Flexible polyurethane foam and method for its production

Abstract

A method for producing a flexible polyurethane foam in an open state, which comprises reacting a polyol with a polyisocyanate compound in the presence of a catalyst, a blowing agent and a foam stabilizer, wherein as the polyol, a polyol having a hydroxyl value of at most 15 mgKOH/g is used.

What is claimed is:  
     
         1 . A method for producing a flexible polyurethane foam in an open state, which comprises reacting a polyol with a polyisocyanate compound in the presence of a catalyst, a blowing agent and a foam stabilizer, wherein as the polyol, a polyol having a hydroxyl value of at most 15 mgKOH/g is used.  
     
     
         2 . The method for producing a flexible polyurethane foam according to  claim 1 , wherein the polyol has an unsaturation value of at most 0.05 meq/g.  
     
     
         3 . The method for producing a flexible polyurethane foam according to  claim 1 , wherein the polyol is a polyol produced by means of a double metal cyanide complex catalyst.  
     
     
         4 . The method for producing a flexible polyurethane foam according to  claim 1 , wherein the polyol contains fine polymer particles.  
     
     
         5 . The method for producing a flexible polyurethane foam according to  claim 1 , wherein as the foam stabilizer, a silicone type foam stabilizer having a silicone content of from 10 to 50 mass %, is used.  
     
     
         6 . The method for producing a flexible polyurethane foam according to  claim 1 , wherein as the polyisocyanate compound, at least one member selected from the group consisting of tolylene diisocyanate, diphenylmethane diisocyanate, polymethylenepolyphenyl polyisocyanate, a tolylene diisocyanate modified product, a diphenylmethane diisocyanate modified product, and a polymethylenepolyphenyl polyisocyanate modified product, is used.  
     
     
         7 . The method for producing a flexible polyurethane foam according to  claim 6 , wherein as the polyisocyanate compound, polymethylenepolyphenyl polyisocyanate or a polymethylenepolyphenyl polyisocyanate modified product is used.  
     
     
         8 . The method for producing a flexible polyurethane foam according to  claim 1 , wherein the polyol has a hydroxyl value of less than 10 mgKOH/g.  
     
     
         9 . The method for producing a flexible polyurethane foam according to  claim 8 , wherein the polyol has an unsaturation value of at most 0.05 meq/g.  
     
     
         10 . The method for producing a flexible polyurethane foam according to  claim 8 , wherein the polyol is a polyol produced by means of a double metal cyanide complex catalyst.  
     
     
         11 . The method for producing a flexible polyurethane foam according to  claim 8 , wherein the polyol contains fine polymer particles.  
     
     
         12 . The method for producing a flexible polyurethane foam according to  claim 8 , wherein as the foam stabilizer, a silicone type foam stabilizer having a silicone content of from 10 to 50 mass %, is used.  
     
     
         13 . The method for producing a flexible polyurethane foam according to  claim 8 , wherein as the polyisocyanate compound, at least one member selected from the group consisting of tolylene diisocyanate, diphenylmethane diisocyanate, polymethylenepolyphenyl polyisocyanate, a tolylene diisocyanate modified product, a diphenylmethane diisocyanate modified product, and a polymethylenepolyphenyl polyisocyanate modified product, is used.  
     
     
         14 . The method for producing a flexible polyurethane foam according to  claim 13 , wherein as the polyisocyanate compound, polymethylenepolyphenyl polyisocyanate or a polymethylenepolyphenyl polyisocyanate modified product is used.  
     
     
         15 . A flexible polyurethane foam which is produced in an open state by reacting a polyol with a polyisocyanate compound in the presence of a catalyst, a blowing agent and a foam stabilizer, wherein as the polyol, a polyol having a hydroxyl value of at most 15 mgKOH/g is used.  
     
     
         16 . The flexible polyurethane foam according to  claim 15 , wherein the polyol has a hydroxyl value of less than 10 mgKOH/g.  
     
     
         17 . The flexible polyurethane foam according to  claim 15 , wherein the polyol is a polyol produced by means of a double metal cyanide complex catalyst.  
     
     
         18 . The flexible polyurethane foam according to  claim 15 , wherein as the foam stabilizer, a silicone type foam stabilizer having a silicone content of from 10 to 50 mass %, is used.  
     
     
         19 . The flexible polyurethane foam according to  claim 15 , wherein as the polyisocyanate compound, at least one member selected from the group consisting of tolylene diisocyanate, diphenylmethane diisocyanate, polymethylenepolyphenyl polyisocyanate, a tolylene diisocyanate modified product, a diphenylmethane diisocyanate modified product, and a polymethylenepolyphenyl polyisocyanate modified product, is used.  
     
     
         20 . The flexible polyurethane foam according to  claim 19 , wherein as the polyisocyanate compound, polymethylenepolyphenyl polyisocyanate or a polymethylenepolyphenyl polyisocyanate modified product is used.