Polyol composition for two-component curable abrasive foam, composition for two-component curable abrasive foam, abrasive foam, and method for producing abrasive foam
A polyol composition contains a polyaminochlorophenylmethane mixture (A) and a polyol (B), in which the component (A) is uniformly dissolved in the component (A) in a weight ratio of 30/70 to 60/40. The component (A) includes 50 to 70% by weight of a specific binuclear polyaminochlorophenylmethane compound, 20 to 40% by weight of a specific trinuclear polyaminochlorophenylmethane compound and 5 to 10% by weight of a specific tetranuclear or higher polyaminochlorophenylmethane compound. The polyol composition exhibits excellent miscibility and dissolution stability, is liquid and enables molding of a foamed article for abrasive in a simple two-component mixing casting machine. According to the present invention, water serving as a foaming agent can be added to the polyol composition containing MBOCA, and the composition for a two-component curable abrasive foam can be held to a temperature equal to or lower than the boiling point of water, thus avoiding water from evaporating upon molding. The resulting abrasive foam has a uniform density distribution and exhibits excellent mechanical properties. A method for satisfactorily producing such an abrasive foam is also provided.
1. A polyol composition (1) for a two-component curable abrasive foam, comprising:
a polyol (B) and
a polyaminochlorophenylmethane mixture (A), which comprises the following compounds which total to a 100% weight basis:
50 to 70% by weight of a binuclear polyaminochlorophenylmethane compound represented by the following formula:
wherein X represents a chlorine atom,
20 to 40% by weight of a trinuclear polyaminochlorophenylmethane compound represented by the following formula:
wherein X represents a chlorine atom, and
5 to 10% by weight of a tetranuclear or higher polyaminochlorophenylmethane compound represented by the following formula:
wherein X represents a chlorine atom; and n represents an integer of 3 or greater,
wherein the polyaminochlorophenylmethane mixture (A) is uniformly dissolved in the polyol (B), and the weight ratio of (A) to (B) ((A)/(B)) stands at 40/60 to 60/40,
wherein the polyol (B) is a polyol containing ether bond in a principal chain thereof and having a molecular weight of 100 to 1500 and/or a polyol containing methyl group in a side chain thereof and having a molecular weight of 50 to 500.
2. The polyol composition for a two-component curable abrasive foam according to claim 1 , wherein the polyol (B) is at least one selected from tetramethylene glycol and polypropylene glycols.
3. A composition for a two-component curable abrasive foam, comprising the polyol composition (1) according to claim 1 , a polyisocyanate (2) and water (3), wherein the composition for a two-component curable abrasive foam, is obtained by
adding water (3) in the polyol composition (1); and
mixing the polyol composition (1) containing water (3), and a polyisocyanate (2).
4. The composition for a two-component curable abrasive foam according to claim 3 , wherein the polyisocyanate (2) is an isocyanate-group-containing urethane prepolymer having an isocyanate equivalent weight of 300 to 580.
5. The composition for a two-component curable abrasive foam according to claim 3 , wherein the polyisocyanate (2) is a toluene diisocyanate urethane prepolymer containing a terminal isocyanate group.
6. An abrasive foam, as a foamed and cured product of the composition for a two-component curable abrasive foam according to claim 3 , wherein the abrasive foam has a specific gravity of 0.3 to 1.2 g/cm 3 .
7. A method for producing an abrasive foam, comprising the steps of casting the composition for a two-component curable abrasive foam of claim 3 in a mold, and foaming and curing the composition.
8. The method for producing an abrasive foam, comprising the steps of
(i.) adding water (3) in a polyol composition (1) for a two-component curable abrasive foam, which comprises
a polyol (B) and
a polyaminochlorophenylmethane mixture (A), which comprises the following compounds which total to a 100% weight basis:
50 to 70% by weight of a binuclear polyaminochlorophenylmethane compound represented by the following formula:
wherein X represents a chlorine atom,
20 to 40% by weight of a trinuclear polyaminochlorophenylmethane compound represented by the following formula:
wherein X represents a chlorine atom, and
5 to 10% by weight of a tetranuclear or higher polyaminochlorophenylmethane compound represented by the following formula:
wherein X represents a chlorine atom; and n represents an integer of 3 or greater,
wherein the polyaminochlorophenylmethane mixture (A) is uniformly dissolved in the polyol (B), and
the weight ratio of (A) to (B) ((A)/(B)) stands at 40/60 to 60/40; wherein the polyol (B) is a polyol containing ether bond in a principal chain thereof and having a molecular weight of 100 to 1500 and/or a polyol containing methyl group in a side chain thereof and having a molecular weight of 50 to 500,
(ii.) separately placing the polyol composition (1) containing water (3) and a polyisocyanate (2) into each tank of a two-component mixing casting machine,
(iii.) heating the polyol composition (1) containing water (3) at 40° C. to 70° C., and heating the polyisocyanate (2) at 40° C. to 90° C.,
(iv.) mixing the heated polyol composition (1) containing water (3) and the heated polyisocyanate (2) in the two-component mixing casting machine to yield a composition for a two-component curable abrasive foam,
(v.) casting the composition for a two-component curable abrasive foam in a mold at 80° C. to 120° C.; and
(vi.) foaming and curing the composition casted in the mold.
9. The abrasive foam, which is obtained by the method for producing an abrasive foam according to claim 8 , wherein the abrasive foam has a specific gravity of 0.3 to 1.2 g/cm 3 .