JP2006257118A - Spongy molding - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To obtain a spongy molding that has excellent application workability, durability, flexibility and waterproofness. <P>SOLUTION: The spongy molding having flame retardance of ≥40 oxygen index is obtained by adding specific amounts of aluminum phosphite and an inorganic filler to a flexible urethane foam composed of a water-based urethane prepolymer. The spongy molding forms a noncombustible firm sponge layer in fire breaking and even if exposed to a high temperature for many hours, the sponge layer is hardly embrittled and its residue has sufficient shape preserving property. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a sponge-like molded body.

  Conventional flame retardant sponge materials include halogen-based flame retardant sponge materials in which an organic phosphorus flame retardant, a halogen compound, a flame retardant such as aluminum hydroxide and antimony trioxide are blended in polyurethane foam, and non-halogen flame retardant materials. There are those that add a phosphorus-based flame retardant into polyurethane called a sponge material (see, for example, Patent Document 1) and those that add a melamine resin and aluminum hydroxide (for example, see Patent Document 2).

Although these flame retardant sponge materials themselves exhibit flame retardancy, they could not be melted and thermally decomposed to retain their shape when exposed to a direct fire for a long time.

JP-A-10-147707 (second page: claims 1 to 2) Japanese Patent Application Laid-Open No. 07-292055 (second page: claims 1 to 4)

  The present invention is used for a clearance of a through-hole of a fire wall, etc., and prevents fire from spreading when a fire occurs, and is used for a part that requires cushioning, soundproof / vibration resistance, and weight reduction to support a penetrating member. It is an object of the present invention to provide a sponge-like molded body.

  The present invention is a sponge-like molded article comprising a flexible urethane foam obtained from an aqueous urethane prepolymer, aluminum phosphite and an inorganic filler, and having an oxygen index of 40 or more. Furthermore, the present invention is a sponge-like molded article comprising 100 parts by mass of a flexible urethane foam obtained from an aqueous urethane prepolymer, 10 to 150 parts by mass of aluminum phosphite, and 10 to 150 parts by mass of an inorganic filler, It is a sponge-like molded body in which the filler is aluminum hydroxide. The molded body is a cut product.

  The sponge-like molded product of the present invention forms a non-combustible, firm sponge layer in the event of a fire, and even when exposed to a high temperature for a long time, the sponge layer is not easily brittle and has excellent fireproof performance.

  The sponge-like molded product of the present invention contains a flexible urethane foam obtained from an aqueous urethane prepolymer, aluminum phosphite and an inorganic filler.

  The flexible urethane foam used in the present invention is a flexible urethane foam obtained from a one-pack type aqueous urethane prepolymer. As the aqueous urethane prepolymer, known products or commercially available products can be used.

  The sponge-like molded product of the present invention contains aluminum phosphite as a shape stabilizer for preventing deformation. The average particle diameter of the aluminum phosphite used in the present invention is preferably 1 to 100 μm as measured by a laser diffraction method from the viewpoint of dispersibility.

  The content of aluminum phosphite is not particularly limited and can be set as appropriate depending on the type of flexible urethane foam obtained from the aqueous urethane prepolymer, the desired expansion ratio, etc., but is obtained from the aqueous urethane prepolymer. 10-150 mass parts is preferable with respect to 100 mass parts of flexible urethane foams. If the amount is less than 10 parts by mass, the shape stabilization performance of the resulting sponge-like molded product is insufficient, and if it exceeds 150 parts by mass, the hardness of the resulting sponge-like molded product tends to increase and flexibility tends to decrease.

In the present invention, an inorganic filler is used in order to further improve the fire resistance. Examples of the inorganic filler include silica, diatomaceous earth, alumina, zinc oxide, titanium oxide, magnesium oxide, iron oxide, magnesium hydroxide, aluminum hydroxide, zinc borate, sodium borate, calcium carbonate, magnesium carbonate, and zinc carbonate. , Barium carbonate, hydrotalcite, calcium sulfate, barium sulfate, calcium silicate, talc, clay, mica, bentonite, activated clay, sepiolite, glass fiber, glass beads, aluminum nitride, boron nitride, carbon black, graphite, etc. It is done. These may be used alone or in combination of two or more. Among these, aluminum hydroxide and magnesium hydroxide are preferable in that an increase in temperature can be suppressed by an endothermic reaction due to a dehydration reaction during heating. Of these, aluminum hydroxide is particularly preferred. From the viewpoint of dispersibility, the average particle diameter of these fillers is preferably 1 to 50 μm as measured by a laser diffraction method.

The content of the inorganic filler is not particularly limited and can be appropriately set depending on the type of flexible urethane foam obtained from the aqueous urethane prepolymer, the desired expansion ratio, etc., but is obtained from the aqueous urethane prepolymer. 10-150 mass parts is preferable with respect to 100 mass parts of flexible urethane foam. When it is used in excess of 150 parts by mass, the hardness of the sponge-like molded product is increased, the flexibility is inferior, and the cutting workability may be deteriorated.

The sponge-like molded product of the present invention has an oxygen index of 40 or more. When the oxygen index is less than 40, the fireproofing property at the time of fire is insufficient and the shape-preventing property is inferior. The oxygen index can be adjusted by adjusting the amounts of aluminum phosphite and inorganic filler.

  The method for preparing the sponge-like molded product of the present invention is not particularly limited. First, water is added to aluminum phosphite and an inorganic filler to form a slurry, and then an aqueous urethane prepolymer is added to the slurry. Then, stirring and mixing is continued until foaming starts, and then it is preferably poured into a mold having a predetermined shape and foam-molded, and further cured at about 50 ° C. to evaporate the contained water. The curing time may be appropriately set according to the size of the foam molded body that is a sponge-shaped molded body and the curing temperature.

  The compounding ratio of aluminum phosphite and inorganic filler is as described above and can be appropriately set depending on the application and purpose, but their total amount in the slurry is usually 20 to 90% by mass, preferably 50 to 70% by mass. %. When the solid content is less than 20% by mass, there is a possibility that a non-combustible, solid sponge layer may not be obtained in a fire. On the other hand, if it exceeds 90% by mass, the viscosity of the slurry increases, and a sponge-like molded product with stable performance may not be obtained.

  In addition, other additives such as surfactants, crosslinking agents, foam stabilizers, catalysts, foaming agents, flame retardants, stabilizers, ultraviolet absorbers, antioxidants, pigments, fillers are added to the slurry as necessary. Etc. can also be blended. These additives are preferably mixed simultaneously or sequentially at the time of slurry adjustment, and then uniformly mixed with a known stirrer or the like.

  The sponge-like molded product of the present invention can be used in various fields that require properties such as elasticity, flexibility, heat insulation, fire resistance, vibration proofing, and soundproofing, and the use site is not particularly limited. It can be used widely in places where performance is required.

  The machined product obtained from the sponge-like molded body of the present invention is machined by machining using an NC milling machine, machining center, or the like among computer-controlled machine tools, or by manual machining using a saw or the like.

The machined product obtained from the sponge-like molded body of the present invention is inserted into the clearance between the power cable, communication cable, pipe, etc., and the fire wall through the through-hole provided in the fire wall, floor slab, etc. It is possible to use by attaching a cut product formed into a shape suitable for the construction part. In addition, it can be used by being attached to a fitting part of a building for vibration and soundproofing, and these can be attached with an adhesive or adhesive, or fixed with bolts or nails.

  EXAMPLES Hereinafter, although an Example and a comparative example demonstrate this invention concretely, these Examples do not limit this invention. In addition, the part and% in the following description are based on a mass reference | standard.

  With the compounding amounts shown in Tables 1 and 2, water was added to a mixture of aluminum phosphite and inorganic filler to prepare a slurry. Aqueous urethane prepolymer was added to the slurry, mixed with stirring, poured into a mold having dimensions of 12 cm × 12 cm × 17 cm, foam-molded, cured in an oven at 100 ° C. for 1 hour, and then demolded. The obtained foamed cured product was further cured in an oven at 50 ° C. for 2 days to evaporate the water and obtain a sponge-like molded product.

The materials used in the examples are as shown below.
(1) Aqueous urethane prepolymer: (Mitsui Chemicals, "EGH-401")
(2) Boric acid: (BORAX Co., Ltd.)
(3) Aluminum phosphite: (Tahei Chemical Industry Co., Ltd., “APA-100”)
(4) Inorganic filler: Aluminum hydroxide (Nippon Light Metal Co., Ltd., “B53”)

“Examples 1 to 3” “Comparative Examples 1 to 4”
In the examples and comparative examples, the following characteristics were evaluated and summarized in Tables 1 and 2.
The measuring method of each characteristic is shown below.
Slurry state: The state of the slurry of aluminum phosphite, inorganic filler and water was examined. The flowable state was evaluated as “good”, and the non-flowable state was evaluated as “impossible”.
Surface hardness: Measured by reading the instruction of the hardness meter immediately after applying a C-type rubber hardness meter (manufactured by Kobunshi Keiki Co., Ltd.) to the foamed molded product.
Shape retention: The foamed molded body was allowed to expand in an atmosphere maintained at 300 ° C. for 0.5 hour, and then the hardness of the expanded body was examined by finger touch. A sponge-like molded body that is hard and firm is "excellent", that it can hold the shape is "good", that the shape is somehow held is "good", those that do not hold the shape, or melted Things were marked as “impossible”.
Oxygen index: Measured according to JIS K7201 using a flammability test apparatus (manufactured by Suga Test Instruments Co., Ltd., ON-1D type).
Durability: A 5 cm square test piece was cut out from the sponge-like molded body, heat-treated in a gear oven at 100 ° C. for 5 days, and then left at room temperature for 1 day to observe the hydrolysis state of the sponge.
“Fair” indicates that there is no change in elasticity due to finger touch, and “impossible” indicates that hydrolysis has occurred and elasticity has been lost.

Claims (4)

  A sponge-like molded article comprising a flexible urethane foam obtained from an aqueous urethane prepolymer, aluminum phosphite and an inorganic filler and having an oxygen index of 40 or more.   The sponge-like molded product according to claim 1, wherein the flexible urethane foam obtained from the aqueous urethane prepolymer is 100 parts by mass, the aluminum phosphite is 10 to 150 parts by mass, and the inorganic filler is 10 to 150 parts by mass. The sponge-like molded product according to claim 1 or 2, wherein the inorganic filler is aluminum hydroxide. The sponge-like molded product according to any one of claims 1 to 3, wherein the sponge-like molded product is a cut product.