JP2000313080A - Urethane foamed molded article and production thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To eliminate the damage caused by a lower coil spring or the like as a reinforcing material, for example, a cushion material and to provide rigidity to impart tension to cushioning properties, by integrating one or more nonwoven fabric layer and a reticulated substrate layer by the foaming curing of the urethane foamable soln. passing through the meshes of the reticulated substrate layer. SOLUTION: The thickness and wt. of fibers of the nonwoven fabric layers 5, 5 of a surface nonwoven fabric layer are set to predetermined ranges and both layers 5, 5' are brought to a three-layered structure holding a reticulated substrate layer 4 between the layers 5, 5' to cut off the exudation of a foamable soln. to a mold. The nonwoven fabric layer 5' is made relatively thin and dense and a urethane foamable soln. is applied to the inner surface of the nonwoven fabric layer 5' and foamed under heating and pressure to integrate the three-layered structure to form a foamed molded urethane layer 3. The nonwoven fabric layer 5 on the contact side with a spring material is formed from a flexible and relatively rough bulky nonwoven fabric to improve cushioning properties. By this constitution, it is prevented that foamed urethane exudes to a surface at the time of molding to form cured matter and the unpleasant friction noise between spring materials is prevented, excellent reinforcing effect, rigidity and durability are provided and a good seating feeling can be imparted.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a urethane foam molded article, and more particularly, to a foam molded article having sufficient surface rigidity and, for example, when used as a reinforcing material for a cushioning material of a seat for a seat. Urethane foam oozes out on the surface of the molded product and does not generate abnormal noise due to friction with metals such as frames and springs. The present invention relates to a urethane foam molded article and a method for producing the same.

[0002]

2. Description of the Related Art As shown in FIG. 1, for example, as shown in FIG.
The urethane layer 3 is provided so as not to be damaged by the pressing force of the above and to have rigidity and to have cushioning.
The reinforcement member 2 is attached to the bottom of the. In the past, slab urethane was installed on the wall surface of a foaming pot as such a reinforcing material 2, and a cold gauze was installed inside the slab urethane, and a urethane liquid was injected, followed by foaming by heating and pressing.

[0003] In order to improve the rigidity shortage in this method, a thin dense layer having a basis weight of 10 to 30 g / m ^2, made of a nonwoven fabric formed by integrating the bulky layer in the coarse of basis weight 40 to 100 g / m ² Reinforcement base cloth for urethane foam molding
No. 2-26193), and furthermore, a basis weight of 110 to 80.
0 g / m ² , 1 to 16 denier high-weight nonwoven fabric (Japanese Unexamined Patent Publication No. 2-258332), a base layer made of the above-mentioned high-weight nonwoven fabric, and a reinforcing coating layer made of a fiber aggregate or the like on one surface thereof. Reinforcing material for foam molding (JP-A-4-14140)
No. 5), a reinforcing material having a base material layer made of a high-weight nonwoven fabric and a reinforcing coating material layer made of a low-weight nonwoven fabric (JP-A-5-57)
No. 827), a bulky substrate layer of 2 to 20 denier and 2 to 1 denier.
Provided is a reinforcing material made of a thin and dense nonwoven fabric of 0 denier (Japanese Patent Application Laid-Open No. 6-136651), which provides rigidity of a foamed molded product and a cured product caused by seepage hardening of a foaming resin liquid onto the surface of the reinforcing material. It is an object of the present invention to prevent the generation of abnormal noise due to friction between a metal member and a holding fitting or the like. However, in the method using the reinforcing material in which the nonwoven fabrics are laminated as described above, there are problems such as an insufficient reinforcing effect and an increase in thickness due to lamination of a bulky nonwoven fabric.

Further, in order to prevent the generation of friction noise with the sheet frame or the like of the cured resin oozing out of the above-mentioned reinforcing material, a non-breathable plastic film is adhered to a breathable reinforcing material such as coarse felt to form a foam material. (Japanese Unexamined Patent Publication No. Hei 5-138772), a method using a composite sheet comprising a woven fabric composed of an elastomer film containing an ethylene-acrylic acid copolymer or the like, polyester fibers and a resin adhesive layer (Japanese Unexamined Patent Publication No. No. 6-8337) has also been proposed. However, these methods not only impair the air permeability but also prevent the penetration of the resin liquid into the nonwoven fabric layer.
Since the resin liquid is not impregnated into the nonwoven fabric as the reinforcing layer, sufficient rigidity cannot be obtained, and there has been a problem that the function as a reinforcing material is reduced.

Further, in a polyethylene terephthalate long-fiber nonwoven fabric having a denier of 5 to 25 denier, a reinforcing material for urethane foam molding having fibers arranged orthogonally under specific conditions and having a basis weight in the range of ²⁰ to 200 g / m ² (JP-A-7-228709)
No.) is provided. According to the present invention, it is pointed out that if the denier is less than 5 deniers, the density of the long-fiber nonwoven fabric increases, causing problems such as poor outgassing during polyurethane foaming and insufficient penetration of the polyurethane resin into the long-fiber nonwoven fabric.

Further, in order to improve urethane barrier properties, noise prevention and moldability, a method of laminating and integrating a bulky nonwoven layer as an upper and lower layer and a dense nonwoven layer as an intermediate layer (Japanese Patent Laid-Open No. 6-171003) and A method has been proposed in which a layer in contact with urethane foam is a dense nonwoven layer and a layer in contact with a coil spring or the like is a bulky nonwoven layer (JP-A-6-171002). In these methods, the basis weight is 20 to 100.
g / m ² and 30 to 200 g / m ² nonwoven fabric porosity 8
7 to 91% and 90 to 94% of the nonwoven fabric are used separately.

In the above-mentioned prior art, for example, a bulky non-woven fabric layer and a dense non-woven fabric layer are overlapped and mechanically entangled by needle punching, impregnated with an adhesive, dried, or heat-sealed. The step of integrating constituent materials by a method such as heat fusion by the use of conductive fibers has been indeterminate. However, adoption of the above-described method requires suitable process equipment, which lowers economic efficiency.

[0008]

DISCLOSURE OF THE INVENTION The present invention is an object of the present invention as a reinforcing material for urethane foam molding. For example, when the present invention is used as a cushion material for a vehicle seat or the like, there is no damage by a coil spring attached to a lower portion. The purpose of the present invention is to provide rigidity and to provide cushioning with tension. Further, the above-mentioned conventional method has a problem to be solved in urethane foam molding, which is an effect of preventing a mold air vent hole from being closed. The object of the present invention is to prevent the generation of abnormal noise due to friction with the urethane cured material on the surface of the reinforcing material in contact with the metal, and to provide a urethane foam molded product having high strength, and has been determined to be undecidable in the conventional process. This substantially eliminates the entanglement step between constituent materials.

[0009]

That is, the present invention comprises at least one or more nonwoven fabric layers and a reticulated base material layer which are integrated by foaming and curing a urethane foaming solution which has passed through the mesh of the reticulated base material layer. It is intended to provide a urethane foam molded article characterized by the above.

In the above-mentioned present invention, it is preferable that the reticulated base material layer is formed of a reticulated base material obtained by laminating or weaving a uniaxially oriented body formed from a thermoplastic resin film so that its orientation axes intersect. .

Further, the basis weight of the nonwoven fabric layer is 20 to 120 g /
m ² , and the nonwoven fabric layer is preferably formed of fibers having a fiber diameter of 1 to 5 denier.

The present invention further comprises forming at least one or more nonwoven fabric layers in contact with the inner surface of the urethane foam molding die, and forming a net-like base material layer on the inner surface side of the nonwoven fabric layer or in the middle of the nonwoven fabric layer. Manufacturing a urethane foam molded article, wherein the nonwoven fabric layer and the mesh substrate layer are integrated by foaming and curing of the urethane foam liquid that has passed through the voids of the mesh substrate layer, followed by urethane foam molding. It also provides a method.

In the reinforcing layer on the surface of the above-mentioned urethane foam molded article, the reticulated base layer comprises a reticulated base portion and a void portion, and the nonwoven fabric layer and the reticulated base layer pass through the void portion of the reticulated base material layer. It is integrated by the foamed cured product of the urethane foam liquid that has oozed into the nonwoven fabric layer.

[0014]

FIG. 2 is a view showing one example of a urethane foam molded article of the present invention. In FIG. 2, 3 is a mold urethane layer, 5 is a nonwoven fabric layer, and 4 is a mesh base layer. As shown in FIG. 3, the nonwoven fabric layer 5 and the reticulated base material layer 4 are integrated by a foamed cured product 3 a of a urethane foam liquid that has passed through the voids of the reticulated base material layer 4 and oozed into the nonwoven fabric layer 5. .

FIG. 4 is a view showing another example of the urethane foam molded article of the present invention, wherein 3 is a urethane layer, 4 is a reticulated base material layer,
5 and 5 'indicate the nonwoven fabric layers, respectively. The nonwoven fabric layers 5, 5 ′ and the intermediate reticulated base material layer 4 are integrated by a foamed cured product of a urethane foam liquid that has passed through the nonwoven fabric layer 5 ′ and the reticulated base material layer 4 and oozed into the nonwoven fabric layer 5. I have.

Materials used as the nonwoven fabric layers 5 and 5 'include synthetic fibers such as polypropylene, polyester, high-density polyethylene, low-density polyethylene, and nylon.
It is possible to use recycled fibers such as rayon, natural fibers such as cotton, or composite fibers thereof, but among them, polyester fibers are effective.

The reticulated base material layer 4 is formed of a reticulated base material obtained by laminating or weaving a uniaxially oriented body formed from a thermoplastic resin film so that its orientation axes intersect. That is, a nonwoven fabric or a woven fabric excellent in reinforcing effect obtained by laminating or configuring a uniaxially oriented body of at least one kind of thermoplastic resin selected from a split web, a slit web and a uniaxially oriented tape so that the orientation axes intersect. Cloth is used. Since the uniaxially oriented body made of this film is flat, the reinforcing material of the present invention can be made thinner and flatter.

The above-mentioned split web may be a single layer. Preferably, at least two or more layers of a multilayer film produced by extrusion such as a multilayer inflation method and a multilayer T-die method are used in a longitudinal (longitudinal) or horizontal direction. This is a uniaxially oriented net-like film that is stretched in the (width direction) and has a number of cracks intermittently in the stretching direction. The slit web is a uniaxially oriented net-like film that is formed in the single-layer or multi-layer film by forming a large number of slits (cuts) in the vertical or horizontal direction and then extending in the slit direction. The uniaxially oriented tape is obtained by stretching the single-layer or multilayer film before and / or after cutting in the longitudinal or transverse direction.

More specifically, for example, a nonwoven fabric obtained by laminating a slit web and then thermocompressing, a nonwoven fabric obtained by laminating a slit web and thermocompressing, a split web and a slit web can be used as the reticulated base material layer composed of the uniaxially oriented body. Examples of the nonwoven fabric include a nonwoven fabric which is laminated and thermocompression-bonded, a nonwoven fabric in which a split web or slit web and a uniaxially oriented tape are laminated so that the orientation axes intersect, or a woven fabric in which a uniaxially oriented tape is woven.

As the non-woven fabric made of a uniaxially oriented body, it is preferable that at least one kind of uniaxially oriented body selected from a split web, a slit web, and a uniaxially oriented tape is laminated so that the orientation axes cross each other as described above. Depending on the application, the layers may be laminated with the orientation being random or in the same direction. In addition, these nonwoven fabrics or woven fabrics can be used as a composite laminate.

The uniaxially oriented body is provided with a second thermoplastic resin layer having a lower melting point than the first thermoplastic resin as an adhesive layer on at least one surface of the crystalline first thermoplastic resin layer. It is desirable that the multi-layer stretched body is formed by stretching.

Examples of the first thermoplastic resin include high- and medium-density polyethylene, polypropylene, polybutene-1, poly-4-methylpentene-1, polyhexene-1 and other homopolymers of α-olefins, propylene- Examples include polyolefins such as α-olefin copolymers such as ethylene copolymers, polyamides, polyesters, polycarbonates, and polyvinyl alcohols.

The second thermoplastic resin having a lower melting point than the first thermoplastic resin includes high-, medium-, and low-density polyethylene, linear low-density polyethylene, ultra-low-density polyethylene, and ethylene-vinyl acetate copolymer. Ethylene-acrylic acid copolymer, ethylene-methacrylic acid copolymer, ethylene-acrylic acid ester copolymer such as ethylene-ethyl acrylate copolymer, and ethylene-methacrylic acid such as ethylene-ethyl methacrylate copolymer Examples include acid ester copolymers, ethylene- (maleic acid or its ester) copolymers, propylene-based polymers such as polypropylene and propylene-ethylene copolymers, and polyolefins modified with unsaturated carboxylic acids. Further, a mixture of these resins and other polyolefin-based resins may be used, such as a high-density polyethylene or an ethylene-α-olefin-copolymer or the like in a random copolymer of propylene and ethylene, 1-butene, or the like. What mixed the polyethylene resin etc. is used.

For reasons of manufacturing and for preventing a decrease in strength increased by stretching or rolling of the uniaxially oriented body, the second
The difference between the melting points of the thermoplastic resin and the first thermoplastic resin is preferably at least 5 ° C or more, more preferably in the range of 10 to 50 ° C.

The specific resin composition of the multilayer film includes high-density polyethylene (HDPE) / low-density polyethylene (LDPE), LDPE / HDPE / LDPE, H
DPE / ethylene-vinyl acetate copolymer (EVA), E
VA / HDPE / EVA, polypropylene (PP) / propylene-ethylene copolymer (PEC), PEC / PP
/ PEC, polyester (PEs) / copolyester (CPEs), CPEs / PEs / CPEs, and the like.

Next, a specific example of a method for manufacturing a split web and a slit web will be described with reference to the drawings.

FIG. 5A is a partially enlarged perspective view showing an example of the split web which is (a) uniaxially stretched and split in the longitudinal direction. The split web 6 made of a thermoplastic resin is made of a first thermoplastic resin and a second thermoplastic resin having a melting point lower than that of the first thermoplastic resin by using a multilayer inflation method, a multilayer T-die method, or the like. Of a multilayer film having at least two or more layers produced by extrusion molding in the longitudinal direction (length direction) of 1.1 to 15 times, preferably 3 times.
It is drawn 10 to 10 times and split (split processing) using a splitter in the same direction in a zigzag manner.
As a result, the multilayer film becomes a net-like shape, and is further expanded to a predetermined width to form a mesh-like split web 6. The split web 6 is a uniaxially oriented body having strength in the longitudinal direction over the entire width direction. In the figure, 7 is a trunk fiber and 8 is a branch fiber.

FIG. 5B is a partially enlarged perspective view of a portion B in FIG. 5A. In the split web 6, a second thermoplastic resin 10 is laminated on both surfaces of a first thermoplastic resin 9. It has a three-layer structure.

FIG. 6A is a partially enlarged perspective view showing an example of a slit web which is formed by forming a large number of slits in the film and then uniaxially stretching the film in the horizontal direction. A slit web 11 made of a thermoplastic resin is formed by forming intermittent slits in a staggered pattern in a lateral direction (width direction), for example, with a hot blade or the like in a portion of the multilayer film except for both ears. A uniaxially oriented body stretched in the transverse direction at an elongation ratio of 1.1 to 15 times, preferably 3 to 10 times, and has strength in the transverse direction. Preferably, the multilayer film is finely oriented by about 1.1 to 3 times in the longitudinal direction by rolling or the like, and then subjected to slit processing in a staggered manner in the horizontal direction with a hot blade, followed by transverse stretching.

FIG. 6B is a partially enlarged perspective view of a portion B in FIG. 6A. The slit web 11 is also provided on both surfaces of the first thermoplastic resin layer 9 with the second thermoplastic resin layer 10. In a three-layer structure.

FIG. 7 is a partially enlarged perspective view showing the uniaxially oriented tape. The uniaxially oriented tape 12 made of a thermoplastic resin is made of a first thermoplastic resin and a second thermoplastic resin having a melting point lower than that of the first thermoplastic resin, using a multilayer inflation method and a multilayer T-die method. Before and / or after cutting, at least two or more multilayer films produced by extrusion molding are uniaxially oriented in a longitudinal and / or transverse direction at an expansion ratio of 1.1 to 15 times, preferably 3 to 10 times. Into a multilayer stretched tape.

The uniaxially oriented tape 12 also has the first
Second thermoplastic resin layers 10 on both surfaces of the thermoplastic resin layer 9
Are laminated to form a three-layer structure.

FIGS. 8 to 10 show specific examples of the reticulated base material layer 4 in the present invention. FIG. 8 is a partial plan view of a net-like base material 13 in which the split web 6 and the slit web 11 are laminated in a manner so that the orientation axes intersect.

FIG. 9 is a partial plan view of a net-like base material 16 formed by laminating two split webs 6 so that their orientation axes intersect.

FIG. 10 is a partial plan view of a reticulated base material 14 in which two sets of uniaxially oriented multilayer tapes 12 are arranged in parallel, and FIG. 11 is a reticulated base material 15 in which the uniaxially oriented multilayer tape 12 is woven. FIG.

The above-described split web-slit web laminated net substrate 13, split web-slit web laminated net substrate 16, uniaxially oriented multilayer tape laminated net substrate 14, and uniaxially oriented multilayer tape woven net substrate 15 are:
The same net-like base material can be further laminated and used, or different kinds of net-like base materials can be laminated and used as a net-like base material layer in the present invention.

As a specific example of the split web-slit web laminated net-like base material 13 and the split web-split web laminated net-like base material 16, "Nisseki Warif" (trade name, registered trademark, manufactured by Nisseki Plast Co., Ltd.) ).

Next, urethane foam molding will be briefly described.

In the present invention, a polyurethane foam is a foam made from a diisocyanate and a polyol. Examples of the diisocyanate include m-phenylene diisocyanate, toluene-2,4-diisocyanate, hexamethylene-1,6-diisocyanate, tetramethylene-1,4-diisocyanate, cyclohexane-1,4-diisocyanate, and naphthalene-
1,5-diisocyanate, 1-methoxyphenyl-
2,4-diisocyanate, diphenylmethane-4,
4'-diisocyanate, 4,4'-biphenylene diisocyanate, and the like.

As the polyol, a polyether type such as polyoxypropylene glycol and polyoxypropylene-polyoxyethylene glycol, and a polyester type having adipic acid and ethylene glycol as a main component are used. Among them, polyether type is preferred.

For the polyurethane foam, the above-mentioned polyol, a liquid A containing a foaming agent, a catalyst, a cell size modifier and the like and a liquid B mainly containing an isocyanate and the like are mixed in a short time. The so-called reaction injection molding method (RI
M).

The method for forming the mesh-like base material layer as an intermediate layer between the upper and lower nonwoven fabric layers or as one of the nonwoven fabric layers in the urethane foam molding reinforcing material of the present invention will be described below.

The reinforcing material for urethane foam molding of the present invention is obtained by calendering a web having a random loop structure made of, for example, polyester fibers having a thickness of, for example, 2 deniers manufactured by a commonly employed spunbonding method using a hot roll. A nonwoven fabric 2 obtained by simply changing the basis weight by the same method as the non-woven fabric 1 subjected to the pre-thermocompression bonding is used to form a reticulated base material layer as an intermediate layer between upper and lower nonwoven fabric layers or as one of the nonwoven fabric layers. Thus, it can be used as a reinforcing material for a urethane foam molded article.

Then, the three-layer or two-layer forming material composed of the nonwoven fabric 1, the nonwoven fabric 2 and the reticulated base material is successively set in a urethane foam molding die, and a foamable urethane resin is added according to a conventional method. The polyurethane is foamed under pressure.

Next, a method of forming a reinforcing layer on the surface of a urethane foam molded article using the urethane foam molding reinforcing material of the present invention will be described.

FIG. 2 is a view showing the state of integration of the nonwoven fabric layer 5 and the net-like base material layer 4 on the surface of the urethane foam molding as described above. In FIG. 2, reference numeral 5 denotes a nonwoven fabric layer in contact with the mold surface in urethane foam molding, and reference numeral 4 denotes a net-like base material forming a net-like base material layer. In the case of the present invention, the reinforcing layer is formed by forming the urethane liquid during urethane foam molding, in other words, the urethane foam liquid permeates the layer by the foam molding pressure, and furthermore, the mesh layer adjacent to the mesh substrate in the mesh substrate layer 4. It passes through the gap with the base material, oozes into a part of the nonwoven fabric layer 5 in contact with the mold surface, foams and hardens in this nonwoven fabric layer 5,
Thus, the nonwoven fabric layer 5 and the reticulated base material layer 4 are integrated,
A surface reinforcing layer is formed as a urethane foam molded article.

The preferred embodiment of the urethane foam molded article of the present invention will be further described.

The thickness of the fibers forming the nonwoven fabric layer 5 forming the surface nonwoven fabric layer and the other nonwoven fabric layer 5 'is preferably in the range of 1 denier to less than 5 denier. Among the above-mentioned fiber materials, a polyester fiber having a thickness of 1 to 3 denier is most preferably used. If the thickness is less than 1 denier, it is difficult to defibrate by a card machine or the like, and uniform web adjustment is performed. When the thickness is 5 denier or more, the effect of preventing the nonwoven fabric layers 5 and 5 'from leaking to the surface of the urethane foam molding material becomes insufficient, and as a result, generation of abnormal noise is prevented. Tends to be difficult.

In the urethane foam molded article having a three-layer structure, the basis weight of the nonwoven fabric layers 5 and 5 ′ is 20 to 120 g / m 2 in total.
It is preferably in the range of ² , and it is necessary to have a basis weight that can completely shut off the urethane liquid so that the urethane does not seep into the mold when the three-layer structure is sandwiched by the reticulated base layer 4. . The nonwoven fabric layer 5 and the nonwoven fabric layer 5 'may be the same or different, but when different ones are used, the nonwoven fabric layer 5' on the side in contact with the mold urethane layer 3 is relatively thin. It is formed of a dense nonwoven fabric and mainly has a role of preventing the passage of urethane liquid. The nonwoven fabric layer 5 on the side in contact with the spring material 1 is formed of a relatively coarse and bulky nonwoven fabric having flexibility. In addition to making the blocking more complete, it is preferable to have a role of improving the cushioning property.

The basis weight of the nonwoven fabric layer 5 forming the surface (the side in contact with the spring material) of the reinforcing material of the urethane foam molded product is usually 3
In the range of 0~80g / m ^2, if less than 30 g / m ² is insufficient leakage prevention effect of the urethane solution, 50
If it exceeds g / m ² , the thickness tends to be large, and the ability to follow a curved surface to a mold tends to be unfavorable.

The basis weight of the nonwoven fabric layer 5 of the mold urethane side 'is usually in the range of ^{20~60g / m 2, 20g / m} 2
If less than the mesh base layer 4 of urethane foam molding material
And the inflow into the nonwoven fabric layer 5 becomes excessive, and as a result, the leakage prevention to the surface of the nonwoven fabric layer 5 becomes insufficient, and when it exceeds 60 g, the thickness increases.

In the case of a two-layer structure, the basis weight of the nonwoven layer 5 is such that the nonwoven layer 5 and the nonwoven layer 5 ′ in the three-layer reinforcing material are sufficient to sufficiently satisfy the urethane barrier property.
It is better to use a combination of
It is in the range of 20 g / m ² .

The basis weight of the nonwoven fabric layer 5 forming the reinforcing material for urethane foam molding having a two-layer structure is usually 30 to 100 g / m ^2.
If it is less than 30 g / m ² , the effect of preventing leakage of the urethane foam molding material is insufficient, and
If it exceeds / m ² , the thickness tends to be large, and the followability of the curved surface tends to deteriorate, which is not preferable.

Reticulated base material in three-layer structure and two-layer structure
The basis weight of the layer 4 is usually 10 to 80 g / m. ^TwoAnd 10 g /
m^TwoIf less than, as a reinforcing material for urethane foam molding
Tends to be difficult to obtain a high strength of 80 g
/ M^TwoIf it exceeds, the rigidity becomes too large and follows the curved surface
It tends to be poor.

The opening ratio of the mesh base layer 4 is 30 to 70.
%, Preferably 40 to 60%. When the opening ratio is less than 30%, the urethane foam liquid does not easily pass through the fine particles, and the adhesiveness between the reticulated base layer 4 and the nonwoven fabric layer 5 tends to be inferior. When the opening ratio exceeds 70%, the strength decreases. In addition, the flow of the urethane liquid into the nonwoven fabric layer 5 tends to be excessive.

[0056]

The present invention will be further described with reference to the following examples.

A spunbonded nonwoven fabric made of polyester having a basis weight of 80 g / m ² was laminated as a nonwoven fabric layer on the side of the foam molding die which is in contact with the mold, and then a split web and a slit web were sequentially laminated as a mesh base layer. Net weight 35
g / m ² , 0.1 mm thick Nisseki Warif HS-T (manufactured by Nisseki Plast Co., Ltd.) is laminated to form a laminate having a two-layer structure, a foamable urethane resin is added, and polyurethane is heated and pressed under pressure. Was molded to produce a urethane foam molded article.

When the state of permeation of the polyurethane resin into the mold side surface of the nonwoven fabric in the obtained molded article was confirmed,
The urethane liquid did not permeate the mold side surface of the nonwoven fabric at all. Further, no abnormal noise was generated even in an abnormal noise generation model test in which the nonwoven fabric layer surface was brought into contact with a coiled spring and pressurization and depressurization were repeated.

[0059]

Industrial Applicability The urethane foam molded article of the present invention is excellent in reinforcing effect, and does not bleed out to the surface during molding to form a cured product. Since noise can be prevented, a vehicle seat or the like having excellent rigidity and durability and good sitting comfort can be obtained. In addition, the manufacturing process can be simplified.

[Brief description of the drawings]

FIG. 1 is a diagram showing an example of a vehicle seat.

FIG. 2 is a view showing one example of a urethane foam molded article.

FIG. 3 is a schematic diagram showing an integrated state of a nonwoven fabric layer and a net-like base material layer on the surface of a urethane foam molded article.

FIG. 4 is a view showing another example of a urethane foam molded article.

FIG. 5 is a diagram showing an example of a split web and a partially enlarged perspective view.

FIG. 6 is a diagram showing an example of a slit web and a partially enlarged perspective view.

FIG. 7 is a partially enlarged perspective view showing a uniaxially oriented tape.

FIG. 8 is a partial plan view of a net-like base material obtained by laminating a split web and a slit web.

FIG. 9 is a partial plan view of a net-like base material obtained by laminating two split webs.

FIG. 10 shows a net-like base material obtained by laminating uniaxially oriented multilayer tapes.

FIG. 11 is a net-like substrate woven with a uniaxially oriented multilayer tape.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Coil spring 2 Reinforcement material 3 Mold urethane layer 4 Reticulated base material layer 5, 5 'nonwoven fabric layer 6 Split web 7 Trunk fiber 8 Branch fiber 9 First thermoplastic resin 10 Second thermoplastic resin 11 Slit web 12 Uniaxially oriented tape DESCRIPTION OF SYMBOLS 13 Split web-slit web laminated net base material 14 Uniaxially oriented multilayer tape laminated net base material 15 Uniaxially oriented multilayer tape woven net base material 16 Split web-slit web laminated net base material

 ──────────────────────────────────────────────────続 き Continuing on the front page F term (reference) 4F100 AK01B AK51B AK51C BA03 BA10A BA10C BA15 DC16B DG12B DG14B DG15A DH00B DJ01B DJ01C EC051 EC202 EH112 EH312 EJ022 EJ082 GB33 JA13A JA20A JK01 JL00AJA02AJK01 JL02A EB13 EB24

Claims (5)

[Claims] 1. A urethane foam molded article wherein at least one or more nonwoven fabric layers and a reticulated base material layer are integrated by foaming and curing of a urethane foaming liquid that has passed through the mesh of the reticulated base material layer. 2. The reticulated base material layer is formed of a reticulated base material obtained by laminating or weaving a uniaxially oriented body formed from a thermoplastic resin film so that its orientation axes intersect. 2. The urethane foam molded article according to 1. 3. The nonwoven fabric layer has a basis weight of 20 to 120 g / m ^2.
The urethane foam molded article according to claim 1 or 2, wherein: 4. The urethane foam molded article according to claim 1, wherein the nonwoven fabric layer is formed of fibers having a fiber diameter of 1 to 5 denier. 5. At least one or more nonwoven fabric layers are formed so as to be in contact with the inner surface of the urethane foam molding die, and a reticulated base material layer is formed on the inner surface side of the nonwoven fabric layer or in the middle of the nonwoven fabric layer. By foam molding,
A method for producing a urethane foam molded article, wherein the nonwoven fabric layer and the reticulated base material layer are integrated by foaming and curing of the urethane foam liquid passed through the voids of the reticulated base material layer.