JP2001061603A - Cushion material, manufacture thereof, and adhesive for cushion material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve moisture absorption, deodorizing properties, antifungal property, mothproofing property, heat retaining properties, and flame retardance by impregnating a foamed material with a liquid, wherein charcoal powder is dispersed, to fill the foamed material with the charcoal powder. SOLUTION: A charcoal powder filled into a foamed material has a smaller surface area than an activated carbon, but preserves the internal structure of wood, as it is, and hence a large hole, equivalent to a vessel of wood, is present, and water or malodorous components are adsorbed in the hole. Thus, the powder has higher moisture absorbing properties or moisture barrier properties than activated carbon and has good far-infrared ray-radiating performance. If a foam material is impregnated with a liquid, wherein charcoal powder is dispersed, to fill the powder into the foam material, when air flows through the interior of the material, sweat or moisture contained in the air or gas such as ammonia, formaldehyde, which causes malodor, is absorbed by the charcoal powder filled into the foam material, and hence moisture absorption, deodorizing properties, antifungal property or the like of the cushion material can be improved.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cushioning material used for beddings such as futons and pillows, a seat portion of a chair, a floor material, a wall material and the like, a method of manufacturing the same, and a method of bonding such a cushioning material. More particularly, the present invention relates to a cushioning material having excellent properties such as hygroscopicity, deodorization, mold resistance, insect repellency, heat retention, flame retardancy and the like, and a method for producing the same. The present invention relates to an adhesive suitable for bonding various cushioning materials to each other and for bonding this cushioning material to a plate material or the like.

[0002]

2. Description of the Related Art Conventionally, cushioning materials used for beddings such as futons and pillows, seats for chairs, flooring materials, wall materials and the like include:
Generally, cotton, sponge, urethane foam, panya, feathers, chaff, glass wool, and the like were used.

[0003] However, these cushioning materials do not always have sufficient properties such as moisture absorption, deodorization, mold resistance, insect repellency, heat retention, and flame retardancy.

For this reason, when such a cushioning material is used for bedding such as a futon or a pillow, the futon or the pillow becomes wet with sweat,
The pillows and pillows become dirty, the pillows and pillows become odorous, mites are formed inside the futons and pillows, and sufficient heat insulation is obtained during the cold winter months. There were various problems such as not being able to be done.

[0005] In addition, cushioning materials such as urethane foam are liable to burn, and when burned, there is a problem that toxic gas is generated.

Accordingly, the present applicant has filed an earlier application (Japanese Unexamined Patent Application Publication No.
0-165260) proposed a cushion material in which charcoal powder is contained in a foam having an open-cell structure.

Here, when charcoal powder is contained in a foam having an open-cell structure as in the cushion material disclosed in the above-mentioned publication, the charcoal powder contained in the foam causes the cushion material to absorb moisture, deodorize, Fungicide, insect repellent,
Characteristics such as heat retention and flame retardancy have been improved.

[0008] In the cushioning material disclosed in the above-mentioned publication, when charcoal powder is contained in a foam having an open-cell structure, foaming is performed in a state where charcoal powder is mixed with the raw material of the foam. .

However, when foaming is performed in a state in which charcoal powder is mixed with the raw material of the foam, if the amount of charcoal powder is increased, foaming cannot be performed properly. A large amount of charcoal powder cannot be contained in the body, and it has become difficult to further improve the properties of the cushioning material such as moisture absorption, deodorization, mold resistance, insect repellency, heat retention, and flame retardancy.

When the above cushioning material is adhered to a board or the like with an adhesive and used as a floor material or a wall material, an odor is generated due to various solvents or the like contained in the adhesive, There is also a problem that the agent itself burns and toxic gas is generated.

[0011]

SUMMARY OF THE INVENTION The present invention relates to a cushioning material used for beddings such as futons and pillows, a seat portion of a chair, a flooring material, a wall material, and the like, and the cushioning material is bonded to a plate material or the like with an adhesive. It is an object of the present invention to solve the above-described various problems when used as floor materials or wall materials.

That is, the present invention provides a cushioning material using a foam, which has a moisture absorbing property, a deodorizing property, a fungicidal property,
In addition to improving properties such as insect repellency, heat retention, and flame retardancy,
When this cushioning material is used as a floor material or wall material by bonding it to a board or the like with an adhesive, a bad smell is generated by various solvents contained in the adhesive, or the adhesive itself burns and toxic gas is emitted. It is an object of the present invention to suppress the occurrence.

[0013]

According to the cushioning material of the present invention, in order to solve the above-mentioned problems, a foamed material is impregnated with a dispersion of charcoal powder to form a foamed material. Charcoal powder was filled.

Here, in the cushioning material of the present invention, the charcoal powder filled in the foam as described above is:
Although the surface area is smaller than activated carbon, the internal structure of the tree is preserved as it is, so there are large holes corresponding to the wooden conduit, where moisture and odorous components are adsorbed, and the moisture absorption is better than activated carbon And has excellent deodorizing properties and excellent far-infrared radiation performance.

[0015] Therefore, when the foam is impregnated with a dispersion of charcoal powder as in the cushioning material of the present invention and the foam is filled with the charcoal powder, the air blows the interior of the foam and the like. When flowing, moisture such as sweat contained in the air and gas that causes an odor such as ammonia, formaldehyde, trimethylamine, and methyl mercaptan are adsorbed by the charcoal powder filled in the foam, and the cushion is used. The moisture absorption, deodorization, and antifungal properties of the wood are improved, and the occurrence of mites is also suppressed. Furthermore, the far-infrared radiation performance of this charcoal powder also improves its heat retention when used in futons, etc. In addition, the charcoal powder improves the flame retardancy of the cushioning material.

Further, when the foam is impregnated with a dispersion of charcoal powder as in the cushioning material of the present invention, and the foam is filled with the charcoal powder, the charcoal powder is used as a raw material of the foam. Compared to the case of containing and foaming, the cushion material can be filled with more charcoal powder, and the above-described characteristics are further improved.

Further, in the cushioning material according to the present invention, when a foam having an open-cell structure is used as the above-mentioned foam, air flows through the inside of the foam having the open-cell structure. It is easy to flow, and the above characteristics are further improved.

In the method of manufacturing a cushioning material according to the present invention, a foam is impregnated with a dispersion of charcoal powder dispersed in a resin solution, and then dried, and the foam is filled with charcoal powder. It was made to do.

Then, as in the method of manufacturing a cushioning material according to the present invention, the foam is impregnated with a dispersion obtained by dispersing the charcoal powder in a resin solution, and then dried. And foams inside the foam are filled in a state that they are sufficiently adhered, the charcoal powder is prevented from detaching from the foam, and the characteristics of the cushion material in which the charcoal powder is filled into the foam are improved. It will be kept stable for a long time.

Here, when impregnating the foam with the dispersion obtained by dispersing the charcoal powder in the resin solution, the foam may be immersed in the dispersion, or the dispersion may be sprayed on the foam. , Coating or the like.

Here, the type of foam used in the present invention is not particularly limited, but it is preferable to use a foam having an open-cell structure as described in claim 2 above, for example, sponge, urethane foam, Various polyolefin foams and the like can be used.

The foaming rate of the foam is not particularly limited. The foaming rate is changed according to the intended use of the cushioning material so that the cushioning material has appropriate flexibility and elasticity according to the intended use. In addition, the charcoal powder is usually set to have a foaming ratio of 50 to 90% so that the charcoal powder sufficiently appears in the cell portion.

On the other hand, as the charcoal powder used in the present invention, various charcoal powders generally used can be used, and examples thereof include charcoal powder made of softwood, hardwood, bamboo and the like.

In filling such a charcoal powder into a foam, if the particle size of the charcoal powder is large, when the charcoal powder is dispersed in a dispersion, the charcoal powder is dispersed in the dispersion. Is not properly dispersed in the foam, and the charcoal powder is not well filled in the foam.On the other hand, charcoal powder having a small particle size is difficult to manufacture and is expensive, so that the particle size is preferably 0.1 to 0.1. Use 50 μm charcoal powder.

In the cushioning material of the present invention, if the amount of charcoal powder to be filled in the foam is small,
While the above-mentioned properties by the charcoal powder cannot be sufficiently obtained, if the amount of the charcoal powder is too large, the charcoal powder is easily detached from the foam, or the cushioning property of the foam decreases, Preferably, the charcoal powder is filled in a range of 2 to 30 parts by weight with respect to 100 parts by weight of the foam because the foam tends to deteriorate. Note that the amount of the charcoal powder to be filled can be appropriately changed according to the use of the cushion material.

In order to impart antibacterial properties to the cushioning material of the present invention, the charcoal powder is adsorbed with a metal ion such as silver or an antibacterial agent using a natural material such as catechinic acid or chitoic acid. Can also be given.

In the present invention, the adhesive used for bonding the above-mentioned cushioning material is as follows.
As described in claim 4, an adhesive in which charcoal powder is kneaded is used.

Then, using the adhesive into which the charcoal powder is kneaded as described above, the cushioning material of the present invention is bonded to each other, or the cushioning material is bonded to a plate material or the like, so that a floor material or a wall material can be used. When used as such, the odor due to various solvents contained in the adhesive is absorbed by the charcoal powder kneaded into the adhesive, and the generation of the odor is suppressed, and the adhesive is provided with flame retardancy, and the adhesive is bonded. The burning of the agent itself and the generation of toxic gas are also suppressed.

Here, when the charcoal powder is kneaded into the adhesive as described above, if the amount of the charcoal powder is small, the above-described effect of the charcoal powder cannot be sufficiently obtained, while the amount of the charcoal powder is not sufficiently obtained. If the amount is too large, the adhesive performance of the adhesive decreases, and the cushion material does not adhere well to the plate material or the like. Therefore, preferably, charcoal powder is used in an amount of 0.1 to 20 parts by weight based on 100 parts by weight of the adhesive. Knead in the range.

[0030]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a cushion material according to an embodiment of the present invention and a manufacturing method thereof will be specifically described, and the superiority of the cushion material according to the embodiment of the present invention will be clarified with reference to comparative examples. .

(Example 1) In Example 1, in producing a cushioning material, urethane foam having a density of about 20 kg / m ³ (manufactured by Toyo Tire & Rubber Co., Ltd .: Sofran # 317) was used as a foam. used.

On the other hand, in preparing a dispersion in which charcoal powder is dispersed, charcoal powder obtained by carbonizing bamboo and having a particle size in the range of 10 μm to 20 μm is used, and a urethane emulsion is used as a binder. This charcoal powder, a binder, water and a small amount of an antifoaming agent were mixed to obtain a resin dispersion in which the charcoal powder was dispersed to about 50% by weight of water.

The foam is immersed in the dispersion prepared as described above, and the foam is impregnated with the dispersion, and then the foam impregnated with the dispersion is used. Was pressed by a roller to adjust the amount of the dispersion liquid impregnated in the foam, and dried to obtain a cushion material containing about 14% by weight of the charcoal powder. The density of the cushion material was about 47 kg / m ³ .

Comparative Example 1 In Comparative Example 1, the foam used in Example 1 was used as it was as a cushioning material, and the foam was not filled with charcoal powder.

Then, using each of the cushioning materials of Example 1 and Comparative Example 1, ammonia,
A test was conducted to determine the deodorizing performance of formaldehyde, methyl mercaptan, and trimethylamine.

Here, ammonia, formaldehyde,
In examining the deodorizing performance for methyl mercaptan and trimethylamine, the above-mentioned Example 1 and Comparative Example 1 were used.
Each of the cushioning material is 10cm long, 20cm wide,
What was cut | disconnected to the magnitude | size of 1 cm in thickness was used.

Then, each of the cushioning materials of Example 1 and Comparative Example 1 thus cut was placed in a test container having a capacity of 5 liters, and the initial concentration of ammonia was 400 ppm in the case of ammonia. In the case of formaldehyde, the initial concentration is 15 ppm, in the case of methyl mercaptan, the initial concentration is 10 ppm, and in the case of trimethylamine, the initial concentration is 20 ppm. 3
After leaving for 0 minutes, the concentration of each gas was measured, and the results are shown in Table 1 below together with the results of the blank test in which nothing was put in the test container.

[0038]

[Table 1]

As is clear from the results, when the cushion material of Example 1 in which the foam was impregnated with carbon powder and filled was used, the cushion material of Comparative Example 1 in which the foam was not filled with carbon powder was used. The concentration of ammonia, formaldehyde, methyl mercaptan, and trimethylamine after standing for 30 minutes is significantly lower than that in the case of using the rubber. The deodorant performance against trimethylamine was far superior to that of the cushion material of Comparative Example 1.

Next, each of the cushioning materials of Example 1 and Comparative Example 1 was applied to a width of 100 cm and a length of 200 cm.
And a profile in which the thickness of the valley portion is 1 cm and the thickness of the crest portion is 3 cm.

Then, urethane foam having a density of about 24 kg / m ³ is supplied with a width of 100 cm, a length of 200 cm, and a thickness of 10 cm.
Each of the cushioning materials of Example 1 and Comparative Example 1 molded as described above is placed on an underlay cushioning material molded to a size of, and the cushioning materials are set in a constant temperature room set at 30 ° C. A person sleeps on a
The temperature and humidity in the cm portion were measured by a temperature sensor and a humidity sensor, and the results are shown in Table 2 below.

[0042]

[Table 2]

As is clear from the results, when the cushion material of Example 1 in which the foam was impregnated with carbon powder and used was used, the cushion material of Comparative Example 1 in which the foam was not filled with carbon powder was used. The increase in humidity was suppressed and the hygroscopicity was improved as compared with the case where was used.

In the first embodiment, bamboo carbonized charcoal powder is used as the charcoal powder.
Similar results were obtained when charcoal powder obtained by carbonizing Bincho charcoal or cedar was used.

[0045]

As described above in detail, in the cushioning material according to the present invention, since the foam is impregnated with the dispersion liquid in which the charcoal powder is dispersed, and the charcoal powder is filled in the foam, air is generated. When flowing through the inside of the foam, the moisture such as sweat contained in the air, ammonia,
Gases that cause odors such as formaldehyde, trimethylamine, and methyl mercaptan are adsorbed by the charcoal powder filled in the foam, and the cushioning material is improved in moisture absorption, deodorization, mold resistance, and mite. In addition, due to the far-infrared radiation performance of the charcoal powder, the heat retention of the charcoal powder when used in a futon or the like was improved, and the charcoal powder also improved the flame retardancy of the cushion material.

Also, when the foam is impregnated with a dispersion of the charcoal powder as in the cushioning material of the present invention and the charcoal powder is filled into the foam, the charcoal powder is mixed with the raw material of the foam. As compared with the case where foaming is performed by foaming, a larger amount of charcoal powder can be filled in the cushion material, and the above-described characteristics are further improved.

Further, in the cushioning material of the present invention, when a foam having an open-cell structure is used and charcoal powder is filled in the foam having the open-cell structure, air is generated inside the foam having the open-cell structure. , Etc., and the characteristics as described above are further improved.

Also, as in the method of manufacturing a cushioning material according to the present invention, a foam is impregnated with a dispersion obtained by dispersing charcoal powder in a resin solution, and then dried, and the foam is filled with charcoal powder. When the charcoal powder is used, the charcoal powder is filled in a state of being sufficiently adhered to the surface of the foam and the bubbles inside the foam, so that the charcoal powder is prevented from detaching from the foam, and the charcoal powder is removed. The characteristics of the cushioning material in which the foam is filled are now stably maintained over a long period of time.

When an adhesive containing charcoal powder is used for bonding the cushioning material as described above in the present invention, an odor caused by various solvents contained in the adhesive is mixed into the adhesive. It is absorbed by the charcoal powder, and the generation of offensive odor is suppressed, and the adhesive is given flame retardancy,
The generation of toxic gas due to the burning of the adhesive itself has also been suppressed.

Claims (4)

[Claims] 1. A cushioning material characterized by impregnating a foam with a dispersion of charcoal powder and filling the foam with charcoal powder. 2. The cushion material according to claim 1, wherein a foam having an open-cell structure is used. 3. A cushion characterized by impregnating a foam with a dispersion obtained by dispersing charcoal powder in a resin solution, and then drying the foam to fill the foam with the charcoal powder. The method of manufacturing the material. 4. An adhesive used for bonding the cushioning material according to claim 1 or 2, wherein charcoal powder is kneaded into the adhesive.