CN106065058A - 变形检测传感器及其制造方法 - Google Patents
变形检测传感器及其制造方法 Download PDFInfo
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- CN106065058A CN106065058A CN201610245262.3A CN201610245262A CN106065058A CN 106065058 A CN106065058 A CN 106065058A CN 201610245262 A CN201610245262 A CN 201610245262A CN 106065058 A CN106065058 A CN 106065058A
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Abstract
本发明提供一种变形检测传感器，其将在树脂中分散有磁性填料的磁性树脂和磁性传感器结合，其中检测性能的稳定性得到进一步提高。因此本发明提供一种变形检测传感器及其制造方法，所述变形检测传感器包括：含有磁性树脂的聚合物泡沫，其包含磁性树脂和聚合物泡沫，所述磁性树脂含有磁性填料，所述聚合物泡沫包括所述磁性树脂；以及磁性传感器，其检测由该含有磁性树脂的聚合物泡沫的变形引起的磁性变化，其中所述磁性树脂的弹性模量为0.1至10Mpa。
Description
技术领域
本发明涉及变形检测传感器，尤其是用于汽车座椅的变形检测传感器，及其制造方法。
背景技术
在汽车等车辆中，实际使用一种检测人是否坐在座椅上，并在未系座椅安全带时报警的报警系统。该报警系统通常在检测到人落座并且落座后未系安全带时会发出警告。该设备通常包含：落座传感器，其检测人是否坐在座椅上；和检测虽然人已经落座但未用带扣系座椅安全带的传感器，其当检测到未系座椅安全带时会发出警告。由于落座传感器必须多次检测人的落座，因此其必须具有高耐久性。还必须在人乘坐时，不会感觉到座椅中有异物感。
特开2012-108113A号公报(专利文件1)公开了一种配置在座椅中检测人的落座的落座传感器，其在坐垫材料中设置彼此相对的电极并借由电极的电接触检测人的落座。这种传感器使用了电极并应配备电线。而电线若承受大的位移则可能会断开，耐久性上存在问题。此外，电极通常是由可引起异物感的金属物质制成。即使电极不是金属的，异物感也容易基于其他的物质而产生。
特开2011-255743 A号公报(专利文件2)公开了一种静电电容式落座传感器，其包括：彼此相对的传感器电极，在传感器电极之间插有介电物质；和测量电极之间静电电容的静电电容式传感器。由于这种传感器也使用电极并应配备电线，其与专利文件1一样会产生耐久性问题。其也难以防止异物感。
特开2007-212196A号公报(专利文件3)公开了一种用于车用座椅的负荷检测装置，其包括配置有可移动的柔性元件的产生磁力的磁力发生器和磁性传感器，所述磁性传感器具有检测由磁力发生器产生的磁场的磁性阻抗元件和配置于车座架的固定元件。由于在该装置中，磁力发生器包括具有特定尺寸的磁体，因此将其设置于坐垫材料的表层而无异物感是相当困难的。为了避免异物感，考虑将其设置于坐垫材料内部，但这会导致检测精度的劣化。
特开2006-014756 A号公报(专利文件4)公开了一种生物信号检测装置，其包括永磁体和磁性传感器。显然由于该装置也使用永磁体而有异物感，因此难以将该装置配置于坐垫材料的表层。此外，将其配置在坐垫材料内部也导致检测精度的劣化。
现有技术文件
专利文件
专利文件1特开2012-108113A号公报
专利文件2特开2011-255743A号公报
专利文件3特开2007-212196A号公报
专利文件4特开2006-014756A号公报
发明内容
发明要解决的课题
本发明人已提出了一种变形检测传感器，其使用树脂中分散有磁性填料的磁性树脂并将磁性树脂与磁性传感器结合，以提高变形检测传感器的耐久性并获得没有任何异物感的座椅，然而需要进一步提高检测性能的稳定性。作为深入研究的结果，本发明人发现通过控制磁性树脂的弹性模量，传感器的稳定性提高而没有异物感，从而完成本发明。
解决课题的方法
因此，本发明提供一种变形检测传感器，其包括：
含有磁性树脂的聚合物泡沫，其包含磁性树脂和聚合物泡沫，所述磁性树脂含有磁性填料，所述聚合物泡沫包含所述磁性树脂，以及
磁性传感器，其检测由所述含有磁性树脂的聚合物泡沫的变形引起的磁性变化，
其特征为所述磁性树脂的弹性模量为0.1至10MPa。
本发明还提供用于制造变形检测传感器的方法，包括以下步骤：
将磁性填料分散于树脂前体溶液的步骤，所述树脂前体溶液包含一元醇组分，
使所述树脂前体溶液固化以形成弹性模量为0.1至10MPa的磁性树脂的步骤，
将所述磁性树脂置于用于聚合物泡沫的模具中的步骤，
将聚合物泡沫原料倾倒至所述模具中发泡，使磁性树脂与聚合物泡沫一体化的步骤，以及
将所述含有磁性树脂的聚合物泡沫与磁性传感器结合的步骤，所述磁性传感器检测由含有磁性树脂的聚合物泡沫的变形引起的磁性变化。
优选所述聚合物泡沫在所述磁性树脂和所述聚合物泡沫之间的界面附近的泡孔平均直径比聚合物泡沫中央部分的泡孔平均直径大。
还优选所述磁性树脂和所述聚合物泡沫由聚氨酯制成。
还优选形成所述磁性树脂的聚氨酯包含一元醇组分。
更优选所述一元醇组分为高极性一元醇。
此外，在聚氨酯原料的总量中一元醇组分的含量优选为0.1至1.0meq/g。
优选所述磁性树脂和所述聚合物泡沫通过自粘作用粘合。
优选所述含有磁性树脂的聚合物泡沫为车用座椅的缓冲垫且检测的变形为人的落座状态。
根据本发明，通过将磁性树脂的弹性模量控制在0.1至10MPa范围内，其符合聚合物泡沫的变形(尤其是弯曲变形)的性能提高，因此检测性能的稳定性提高。
因为对于本发明的磁性树脂而言，磁性填料分散于树脂中，所以与使用固体磁体相比，其几乎不产生异物感而在用于车用座椅时乘坐舒适性良好。此外，磁性传感器检测磁性树脂中的磁性填料的磁性改变，因此可将其设置于离磁性树脂一定距离处，与还使用电极的传感器不同，无需电线来连接电极，消除了电线的切断等耐久性的问题。此外，由于无需电线连接电极，因此也不必在聚合物泡沫中设置任何的异物，制造方面也变得容易。
附图说明
图1示出将本发明的变形检测传感器应用于车用座椅中的实施方案的示意截面图。
图2为本发明的图1示出的含有磁性树脂的聚合物泡沫的示意透视图。
具体实施方式
参照附图进行说明。
图1示出将本发明的变形检测传感器应用于车用座椅中的实施方案的示意截面图。
图2示出本发明的含有磁性树脂的聚合物泡沫的示意透视图。
如图1所示，本发明的变形检测传感器基本上是由乘坐部分1和磁性传感器3组成。当变形检测传感器用于车用座椅时，靠背部分2与乘坐部分1的端部接触。乘坐部分1由包含磁性树脂4和聚合物泡沫5的含有磁性树脂的聚合物泡沫6，以及覆盖含有磁性树脂的聚合物泡沫6的外皮7组成。而磁性树脂4以层状形成于聚合物泡沫5的座位表面的一部分。优选将磁性传感器3固定于支持车用座椅的底座8上。在汽车中底座8固定于车体(未在图中示出)。
图2示出包括磁性树脂4和聚合物泡沫5的本发明的含有磁性树脂的聚合物泡沫6的透视图，还示出了底座8和安装于底座8上的磁性传感器3。磁性树脂4设置于人落座时最容易接收变形的聚合物泡沫的最上部。图2未示出存在于含有磁性树脂的聚合物泡沫6上的外皮7。外皮7通常由皮革、织物、合成树脂等制成，但不限于此。
磁性树脂4中分散有磁性填料，磁性填料通过磁化法或其他方法而具有磁性。当人落座于乘坐部分1时，含有磁性树脂的聚合物泡沫6变形并且磁场由此改变。磁场的变化通过磁性传感器3检测而识别出人已落座。在上述图1和2中，含有树脂材料4的聚合物泡沫6存在于人坐的臀部附近，识别有人乘坐，例如在没有系安全带时可发出警告。此外，本发明的含有磁性树脂的聚合物泡沫6可用于与人的背部接触的靠背部分2，这种情况可检测人的乘坐姿势。
在本发明中，磁性树脂4的弹性模量优选为0.1至10MPa。磁性树脂的弹性模量小于0.1MPa，会使处理性能劣化且性能稳定性降低，反之大于10MPa的弹性模量会使传感器精度降低。弹性模量优选为0.15～3MPa。弹性模量可根据JIS K-7312测定。具体而言，使用Autograph AG-X(株式会社岛津制作所制)测定。更详细的测量条件描述于实施例中。
控制磁性树脂4的弹性模量的方法可使用公知的多种方法。例如，可以考虑减少形成磁性树脂的树脂分子量的方法，或减少磁性树脂的交联剂的量的方法。在说明磁性树脂的成分或制造方法时进行详细地说明。
磁性树脂4的厚度优选为0.5至20mm，更优选为1.0至5.0mm。若磁性树脂的厚度小于0.5mm，则磁性填料的添加量不足而传感器精度有劣化倾向，反之若厚于20mm则有变得容易感到磁性树脂的异物感的倾向。
磁性树脂
本说明书中所采用的术语“磁性树脂”意指其中分散有磁性填料(即，具有磁性的无机填料)的树脂。
磁性填料通常有稀土系、铁系、钴系、镍系、氧化物系填料，其中任一种即可。稀土系磁性填料因显示出高磁性而优选，但并不限于此。优选钕系磁性填料。磁性填料的形状没有特别限定，可为球状、扁平状、针状、柱状及不定形状的任一种。磁性填料的平均粒径为0.02至500μm，优选为0.1至400μm，更优选为0.5至300μm。如果其平均粒径小于0.02μm，则磁性填料的磁性性能变差。如果平均粒径大于500μm，则磁性树脂的机械性能(脆性)变差。
可将磁性填料在磁化之后引入至树脂中，但优选在将磁性填料引入至树脂中之后使其磁化。引入至树脂中之后使其磁化，则磁性填料的极性变得容易控制且磁性的检测变得容易。
用于磁性树脂的树脂可为一般的树脂，但优选使用热塑性弹性体、热固性弹性体或其混合物。热塑性弹性体的实例为苯乙烯系热塑性弹性体、聚烯烃系热塑性弹性体、聚氨酯系热塑性弹性体、聚酯系热塑性弹性体、聚酰胺系热塑性弹性体、聚丁二烯系热塑性弹性体、聚异戊二烯系热塑性弹性体、氟橡胶系热塑性弹性体等。热固性弹性体的实例为二烯系合成橡胶，如聚异戊二烯橡胶、聚丁二烯橡胶、苯乙烯-丁二烯橡胶、聚氯丁二烯橡胶、丁腈橡胶和乙烯-丙烯橡胶等；非二烯系合成橡胶，如乙烯-丙烯橡胶、丁基橡胶、丙烯酸酯橡胶、聚氨酯橡胶、氟橡胶、硅橡胶、氯醇橡胶等；以及天然橡胶等。其中，优选热固性弹性体，因为其可抑制随着长期使用磁性树脂的劣化。进一步优选聚氨酯弹性体(也称聚氨酯橡胶)或硅弹性体(也称硅橡胶)。
所述树脂可优选为聚氨酯弹性体或硅弹性体。在聚氨酯弹性体的情况下，含有活性氢的化合物与磁性填料混合，向其中加入异氰酸酯组分并且混合以制得混合物溶液。此外，也可通过异氰酸酯组分与磁性填料混合，向其中加入含有活性氢的化合物并且混合以制得混合物溶液。将所得的混合物溶液倾倒至已用脱模剂处理的模具中，然后加热至固化温度以固化，从而获得聚氨酯弹性体。在硅弹性体的情况下，在硅弹性体的前体中投入磁性填料并混合，接着通过加热以固化，从而获得硅弹性体。如果需要，在制备混合物溶液时可在其中加入溶剂。
此处，能用于聚氨酯弹性体的异氰酸酯组分和含有活性氢的化合物可列举如下。根据本发明，如上所述，需要进行控制以降低磁性树脂的弹性模量，因此可将一元醇作为含有活性氢的化合物的一部分进行配制。进一步地，弹性模量也可通过调节NCO指数来控制，而不使用一元醇。
对于异氰酸酯组分没有特别限定，可为聚氨酯领域中的公知的化合物。异氰酸酯组分的实例为芳族二异氰酸酯，如2,4-甲苯二异氰酸酯、2,6-甲苯二异氰酸酯、2,2'-二苯基甲烷二异氰酸酯、2,4'-二苯基甲烷二异氰酸酯、4,4'-二苯基甲烷二异氰酸酯、1,5-萘二异氰酸酯、对苯二异氰酸酯、间苯二异氰酸酯、对苯二甲基二异氰酸酯和间苯二甲基二异氰酸酯等；脂族二异氰酸酯，如亚乙基二异氰酸酯、2,2,4-三甲基六亚甲基二异氰酸酯和1,6-六亚甲基二异氰酸酯；脂环族二异氰酸酯，如1,4-环己烷二异氰酸酯、4,4'-二环己基甲烷二异氰酸酯、异佛尔酮二异氰酸酯和降冰片烷二异氰酸酯(norbornane diisocyanate)等。该化合物可单独使用，或两种以上结合使用。此外，所述异氰酸酯可通过氨基甲酸乙酯改性、脲基甲酸酯改性、缩二脲改性及异氰脲酸酯改性等进行改性。
含有活性氢的化合物可为常用于聚氨酯领域中的化合物。实例为聚醚多元醇，如聚丁二醇、聚丙二醇、聚乙二醇、环氧丙烷和环氧乙烷的共聚物；聚酯多元醇，如聚己二酸丁二醇酯、聚己二酸乙二醇酯、3-甲基-1,5-戊烷己二酸酯；聚酯聚碳酸酯多元醇，如聚酯二醇(例如聚己内酯多元醇和聚己内酯)与碳酸亚烷基酯的反应产物；通过使碳酸亚乙酯与多元醇反应以形成反应混合物，接着使所得的反应混合物与有机二羧酸反应获得的聚酯聚碳酸酯多元醇；通过多羟基化合物与碳酸芳基酯的酯交换反应获得的聚碳酸酯多元醇等。这些可单独使用，或两种以上结合使用。
除了上述提及的高分子量多元醇组分，含有活性氢的化合物也包括低分子量多元醇，如乙二醇、1,2-丙二醇、1,3-丙二醇、1,4-丁二醇、1,6-己二醇、新戊二醇、1,4-环己烷二甲醇、3-甲基-1,5-戊二醇、二乙二醇、三乙二醇、1,4-双(2-羟基乙氧基)苯、三羟甲基丙烷、丙三醇、1,2,6-己三醇、季戊四醇、四羟甲基环己烷、甲基葡糖苷、山梨糖醇、甘露糖醇、半乳糖醇、蔗糖、2,2,6,6-四(羟甲基)环己醇和三乙醇胺等；以及低分子量多胺、如乙二胺、甲苯二胺、二苯基甲烷二胺、二亚乙基三胺等。这些化合物可单独使用，或两种以上结合使用。其中也可进一步加入多胺，包括4,4'-亚甲基双(邻氯苯胺)(MOCA)、2,6-二氯对苯二胺、4,4'-亚甲基双(2,3-二氯苯胺)、3,5-双(甲硫基)-2,4-甲苯二胺、3,5-双(甲硫基)-2,6-甲苯二胺、3,5-二甲基甲苯-2,4-二胺、3,5-二乙基甲苯-2,6-二胺、丙二醇-双(对氨基苯甲酸酯)、聚氧亚丁基-双(对氨基苯甲酸酯)、1,2-双(2-氨基苯硫基)乙烷、4,4'-二氨基-3,3'-二乙基-5,5'-二甲基二苯基甲烷、N,N'-二仲丁基-4,4'-二氨基二苯基甲烷、4,4'-二氨基-3,3'-二乙基二苯基甲烷、4,4'-二氨基-3,3'-二乙基-5,5'-二甲基二苯基甲烷、4,4'-二氨基-3,3'-二异丙基-5,5'-二甲基二苯基甲烷、4,4'-二氨基-3,3',5,5'-四乙基二苯基甲烷、4,4'-二氨基-3,3',5,5'-四异丙基二苯基甲烷、间苯二甲胺、N,N'-二(仲丁基)对苯二胺、间苯二胺和对苯二甲胺等。
用于控制弹性模量的一元醇组分可使用聚氨酯领域中公知的一元醇，本发明中尤其适合采用具有高极性基团(如腈基、硝基等)的高极性一元醇。如果一元醇组分具有高极性基团，则高极性基团会吸收水，所吸收的水在制备聚合物泡沫时会引起水发泡，并且会引起在磁性树脂附近的聚合物泡沫的泡孔平均直径大于聚合物泡沫中央部分的泡孔平均直径。
高极性一元醇的实例为氰乙醇(2-氰基乙醇)、2-羟基丁腈、2-羟基异丁腈、3-羟基丁腈、3-羟基戊二腈、3-羟基-3-苯基丙腈、邻氰基苄醇、间氰基苄醇、对氰基苄醇、4-(2-羟乙基)苄腈、2-硝基乙醇、2-甲基-2-硝基-1-丙醇、3-硝基-2-丁醇、3-硝基-2-戊醇、邻硝基苄醇、间硝基苄醇、对硝基苄醇、2-甲基-3-硝基苄醇、3-甲基-2-硝基苄醇、3-甲基-4-硝基苄醇、4-甲基-3-硝基苄醇、5-甲基-2-硝基苄醇、3-甲氧基-4-硝基苄醇、4,5-二甲氧基-2-硝基苄醇、4-甲氧基-3-硝基苄醇、5-羟基-2-硝基苄醇、4-羟基-3-硝基苄醇、2-(4-硝基苯基)乙醇等。
一元醇组分也可使用上述高极性一元醇以外的一元醇。可用的其他一元醇组分可为本领域公知的一元醇，例如简单的醇，如甲醇、乙醇、正丙醇和异丙醇等；或具有以下通式(1)的(聚)亚烷基二醇单烷基醚：
R1-(OCH2CHR2)n-OH (1)
(其中R1表示甲基、乙基、丙基、丁基、芳基和取代的芳基，R2表示氢原子或甲基，n为1至5的整数)，具体例如二乙二醇单乙基醚、二乙二醇单甲基醚、二丙二醇单乙基醚、二丙二醇单甲基醚、2-甲氧基乙醇、乙二醇单乙基醚、乙二醇单丁基醚、乙二醇单叔丁基醚、乙二醇单苯基醚、二乙二醇单丁基醚、三乙二醇单丁基醚和聚乙二醇单对异辛基苯基醚。一元醇组分也可为羧酸与氧化烯烃加成的产物，例如氧化烯烃与羧酸类(如乙酸、丙烯酸、甲基丙烯酸等)加成的产物。
一元醇的配制量为0.1至1.0meq/g，优选0.15至0.9meq/g，基于聚氨酯原料的总量计。可认为由于使用一元醇组分，特别是高极性一元醇组分，高极性基团会吸收水，所吸收的水在制备聚合物泡沫时会引起水发泡，并且会引起在磁性树脂附近的聚合物泡沫的泡孔平均直径大于聚合物泡沫中央部分的炮孔平均直径。如果一元醇的配制量小于0.1meq/g，则无法实现控制磁性树脂附近的聚合物泡沫的泡孔平均直径。反之如果其大于1.0meq/g，则难以获得固化的聚合物泡沫。
磁性树脂中磁性填料的量可为1至450重量份，优选为2至400重量份，基于100重量份的树脂计。小于1重量份则难以检测磁性变化。大于450重量份则树脂变脆等而不能获得所需的性能。
在本发明中，磁性树脂也可使用双面胶带或粘合剂粘合至聚合物泡沫，但是优选通过自粘作用与聚合物泡沫整合成一体。如果是自粘作用，则磁性树脂不易于从聚合物泡沫脱落且显示出优异的耐久性。由于磁性树脂是柔性的，因此含有磁性树脂的聚合物泡沫是柔软的且显示出良好的乘坐舒适性。
当磁性树脂由聚氨酯弹性体制成时，磁性树脂的NCO指数通常为0.35至1.15，优选为0.4至1.1。如果NCO指数小于0.35，磁性弹性体倾向于固化不充分。如果NCO指数大于1.15，则弹性模量变高且检测精度倾向于变低。如上所述，磁性树脂的弹性模量的控制可通过控制交联剂的量来实施。当磁性树脂由聚氨酯弹性体制成时，磁性树脂的弹性模量可通过NCO指数控制。当磁性树脂的弹性模量是通过NCO指数控制时，可将NCO指数控制在较低范围，即0.35至0.7，优选0.4至0.65。磁性树脂的弹性模量的控制可通过使用一元醇或控制NCO指数而实施，或可通过两者的结合进行。
磁性树脂可为不具有任何泡孔的非泡沫，但从提高稳定性或磁性传感器的精度方面，此外从轻量化方面出发，也可为具有泡孔的泡沫。该泡沫体可为发泡树脂，但考虑到其压缩永久变形等物理特性则优选使用热固性树脂泡沫。热固性树脂泡沫可为聚氨酯树脂泡沫、硅树脂泡沫等，其中更优选聚氨酯树脂泡沫。聚氨酯树脂泡沫可由上述异氰酸酯组分和含有活性氢的化合物获得。
在本发明中，以不损害磁性树脂的柔性的程度可在磁性树脂的周边设置密封材料。设置密封材料时，不可能通过在磁性树脂中使用高极性一元醇等方法来控制泡孔平均直径，但是可通过调节厚度等来控制弹性模量。密封材料可使用热塑性树脂、热固性树脂或其混合物。热塑性树脂可以列举例如苯乙烯系热塑性弹性体、聚烯烃系热塑性弹性体、聚氨酯系热塑性弹性体、聚酯系热塑性弹性体、聚酰胺系热塑性弹性体、聚丁二烯系热塑性弹性体、聚异戊二烯系热塑性弹性体、氟系热塑性弹性体、乙烯-丙烯酸乙酯共聚物、乙烯-乙酸乙烯酯共聚物、聚氯乙烯、聚偏二氯乙烯、氯化聚乙烯、氟树脂、聚酰胺、聚乙烯、聚丙烯、聚对苯二甲酸乙二醇酯、聚对苯二甲酸丁二醇酯、聚苯乙烯、聚丁二烯等。热固性树脂可以列举例如二烯系合成橡胶，如聚异戊二烯橡胶、聚丁二烯橡胶、苯乙烯-丁二烯橡胶、聚氯丁二烯橡胶和丙烯腈-丁二烯橡胶等；非二烯系橡胶，如乙烯-丙烯橡胶、乙烯-丙烯-二烯橡胶、丁基橡胶、丙烯酸酯橡胶、聚氨酯橡胶、氟橡胶、硅橡胶和氯醇橡胶等；天然橡胶；聚氨酯树脂；硅树脂；环氧树脂等。当密封材料为所述热塑性树脂、热固性树脂或其混合物时，其可适合以例如膜的形式使用。所述膜可为层压膜、金属箔(例如铝箔)或具有气相沉积膜的膜，所述具有气相沉积膜的膜由其上气相沉积金属的膜组成。密封材料具有抑制在磁性树脂中的磁性填料生锈的效果。
变形检测传感器的制造方法
本发明也提供一种制造变形检测传感器的方法，其包括以下步骤：
将磁性填料分散于包含一元醇组分的聚氨酯树脂前体溶液的步骤；
使所述树脂前体溶液固化而制备弹性模量为0.1至10MPa的磁性树脂的步骤；
将所述磁性树脂置于用于聚合物泡沫的模具中的步骤；
将聚合物泡沫的聚氨酯原料倾倒至所述模具中发泡，使磁性树脂与聚合物泡沫一体化的步骤；以及
将所述含有磁性树脂的聚合物泡沫与磁性传感器结合的步骤，所述磁性传感器检测由含有磁性树脂的聚合物泡沫的变形引起的磁性变化。
在形成树脂时，通过在含有一元醇组分的聚氨酯树脂前体溶液中混合磁性填料并在容器中反应，可制备弹性模量为0.1至10MPa的磁性树脂。
接着，将所得的具有特定弹性模量的磁性树脂置于用于聚合物泡沫的模具中，将聚氨酯聚合物泡沫原料倾倒至模具中发泡，使磁性树脂和聚合物泡沫一体化。在将磁性树脂置于用于聚合物泡沫的模具中时，若通过在模具中预先配置磁体，运用磁性树脂吸附于磁体的性能，则配置可容易进行。可将磁体设于模具中配置磁性树脂的地方，或在模具外通过强磁体而操作。除了使用上述磁体以外，还可使用双面胶带或粘合剂粘合而配置磁性树脂。
聚合物泡沫
在本发明中，其特征在于聚合物泡沫中央部分的泡孔平均直径小于磁性树脂和聚合物泡沫之间的界面附近的聚合物泡沫的泡孔平均直径，即在磁性树脂的界面附近泡孔平均直径变大。由于泡孔平均直径不同，能制得即使压力较小也可检出的变形检测传感器。磁性树脂附近的泡孔平均直径可通过下述方法测定：沿着界面将从磁性树脂和聚合物泡沫的界面起约1mm的部分切断，用扫描电子显微镜(SEM；日立科学系统株式会社制，S-3500N)在50倍的倍率下观察断面，对获得的图像，通过图像分析软件(三谷商事柱式会社制，WinROOF)测定所需范围的泡孔直径，算出泡孔平均直径。聚合物泡沫中央部分的泡孔平均直径通过下述方法测定：沿着磁性树脂将从磁性树脂和聚合物泡沫的界面起约5cm的部分切断，然后按照与测定磁性树脂附近的泡孔平均直径相同的方法对其进行测定。
可以认为上述泡孔平均直径的不同是由于在制备磁性树脂时，在磁性树脂的原料中混合高极性一元醇，磁性树脂的极性变高，并且吸附水分而使磁性树脂附近的泡孔直径变大。
聚合物泡沫在磁性树脂附近的泡孔平均直径为400至700μm，优选为400至600μm；聚合物泡沫中央部分的泡孔平均直径为300至450μm，优选为330至400μm。两者的泡孔直径之差为30至300μm，优选为50至250μm。
聚合物泡沫如上所述可通过使聚合物泡沫原液发泡而获得。聚合物泡沫可为一般的树脂泡沫，其中优选热固性树脂泡沫，更具体而言优选聚氨酯树脂泡沫或硅树脂泡沫。在聚氨酯树脂泡沫的情况下，其原液通常包含多异氰酸酯组分、多元醇和水等含有活性氢的化合物。此处，关于可使用的多异氰酸酯组分和含有活性氢的化合物可列举如下。
多异氰酸酯组分可无特别限定地使用聚氨酯领域中公知的化合物。实例为芳族二异氰酸酯，如2,4-甲苯二异氰酸酯、2,6-甲苯二异氰酸酯、2,2'-二苯基甲烷二异氰酸酯、2,4'-二苯基甲烷二异氰酸酯、4,4'-二苯基甲烷二异氰酸酯、1,5-萘二异氰酸酯、对苯二异氰酸酯、间苯二异氰酸酯、对苯二甲基二异氰酸酯、间苯二甲基二异氰酸酯等。也可为二苯基甲烷二异氰酸酯的多核化合物(粗MDI)。多异氰酸酯化合物还可为脂族二异氰酸酯，如亚乙基二异氰酸酯、2,2,4-三甲基六亚甲基二异氰酸酯和1,6-六亚甲基二异氰酸酯等；脂环族二异氰酸酯，如1,4-环己烷二异氰酸酯、4,4'-二环己基甲烷二异氰酸酯、异佛尔酮二异氰酸酯、降冰片烷二异氰酸酯等。这些可单独使用，或两种以上结合使用。此外，所述异氰酸酯可通过氨基甲酸乙酯改性、脲基甲酸酯改性、缩二脲改性及异氰脲酸酯改性等进行改性。
含有活性氢的化合物可为一般用于聚氨酯领域中的化合物。实例为聚醚多元醇，如聚四亚甲基醚二醇、聚丙二醇、聚乙二醇和环氧丙烷与环氧乙烷的共聚物；聚酯多元醇，如聚己二酸丁二醇酯、聚己二酸乙二醇酯和3-甲基-1,5-戊烷己二酸酯；聚酯聚碳酸酯多元醇，如聚酯二醇(例如聚己内酯多元醇或聚己内酯)与碳酸亚烷基酯的反应产物；通过使碳酸亚乙酯与多元醇反应以形成反应混合物，接着使所得的反应混合物与有机二羧酸反应获得的聚酯聚碳酸酯多元醇；通过多羟基化合物与碳酸芳基酯的酯交换反应获得的聚碳酸酯多元醇；聚合物多元醇，其为聚合物微粒分散的聚醚多元醇等。含有活性氢的化合物可单独使用，或两种以上结合使用。其具体实例可使用三井化学株式会社制的商品(例如EP 3028、EP 3033、EP 828、POP 3128、POP 3428和POP 3628)等。
当制备聚合物泡沫时，除上述调配物外可使用常用的交联剂、泡沫稳定剂、催化剂等，对其种类无特别限定。
交联剂可列举三乙醇胺、二乙醇胺等。泡沫稳定剂可列举DowCorning Toray株式会社制的SF-2962、SRX-274C、2969T等。催化剂的实例可列举Dabco 33LV(Air Products Japan株式会社制)、Toyocat ET、SPF2、MR(东曹株式会社制)等。
此外，如果需要，还可合适地使用添加剂，如水、调色剂、阻燃剂等。
阻燃剂的实例为大八化学株式会社制的CR 530或CR 505。
变形检测传感器
可将如上获得的含有磁性树脂的聚合物泡沫与磁性传感器结合以获得本发明的变形检测传感器。在本发明的变形检测传感器中，含有磁性树脂的聚合物泡沫由于人的落座而变形，磁场因此改变。磁性传感器检测该磁场的改变以检测人的落座。在本发明中，由于磁性树脂的弹性模量低，磁性树脂易于随着聚合物泡沫的变形而变形并且易于发生大的变形，从而提高了检测灵敏度。低的弹性模量也增加了稳定性或耐久性。
在本发明的变形检测传感器的制备方法中，磁性树脂可存在于聚合物泡沫的上表面或下表面。磁性树脂还可存在于聚合物泡沫内部。
本发明的磁性传感器可为一般用于检测磁场变化的传感器即可，例如磁阻元件(例如，半导体化合物磁阻元件、各向异性磁阻元件(AMR)、巨磁阻元件(GMR)或隧道磁阻元件(TMR))、霍尔元件、电感器、MI元件、磁通门传感器等。从更广的范围里具有高灵敏度的角度看，优选霍尔元件。
此外，可将上述变形检测传感器用于除了车辆的缓冲垫之外的用途，如可用于机器人的手或皮肤、床等的表面压力分布、路面状况或轮胎的空气压力、活体的运动状态(例如运动捕捉、呼吸状态、肌肉的放松状态等)、禁区的侵入、滑动门的异物等的检测。
实施例
基于下述实施例进一步说明本发明，然而，本发明不限于所述实施例。
实施例1
磁性树脂的制备
向反应容器中投入42.6重量份的多元醇A(以3-甲基-1,5-戊二醇、三羟甲基丙烷和己二酸为起始原料制备的聚酯多元醇，OH值为56，官能度为3；可乐丽株式会社制，F-3010)和42.6重量份的多元醇B(3-甲基-1,5-戊二醇己二酸酯，OH值为56，官能度为2；可乐丽株式会社制，P-2010)并在搅拌的同时减压脱水1小时。然后将反应容器内转换为氮气气氛。接着，向反应容器中加入14.8重量份的甲苯二异氰酸酯(2,4构型＝80％；三井化学株式会社制，商品名为Cosmonate T-80)，并将反应容器内的温度保持在80℃反应3小时而合成具有末端异氰酸酯基团的预聚物A(NCO％＝3.58％)。
然后，将30.0重量份的甲苯加入下述混合液：15.0重量份的多元醇A、5.0重量份的氰乙醇(东京化成株式会社制)和0.12重量份的二月桂酸二正丁基锡(Nacalai Tesque株式会社制)的混合液，向其中加入360.0重量份的钕系填料(NdFeB磁性粉末；Molycorp Magnequench株式会社制，商品名为MQP-14-12；平均粒径为15μm)，以制备填料分散液。接着，将100重量份的所述预聚物A与30.0重量份的甲苯混合以制备预聚物溶液。将所述预聚物溶液添加至所述填料分散液中，并使用自转公转搅拌机(Thinky公司制)进行混合并进行脱泡。用轧辊(nip roller)将反应溶液的厚度调节至1.5mm。然后在60℃下进行18个小时的固化而获得磁体填料分散树脂。然后使用磁化设备(玉川制作所制)在2.0T下将所得的该磁性填料分散树脂磁化而获得磁性树脂。所得磁性树脂的弹性模量如下所述进行测定且结果示于表1。表1也示出制备磁性树脂时的NCO指数和磁性树脂的一元醇含量。
弹性模量
磁性树脂的弹性模量如下所述进行测定：使用Autograph AG-X(岛津制作所制)，根据JIS K-7312在室温下以1mm/min的压缩速度进行压缩试验。试验片使用厚度12.5mm且直径29.0mm的直圆柱形样品。压缩弹性模量由2.4％至2.6％的压缩下的应力值算出。
含有磁性树脂的聚合物泡沫的制备
接着，在搅拌下将60.0重量份的聚丙二醇(三井化学株式会社制，EP-3028；OH值28)、40.0重量份的聚合物多元醇(三井化学株式会社制，POP-3128；OH值28)、2.0重量份的二乙醇胺(三井化学株式会社制)、3.0重量份的水、1.0重量份的泡沫稳定剂(Dow Corning Toray株式会社制，SF-2962)和0.5重量份的胺催化剂(Air Products Japan株式会社制，Dabco 33LV)混合以获得混合物A，将温度控制在23℃。此外，将甲苯二异氰酸酯和粗MDI的80/20(重量比)的混合物(三井化学株式会社制，TM-20；NCO％＝44.8％)调温至23℃以获得混合物B。
接着，将所述磁性树脂切成，并将其放置在模具中的长宽各400mm且厚度为70mm的模具的腔内的特定位置中，并将模具温度调节至62℃。使用高压发泡机通过使所述混合物A与所述混合物B混合以使NCO指数＝1.0而获得的原液倾倒至模具中，在62℃的模具温度下发泡并固化5分钟，获得含有磁性树脂的聚合物泡沫。对聚合物泡沫进行如下文中说明的的下述测定：磁性树脂和聚合物泡沫之间的界面附近的泡孔平均直径、该泡沫中央部分的泡孔平均直径、泡孔平均直径之差、平均磁通量密度变化(高斯)、性能稳定性(％)和异物感。结果示于表1。
泡孔平均直径
通过扫描电子显微镜(SEM)(日立科学系统株式会社制，S-3500N)，在50倍的倍率下，观察制得的含有磁性树脂的聚合物泡沫的磁性树脂与聚合物泡沫的界面附近的聚合物泡沫部分的横截面(距离界面1mm)和聚合物泡沫中央部分的横截面(距离界面5cm)，对获得的图像，通过图像分析软件(三谷商事柱式会社制，WinROOF)测定所需范围的泡孔直径，算出泡孔平均直径。此外，泡孔直径之差通过下式计算：
泡孔直径之差＝(界面附近的泡孔平均直径)-(中央部分的泡孔平均直径)
结果示于表1。
平均磁通量密度变化
将霍尔元件(旭化成微电子公司，EQ-430L)粘合至丙烯酸板上，然后将其粘合至与所得的含有磁性树脂的聚合物泡沫中磁性树脂一面相反的聚合物泡沫的表面。将具有的压力压头在5kPa的压力下施加在磁性树脂的中心部分，通过霍尔元件输出电压的变化而获得磁通量密度变化(高斯)。测量此磁通量密度变化10次，取其平均值为平均磁通量密度变化。此外，测定在20℃的温度下进行。
性能稳定性
磁通量密度变化的分布根据下式确定，值为性能稳定性(％)。所得结果作为性能稳定性(％)示于表1中。
异物感
通过接触按压含有磁性树脂的聚合物泡沫的界面且通过感官评估对其异物感进行评价。
○：没有异物感
△：稍微存在异物感
x：存在异物感
实施例2至5和比较例1至2
与实施例1相同地制备含有磁性树脂的聚合物泡沫，使用表1中的条件，并与实施例1相同地测定磁性树脂的弹性模量、聚合物泡沫的泡孔平均直径、磁通量密度变化、性能稳定性和异物感，结果示于表1。表1还示出了磁性树脂的NCO指数和一元醇含量。
由表1显示，本发明的实施例在磁通量密度变化(高斯)、性能稳定性和异物感方面是优异的。实施例2的一元醇含量较多，弹性模量降低。此外聚合物泡沫中磁性树脂附近的泡孔平均直径变大。因此，磁通量密度变化大，但性能稳定性稍微降低。实施例3的一元醇含量较少，弹性模量稍微提高，聚合物泡沫中磁性树脂附近的泡孔平均直径稍微减小。因此，磁通量密度变化稍微减小，但性能稳定性变优异。实施例4的一元醇含量较少，但因为低的NCO指数(OH基团)，弹性模量稍微提高，聚合物泡沫的磁性树脂附近的泡孔平均直径稍微减小。因此，磁通量密度变化稍微减小，但性能稳定性变优异。实施例5未使用一元醇且因为低的NCO指数的影响，弹性模量降低，其与实施例1的弹性模量近似，但也显示出聚合物泡沫中磁性树脂附近较小的泡孔平均直径。因此，磁通量密度变化稍微减小，且性能稳定性变优异。比较例1因为低的NCO指数的影响而使弹性模量减小，但是由于弹性模量太低，处理性能劣化，因此所得的样品容易皱曲。因此，其表现出差的磁通量密度变化和差的稳定性。比较例2增加了NCO指数以使弹性模量增加，但是由于弹性模量太高，磁通量密度变化降低，性能稳定性也差。
工业应用
本发明的变形检测传感器可用于车辆的座椅并具有优异的耐久性以便承受长时间的使用。此外，本发明的变形检测传感器具有优异的稳定性。
附图标记说明
1 乘坐部分
2 靠背部分
3 磁性传感器
4 磁性树脂
5 聚合物泡沫
6 含有磁性树脂的聚合物泡沫
7 外皮
8 底座
Claims (12)
1.一种变形检测传感器，其包括：
含有磁性树脂的聚合物泡沫，其包含磁性树脂和聚合物泡沫，所述磁性树脂含有磁性填料，所述聚合物泡沫包含所述磁性树脂；以及
磁性传感器，其检测由该含有磁性树脂的聚合物泡沫的变形引起的磁性变化，
其中所述磁性树脂的弹性模量为0.1至10MPa。
2.根据权利要求1所述的变形检测传感器，其特征为所述聚合物泡沫在所述磁性树脂和所述聚合物泡沫之间的界面附近的泡孔平均直径大于聚合物泡沫中央部分的泡孔平均直径。
3.根据权利要求1或2所述的变形检测传感器，其特征为所述磁性树脂和所述聚合物泡沫由聚氨酯制成。
4.根据权利要求1至3中任一项所述的变形检测传感器，其特征为形成所述磁性树脂的聚氨酯包含一元醇组分。
5.根据权利要求4所述的变形检测传感器，其特征为所述一元醇组分为高极性一元醇。
6.根据权利要求4或5所述的变形检测传感器，其特征为在聚氨酯原料的总量中所述一元醇组分的含量为0.1至1.0meq/g。
7.根据权利要求1至6中任一项所述的变形检测传感器，其特征为所述磁性树脂和所述聚合物泡沫通过自粘作用而粘合。
8.根据权利要求1至7中任一项所述的变形检测传感器，其中所述含有磁性树脂的聚合物泡沫为用于车辆座椅的缓冲垫，检测的变形为人的落座状态。
9.一种制造变形检测传感器的方法，其包括以下步骤：
将磁性填料分散于包含一元醇组分的聚氨酯树脂前体溶液的步骤，
使所述树脂前体溶液固化以制备弹性模量为0.1至10MPa的磁性树脂的步骤，
将所述磁性树脂置于用于聚合物泡沫的模具中的步骤，
将聚合物泡沫的聚氨酯原料倾倒至所述模具中发泡，使磁性树脂与聚合物泡沫一体化的步骤，以及
将该含有磁性树脂的聚合物泡沫与磁性传感器结合的步骤，所述磁性传感器检测由含有磁性树脂的聚合物泡沫的变形引起的磁性变化。
10.根据权利要求9所述的制造变形检测传感器的方法，其特征为所述一元醇组分为高极性一元醇。
11.根据权利要求9或10所述的制造变形检测传感器的方法，其中在聚氨酯原料的总量中所述一元醇组分的含量为0.1至1.0meq/g。
12.根据权利要求9至11中任一项所述的制造变形检测传感器的方法，其特征为所述磁性树脂和所述聚合物泡沫通过自粘作用而粘合。
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| US20180035813A1 (en) * | 2015-04-09 | 2018-02-08 | Toyo Tire & Rubber Co., Ltd. | Deformation detection sensor and production of the same |
| JP2019002695A (ja) * | 2017-06-12 | 2019-01-10 | 東洋ゴム工業株式会社 | 監視センサ、及び密閉型二次電池 |
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| CN114732247A (zh) * | 2022-04-01 | 2022-07-12 | 佛山市优迪家居制品有限公司 | 一种高回弹海绵坐垫及其制备方法 |
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| Publication number | Publication date |
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| US9939337B2 (en) | 2018-04-10 |
| JP2016203741A (ja) | 2016-12-08 |
| EP3085572A1 (en) | 2016-10-26 |
| US20160305831A1 (en) | 2016-10-20 |
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