CN101376742B - Urethane foam molded article, manufacturing method thereof, and magnetic induction foam molding apparatus - Google Patents

Urethane foam molded article, manufacturing method thereof, and magnetic induction foam molding apparatus Download PDF

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CN101376742B
CN101376742B CN2008101467400A CN200810146740A CN101376742B CN 101376742 B CN101376742 B CN 101376742B CN 2008101467400 A CN2008101467400 A CN 2008101467400A CN 200810146740 A CN200810146740 A CN 200810146740A CN 101376742 B CN101376742 B CN 101376742B
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foam molding
magnetic
foaming
polyurethane foam
mentioned
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CN101376742A (en
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富山幸治
井门康司
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Sumitomo Riko Co Ltd
Nagoya Institute of Technology NUC
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Sumitomo Riko Co Ltd
Nagoya Institute of Technology NUC
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Abstract

The invention provides a magnetic induction foam molding apparatus comprising: a pair of electromagnet parts, each of which has a core part composed of a ferromagnet and a coil part placed on the outer circumference surface of the core part, and that are placed so as to face each other and depart from each other with a predetermined distance in the axis direction of the core part; a foaming mold interposed between the pair of electromagnet parts, inside which a cavity is defined; and a yoke part connecting back surfaces of the respective core parts of the pair of the electromagnet pats so as to form a magnetic path between a pair of the back surfaces. In the cavity of the foaming mold, a uniform magnetic field is formed.

Description

Polyurethane foam molding and manufacture method thereof, and magneticinduction foam forming device
Technical field
The present invention relates to for example be used as the polyurethane foam molding and the manufacture method thereof of sound-absorbing material, absorption of vibrations material etc. and the magneticinduction foam forming device that is fit to manufacturing polyurethane foam molding.
Background technology
The polyurethane foam molding can be extensive use of in various fields such as daily necessities, automobile, building as cushioning material, sound-absorbing material, absorption of vibrations material etc.The polyurethane foam molding is made (for example, with reference to patent documentation 1,2) by aqueous foaming polyurethane resin raw material is carried out foaming and molding in the die cavity of foaming mould usually.On the other hand, in order to eliminate the problems such as misrun in the polyurethane foam molding, in patent documentation 3, disclose such method, promptly, mictomagnetism body in the foaming polyurethane resin raw material, Yi Bian apply magnetic field and attract this magnetic substance to carry out foaming and molding on one side from a direction.In addition, as not being foaming and molding but giving the method for electroconductibility, thermal conductivity, disclose and in resin, be mixed into metallic magnetic gonosome powder, the method that in magnetic field, forms (for example, with reference to patent documentation 4) resin forming product.
Patent documentation 1: TOHKEMY 2003-97645 communique
Patent documentation 2: TOHKEMY 2005-48023 communique
Patent documentation 3: TOHKEMY 2006-181777 communique
Patent documentation 4: TOHKEMY 2002-11758 communique
But, up to now, in utilizing the manufacturing process in magnetic field, all do not consider the interior magnetic force distributions of die cavity such as foaming mould.For example, under situation about forming between the magnet of facing mutually, the closer to the periphery of magnet, the magnetic line of force of She Chuing is many more laterally.Therefore, magneticflux-density diminishes along the hole enlargement direction of magnet.In addition, when interval between magnet increases, corresponding to the distance of magnet, magneticflux-density is easy to generate difference.Therefore, be difficult to make roughly the whole shaped material of the action of a magnetic field in being filled in die cavity uniformly.Under the situation about in magnetic field the shaped material that is mixed with magnetic substance being formed, magnetic substance is along the magnetic line of force orientation.Thereby, in the magnetic field inhomogeneous at magnetic line of force, that the magneticflux-density difference is bigger, produce magnetic substance according to magneticflux-density different and inhomogeneous dispersive molding.
Thereby, carrying out under the situation of foaming and molding in inhomogeneous in magneticflux-density, as the to have field gradient magnetic field, the magnetic substance in the foaming polyurethane resin raw material moves to unwanted direction along magnetic line of force.Therefore, the directed state that can't obtain to expect.Thereby the polyurethane foam molding of making is difficult to obtain desired characteristics.In this case, for example, can improve the dispersiveness of magnetic substance by the combined amount that increases magnetic substance.But, with increase the magnetic substance combined amount accordingly, magnetic substance increases the influence of foaming and molding.As a result, may reduce various characteristicses such as sound absorption characteristics, thermal insulation, resiliency.In addition, the weight of polyurethane foam molding increases, and manufacturing cost also increases.
Summary of the invention
The present invention promptly makes in view of such practical situation, and its purpose is to provide with the directed state of regulation and contains the polyurethane foam molding and the manufacture method thereof of magnetic substance and the magneticinduction foam forming device that is fit to manufacturing polyurethane foam molding.
(1) polyurethane foam molding of the present invention is characterised in that, it has the magnetic substance that has been directed, this magnetic substance with the direction of orientation direction approximate vertical on roughly disperse equably.
In polyurethane foam molding of the present invention, ground disposes along prescribed direction as long as magnetic substance has certain systematicness.For example, at one end linearly configuration between face and other end (also can not be the end face that becomes 180 ° of ground to face mutually with an end face) also can form curve-like.In addition, also can form and be radial from the center outward week.At this, magnetic substance with the direction of orientation direction approximate vertical on roughly disperse equably.Since magnetic substance with the direction of orientation direction approximate vertical on homodisperse, therefore, can give full play to the directional effect of magnetic substance, thereby can obtain desired characteristics corresponding to directed state.In addition, because magnetic substance is roughly disperseed equably, therefore,, also can obtain the directional effect of magnetic substance even the amount of magnetic substance is less.
(2) in addition, the manufacture method of polyurethane foam molding of the present invention is characterised in that it comprises: the raw material injection process, and the raw material that will contain foaming polyurethane resin raw material and magnetic substance is injected in the die cavity of foaming mould; The foaming and molding operation, on one side so that the magneticflux-density in this die cavity roughly uniformly the mode magnetic field of working carry out foaming and molding on one side.
In the foaming and molding operation, the magneticflux-density in die cavity is roughly carried out foaming and molding in the magnetic field uniformly.Therefore, can suppress because the magnetic substance dispersion that the magneticflux-density difference causes is inhomogeneous, thus the directed state that can obtain to expect.In addition, even the combined amount of magnetic substance is less, also can make magnetic substance with dispersive state orientation equably roughly.Thereby, adopt the manufacture method of polyurethane foam molding of the present invention, can make polyurethane foam molding easy and at low cost with desired characteristic.
(3) in addition, magneticinduction foam forming device of the present invention is characterised in that, it comprises a pair of electro-magnet portion, foaming mould and yoke portion; Above-mentioned a pair of electro-magnet portion comprises the core that is made of ferromagnetic substance and is disposed at the coil portion of this core periphery, and should be a pair of electro-magnet portion on the axis direction of this core, separately practise physiognomy predetermined distance and dispose over the ground; Above-mentioned foaming mould is located between this a pair of electro-magnet portion, in internal separation die cavity is arranged; Above-mentioned yoke portion will this a pair of electro-magnet portion the coupling together between the face dorsad of this core separately, a pair of this dorsad face form magnetic circuit each other; In this die cavity of this foaming mould, be formed with the magnetic substance that is used to make the described polyurethane foam molding of technical scheme (1) with the direction of the orientation direction approximate vertical of this magnetic substance on the magnetic field of dispersed uniform equably roughly.
Adopt magneticinduction foam forming device of the present invention, in by the die cavity of the core separately of a pair of electro-magnet portion, foaming mould and magnetic circuit that yoke portion constitutes, magnetic line of force forms the loop line.Therefore, can suppress magnetic line of force and leak, thereby can in die cavity, form stable roughly uniform magnetic field.In addition, the intensity of easy controlling magnetic field etc. are because magnetic line of force leaks cause also less to externalities.In addition, leak owing to can suppress magnetic line of force, therefore, the magnetic force waste is less, can make device self miniaturization.Like this, adopt magneticinduction foam forming device of the present invention, can in die cavity, easily form roughly magnetic field uniformly.Therefore, be fit to make the polyurethane foam molding of the invention described above.
Description of drawings
Fig. 1 is the explanatory view about the length of the cross section longitudinal edge of the length of the cross section horizontal edge of the maximum length in each shape of magnetic fillers, square with the axis direction, square with the axis direction.
Fig. 2 is the synoptic diagram that the part of reaction under the situation be mixed with magnetic viscosity fluidic mixing material, in the foaming and molding operation is used in expression.
Fig. 3 is the stereographic map as the magneticinduction foam forming device of an embodiment of the invention.
Fig. 4 is the part sectioned view of this magneticinduction foam forming device.
Fig. 5 is the graphic representation of an example of the measurement result of the magneticflux-density in the expression foaming mould die cavity.
Fig. 6 is the sectional view of non-uniform magnetic-field foam forming device.
Fig. 7 is the explanatory view of the coordinate axis in the die cavity.
Fig. 8 is a cross-section photograph of cutting off the foam molding of embodiment A 2 along the vertical direction.
Fig. 9 is a cross-section photograph of cutting off the foam molding of embodiment A 3 along the vertical direction.
Figure 10 is the upper surface photo of the foam molding of Comparative examples A 1.
Figure 11 is the lower surface photo of this foam molding.
Figure 12 is near the cross-section photograph of thickness direction that this foam molding has been cut off the center.
Figure 13 is the sectional view of the heat test device of (embodiment A).
Figure 14 is upper surface temperature measuring result's the graphic representation of each foam molding of expression embodiment A 1～A3 and Comparative examples A 2.
Figure 15 is the graphic representation of sound absorbing coefficient measurement result of each foam molding of expression embodiment A 1～A3.
Figure 16 is the upper surface photo of the foam molding of Embodiment B 1.
Figure 17 is a photo of taking the foam molding of Embodiment B 1 from front side top.
Figure 18 is a photo of taking the foam molding of Embodiment B 2 from front side top.
Figure 19 is the SEM photo (multiplying power is 2000 times) in cross section of the foam molding of Embodiment B 2.
Figure 20 is the upper surface photo of the foam molding of comparative example B3.
Figure 21 is a photo of taking this foam molding from front side top.
Figure 22 is the load-displacement curve about each foam molding of Embodiment B 2 and comparative example B1, B2.
Figure 23 is about Determination of thickness results each foam molding of Embodiment B 2 and comparative example B1, B2, the load test front and back.
Figure 24 is the load-displacement curve by the foam molding manufactured samples of Embodiment B 2.
Figure 25 is the load-displacement curve by the foam molding manufactured samples of comparative example B1.
Figure 26 is the load-displacement curve by the foam molding manufactured samples of comparative example B2.
Figure 27 is the photo of lower surface of the foam molding of Embodiment C.
Figure 28 is the photo of the upper surface of this foam molding.
Figure 29 is the lateral photo of this foam molding.
Figure 30 is the cross-section photograph of cutting off along the vertical direction behind this foam molding.
Figure 31 is the graphic representation of sound absorbing coefficient measurement result of the foam molding of expression Embodiment C and comparative example C.
Figure 32 is a part sectioned view of making the employed magneticinduction foam forming device of foam molding of embodiment D.
Figure 33 is the upper surface photo of the foam molding of embodiment D.
Figure 34 be by microscope photographing to the enlarged photograph (multiplying power is 175 times) of this foam molding upper surface.
Figure 35 is the upper surface photo of the foam molding of Comparative Example D.
Figure 36 be by microscope photographing to the enlarged photograph (multiplying power is 175 times) of this foam molding upper surface.
Embodiment
Below, the embodiment of polyurethane foam molding of the present invention and manufacture method thereof and magneticinduction foam forming device is described.In addition, polyurethane foam molding of the present invention and manufacture method thereof and magneticinduction foam forming device are not limited to following embodiment, can implement with the variety of way of having implemented the change that those skilled in the art can carry out, improvement etc. in the scope that does not break away from purport of the present invention.
The polyurethane foam molding
As mentioned above, polyurethane foam molding of the present invention has the magnetic substance that has been directed.Magnetic substance is so long as so-called magneticsubstance gets final product not special the qualification.For example, be suitably for ferromagnetic substance, MnO, Cr such as iron, nickel, cobalt, gadolinium, stainless steel 2O 3, FeCl 2, antiferromagnetic material such as MnAs and adopt the alloy type that they make.For example, improve in desire under the situation of thermal diffusivity of polyurethane foam molding, be suitably for stainless steel, copper-iron alloy etc.At this, stainless rustless property is good, and the bond strength of itself and urethane foam is also higher.In addition, copper-iron alloy is the eutectic alloy of copper and iron.As copper-iron alloy, for example be contemplated to be such semi-rigid magnetic copper-iron alloy described in the special fair 3-064583 communique of Japan.Even such copper-iron alloy is pulverized very carefully, can not produce peeling off of copper and iron yet.Therefore, these 2 characteristics of the magnetic that high thermal conductivity coefficient and iron had that have copper simultaneously and had.Therefore, even identical content is compared also with other magnetic substances and can be obtained higher radiating effect.
Do not limit for the size of magnetic substance, shape etc. are special.For example, can be to constitute magnetic fluid (Magnetic fluid; MF) nanoparticle, formation magnetic viscosity fluid (Magneto-Rheological fluid; The MR fluid) micron particle.In addition, also can be magnetic fillers with different shapes such as spherical, oval spherical, oval spherical (linking the shape that a pair of hemisphere of facing mutually forms), water droplet shape, column, lamellar, paper tinsel shape, fibrous, needle-likes with cylinder.
The thermal conductivity of magnetic fillers is good.Therefore, under situation about containing, become the polyurethane foam molding of fine heat radiation property as the magnetic fillers of magnetic substance.In addition, form at magnetic fillers under the situation of the shape except that spherical, directed magnetic fillers is not with point but with at least a contact the in line and the face each other.Therefore, and compare with a situation about contacting, the mutual contact area of magnetic fillers increases.Thus, be easy to guarantee the conducting path of heat, and the heat that is conducted increases also.Therefore, thermal diffusivity is higher.
Form at magnetic fillers under the situation of the shape except that spherical, consider from the aspect of further raising thermal diffusivity, the aspect ratio of expectation magnetic fillers is more than 2.In this manual, define aspect ratio by following formula (1).
Aspect ratio=b 2/ (aa ') ... formula (1)
In formula (1), b represents the maximum length of magnetic fillers, and a represents the length of the cross section horizontal edge of square with the axis direction, the length of the cross section longitudinal edge of the square with the axis direction of a ' expression.At this, " length of the cross section horizontal edge of square with the axis direction ", " length of the cross section longitudinal edge of square with the axis direction " by as make decision.That is, serve as axially with the maximum length b of magnetic fillers, be connected to tetragon in the foundation with the cross-sectional shape of this axial vertical direction (square with the axis direction).Make the lateral length when overlooking this tetragon be " the length a of the cross section horizontal edge of square with the axis direction ", making longitudinal length is " the length a ' of the cross section longitudinal edge of square with the axis direction ".Below, enumerate concrete shape and describe.
Fig. 1 represents the length of the cross section longitudinal edge of the length of the cross section horizontal edge of the maximum length in each shape of magnetic fillers, square with the axis direction, square with the axis direction.In Fig. 1, (a) the expression magnetic fillers is columned situation, and (b) the expression magnetic fillers is laminal situation, and (c) the expression magnetic fillers is fibrous situation.In addition, the shape shown in Fig. 1 (a)～(c) is an illustration, and magnetic fillers is not limited to these shapes.At first, under the columned situation shown in (a), axial length is maximum length b.The cross-sectional shape of square with the axis direction is circular.In be connected to this circle tetragonal lateral length be " the length a of the cross section horizontal edge of square with the axis direction ", longitudinal length is " the length a ' of the cross section longitudinal edge of square with the axis direction ".Then, under the laminal situation shown in (b), length direction is that axially the length on the length direction is maximum length b.The cross-sectional shape of square with the axis direction is a rectangle, and therefore, this rectangular lateral length is " the length a of the cross section horizontal edge of square with the axis direction ", and longitudinal length (being equivalent to thickness) is " the length a ' of the cross section longitudinal edge of square with the axis direction ".Then, under the fibrous situation shown in (c), axial length is maximum length b.The cross-sectional shape of square with the axis direction is a substantially elliptical.But, under the fibrous situation shown in (c), be that the length direction central part is big, less " elongated tube " the such shape in both ends.Therefore, in the length direction total length, the size in the cross section of square with the axis direction is non-constant.That is, at position alpha, position β and position γ place, oval section area difference.In this case, in be connected to the section area maximum the tetragonal lateral length of ellipse at β place, position for " the length a of the cross section horizontal edge of square with the axis direction ", longitudinal length is " the length a ' of the cross section longitudinal edge of square with the axis direction ".
Usually, exist on the surface of polyurethane foam molding alveolate peristome, because of the die surface transfer printing of foaming mould form fine concavo-convex.Therefore, the contact area when causing the polyurethane foam molding to contact with counter-element diminishes, with its correspondingly, thermal conductivity reduces.Thereby, for example,, also can be difficult to because of condition of surface is relatively poor between polyurethane foam molding and counter-element, conduct heat even improve inner thermal diffusivity by the orientation of magnetic fillers.In order to solve such problem, the glossiness that makes the thermal conductive surface in the polyurethane foam molding of the present invention is to get final product more than 10%.It is 15% better when above making glossiness.At this, thermal conductive surface is the face that contacts and conduct heat with counter-element.Counter-element both can be a heating element, also can be heat-absorbing body.Thermal conductive surface is configured to intersect with the orientation direction of magnetic substance.Thermal conductive surface can be one, also can be more than two.
Glossiness is measured according to JIS Z8741 (1997).That is, in the whole zone of specific refractory power, be in the glass surface of steady state value 1.567 in the visible wavelengths scope, be that 60 ° of mirror surface lusters of locating are benchmark with input angle, be 100% with this value representation.Be considered as in this manual, glossiness is big more, thermal conductive surface surface concavo-convex few more, level and smooth more.
Compare with the condition of surface of common polyurethane foam molding, glossiness is thermal conductive surface concavo-convex less, comparatively level and smooth more than 10%.Therefore, the contact area of thermal conductive surface and counter-element (heat-conducting area) increases, and the heat of between conduction increases.For example, the heat that is transmitted to thermal conductive surface (end) from counter-element mainly is transmitted to the other end of its orientation direction via magnetic substance in the inside of polyurethane foam molding.Then, dispel the heat rapidly from the other end.Like this, when adopting the polyurethane foam molding of present embodiment, can not given full play to the effect of the raising thermal conductivity that produces by the inner magnet gonosome by the condition of surface of thermal conductive surface with hindering.As a result, can further improve the thermal conductivity of whole polyurethane foam molding.
But during with foaming polyurethane resin raw material foaming and molding, the foaming polyurethane resin raw material contacts with the die surface of foaming mould in airtight foaming mould.Because of this contact suppresses foaming, form the higher epidermal area of density.Magnetic substance, the bubble that produces because of foaming are sealed by epidermal area, are difficult to be exposed to the surface.Thereby expectation is made thermal conductive surface with the surface of epidermal area.Do not limit for the thickness of epidermal area is special, for example make that 20 μ m are following to get final product.
In the polyurethane foam molding of the present invention, the magnetic substance that has been directed with the direction of orientation direction approximate vertical on roughly disperseed equably.As an example, list magnetic substance and be oriented the form that is spike from the outwards interior direction of an end face.When adopting this form, almost constant with the concentration of magnetic substance on the direction of orientation direction approximate vertical.That is, magnetic substance with the direction of orientation direction approximate vertical on roughly disperseed equably.On the other hand, on orientation direction, the concentration of magnetic substance changes.At this, the concentration of magnetic substance can change smoothly gradually along orientation direction, also can change steppedly.Relative therewith, magnetic substance not only with the direction of orientation direction approximate vertical on roughly disperse equably, also can on orientation direction, roughly disperse equably.That is, in whole polyurethane foam molding, also can make the concentration of magnetic substance that magnetic substance is roughly disperseed equably.In this case, in whole polyurethane foam molding, the directed state of magnetic substance is roughly even.
The manufacture method of polyurethane foam molding
The manufacture method of polyurethane foam molding of the present invention has raw material injection process and foaming and molding operation.Below, describe for each operation.
(1) raw material injection process
This operation is that the raw material that will comprise foaming polyurethane resin raw material and magnetic substance is injected into the operation in the die cavity of foaming mould.The foaming polyurethane resin raw material is got final product by known in the past raw material modulation such as polymeric polyisocyanate composition and polyhydroxy reactant.
The polyisocyanates composition can suitably be selected from for example tolylene diisocyanate, phenylene diisocyanate, Xylene Diisocyanate, diphenylmethanediisocyanate, triphenylmethane triisocyanate, polymethylene multi-phenenyl isocyanate, naphthalene diisocyanate and these derivative (for example, the prepolymer class that obtains by the reaction with polyalcohols, modified polyisocyanate class etc.) etc.In addition, polyhydroxy reactant can suitably be selected from multi-hydroxy compound, polyether glycol class, polyester polyols alcohols, polymer polyatomic alcohol class, the polynary amine of polyethers, polyester polyols amine, alkylidene polyol class, urea dispersed polyol class (urea-dispersed polyols), melamine-modified polyalcohols, polycarbonate polyalcohols, acrylic polyol (Acryl polyol) class, polybutadiene polyol class, phenol-modified polyalcohols etc.
Can also suitably cooperate catalyzer, whipping agent, surfactant, linking agent, fire retardant, static inhibitor, viscosity depressant, stablizer, packing material, tinting material etc.For example, catalyzer can list amine series catalysts or organo-metallic series catalysts such as tin laurate, stannous octoate such as four ethylene diamines, triethylenediamine, dimethylethanolamine.In addition, whipping agent is suitably for water.Whipping agent beyond the water can list methylene dichloride, freonll-11, CO 2Gas etc.In addition, surfactant is suitably for the silicone-based surfactant, and linking agent is suitably for trolamine, diethanolamine etc.
Be injected into raw material in the die cavity of foaming mould with above-mentioned foaming polyurethane resin raw material as must composition, can adopt various forms.For example, state in the use under the situation of magnetic fillers as magnetic substance, this raw material is made mixed the mixing material that foaming polyurethane resin raw material and magnetic fillers form and get final product (first form).In this case, raising effect, sound absorption characteristics, the cost of consideration thermal diffusivity wait and suitably determine the combined amount of magnetic fillers to get final product.For example, consider, more than the 0.1 volume % when expectation makes the combined amount of magnetic fillers be 100 volume % for the volume with the polyurethane foam molding from the aspect that improves thermal diffusivity.If it is better more than the 1 volume %.On the other hand, consider dispersiveness to magnetic fillers, to the influence of sound absorption characteristics etc., it is below the 20 volume % that expectation makes the combined amount of magnetic fillers.If it is better below the 3 volume %.
In addition, the polyurethane foam molding that the characteristic on the orientation direction of magnetic substance is different with characteristic on the direction of intersecting with this orientation direction is suitable for the anisotropic purposes of requirement.Have anisotropic polyurethane foam molding and for example can constitute and have the foaming main body, this foaming main body has the emptying aperture that has been directed in the mode that is communicated with towards the other end from an end.In this case, according to the load-displacement curve of polyurethane foam molding, the static spring constant on the orientation direction of expectation emptying aperture is more than 2 times of static spring constant on the direction with this orientation direction approximate vertical.If more than 4 times or even then better more than 10 times.In addition, the static spring constant in this specification sheets is that using thickness is the value that the load of sample when thickness direction compresses 2mm (10%) of 20mm calculates divided by displacement.
Under the situation of making such polyurethane foam molding, making above-mentioned raw materials is to have mixed the mixing material that foaming polyurethane resin raw material and magnetic viscosity fluid form to get final product (second form).In this form, " magnetic viscosity fluid " not only is meant above-mentioned MR fluid, more broadly refers to " being dispersed with the atomic fluid of magnetic substance in solvent ".Thereby, except comprising the MR fluid that contains micron order magnetic substance particle, also be included in and mixed magnetic mixed solution (the Magnetic compoundfluid that micron magnetic substance particle forms among the MF that contains nano-scale magnetic body particle in " magnetic viscosity fluid "; MCF) etc.Here said magnetic mixed solution (MCF) for example is the particle dispersion-type mixing functions fluid described in the TOHKEMY 2002-170791 communique.As " the magnetic viscosity fluid " sold on the market, for example, can use commodity " MRF-122-2ED ", " MRF-132DG ", " MRF-140CG " of commodity " E-600 ", the ロ-De corporate system of シ グ マ Ha イ ケ ミ カ Le corporate system etc.
When the magnetic viscosity fluid was applied magnetic field, dispersed magnetic substance particle linked up along the direction in magnetic field and forms the catenate bundle.Thus, magnetic viscosity fluidic viscosity sharply rises.When carrying out foaming and molding in magnetic field, the magnetic viscosity fluid viscosity increases, and on the field direction, promptly directed on the direction of the other end from an end of foaming mould.To this aftermentioned.
From improving foaminess, make more the aspects such as polyurethane foam molding of light weight and consider, expectation uses the amount less substance that hinders the such additive of foaming (stablizer etc. that for example, has broken bubble effect) as the magnetic viscosity fluid.In addition, expectation magnetic substance particle roughly is scattered in the solvent equably.In order to satisfy such requirement, for example, preferably the magnetic viscosity fluid precipitation that comprises solvent, be scattered in the magnetic substance particle in this solvent and be used to suppress this magnetic substance particle precipitation prevents agent.In addition, in the magnetic viscosity fluid of this formation, also can be mixed with other additives (for example, tinting material etc.) that do not hinder foaming.Adopt this formation, compare, can improve frothing percentage with the situation of using above-mentioned MR fluid, MCF.And for example can make density is 0.2g/cm 3The polyurethane foam molding of following light weight.And, when only preventing that by solvent, the precipitation that is scattered in the magnetic substance particle in this solvent and is used to suppress this magnetic substance particle precipitation agent from constituting the magnetic viscosity fluid, because of lightweight, the cost degradation of polyurethane foam molding better.
At this, be used to disperse the solvent of magnetic substance particle can list for example solvent of oil bases such as kerosene, isoparaffin, polyalphaolefin.Wherein, not volatile reason under normal temperature, the high-temperature atmosphere, polyalphaolefin is more suitable.In addition, anti-sedimentation agent is suitably for montmorillonite.
The particle dia of expectation magnetic substance particle is below the above 10 μ m of 1 μ m.At this, the maximum diameter that adopts the magnetic substance particle is as particle dia.See below in detail and state, but in the foaming and molding operation, generating in the foaming polyurethane resin raw material there is bubble.The magnetic viscosity fluid enters in the film (vacuolar membrane) of bubble, and control is as the vacuolar membrane of bubble skeleton flow (reference Fig. 2 described later) under the effect in magnetic field.Under the situation of particle dia less than 1 μ m, the magnetic substance particle when having applied magnetic field reduces the influence of vacuolar membrane.Therefore, be difficult to control vacuolar membrane.On the other hand, at particle dia during greater than 10 μ m, solvent and magnetic substance separate particles and the magnetic substance particle precipitates easily.Therefore, may only carry out orientation and be difficult to control vacuolar membrane the magnetic substance particle.
For the emptying aperture that forms expectation or consider the rerum natura of the polyurethane foam molding that obtains, suitably adjust the magnetic viscosity fluid and get final product with respect to the combined amount of foaming polyurethane resin raw material.For example, in order to ensure the responsiveness with respect to magnetic field, expectation mixes the above magnetic viscosity fluid of 10 mass parts with respect to having mixed foaming polyurethane resin raw material 100 mass parts that polymeric polyisocyanate composition and polyhydroxy reactant form.It is better when above to mix 15 mass parts.On the contrary, consider the rerum natura of polyurethane foam molding, during to the influencing of response behaviour, expectation is with respect to mixing foaming polyurethane resin raw material 100 mass parts that polymeric polyisocyanate composition and polyhydroxy reactant form, and making magnetic viscosity fluidic combined amount is below 70 mass parts.It is better when if mixing 40 mass parts are following.
The foaming polyurethane resin raw material, the magnetic viscosity fluid that constitute mixing material are liquid.Therefore, foaming polyurethane resin raw material and magnetic viscosity fluidic admixture are good.In addition, can not be created in the powder particle precipitation that is easy to produce when using the powder magnetic substance, dispersed bad such problem.In addition, also handle easily, also less to the burden of equipment.
In addition, making, containing fluid by foaming polyurethane resin raw material and at least one magnetic substance of from MF, MR fluid, MCF, selecting and constitute above-mentioned raw materials and get final product along under the situation of the different polyurethane foam molding of the orientation direction characteristic of magnetic substance.Then, mixed foaming urethane resin raw material and magnetic substance do not contain fluid, get final product (the 3rd form) but they are injected in the die cavity respectively.For example, before injecting the foaming polyurethane resin raw material, in advance when the bottom of die cavity is injected magnetic substance and contained fluid, the magnetic substance that magnetic substance contains in the fluid to be contained contains the fluidic face and carries out orientation along the direction of magnetic line of force from being laid with magnetic substance.Thus, can change the bubble structure along the orientation direction of magnetic substance.
As the MF that uses in this form, MR fluid, MCF, expectation uses the solvent be dispersed with magnetic substance easily the magnetic substance that the foamable reaction of foaming polyurethane resin raw material exerts an influence to be contained fluid.For example, can enumerate water outlet, polyalphaolefin etc.Particularly preferably use at least one among MR fluid and the MCF.MR fluid, MCF influence bigger to the foamable reaction of foaming polyurethane resin raw material.That is, to the MR fluid, when MCF applies magnetic field, viscosity sharply rises.Therefore, when carrying out foaming and molding in magnetic field, MR fluid, MCF carried out directed flow before the foamable reaction of foaming polyurethane resin raw material, constraint foaming polyurethane resin raw material.Therefore, foamable reaction is difficult to carry out.As a result, can change the bubble structure of the part that MR fluid, MCF acted on significantly.
More than, as the formation illustration of raw material three kinds of forms.Be injected with the raw material of regulation and airtight foaming mould and supplied to next foaming and molding operation rapidly.But in order to bring into play the effect of the raising thermal conductivity that is produced by magnetic substance fully, the thermal conductive surface of expectation polyurethane foam molding is level and smooth as far as possible.As the method for the level and smooth thermal conductive surface that is shaped, for example, consider to carry out the method for foaming and molding at releasing agent such as the die surface coating silicone grease of foaming mould.But, when using releasing agent, may releasing agent be arranged in the surface attachment of the polyurethane foam molding that obtains, all characteristics such as sound absorption characteristics are exerted an influence.In addition, the releasing agent that adheres to also might wear out and produce bad.In addition, may smear the condition of surface variation that inhomogeneous grade makes thermal conductive surface on the contrary because of releasing agent.In addition, because of the materials cost of releasing agent, append working procedure of coating etc. and increase manufacturing cost.
Therefore, for foaming mould, it is below the 0.5 μ m that expectation makes the surfaceness of thermal conductive surface forming mould surface of the thermal conductive surface of formed polyurethane foam molding.That is, to be that 0.5 μ m is following get final product the surfaceness of the part of thermal conductive surface (thermal conductive surface forming mould surface) that is used to be shaped at least in the die surface of foaming mould.In addition, also can be that the surfaceness of the whole die surfaces in the foaming mould is below the 0.5 μ m.The surfaceness of thermal conductive surface forming mould surface is that the following or even 0.1 μ m of 0.3 μ m is better when following.In this manual, surfaceness adopts the value of the arithmetic average roughness (Ra) that calculates according to JISB0601 (2001).
By the surfaceness that makes the thermal conductive surface forming mould surface in the foaming mould is below the 0.5 μ m, and concavo-convex less level and smooth thermal conductive surface can be shaped.That is, for example can easily obtain to have the polyurethane foam molding that glossiness is the thermal conductive surface more than 10%.In addition, owing to can not use releasing agent, therefore, do not exist owing to the above-mentioned problem that produces of adhering to etc. because of releasing agent yet.
Such foaming mould for example can obtain by the thermal conductive surface forming mould surface being implemented surface treatments such as grinding.In addition, also can use demoulding resin molding.That is, comprising thermal conductive surface forming mould surface ground at least is that the demoulding below the 0.5 μ m gets final product with resin molding along the die surface configuration surface roughness of foaming mould.In this case, the thermal conductive surface forming mould surface is formed with resin molding by this demoulding.As long as use demoulding resin molding, just can directly use the foaming mould of present situation.In addition, do not need release agent application yet.
Expectation demoulding resin molding is the film that is difficult for being attached on the polyurethane foam molding.For example, can list the film of polyethylene terephthalate (PET), polyester, polyethylene (PE), polypropylene (PP), silicone resin, polytetrafluoroethylene (PTFE) etc.The demoulding can be cut off the back with commercially available film with resin molding and use.Use after perhaps can being configured as the die surface shape of setting by known methods such as vacuum forming, injection forming, blow moldings.
(2) foaming and molding operation
This operation is on one side so that the operation of foaming and molding is carried out in the roughly uniform mode effect magnetic field of the magneticflux-density in the foaming mould die cavity on one side.For example magnetic substance is being orientated under the situation of linearity, the magnetic line of force in the die cavity of expectation foaming mould forms a end from die cavity towards the other end almost parallel.In this case, for example clipping the mode of foaming mould, distributed magnet gets final product near the two sides of the end of foaming mould and the other end.Use permanent magnet or electro-magnet to get final product for magnet.When using electro-magnet, can moment the switching field unlatching, the closing condition that form, easily controlling magnetic field intensity.Therefore, control foaming and molding easily.At this, the magnetic line of force that expectation constitutes magnetic field constitutes the loop line.By constituting in this wise, suppress the leakage of magnetic line of force, can in die cavity, form stable roughly uniform magnetic field.In addition, owing to utilize the magnet be disposed at the foaming mould outside to form magnetic field, therefore preferably use the lower material of permeability, be that the material of non magnetic material is as foaming mould in the inside of foaming mould.For example, the foaming mould of common employed aluminium, aluminium alloy system is just no problem if polyurethane foam is shaped.In this case, the magnetic field, the magnetic line of force that produce from electro-magnet isodynamic source are difficult for being affected, and are easy to the controlling magnetic field state.But, also can suitably use magneticsubstance according to the magnetic field of necessity, the state of magnetic line of force.
In this operation, the magneticflux-density in the die cavity is roughly even.For example, the difference of the magneticflux-density in the die cavity be preferably in ± 10% in.± 5% with interior or even ± 3% with Nei Shigengjia.By form roughly magnetic field uniformly in the die cavity of foaming mould, the dispersion that can suppress magnetic substance is inhomogeneous, thus the directed state that can obtain to expect.
Be desirably in the viscosity of foaming polyurethane resin raw material lower during in apply magnetic field.If apply magnetic field at the increase of foaming polyurethane resin raw material viscosity, foaming and molding when being through with to a certain extent, then magnetic substance is difficult to orientation, therefore, is difficult to obtain desired characteristics.In addition, in the full time that carries out foaming and molding, do not need to apply magnetic field.
For example, in the above-mentioned raw materials injection process, under the situation of the raw material of employing first form, be scattered in the magnetic fillers in the foaming polyurethane resin raw material, when foaming and molding, link up and be directed along field direction.
In addition, as mentioned above, under the situation of the raw material that adopts second form, the magnetic viscosity fluid viscosity increases during foaming and molding, and along the field direction orientation.In this case, the reaction in the foaming and molding operation is as follows.Fig. 2 represents the part of the reaction in the foaming and molding operation of this form with synoptic diagram.Shown in Fig. 2 (a), in the foaming and molding operation, generating in foaming polyurethane resin raw material 90 has bubble 92.Surfactant 900 stabilizations that the film of bubble 92 (vacuolar membrane) 920 surfaces are contained because of foaming polyurethane resin raw material 90.In foaming polyurethane resin raw material 90, be mixed with magnetic viscosity fluid 91.Magnetic viscosity fluid 91 is dispersed with magnetic substance particle 911 and constitutes in solvent 910.When generating bubble 92, magnetic viscosity fluid 91 enters into vacuolar membrane 920.That is, solvent 910 makes magnetic substance particle 911 enter into vacuolar membrane 920 as carrier.On the other hand, solvent 910 has broken bubble effect.Therefore, shown in Fig. 2 (b), utilize the solvent 910 that enters into vacuolar membrane 920 to destroy bubble 92.At this, when applying magnetic field (among the figure, magnetic field is above-below direction), vacuolar membrane 920 flows according to the orientation of magnetic substance particle 911, forms the skeleton of polyurethane foam molding.As a result, be formed with the emptying aperture that has been directed in the mode that is communicated with towards the other end from an end.
Emptying aperture is oriented the identical direction of orientation direction of the magnetic substance that is contained with the magnetic viscosity fluid.Emptying aperture can be communicated with towards the other end from an end, also can be communicated with halfway each other by each emptying aperture.In addition, for not special qualifications the such as quantity of the shape of the emptying aperture that is exposed to end face (peristome), size, per unit area.These can wait by method, the condition of raw material, foaming and adjust, and therefore, suitably adjust according to purposes and to get final product.
In addition, under the situation of the raw material that adopts the 3rd form,, thereby make magnetic substance contain fluid flow because magnetic substance contains magnetic substance that fluid contains along the field direction orientation when foaming and molding.In the above-mentioned raw materials injection process, foaming polyurethane resin raw material and magnetic substance contain fluid and do not mix and be injected in the die cavity respectively.Therefore, the close magnetic substance in the foaming polyurethane resin raw material contains fluidic part and is directed the mobile magnetic substance and contains fluid and retrain and foam on one side.At this moment, it is high more that magnetic substance contains concentration of fluid, big more to the influence of foamable reaction.Thereby, contain fluid according to magnetic substance the influence degree of foamable reaction is changed formed bubble structure.In addition, can easily control the bubble structure by the intensity etc. that magnetic substance contains fluidic kind, combined amount, magnetic field.
Foaming and molding carries out the demoulding after finishing in this operation, obtains polyurethane foam molding of the present invention.At this moment, utilize the method for foaming and molding, on an end of polyurethane foam molding and in the other end at least one, form epidermal area.Also can excise this epidermal area (self-evident, as also can not excise) according to purposes.
The magneticinduction foam forming device
Below, an embodiment of magneticinduction foam forming device of the present invention is described.The structure of the magneticinduction foam forming device of present embodiment at first, is described.Fig. 3 represents the stereographic map of magneticinduction foam forming device.Fig. 4 represents the part sectioned view of magneticinduction foam forming device.As shown in Figure 3, Figure 4, magneticinduction foam forming device 1 comprises a pair of electro-magnet 2U of portion, 2D, yoke portion 3 and foaming mould 4.
The 2U of electro-magnet portion comprises core 20U and coil portion 21U.Core 20U is a ferromagnetic substance system, forms extend along the vertical direction cylindric.Coil portion 21U is disposed at the periphery of core 20U.Coil portion 21U is formed by the lead 210U that coiling is installed on core 20U periphery.Lead 210U is connected with power supply (figure slightly).
The 2D of electro-magnet portion clips the below that foaming mould 4 ground are disposed at the above-mentioned electro-magnet 2U of portion.The 2D of electro-magnet portion has the same structure with the above-mentioned electro-magnet 2U of portion.That is, the 2D of electro-magnet portion comprises core 20D and coil portion 21D.Coil portion 21D is formed by the lead 210D that coiling is installed on core 20D periphery.Lead 210D is connected with power supply (figure slightly).
Yoke portion 3 is C word shape.The C word upper end of yoke portion 3 is connected with the upper end of the core 20U of the 2U of electro-magnet portion.On the other hand, the C word lower end of yoke portion 3 is connected with the lower end of the core 20D of the 2D of electro-magnet portion.
Foaming mould 4 comprises mold 40U and bed die 40D.Foaming mould 4 is located between the core 20D of the core 20U of the 2U of electro-magnet portion and the 2D of electro-magnet portion.Mold 40U is prism-shaped.Lower surface at mold 40U is formed with recess cylindraceous.Equally, bed die 40D is prism-shaped.Upper surface at bed die 40D is formed with recess cylindraceous.Mold 40U and bed die 40D dispose in the mutual opposed facing mode of recess opening.Between mold 40U and bed die 40D, mutually combining by above-mentioned recess marks off die cavity 41.In die cavity 41, be filled with the raw material of regulation.
The work of the magneticinduction foam forming device of present embodiment then, is described.When making the power supply that is connected with lead 210U and the power supply that is connected with lead 210D being opened condition, the upper end of the core 20U of the 2U of electro-magnet portion of top is geomagnetic into the S utmost point, and the lower end is geomagnetic into the N utmost point.Therefore, in core 20U, from the top towards below real estate magnetisation line of force L (being represented by dotted lines among Fig. 4).In addition, the upper end of the core 20D of the 2D of electro-magnet portion of below is geomagnetic into the S utmost point, and the lower end is geomagnetic into the N utmost point.Therefore, in core 20D, from the top towards below real estate magnetisation line of force L.In addition, the lower end of core 20U is the N utmost point, and the upper end of core 20D is the S utmost point.Therefore, between core 20U and core 20D, from the top towards below real estate magnetisation line of force L.As mentioned above, foaming mould 4 is located between core 20U and the core 20D.Therefore, in the die cavity 41 of foaming mould 4, by towards the L shaped one-tenth of the magnetic line of force of below almost parallel magnetic field uniformly being arranged roughly from the top.
Fig. 5 represents the measurement result as the magneticflux-density in the die cavity 41 of an example of the roughly uniform magnetic field that forms.At this, the coordinate axis in the die cavity 41 defines as follows.As the orientation of representing among above-mentioned Fig. 3, be true origin with the center of die cavity 41, as the Z axle, fore-and-aft direction is as X-axis with above-below direction, and left and right directions is as Y-axis.On X-direction and Z-direction, measure magneticflux-density.In addition, among Fig. 5, the interval of X-axis position-50mm～50mm is the inside of die cavity 41.As shown in Figure 5, difference on the Z-direction (direction of magnetic line of force L), the magneticflux-density when being benchmark with Z=0mm is in ± 3%.Equally, difference on the X-direction, the magneticflux-density when being benchmark with X=0mm is also in ± 3%.Like this, on Z axle, X-axis either direction, the magneticflux-density in the die cavity 41 is all roughly even.
At this, the measurement result of the magneticflux-density in the uneven foam forming device of said determination result and magnetic field of the magneticflux-density in the magneticinduction foam forming device 1 (below be called " non-uniform magnetic-field foam forming device ") is compared.Fig. 6 represents the sectional view of non-uniform magnetic-field foam forming device.In addition, to marking identical Reference numeral with the corresponding member of Fig. 3, Fig. 4.As shown in Figure 6, non-uniform magnetic-field foam forming device 6 comprises pair of magnet 60U, 60D and foaming mould 4.Pair of magnet 60U, 60D form the rectangular parallelepiped of vertical 50mm * horizontal 50mm * thick 25.4mm respectively.Foaming mould 4 is located between pair of magnet 60U, the 60D.Foaming mould 4 comprises mold 40U and bed die 40D.Between mold 40U and bed die 40D, mark off die cavity 41 (round shape of diameter 100mm * thick 20mm).In die cavity 41, be filled with the raw material of regulation.
Coordinate axis in the non-uniform magnetic-field foam forming device 6 is as giving a definition.Fig. 7 represents the coordinate axis in the die cavity 41.For convenience of explanation, in Fig. 7, be represented by dotted lines the die surface of die cavity 41.As Fig. 6, shown in Figure 7, be true origin E (0,0,0) with the center of foaming mould 4, as the Z axle, left and right directions is as X-axis with above-below direction, and fore-and-aft direction is as Y-axis.In Fig. 7, solid line is represented the imaginary plane of X=0, Y=0, Z=0.At each face of Z=0mm (median plane of foaming mould 4), Z=25mm (its upper surface), Z=-25mm (its lower surface), measure magneticflux-density at A, B, C, D, E five places.The result is shown in the table 1.
Table 1
Figure G2008101467400D00211
As shown in table 1, for example poor (it is poor that E point and D are ordered) of the magneticflux-density on the X-direction in the face of Z=0 is 32.5%.In addition, the difference of the E point magneticflux-density in each face on the Z-direction is 51.3%.So as can be known, non-uniform magnetic-field foam forming device 6 is compared with the magneticinduction foam forming device 1 of present embodiment, and the difference of the magneticflux-density in the die cavity 41 is very big.
The action effect of the magneticinduction foam forming device of present embodiment then, is described.Adopt present embodiment, between the 2U of electro-magnet portion, 2D, towards the generation of ground, below magnetic line of force L is arranged from the top.The magnetic line of force L that radiates from the lower end of the core 20D of the below electro-magnet 2D of portion flow into the upper end of the core 20U of the top electro-magnet 2U of portion by yoke portion 3.Like this, in the magnetic circuit that constitutes by core 20U, die cavity 41, core 20D, yoke portion 3, the L shaped one-tenth of magnetic line of force loop line.Therefore, can suppress magnetic line of force L leaks.Thereby can be as the above-mentioned stable roughly uniform magnetic field of formation in die cavity 41 shown in Figure 5ly.In addition, the leakage of magnetic line of force L is also less to externalities.In addition, the waste of magnetic force is less, can make device self miniaturization.In addition owing to use the electro-magnet 2U of portion, 2D, therefore, can moment the unlatching that forms of switching field, close, be easy to controlling magnetic field intensity etc.
Embodiment
Then, enumerate embodiment and be described more specifically the present invention.
Embodiment A
(1) manufacturing of polyurethane foam molding
Manufacturing contains three kinds of polyurethane foam moldinies as the magnetic fillers of magnetic substance.Modulate the foaming polyurethane resin raw material at first, as described below.Will be as the polyether glycol of polyhydroxy reactant (firmly changing バ イ ェ Le ウ レ タ Application company (SumikaBayer Urethane Co Ltd) system " S-0248 ", molecular-weight average 6000, sense radix 3, OH value 28mgKOH/g) 100 mass parts, mix as diethylene glycol (Mitsubishi Chemical Ind's system) 2 mass parts of linking agent, water 2 mass parts, four ethylene diamine series catalysts (KAO. Corp. SA's system " No.31 ") 1 mass parts and silicone-based surfactant (Japanese ユ ニ カ corporate system " SZ-1313 ") 0.5 mass parts as whipping agent, modulate the premix polyvalent alcohol.In the premix polyvalent alcohol that modulates, add diphenylmethanediisocyanate (MDI) (BASFINOAC Port リ ウ レ タ Application corporate system " NE1320B ", NCO=44.8wt%) and mixing, make the foaming polyurethane resin raw material as the polymeric polyisocyanate composition.At this, the ratio of mixture of polyhydroxy reactant and polymeric polyisocyanate composition is (PO:ISO): the total weight that makes both is 100%, PO:ISO=78.5:21.5.
On the other hand, prepare three kinds of magnetic fillers.Promptly, use Stainless Steel Ball (Datong District's special steel corporate system " DAP440C-30M ": diameter 30 μ m are following, the about 10 μ m of mean diameter, sphere) as first magnetic fillers, use Stainless Steel Fibre (rainbow skill corporate system " KC steel fiber SUS430F ": the about 30 μ m of diameter, the about 2mm of length) as second magnetic fillers, use copper-iron alloy powder (copper-iron alloy corporate system " CFA90 ": vertical about 0.5mm * horizontal about 0.5mm * thick about 0.1mm's is lamellar) as the 3rd magnetic fillers.Try to achieve after the aspect ratio separately, first magnetic fillers is that 1, the second magnetic fillers is that 4444, the three magnetic fillers are 5.
Then, in the foaming polyurethane resin raw material that modulates, mix various magnetic fillers and make mixing material.Magnetic fillers is with respect to polyether glycol 100 mass parts of polyhydroxy reactant, and first and second magnetic fillers mixes 121 mass parts, and the 3rd magnetic fillers mixes 129 mass parts.
Afterwards, mixing material is injected in the die cavity (round shape of diameter 100mm * thick 20mm) of foaming mould (with reference to earlier figures 3, Fig. 4) of aluminum, it is airtight.Then, foaming mould is arranged in earlier figures 3, the magneticinduction foam forming device shown in Figure 4, the magneticflux-density in die cavity is roughly roughly carried out foaming and molding in the uniform magnetic field uniformly.After foaming mould is arranged at the magneticinduction foam forming device,, did not apply ground, magnetic field and carry out foaming and molding in about 5 minutes that follow while applied magnetic field and carry out foaming and molding in initial about 2 minutes.
After foaming and molding finishes, carry out the demoulding, obtain three kinds of polyurethane foam moldinies.To be mixed with the foam molding of the polyurethane foam molding of first magnetic fillers (Stainless Steel Ball) as embodiment A 1, the foam molding of the polyurethane foam molding of second magnetic fillers (Stainless Steel Fibre) will be mixed with, the foam molding of the polyurethane foam molding of the 3rd magnetic fillers (copper-iron alloy powder) will be mixed with as embodiment A 3 as embodiment A 2.At this, the about 1 volume % the when combined amount of the magnetic fillers in the foam molding of embodiment A 1～A3 is the volume that makes the polyurethane foam molding and is 100 volume %.The photo of the foam molding of embodiment A 2, A3 is shown among Fig. 8, Fig. 9.Fig. 8 represents on the right side to cut off along the vertical direction the cross-section photograph of the foam molding of embodiment A 2.Fig. 8 left side is in order relatively identical mixing material not to be applied the cross-section photograph that ground, magnetic field does not carry out the foam molding behind the foaming and molding.In addition, the cross-section photograph of the foam molding of embodiment A 3 is represented to cut off along the vertical direction in Fig. 9 right side.Fig. 9 left side is in order relatively identical mixing material not to be applied the cross-section photograph that ground, magnetic field does not carry out the foam molding behind the foaming and molding.As Fig. 8, shown in Figure 9, when carrying out foaming and molding, magnetic fillers only is to disperse with not applying magnetic field, but in the foam molding of embodiment A 2, A3, magnetic fillers is oriented above-below direction.In addition, magnetic fillers roughly disperses on left and right directions (with the direction of orientation direction approximate vertical) equably.In addition, though there is not photo,,, and can be observed roughly dispersive magnetic fillers equably also by similarly directed at the foam molding of embodiment A 1.Like this, in the foam molding of embodiment A 1～A3, magnetic fillers does not disperse inhomogeneous, but roughly disperses equably in whole foam molding.
On the other hand, for the mixing material that is mixed with second magnetic fillers (Stainless Steel Fibre), use aforementioned non-uniform magnetic-field foam forming device shown in Figure 6 to carry out foaming and molding.,, do not apply ground, magnetic field and do not carry out foaming and molding in about 5 minutes that follow similarly after foaming mould being arranged on the non-uniform magnetic-field foam forming device with above-mentioned while applied magnetic field and carry out foaming and molding in initial about 2 minutes.With the polyurethane foam molding that the obtains foam molding of A1 as a comparative example.Figure 10～Figure 12 represents the photo of the foam molding of Comparative examples A 1.Figure 10 is the upper surface photo of this foam molding.Figure 11 is the lower surface photo of this foam molding.Figure 12 is the cross-section photograph with near the thickness direction of this foam molding after cutting off the center.As Figure 10～shown in Figure 12, when carrying out foaming and molding in non-uniform magnetic-field, magnetic fillers is dispersed near the center morely.And, compare with upper surface, be dispersed near the lower surface morely.Like this, when carrying out foaming and molding in non-uniform magnetic-field, the magnetic fillers of bearing heat radiation is according to magneticflux-density and inhomogeneous dispersion.
(2) heat conduction test
Be different from the foam molding of embodiment A 1～A3, not the mictomagnetism filler, also do not apply magnetic field ground above-mentioned same foaming polyurethane resin raw material do not carried out foaming and molding, make the polyurethane foam molding.With this polyurethane foam molding foam molding of A2 as a comparative example.Embodiment A 1～the A3 that makes from lower face side heating and the foam molding of Comparative examples A 2 are estimated heat conductivility.Figure 13 represents the sectional view of heat test device.
As shown in figure 13, heat test device 5 comprises supporting mass 50, hot-plate 51 and thermal insulation material 52a, 52b, 52c.Hot-plate 51 is rectangular tabular, is supported body 50 horizontal supportings.The temperature of hot-plate 51 can be adjusted to by not shown heating unit about 100 ℃.Dispose the sample (polyurethane foam molding) 53 of determination object at the upper surface of hot-plate 51.Upper surface at sample 53 disposes aluminium sheet 54.Thermal insulation material 52a, 52b, 52c all are urethane foam systems, are disposed at the upper surface of supporting mass 50.Thermal insulation material 52a, 52b, 52c are divided into three, so that the mode that sample 53 and aluminium sheet 54 do not expose covers it.
Each foam molding of embodiment and comparative example was remained on the hot-plate 51 about 150 minutes, measure its upper surface temperature over time.At this, the value that will be obtained by the upper surface temperature of thermocouple measurement aluminium sheet 54 is as the upper surface temperature of each foam molding.Figure 14 represents the measurement result of the upper surface temperature of each foam molding.In addition, Figure 14 represents to consider the influence of external air temperature and revises result after the temperature.As shown in figure 14, when comparing with the foam molding of the Comparative examples A 2 that does not contain magnetic fillers, the upper surface temperature of the foam molding of embodiment A 1～A3 all raises.Wherein, contain the embodiment A 2 of the magnetic fillers of the shape except that spherical, the foam molding of A3 is compared with the foam molding of the embodiment A 1 that contains spherical magnetic fillers, the upper surface temperature is higher.By this result as can be known, under the situation of the magnetic fillers that has mixed the shape except that spherical, the conductive quantity of heat increases, and thermal diffusivity improves.Like this, the foam molding of embodiment A 1～A3 that thermal diffusivity is higher, the electric motor of sound-absorbing material, OA (Office Automation) equipment, household appliances that for example is suitable for reducing indoor ceiling of the hood of the engine room that is disposed at vehicle by the soundproof tire of the concavo-convex noise that causes in road surface, for the noise that reduces engine and side cover, car or column sections etc. with the inside and outside wall in the thermal diffusivity sound-absorbing material of electronicss such as sound-absorbing material, PC, family house with sound-absorbing material etc.
(3) sound absorbing coefficient is measured
Measure the sound absorbing coefficient of the foam molding of embodiment A 1～A3.Sound absorbing coefficient is measured according to the vertical incidence sound absorbing coefficient method of JIS A 1405.At this, make the incident direction of sound wave identical with the orientation direction of magnetic fillers.Figure 15 represents the measurement result of sound absorbing coefficient.
As shown in figure 15, the foam molding of embodiment A 2, A3 is compared with the foam molding of embodiment A 1, and the sound absorbing coefficient in the high-frequency region more than the 1000Hz raises.That is, the foam molding of embodiment A 2, A3 demonstrates higher sound absorption in the designated frequency zone.Like this, when mixing the magnetic fillers that forms the shape except that spherical, can seek not reduce sound absorption characteristics ground and improve thermal diffusivity.By above content, a form as preferable polyurethane foam molding of the present invention, this polyurethane foam molding has the base material that is made of urethane foam and is mixed in magnetic fillers in this base material, and this magnetic fillers can list the shape that forms except that spherical, at least a interconnection in contacting by line contact and face and the form that is directed.
(Embodiment B)
(1) manufacturing of polyurethane foam molding
The one or both ends that are manufactured on the foaming main body have two kinds of polyurethane foam moldinies of epidermal area.At first, similarly modulate the foaming polyurethane resin raw material with above-mentioned (embodiment A) (1).In addition, in the present embodiment, in above-mentioned premix polyvalent alcohol, mix carbon series pigments (the industrial's system " FT-1576 " of refining big day) 2 mass parts.
Then, in the foaming polyurethane resin raw material that modulates, mix MR fluid (シ グ マ Ha イ ケ ミ カ Le corporate system " E-600 "), make mixing material.With respect to foaming polyurethane resin raw material 100 mass parts that the MDI of the polyether glycol of polyol blend composition and polymeric polyisocyanate composition forms, mix 29.2 mass parts MR fluids.
Afterwards, similarly mixing material is injected in the die cavity (round shape of diameter 100mm * thick 20mm) of foaming mould (with reference to earlier figures 3, Fig. 4) of aluminum with above-mentioned (embodiment A) (1), it is airtight.At this moment, change the injection rate of mixing material, prepare two kinds.A kind of mode that is foam molding does not reach the die cavity end face when finishing with foaming is injected mixing material (open state).Another kind is that the mode that foam molding reaches the die cavity end face when finishing with foaming is injected mixing material (closed state).Under the former situation of open state, only the lower surface in the foaming main body is formed with epidermal area.On the other hand, under the situation of the latter's closed state, be formed with epidermal area at the upper and lower surface of foaming main body.
Then, foaming mould is arranged in earlier figures 3, the magneticinduction foam forming device shown in Figure 4, the magneticflux-density in die cavity is roughly roughly carried out foaming and molding in the magnetic field uniformly.After foaming mould being arranged on the magneticinduction foam forming device,, applying ground, magnetic field and carry out foaming and molding in about 5 minutes that follow while applied magnetic field and carry out foaming and molding in initial about 2 minutes.
After foaming and molding finished, the demoulding obtained two kinds of polyurethane foam moldinies.With only the foaming main body lower surface be formed with the foam molding of the polyurethane foam molding of epidermal area as Embodiment B 1, will the foaming main body upper and lower surface be formed with the foam molding of the polyurethane foam molding of epidermal area as Embodiment B 2.The photo of the foam molding of Embodiment B 1, B2 is shown among Figure 16～Figure 18.Figure 16 is the upper surface photo of the foam molding of Embodiment B 1.Figure 17 is a photo of taking the foam molding of Embodiment B 1 from front side top.Figure 18 is a photo of taking the foam molding of Embodiment B 2 from front side top.
As shown in figure 16, can be observed the peristome of the emptying aperture of many different shapes at the upper surface of the foam molding of Embodiment B 1.In addition, owing to this photo is that lower face side (paper inboard) irradiates light from the foam molding of Embodiment B 1 is taken, therefore, the peristome of emptying aperture shines whitelyr.By the situation that arrives upper surface by emptying aperture from the light of lower face side as can be known, emptying aperture is communicated with on above-below direction and orientation.But the foam molding of Embodiment B 1 has epidermal area in its lower face side.Therefore, in the lower face side of the foam molding of Embodiment B 1, emptying aperture is sealed by epidermal area.On the other hand, as shown in figure 17, do not form epidermal area in the upper surface side of the foam molding of Embodiment B 1.On the upper surface of the foam molding of Embodiment B 1, the division wall of dividing emptying aperture resembles the labyrinth and connects, and forms the labyrinth pattern.
As shown in figure 18, the foam molding of Embodiment B 2 thereon face side have epidermal area.In addition, though in this photo, can't see also having same epidermal area in lower face side.Therefore, the emptying aperture that is communicated with at above-below direction is sealed by epidermal area.In addition, as can be known, emptying aperture is communicated with and orientation at above-below direction when the side section of the foam molding of seeing Embodiment B 2.In addition, can be observed the division wall of extension along the vertical direction as bark.
In addition, observe the cross section that the foam molding cut off Embodiment B 2 along the vertical direction forms with scanning electronic microscope (SEM).Figure 19 represents the SEM photo (multiplying power is 2000 times) in the cross section of this foam molding.By the SEM photo of Figure 19 as can be known, in the foam molding of Embodiment B 2, magnetic substance links along the vertical direction and is directed.Simultaneously as can be known, magnetic substance roughly disperses on left and right directions (with the direction of orientation direction approximate vertical) equably.
On the other hand, at having mixed the above-mentioned mixing material that foaming polyurethane resin raw material and MR fluid form, use aforementioned non-uniform magnetic-field foam forming device shown in Figure 6 to carry out foaming and molding.Make the injection rate of mixing material identical with above-mentioned closed state.,, do not apply ground, magnetic field and do not carry out foaming and molding in about 5 minutes that follow similarly after foaming mould being arranged on the non-uniform magnetic-field foam forming device with above-mentioned while applied magnetic field and carry out foaming and molding in initial about 2 minutes.With the polyurethane foam molding that the obtains foam molding of B3 as a comparative example.Figure 20, Figure 21 represent the photo of the foam molding of comparative example B3.Figure 20 is the upper surface photo of this foam molding.Figure 21 is a photo of taking this foam molding from front side top.As Figure 20, shown in Figure 21, when in non-uniform magnetic-field, carrying out foaming and molding, only near the bigger central authorities of magneticflux-density, be formed with at above-below direction and be communicated with and directed emptying aperture.Do not form the shape of foam molding in part in addition.Like this, even in non-uniform magnetic-field, carry out foaming and molding, also can't obtain to have the foam molding of the emptying aperture that has been directed in the mode that is communicated with towards the other end from an end to being mixed with MR fluidic mixing material.
(2) load test
At the foam molding of the Embodiment B of making 2, (orientation direction of emptying aperture) is to its upper surface (area ≈ 78.5cm of diameter 100mm from the top 2) apply load, measure and the corresponding displacement of load.In addition, in order to compare, make the foaming polyurethane resin raw material of composition same as described above increase with above-mentioned mixing material in the corresponding amount of MR fluidic weight, do not apply ground, magnetic field and do not carry out foaming and molding, produce polyurethane foam molding (below be called comparative example B1 foam molding).In addition, do not apply magnetic field ground will with above-mentioned same mixing material foaming and molding, manufacture polyurethane foam molding (below be called comparative example B2 foam molding).The unmixed foam molding that MR fluidic comparative example B1 arranged is from needless to say, even do not apply in the foam molding of comparative example B2 that magnetic field ground does not carry out foaming and molding being mixed with the MR fluid, do not form the emptying aperture that has been directed in the mode that is communicated with towards the other end from an end yet yet.At the foam molding of these comparative examples B1, B2, measure and the corresponding displacement of load similarly.At this, will be up to the load that applies regulation and till being removed as the load test in 1 cycle.Figure 22 represents the load-displacement curve of each foam molding.
As shown in figure 22 as can be known, with respect to the foam molding of comparative example B1, B2, the rigidity of the foam molding of Embodiment B 2 is higher.In addition, in the foam molding of Embodiment B 2, temporarily reduce above near the load-carrying 2mm, can find out the decay of energy from displacement.But the foam molding of the foam molding of Embodiment B 2 and comparative example B1, B2 is similarly removing the shape that roughly returns to script when unloading.In addition, at the foam molding of Embodiment B 2, after 1 hour of the load test of having carried out 1 cycle, carry out same load test (the 2nd time) once more.Load-the displacement curve of the 2nd load test is shown among Figure 22 in the lump.As shown in figure 22 as can be known, though overall loading reduces slightly, inflexible size, Energy Decay, Restoration are still kept.In addition, in order to estimate Restoration, before and after the load test in 1 cycle, measure the thickness of each foam molding.The result is shown among Figure 23.As shown in figure 23, no matter the thickness of the sort of foam molding is all almost constant before and after load test.
Like this, adopt the foam molding of Embodiment B 2, the characteristic that can bring into play polyurethane foam molding inherent characteristic originally and the characteristic that obtains by distinctive emptying aperture structure compound and form.Specifically, the foam molding of Embodiment B 2 is brought into play Energy Decay and high rigidity simultaneously.Therefore, for example can be used as impact absorbing member etc.
(3) anisotropy test
Foam molding from the foregoing description B2 downcuts the square bulk sample of 20mm.Upper and lower surface at sample is formed with epidermal area.Upper surface (20mm * 20mm=4cm to this sample 2) apply load (compression direction is identical with the orientation direction of emptying aperture), measure and the corresponding displacement of load.Equally, to the surperficial (20mm * 20mm=4cm in the right side of sample 2) apply load (compression direction is the direction with the orientation direction approximate vertical of emptying aperture), measure and the corresponding displacement of load.Figure 24 represents the load-displacement curve of each mensuration.
For relatively, similarly downcut the square bulk sample of 20mm from the foam molding of above-mentioned comparative example B1, B2.Upper surface to these samples applies load, measures and the corresponding displacement of load.In addition, the right surface to sample applies load, mensuration and the corresponding displacement of load.Figure 25, Figure 26 represent the load-displacement curve of each mensuration.
As shown in figure 24 as can be known, upward rigidity is higher at above-below direction (orientation direction of emptying aperture) for the sample of Embodiment B 2.In addition, at from the situation of upper surface compression with from the situation of right surface compression, compared after the static spring constant of (rate of compression is 10%) when displacement is 2mm, the former is 18.83 times of the latter.On the other hand, as Figure 25, shown in Figure 26, the sample of comparative example B1, B2 is according to the difference of compression direction and rigidity there are differences hardly.At each sample, with Embodiment B 2 similarly relatively static spring constant when upper surface compresses and the static spring constant during from right surface compression.As a result, the sample of comparative example B1 is 0.99 times, and the sample of comparative example B2 is 1.58 times.So as can be known, in the foam molding of Embodiment B 2, the characteristic on the orientation direction of emptying aperture with have with the characteristic on the direction of this orientation direction approximate vertical bigger different.Therefore, for example as the pliability of considering to require the vehicle above-below direction from the aspect of ride comfort sense, consider to require rubber component etc. that the suspension of horizontal direction hardness uses support component of great use from the control stability aspect.
Embodiment C
(1) manufacturing of polyurethane foam molding
Manufacturing have from an end face outwards in direction be the polyurethane foam molding of the magnetic substance of spike orientation.At first, contain fluid, prepare MR fluid (シ グ マ Ha イ ケ ミ カ Le corporate system " E-600 ") as magnetic substance.Then, similarly modulate the foaming polyurethane resin raw material with above-mentioned (embodiment A) (1).
Then, the MR fluid is injected in the die cavity (round shape of diameter 100mm * thick 20mm) with the foaming mould (with reference to earlier figures 3, Fig. 4) of above-mentioned (embodiment A) (1) same aluminum.The degree that MR fluid and die cavity bottom surface hide is roughly similarly applied full.MR fluidic thickness is about 1mm.Then, on the MR fluid, inject foaming polyurethane resin raw material and the sealed mold that modulates.Afterwards, foaming mould is arranged in earlier figures 3, the magneticinduction foam forming device shown in Figure 4, the magneticflux-density in die cavity is roughly roughly carried out foaming and molding in the uniform magnetic field uniformly.After foaming mould being arranged on the magneticinduction foam forming device,, applying ground, magnetic field and carry out foaming and molding in about 5 minutes that follow while applied magnetic field and carry out foaming and molding in initial about 2 minutes.
After foaming and molding finishes, carry out the demoulding, obtain the polyurethane foam molding.Two surfaces up and down at the polyurethane foam molding that obtains are formed with epidermal area.Below, this polyurethane foam molding is called the foam molding of Embodiment C.The photo of the foam molding of Embodiment C is shown among Figure 27～Figure 30.Figure 27 is the photo of the lower surface of this foam molding.Figure 28 is the photo of the upper surface of this foam molding.Figure 29 is the lateral photo of this foam molding.In addition, the side photo of Figure 29 is that the lower surface of this foam molding is taken as the top.Figure 30 is the cross-section photograph of cutting off along the vertical direction behind this foam molding.In the cross-section photograph of Figure 30, the lower surface of this foam molding disposes towards the right side.The photo of the lower surface of this foam molding after in addition, Figure 30 also represents to cut off in the lump.
As shown in figure 27, be dispersed with the magnetic substance of black in the lower surface of the foam molding of Embodiment C.Therefore, lower surface integral body seems blackout.On the contrary, as shown in figure 28, though can see the magnetic substance of a little black around the upper surface of this foam molding, the upper surface is white in color.In addition, the texture of upper surface is thinner, and the texture of lower surface is thicker.Like this, magnetic substance concentration is different with the upper surface in the lower surface.Equally, to be configured in the lower surface also different with the upper surface for bubble.This point also can be clear and definite by Figure 29, Figure 30.That is, as shown in figure 29, magnetic substance is dispersed near the lower surface morely.In addition, by the cross-section photograph of Figure 30 as can be known, magnetic substance is oriented from the lower surface and is spike to the upper surface direction.In addition, be dispersed in morely near the lower surface magnetic substance with the direction of orientation direction approximate vertical, be roughly to disperse equably in the cross section of square with the axis direction.At this, near the bubble size the lower surface of magnetic substance orientation is greater than near the bubble diameter the upper surface.Can confirm that like this in the foam molding of Embodiment C, magnetic substance is oriented from the lower surface and is spike to the upper surface direction, in magnetic substance more lower surface side and the less upper surface side of magnetic substance, the bubble structure is different.Also can confirm in addition, in the foam molding of Embodiment C, the magnetic substance that has been directed with the direction of orientation direction approximate vertical on roughly disperse equably.
(2) sound absorbing coefficient is measured
Measure the sound absorbing coefficient of the foam molding of Embodiment C.Sound absorbing coefficient is measured according to the vertical incidence sound absorbing coefficient method of JIS A1405.Sound wave is from the less upper surface side incident of magnetic substance.In addition, for relatively, do not use the MR fluid, foaming and molding manufactures foam molding (below be called comparative example C foam molding) with only above-mentioned same foaming polyurethane resin raw material not being applied magnetic field.At the foam molding of comparative example C, measure sound absorbing coefficient similarly.Figure 31 represents the measurement result of sound absorbing coefficient.
As shown in figure 31, the foam molding of Embodiment C is compared with the foam molding of comparative example C, and particularly the sound absorbing coefficient in the low frequency region of 500～800Hz raises.In addition, in the high-frequency region of the low frequency region of 500～800Hz and 1250～2000Hz, the peak value of two sound absorbing coefficienies appears.Like this, it is different with the lower surface side that the bubble of the foam molding of Embodiment C is configured in the upper surface side, therefore, has distinctive sound absorption characteristics.Therefore, for example be fit to be disposed at for the noise that reduces engine the hood of engine room of vehicle or side cover, inhibition from the noise of engine room to the inside and outside wall in the sound-absorbing material of the indoor ceiling of preceding coaming plate sourdine, the car of car indoor propagation, column sections etc. or even family house with sound-absorbing material etc.
Embodiment D
(1) manufacturing of polyurethane foam molding
Use two kinds of different foaming moulds of surfaceness of thermal conductive surface forming mould surface, make the polyurethane foam molding.At first, similarly modulate the foaming polyurethane resin raw material with above-mentioned (embodiment A) (1).In addition, in the present embodiment, in above-mentioned premix polyvalent alcohol, mix carbon series pigments (the industrial's system " FT-1576 " of refining big day) 2 mass parts.
Then, mictomagnetism filler and make mixing material in the foaming polyurethane resin raw material that modulates.For magnetic fillers, use the Stainless Steel Fibre (aspect ratio=4444) that in above-mentioned (embodiment A), uses as second magnetic fillers.With respect to polyether glycol 100 mass parts of polyhydroxy reactant, mictomagnetism filler 121 mass parts.
As first foaming mould, the surfaceness of using the thermal conductive surface forming mould surface is the following foaming mould of 0.5 μ m.Inject mixing material and it is airtight in the picture die cavity of this foaming mould.Afterwards, foaming mould is arranged on the magneticinduction foam forming device, carries out foaming and molding.Figure 32 represents the part sectioned view of magneticinduction foam forming device.In addition, to marking identical Reference numeral with the corresponding member of above-mentioned Fig. 3, Fig. 4.The difference of magneticinduction foam forming device shown in Figure 32 and earlier figures 3, magneticinduction foam forming device shown in Figure 4 only is a foaming mould.Thereby, at this difference only is described.
Shown in figure 32, foaming mould 4 comprises mold 40U and bed die 40D.Foaming mould 4 is located between the core 20D of the core 20U of the 2U of electro-magnet portion and the 2D of electro-magnet portion.Mold 40U is prism-shaped.Lower surface at mold 40U is formed with recess 400U cylindraceous.Upper bottom surface at recess 400U disposes circular demoulding PET film 401U (toray film company's T oray Advanced Film Co., the about 145 μ m of Ltd system " セ ラ ピ-Le (registered trademark): グ レ-De Q " thickness).Measured the surfaceness of the demoulding with roughmeter (Tokyo Micronics Inc. system " SURFCOM (registered trademark) SP-828A ") after with PET film 401U, Ra=0.08 μ m.The demoulding becomes the thermal conductive surface forming mould surface with PET film 401U.Equally, bed die 40D is prism-shaped.Upper surface at bed die 40D is formed with recess 400D cylindraceous.Bottom surface at recess 400D disposes demoulding PET film 401D (the same).The demoulding becomes the thermal conductive surface forming mould surface with PET film 401D.In addition, for convenience of explanation, the thickness of the demoulding with PET film 401U, 401D has been described turgidly among Figure 32.
Mold 40U and bed die 40D dispose in the opposed facing mode of opening of mutual recess 400U, 400D.Between mold 40U and bed die 40D, mutually combining by recess 400U, 400D marks off die cavity 41.In die cavity 41, be filled with above-mentioned mixing material.
In the die cavity 41 of foaming mould 4, by towards the L shaped one-tenth of the magnetic line of force of below almost parallel magnetic field uniformly being arranged roughly from the top.Magneticflux-density in the die cavity 41 is about 200mT.After being arranged at foaming mould 4 on the magneticinduction foam forming device 1, while applied magnetic field and carry out foaming and molding in initial about 2 minutes.Then about 5 minutes do not apply ground, magnetic field and carry out foaming and molding.
After foaming and molding finishes, carry out the demoulding, obtain the columned polyurethane foam molding that upper and lower surface has thermal conductive surface.With the polyurethane foam molding that obtains foam molding as embodiment D.The combined amount of the magnetic fillers in the foam molding of embodiment D is 1 volume % the when volume that makes the polyurethane foam molding is 100 volume %.
As second foaming mould, use and do not dispose the foaming mould of the demoulding with PET film 401U, 401D.This foaming mould uses and the identical member (with reference to Fig. 3, Fig. 4) of member that uses in above-mentioned (embodiment A).In this case, be formed at the upper bottom surface of recess 400U of mold 40U lower surface and the bottom surface that is formed at the recess 400D of bed die 40D upper surface and become the thermal conductive surface forming mould surface respectively.After the surfaceness of the bottom surface of the upper bottom surface of having measured recess 400U with roughmeter (the same) and recess 400D, Ra=0.66 μ m.With the polyurethane foam molding that the obtains foam molding of D as a comparative example.
(2) glossiness of thermal conductive surface is measured
At first, Figure 33～Figure 36 represents the photo of the thermal conductive surface (upper surface) of the foam molding of embodiment D and Comparative Example D.Figure 33 is the upper surface photo of the foam molding of embodiment D, Figure 34 be by microscope photographing to the enlarged photograph (multiplying power is 175 times) of this foam molding upper surface.In addition, Figure 35 is the upper surface photo of the foam molding of Comparative Example D, Figure 36 be by microscope photographing to the enlarged photograph (multiplying power is 175 times) of this foam molding upper surface.As can be known, the foam molding of embodiment D is glossy when comparing Figure 33, Figure 35.In addition, relatively when Figure 34, Figure 36, the upper surface of the foam molding of embodiment D not transfer printing upper bottom surface concavo-convex of mold recess arranged.Relative therewith, upper bottom surface concavo-convex of mold recess arranged in the upper surface transfer printing of the foam molding of Comparative Example D.
Then, measure the glossiness of two foam molding upper surfaces.Use the digital varied-angle glossmeter " UGV-5K " of ス ガ Try Omen Machine tool corporate system to measure glossiness (input angle is 60 °).As a result, the upper surface glossiness of the foam molding of embodiment D is 17.1%.Relative therewith, the upper surface glossiness of the foam molding of Comparative Example D is 9.5%.That is, the upper surface glossiness of the foam molding of embodiment D is 1.8 times of upper surface glossiness of the foam molding of Comparative Example D.Like this, the surfaceness of the thermal conductive surface forming mould surface by making foaming mould is below the 0.5 μ m, and the glossiness that can be shaped is the thermal conductive surface more than 10%.
(3) thermal Conductivity Determination
Measure the thermal conductivity of the foam molding of embodiment D and Comparative Example D.Use the Hot Disk Methods hot physical property measurement device of method " TPA-501 " of capital of a country Electronics Industry Company system to measure thermal conductivity.In thermal Conductivity Determination, prepare the foam molding of two embodiment D and Comparative Example D respectively.Then, dispose respectively having the mode that a pair of foam molding faces mutually with thermal conductive surface of one's own, the transmitter of between clamping said determination device is measured thermal conductivity.Adopt this mensuration, because transmitter is contacted with thermal conductive surface, therefore, the condition of surface of thermal conductive surface can be reflected as measured value.As a result, the thermal conductivity of the foam molding of embodiment D is 0.12W/ (mK), and the thermal conductivity of the foam molding of Comparative Example D is 0.10W/ (mK).That is, the thermal conductivity of the foam molding of embodiment D is 1.2 times of thermal conductivity of the foam molding of Comparative Example D.The surfaceness of the thermal conductive surface forming mould surface of the value of the glossiness of the thermal conductivity of the foam molding of embodiment D and Comparative Example D and thermal conductive surface and employed foaming mould together is summarized in the table 2 represented.
Table 2
? Embodiment Comparative example
Foaming mould (thermal conductive surface forming mould surface) surface roughness Ra (μ m) 0.08? 0.66?
The glossiness of thermal conductive surface (%) 17.1 9.5
Thermal conductivity (W/ (mK)) 0.12 0.10
Incidentally, the thermal conductivity (theoretical value) that does not contain the polyurethane foam molding of magnetic substance is 0.03W/ (mK).Compare as can be known with this value, improved thermal conductivity, and the glossiness of the thermal conductive surface that intersects by the orientation direction that makes with magnetic substance is more than 10%, has further improved thermal conductivity by the magnetic substance that contains directed.Under the glossiness of thermal conductive surface was situation more than 10%, the contact area of thermal conductive surface and counter-element increased, and the heat of between conduction increases.Therefore, it is generally acknowledged, can give full play to by the directed thermal conductivity that produces of magnetic substance and improve effect, further improve the thermal conductivity of whole polyurethane foam molding integral body.
Like this, the foam molding of embodiment D can similarly be used in extensive fields such as motor vehicle, electronics, building with the foam molding of the foregoing description A1～A3.That is, the electric motor of sound-absorbing material, OA equipment, household appliances that is fit to the indoor ceiling of soundproof tire, the hood of engine room that is disposed at vehicle or side cover, car, column sections etc. with the inside and outside wall in the thermal diffusivity sound-absorbing material of electronicss such as sound-absorbing material, PC, family house with sound-absorbing material etc.

Claims (13)

1. a polyurethane foam molding is characterized in that,
This polyurethane foam molding has the magnetic substance that has been directed, this magnetic substance with the direction of orientation direction approximate vertical on roughly disperseed equably.
2. polyurethane foam molding according to claim 1, wherein,
Above-mentioned magnetic substance comprises magnetic fillers;
This magnetic fillers itself forms the shape except that spherical, couples together and orientation by at least a contact in line contact and the face contact mutually.
3. polyurethane foam molding according to claim 1 and 2, wherein,
The thermal conductive surface that contacts with counter-element and conduct heat is configured to intersect with the orientation direction of above-mentioned magnetic substance, and the glossiness of this thermal conductive surface is more than 10%.
4. polyurethane foam molding according to claim 1, wherein,
Above-mentioned magnetic substance is oriented at least from an end face and is spike from outside to inside;
The size of bubble changes on the orientation direction of this magnetic substance.
5. manufacture method that is used to make the described polyurethane foam molding of claim 1, wherein, this manufacture method comprises:
The raw material injection process, the raw material that will contain foaming polyurethane resin raw material and magnetic substance is injected in the die cavity of foaming mould;
The foaming and molding operation is on one side so that foaming and molding is carried out in the uniform mode effect of the magneticflux-density magnetic field in this die cavity on one side.
6. the manufacture method of polyurethane foam molding according to claim 5, wherein,
In the above-mentioned raw materials injection process, above-mentioned raw materials is that above-mentioned foaming polyurethane resin raw material and shape own are formed the mixing material that the magnetic fillers of shape mixes except that spherical.
7. according to the manufacture method of claim 5 or 6 described polyurethane foam moldinies, wherein,
In above-mentioned foaming mould, the surfaceness of the thermal conductive surface forming mould surface of the thermal conductive surface of formed polyurethane foam molding is below the 0.5 μ m.
8. the manufacture method of polyurethane foam molding according to claim 5, wherein,
In the above-mentioned raw materials injection process, above-mentioned raw materials is the mixing material that above-mentioned foaming polyurethane resin raw material of mixing and magnetic viscosity fluid form;
In above-mentioned foaming and molding operation, make the magnetic line of force that constitutes above-mentioned magnetic field form a end from above-mentioned die cavity towards the other end almost parallel, in the polyurethane foam molding, form the emptying aperture that has been directed in the mode that is communicated with towards the other end from an end.
9. the manufacture method of polyurethane foam molding according to claim 5, wherein,
In the above-mentioned raw materials injection process, above-mentioned raw materials contains fluid by above-mentioned foaming polyurethane resin raw material and at least a magnetic substance chosen and constitutes from magnetic fluid (MF), magnetic viscosity fluid (MR fluid), magnetic mixed solution (MCF), this foaming polyurethane resin raw material and this magnetic substance are not contained fluid and mix and they are injected into respectively in the above-mentioned die cavity.
10. the manufacture method of polyurethane foam molding according to claim 5, wherein,
In above-mentioned foaming and molding operation, the magnetic line of force that constitutes above-mentioned magnetic field forms the loop line.
11. the manufacture method of polyurethane foam molding according to claim 5, wherein,
The difference of the above-mentioned magneticflux-density in the above-mentioned die cavity is in ± 10%.
12. a magneticinduction foam forming device that is used to make the described polyurethane foam molding of claim 1 is characterized in that this device comprises:
A pair of electro-magnet portion, the coil portion that it comprises the core that is made of ferromagnetic substance and is disposed at this core periphery, this a pair of electro-magnet portion practises physiognomy along the axis direction of this core with separating predetermined distance and disposes over the ground;
Foaming mould, it is located between this a pair of electro-magnet portion, in internal separation die cavity is arranged;
Yoke portion, with coupling together between the face dorsad of this core separately in this a pair of electro-magnet portion, a pair of this dorsad face form magnetic circuit each other;
In this die cavity of this foaming mould, be formed with the magnetic substance that is used to make the described polyurethane foam molding of claim 1 with the direction of the orientation direction approximate vertical of this magnetic substance on the magnetic field of dispersed uniform equably roughly.
13. magneticinduction foam forming device according to claim 12, wherein,
The difference of the magneticflux-density in the above-mentioned die cavity is in ± 10%.
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Patentee before: Tokai Rubber Industries, Ltd.

Patentee before: Nagoya Inst Technology