选的实施方案中,在上述温度下,在大气压力下,随后在小于500毫巴,优选50至150毫巴的压力下,将酯化混合物缩聚至酸值为80至30,优选40至30。可用的酯化催化剂为,例如,金属、金属氧化物或金属盐形式的铁、镉、钴、铅、锌、锑、镁、钛和锡催化剂。然而,缩聚也可以在液相中在稀释剂和/或夹带剂例如苯、甲苯、二甲苯或氯苯的存在下以共沸蒸馏掉缩合的水来进行。为制备聚酯多元醇,有机多元羧酸和/或多元羧酸衍生物与多元醇的摩尔比为1:1-1.8,优选1:1.05-1.2是有利于缩聚的。
所获得的聚酯多元醇优选官能度为1.8至4、更优选1.9至3、甚至更优选1.95至2.7、最优选1.95至2.3,以及数均分子量为480至3000g/mol、优选1000至3000g/mol、更优选1500至2500g/mol、特别是1800至2300g/mol。
聚醚醇(a3)通过已知的方法制备,例如由一种或多种在亚烷基基团中具有2至4个碳原子的环氧烷通过用碱金属氢氧化物或碱金属醇盐作为催化剂并且添加至少一种引发剂(每分子中包含2至6个、优选2至4个、更优选2至3个对异氰酸酯基团呈反应性的键合的氢原子)进行阴离子聚合来制备,或者通过用路易斯酸如五氯化锑或氟化硼醚合物进行阳离子聚合来制备。合适的环氧烷为,例如,四氢呋喃、1,3-环氧丙烷、1,2-或2,3-环氧丁烷,并且优选环氧乙烷和1,2-环氧丙烷。此外,也可以使用多金属氰化物(所谓的DMC催化剂)作为催化剂。所述环氧烷可以单独地使用、连续交替地使用或作为混合物使用,因此,聚醚醇(a3)含有的环氧乙烷单元在13至30重量%范围内,优选15至25重量%并且更优选18至22重量%,基于聚醚醇(a3)的总重量计。优选为1,2-环氧丙烷和环氧乙烷的混合物,其中所述环氧烷优选以嵌段方式施用(applied block wise),优选作为末端环氧乙烷嵌段(“EO封端”)使所得的多元醇具有大于70%的末端伯羟基。
适合作为引发剂分子的物质有水或者二元或三元醇,例如乙二醇、1,2-和1,3-丙二醇、二乙二醇、二丙二醇、1,4-丁二醇、丙三醇或三羟甲基丙烷,优选乙二醇、1,2-和1,3-丙二醇、二乙二醇、二丙二醇、三丙二醇和1,4-丁二醇。
聚醚多元醇(优选聚氧丙烯聚氧乙烯多元醇)的平均官能度为1.7至3.0、优选1.7至2.7、更优选1.8至2.5、最优选2.0至2.5,和分子量为2000至6000g/mol、优选3000至5500g/mol、最优选4000至5500g/mol,并且羟基值优选20至65mg KOH/g、更优选22至35mgKOH/g、最优选25至30mg KOH/g。
为了获得多异氰酸酯预聚物(a),例如在30至100℃、优选约80℃的温度下,将上述多异氰酸酯(a1)以化学计量过量的量与聚酯醇(a2)和聚醚醇(a3)反应以形成预聚物。通常,所得的多异氰酸酯预聚物的游离NCO含量在12至32范围内、优选15至30、更优选18至28并且最优选20至25。就本发明而言,必须使聚醚醇(a3)的含量基于多异氰酸酯预聚物(a)的总重量计在3至15重量%范围内、优选3至10重量%范围内,并且更优选3至7重量%范围内。
对于本发明而言,多异氰酸酯(a)没有必要包含任何的分散颗粒,特别是任何的聚合物多元醇。不过,可向组分(a)中加入少量的聚合物多元醇。在本发明的一个优选实施方案中,多异氰酸酯(a)不含任何的分散颗粒。
作为第二聚酯多元醇(b),可以使用在聚氨酯化学中通常使用的所有聚酯醇。优选地,作为聚酯多元醇(b),可以使用如以上(a2)部分中所述的聚酯多元醇。第一聚酯醇(a2)和第二聚酯醇(b)可以相同或不同,并且在本发明的一个优选实施方案中其为相同的聚酯醇。
对于本发明而言,第二聚酯醇(b)没有必要包含任何的分散颗粒,特别是任何的聚合物多元醇。不过,可以向组分(b)中加入少量的聚合物多元醇。在本发明的一个优选实施方案中,第二聚酯多元醇(b)不含任何的分散颗粒。除聚酯多元醇(b)外,反应组合物可含有本领域中已知的其他的多元醇。根据本发明,其他的多元醇为这样的化合物:在每分子中具有至少2个对异氰酸酯基团呈反应性的氢原子并且分子量为至少500g/mol。在本发明的一个优选实施方案中,反应混合物不包含除化合物(a2)、(a3)和(b)以外的任何多元醇。
此外,在聚氨酯泡沫模制品的制备中存在发泡剂c)。这些发泡剂c)可以包含水。除水以外,额外还可以使用通常已知的化学和/或物理作用的化合物作为发泡剂c)。为了本发明的目的,化学发泡剂为与异氰酸酯反应以形成气体产物的化合物,例如水或甲酸。物理发泡剂为在用于制备聚氨酯的起始物料中溶解或乳化并在聚氨酸形成条件下汽化的化合物。这些发泡剂为,例如,烃、卤代烃和其他化合物,例如全氟化烷烃(如全氟己烷)、含氯氟烃以及醚、酯、酮、缩醛或其混合物,例如具有4至8个碳原子的(环)脂族烃或氟化烃(如购自Solvay Fluorides LLC的365mfc)。在一个优选的实施方案中,使用包含这些发泡剂中的至少一种和水的混合物作为发泡剂;特别地,使用水作为唯一的发泡剂。如果不使用水作为唯一的发泡剂,则优选仅使用物理发泡剂。
在一个优选的实施方案中,水的含量为0.1至2重量%,优选0.2至1.5重量%,特别优选0.3至1.2重量%,基于组分b)至f)的总重量计。
在另一个优选的实施方案中,加入包含物理发泡剂的中空微球作为组分a)至f)的反应中附加的发泡剂。所述中空微球也可以与上述发泡剂混合使用。
所述中空微球通常包括热塑性聚合物的壳,并以基于烷烃的液态、低沸点物质填充于核中。这种中空微球的制备记载于例如US 3615972中。中空微球的直径通常为5至50μm。合适的中空微球的实例可以从Akzo Nobel以商品名获得。
所述中空微球的加入量通常为0.5至5重量%,基于组分b)、c)和d)的总重量计。
作为扩链剂和/或交联剂d),使用分子量优选小于500g/mol、特别优选60至400g/mol的物质,并且扩链剂具有2个对异氰酸酯呈反应性的氢原子且交联剂具有3个对异氰酸酯呈反应性的氢原子。这些物质可优选地单独使用或以混合物的形式使用。优选使用分子量小于400、特别优选为60至300并且特别是60至150的二醇和/或三醇。可能的扩链剂/交联剂为,例如,具有2至14个、优选2至10个碳原子的脂族、脂环族和/或芳脂族二醇,如乙二醇、1,3-丙二醇、1,10-癸二醇、1,2-二羟基环己烷、1,3-二羟基环己烷、1,4-二羟基环己烷、二乙二醇、二丙二醇和1,4-丁二醇、1,6-己二醇和双(2-羟基乙基)氢醌;三醇,如1,2,4-三羟基环己烷、1,3,5-三羟基环己烷、丙三醇和三羟甲基丙烷;以及低分子量的含羟基的基于环氧乙烷和/或1,2-环氧丙烷以及上述二醇和/或三醇作为起始分子的聚环氧烷。特别优选使用单乙二醇、1,4-丁二醇、丙三醇或其混合物作为扩链剂d)。
如果使用扩链剂、交联剂或其混合物,则有利的是其用量为1至60重量%,优选1.5至50重量%并且特别是2至40重量%,基于组分b)和d)的重量计。
作为用于制备聚氨酯泡沫的催化剂e),优选使用这样的化合物,其能极大地促进多元醇b)和任选地扩链剂和交联剂d)与有机、任选改性的多异氰酸酯a)的反应。可提及的实例有:脒,例如2,3-二甲基-3,4,5,6-四氢嘧啶;叔胺,例如三乙胺、三丁胺、二甲基苄胺、N-甲基吗啉、N-乙基吗啉、N-环己基吗啉、N,N,N',N'-四甲基乙二胺、N,N,N',N'-四甲基丁二胺、N,N,N',N'-四甲基己二胺、五甲基二亚乙基三胺、双(二甲基氨基乙基)醚、双(二甲基氨基丙基)脲、二甲基哌嗪、1,2-二甲基咪唑、1-氮杂双环[3.3.0]辛烷和优选的1,4-二氮杂双环[2.2.2]辛烷;以及烷醇胺化合物,例如三乙醇胺、三异丙醇胺、N-甲基-二乙醇胺和N-乙基二乙醇胺和二甲基乙醇胺。还可用的为有机金属化合物,优选有机锡化合物,例如有机羧酸的锡(II)盐如乙酸亚锡(II)、辛酸亚锡(II)、乙基己酸亚锡(II)和月桂酸亚锡(II),和有机羧酸的二烷基锡盐(IV)如二乙酸二丁基锡、二月桂酸二丁基锡、马来酸二丁基锡和二乙酸二辛基锡;以及铋的羧酸盐,例如新癸酸铋(III)、2-乙基己酸铋和辛酸铋,或其混合物。所述有机金属化合物可以单独使用或优选与强碱性胺组合使用。如果组分b)为酯,则优选仅使用胺催化剂。
优选使用0.001至5重量%,特别是0.05至2重量%的催化剂或催化剂组合,基于组分b)的重量计。
如果合适,可额外地将助剂和/或添加剂f)加入至用于制备聚氨酯泡沫的反应混合物。可提及的实例有:表面活性物质、泡沫稳定剂、孔调节剂、其他脱模剂、填料、染料、颜料、水解抑制剂、气味吸收物质以及抑制真菌和/或抑制细菌物质。
可能的表面活性物质为,例如,用于帮助起始物料均化,并且还任选地适于调节孔结构的化合物。可提及的实例有:乳化剂,例如蓖麻油硫酸盐或脂肪酸的钠盐,以及脂肪酸与胺的盐如二乙胺油酸盐、二乙醇胺硬脂酸盐、二乙醇胺蓖麻醇酸盐,磺酸的盐如十二烷基苯磺酸或二萘基甲烷二磺酸以及蓖麻油酸的碱金属盐或铵盐;泡沫稳定剂,例如硅氧烷-氧化烯共聚物和其他有机聚硅氧烷(如以商品名193购自Air Products的产品或以商品名为B8905购自Evonik的产品)、乙氧基化烷基酚、乙氧基化脂肪醇、石蜡油、蓖麻油酯或蓖麻油酸酯、土耳其红油和花生油;以及孔调节剂,例如石蜡、脂肪醇和二甲基聚硅氧烷。具有聚氧化烯和氟代烷基团作为侧基的低聚丙烯酸酯也适合于改善乳化作用、孔结构和/或稳定泡沫。优选使用基于聚硅氧烷的表面活性剂,特别是以商品名193或B8905购得的产品。所述表面活性物质的用量通常为0.3至3重量份,优选0.5至2重量份并且最优选0.8至1.5重量份,基于100重量份的组分b计。
作为合适的其他脱模剂,可提及的实例有:脂肪酸酯与多异氰酸酯的反应产物、包含氨基的聚硅氧烷和脂肪酸的盐、具有至少8个碳原子的饱和或不饱和(环)脂族羧酸和叔胺的盐,以及特别是内脱模剂,例如羧酸酯和/或羧酰胺,其通过褐煤酸和至少一种具有至少10个碳原子的脂族羧酸的混合物与至少双官能烷醇胺、多元醇和/或分子量为60至400g/mol的多胺的酯化或酰胺化而制备(如例如EP 153639中所公开的);通过有机胺、硬脂酸金属盐和有机单羧酸和/或二羧酸或其酸酐的混合物的酯化或酰胺化而制备(如例如DE-A-3607447中所公开的);或者通过亚氨基化合物、羧酸金属盐以及如果合适羧酸的混合物的酯化或酰胺化而制备(如例如US 4764537中所公开的)。根据本发明的反应混合物优选不含其他的脱模剂。
填料,特别是增强填料,为本身已知的常规有机和无机填料、增强材料、增重剂、涂布剂等。可提及的具体实例为:无机填料,例如含硅矿物,例如片状硅酸盐如叶蛇纹石、膨润土、蛇纹石、角闪石、闪石、温石棉和滑石;金属氧化物,例如高岭土、氧化铝、二氧化钛、氧化锌和氧化铁;金属盐,例如白垩和重晶石;和无机颜料,例如硫化镉、硫化锌以及玻璃等。优选使用高岭土(中国粘土)、硅酸铝以及硫酸钡和硅酸铝的共沉淀物。可能的有机填料为,例如:炭黑、三聚氰胺、松香、环戊二烯基树脂和接枝聚合物,以及纤维素纤维、聚酰胺纤维、聚丙烯腈纤维、聚氨酯纤维、基于芳族和/或脂族二羧酸酯的聚酯纤维,并且特别是碳纤维。
所述无机和有机填料可以单独或作为混合物使用,并且加入至反应混合物中的有利的用量为0.5至50重量%,优选1至40重量%,基于组分a)至d)的重量计。
本发明还提供一种用于制备聚氨酯泡沫模制品的方法,其中将组分a)至c)以及任选地d)、e)和/或f)以这样的量相互混合:多异氰酸酯(a)的NCO基团与组分(b)、(c)和(d)的反应性氢原子总和的当量比为1:0.8至1:1.25,优选1:09至1:1.15。
本发明的聚氨酯泡沫模制品优选通过一步法、借助低压或高压技术在密闭的、优选加热的模具中制备。模具通常包含金属例如铝或钢。这些方法例如由Piechota和记载于“Integralschaumstoff”,Carl-Hanser-Verlag,Munich,Vienna,1975中,或记载于“Kunststoff-handbuch”,第7卷,Polyurethane,第3版,1993,第7章中。
为此,将起始组分a)至f)优选在15至90℃,特别优选25至55℃的温度下混合,并任选地在超大气压下,将反应混合物引入至模具中。可借助搅拌器或搅拌螺杆或在高压下以逆流喷射法实施机械混合。模具温度有利地为20至160℃,优选30至120℃,特别优选30至60℃。为了本发明的目的,将基于异氰酸酯基团计,反应转化率小于90%的组分a)至f)的混合物称为反应混合物。
计算引入至模具中的反应混合物的量,使得所获得的模制品的密度为优选200g/dm3至500g/dm3,特别优选250g/dm3至350g/dm3。制备本发明的整体聚氨酯泡沫的压实度在1.1至8.5范围内,优选1.7至7.0。
本发明的聚氨酯泡沫模制品优选用作例如拖鞋、街鞋、运动鞋和靴子的鞋底。特别地,本发明的聚氨酯泡沫用作拖鞋和高跟女鞋的底部材料。底部最厚处的厚度优选大于3cm,特别优选大于5cm。此外,根据本发明的聚氨酯泡沫可以用于车辆内部,例如在小汽车中作为方向盘、头枕或变速杆把手或者作为扶手。还可能用作椅子扶手或用作摩托车座椅。
下面通过实施例说明本发明。
实施例
所用的起始物料
多元醇1:基于丙三醇、环氧丙烷和环氧乙烷的聚醚醇,其具有环氧乙烷含量为73重量%、OH数为42mg KOH/g且在25℃下粘度为950mPas。
多元醇2:基于丙三醇、环氧丙烷和环氧乙烷的聚醚醇,其具有环氧乙烷含量为11重量%、OH数为56mg KOH/g且在25℃下粘度为475mPas。
多元醇3:基于丙三醇、环氧丙烷和环氧乙烷的聚醚醇,其具有环氧乙烷含量为21重量%、OH数为27mg KOH/g且在25℃下粘度为1225mPas。
多元醇4:基于己二酸、单乙二醇、二乙二醇和丙三醇的聚酯醇,其具有OH数为60mgKOH/g且在75℃下粘度为1150mPas。
多元醇5:基于琥珀酸、戊二酸和己二酸的混合物,单乙二醇和丙三醇的聚酯醇,其具有OH数为58mg KOH/g且在100℃下粘度为430mPas。
多元醇6:基于己二酸、单乙二醇、二乙二醇的聚酯醇,其具有OH数为56mg KOH/g且在75℃下粘度为525mPas。
多元醇7:基于琥珀酸、戊二酸和己二酸的混合物和单乙二醇的聚酯醇,其具有OH数为56mg KOH/g且在75℃下粘度为650mPas。
CE:单乙二醇
CL:溶解于单乙二醇中的三亚乙基二胺
Stabi:来自Air Products的DC 193
ISO 1:单体MDI
ISO 2:单体MDI,包含约25重量%的碳二亚胺改性的单体MDI
预聚物的制备:
预聚物1:
将1004.95g ISO 1、90g ISO 2和0.045g苯甲酰氯放置在2l的装有氮气入口、搅拌器、冷凝器和滴液漏斗的四颈烧瓶中并加热至约60℃。在60℃下,于15分钟内缓慢加入405g多元醇4,并在80℃下将该混合物再搅拌2小时。所获得的预聚物的NCO含量为23.0%。
预聚物P2:
将1004.95g ISO 1、90g ISO 2和0.045g苯甲酰氯放置在2l的装有氮气入口、搅拌器、冷凝器和滴液漏斗的四颈烧瓶中并加热至约60℃。在60℃下,于15分钟内缓慢加入101.25g多元醇1和303.75g多元醇4,并在80℃下将该混合物再搅拌2小时。所获得的预聚物的NCO含量为23.0%。
预聚物P3:
将1004.95g ISO 1、90g ISO 2和0.045g苯甲酰氯放置在2l的装有氮气入口、搅拌器、冷凝器和滴液漏斗的四颈烧瓶中并加热至约60℃。在60℃下,于15分钟内缓慢加入101.25g多元醇2和303.75g多元醇4,并在80℃下将该混合物再搅拌2小时。所获得的预聚物的NCO含量为23.0%。
预聚物P4:
将1004.95g ISO 1、90g ISO 2和0.045g苯甲酰氯放置在2l的装有氮气入口、搅拌器、冷凝器和滴液漏斗的四颈烧瓶中并加热至约60℃。在60℃下,于15分钟内缓慢加入30g多元醇3和375g多元醇5,并在80℃下将该混合物再搅拌2小时。所获得的预聚物的NCO含量为23.0%。
预聚物P5:
将1004.95g ISO 1、90g ISO 2和0.045g苯甲酰氯放置在2l的装有氮气入口、搅拌器、冷凝器和滴液漏斗的四颈烧瓶中并加热至约60℃。在60℃下,于15分钟内缓慢加入101.25g多元醇3和303.75g多元醇4,并在80℃下将该混合物再搅拌2小时。所获得的预聚物的NCO含量为23.1%。
预聚物P6:
将1004.95g ISO 1、90g ISO 2和0.045g苯甲酰氯放置在2l的装有氮气入口、搅拌器、冷凝器和滴液漏斗的四颈烧瓶中并加热至约60℃。在60℃下,于15分钟内缓慢加入60g多元醇3和345g多元醇5,并在80℃下将该混合物再搅拌2小时。所获得的预聚物的NCO含量为22.9%。
预聚物P7:
将1004.95g ISO 1、90g ISO 2和0.045g苯甲酰氯放置在2l的装有氮气入口、搅拌器、冷凝器和滴液漏斗的四颈烧瓶中并加热至约60℃。在60℃下,于15分钟内缓慢加入101.25g多元醇4和303.75g多元醇3,并在80℃下将该混合物再搅拌2小时。所获得的预聚物的NCO含量为23.4%。
实施发明实施例E1至E4和对比实施例C1至C5。为此,将表1中示出的组分(数值以重量份计)与示出的具有示出的异氰酸酯指数的异氰酸酯预聚物混合,并且在每种情况下,使其首先自由发泡,其次引入至鞋跟高度为10cm的底部模具中以形成密度为350g/dm3的模制品。自由发泡的聚氨酯泡沫的密度以g/l为单位(FR密度),也示于表1中。
表1
在完成制备24小时后,对模制品进行评价。根据对比实施例C1至C4的自由发泡泡沫和模制品在表面上均表现出明显收缩或局部收缩。对比实施例5中所获得的泡沫的尺寸稳定并且未显示出收缩,然而表皮质量差——观察到在表面上有粗纹理的表皮和一些针孔。
根据发明实施例E1至E4的自由发泡泡沫和模制品均未显示出收缩迹象并显示出良好的微孔泡沫结构。此外,所述模制品具有良好的表面质量。类似的结果在模塑密度为270g/dm3、使用鞋跟高度为3.5cm的底部模具时得到。
Claims (8)
1.一种用于制备密度为200至500g/dm3的聚氨酯泡沫模制品的方法,其中
将a)多异氰酸酯预聚物,其通过使下列物质反应而获得:至少一种有机多异氰酸酯(a1)、至少一种第一聚酯醇(a2)和至少一种聚醚醇(a3);所述聚醚醇(a3)由包含环氧乙烷的环氧烷使起始分子烷氧基化获得,其中聚醚醇(a3)的羟基数在20至65mg KOH/g范围内、数均分子量为2000至6000、官能度为1.7至3.0以及环氧乙烷单元的含量在13至30重量%范围内,基于该聚醚醇(a3)的总重量计;并且其中聚醚醇(a3)的含量基于有机多异氰酸酯预聚物(a)的总重量计在3至15重量%范围内;与
b)至少一种第二聚酯醇,
c)发泡剂,以及任选地
d)扩链剂和/或交联剂,
e)催化剂,和
f)其他助剂和/或添加剂,
混合以形成反应混合物,然后将该反应混合物引入至模具中并使其反应以形成聚氨酯泡沫模制品。
2.权利要求1的方法,其中异氰酸酯预聚物a)的NCO含量在12至32重量%的范围内。
3.权利要求1或2中任一项的方法,其中所述第一聚酯醇(a2)的官能度在1.9至3的范围内,数均分子量在1000至3000g/mol的范围内。
4.权利要求1的方法,其中第二聚酯醇(b)的官能度在1.9至3的范围内,数均分子量在1000至3000g/mol的范围内。
5.权利要求1的方法,其中第一聚酯醇(a2)和第二聚酯醇(b)相同。
6.权利要求1的方法,其中所述反应在异氰酸酯指数为80至120范围内进行。
7.由权利要求1至6中任一项的方法获得的聚氨酯泡沫模制品。
8.权利要求7的聚氨酯模制品作为鞋底的用途。
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