JP2001128913A - Urethane resin product and method for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a resin product suitable for a cleaner, health mattress, non-skid sheet, and the like, by a simple equipment and to make recycling or the like of the product easy. SOLUTION: This urethane resin product 1 comprises urethane prepolymer applied parts 3 formed in dots or partly with gaps on the surface made of a soft or semi-hard urethane foam 2. In the urethane resin product 1, the hardness, elasticity, shape, or the like, of the urethane foam 2 are selected appropriately according to uses of the product. As for the method of its manufacture, the urethane resin product 1 is manufactured by putting a punching plate 12 on the surface to be treated of the urethane foam 2, applying a viscous liquid- type urethane polymer P with a roll coater 10, and then hardening the polymer.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a urethane resin product applicable to various uses such as a cleaner for polishing the surface of various materials, a health mattress, an insole of a shoe, an anti-slip sheet and the like, and a production technique thereof.

[0002]

2. Description of the Related Art Conventionally, in a cleaner for polishing a kitchen, a toilet or a floor, for example, a soft or semi-rigid urethane foam having a nonwoven fabric or a reticulated fiber adhered to the outer surface thereof, or a soft or semi-rigid urethane foam impregnated. By treating with a liquid, it is known to form a highly robust impregnated layer on the foam surface, or to add an abrasive such as zirconium powder to the impregnated layer.For example, a cleaning liquid is applied to the inner urethane foam. And the surface is polished with a nonwoven fabric, a reticulated fiber, an impregnated layer, an abrasive or the like on the outer surface.

[0003] Also, for the purpose of, for example, preventing slippage, a molded product in which vinyl chloride projections are formed in a scattered manner on the surface of a rubber layer or the like is known. Well known.

[0004]

However, in the case of the above-mentioned cleaner, the technique of affixing a nonwoven fabric or a reticulated fiber to the surface of a soft urethane foam or the like involves a partial adhesion between the fiber and the foam. In addition to the fact that it is difficult to peel off, and that the sticking work is also troublesome and troublesome, the nonwoven fabric is ragged and falls off as it is used, and the fibers and the like lose their shape and their appearance deteriorates. There is a problem. In the technique of forming an impregnated layer on the surface with an impregnating liquid or the like, since the entire surface of the foam is solidified by the impregnating liquid, the cleaning liquid or the like cannot be impregnated into the urethane foam inside, impairing the function as a cleaner. May be

In the case of a technique of forming projections of polyvinyl chloride on the surface of a rubber layer or the like for the purpose of preventing slippage, etc., the polyvinyl chloride material is not so preferable due to environmental problems and the like, and it is difficult to separate and collect it. At the same time, such a spotting process is generally performed manually, which causes a problem that it takes time and effort.

Accordingly, the present invention is particularly suitable for use as a cleaner because a high cleaning effect and durability can be obtained. In addition, the present invention is a urethane resin product which can be used for various purposes such as local finger pressure and non-slip. It is an object of the present invention to provide a low cost and efficient production at a low facility cost.

[0007]

According to the present invention, there is provided a sheet-like flexible or semi-rigid urethane foam in which at least one surface of a sheet-like flexible or semi-rigid urethane is provided with gaps or partial gaps of a urethane prepolymer. And applied it.

[0008] If the urethane prepolymer is applied to the surface of the soft or semi-rigid urethane foam in the form of scattered spots or partial gaps, the surface properties of the urethane foam can be partially changed. For example, it is possible to increase the hardness, the rigidity, etc. of the coated portion to enhance the polishing action, the anti-slip action, etc., and to obtain the local acupressure effect. At this time, since it is a combination of the same materials of the urethane foam and the urethane prepolymer, there is no need for separate collection and the like, and there is no environmental problem. Moreover, since the viscous liquid urethane prepolymer is applied to the surface of the foam in the manufacturing process, at least a part of the urethane prepolymer is impregnated in the foam, and the two are firmly joined and integrated.

Here, the type and content of the isocyanate to be the urethane prepolymer composition are arbitrary, and the viscosity of the urethane prepolymer is lowered so that the dispersed impregnated portions are formed in the urethane foam. Alternatively, the viscosity of the urethane prepolymer may be increased to form scattered raised protrusions on the urethane foam surface.
Further, the design such as the shape and the coating interval of the coating portion of the urethane prepolymer is arbitrary, and may be irregularly dispersed.
It may be a regular repetition of circular dots, a lattice shape, or any other design, but it is applied at least partially with a gap. When the viscosity of the urethane prepolymer is relatively low, such as 300 to 30,000 cp / 25 ° C., it is easy to impregnate the urethane foam,
Suitable for forming an impregnated layer, having a viscosity of 100,0
A relatively high viscosity of 00 cp / 25 ° C. is suitable for forming a raised pattern on the urethane foam in a convex manner.

[0010] Such a urethane resin product can be used for various purposes such as a cleaner for polishing the surface of various materials, a health mattress, a shoe insole, and a slip-resistant sheet.

According to the present invention, the urethane resin product is used for a cleaner for cleaning the surface of various materials.

That is, by applying a urethane prepolymer to the surface of a soft or semi-rigid urethane foam in a scattered manner or with a partial gap, the water absorption of the foam surface other than the coated portion is ensured. This makes it possible to impregnate the cleaning liquid or the like into the foam. On the other hand, in the coated portion, hardness and robustness are increased, and abrasiveness is improved. For this reason, urethane resin products for such uses, for example, impregnated with a cleaning solution
Polishing the surfaces of various materials such as toilets, floors, automobile bodies, lenses, etc., can effectively remove dirt from the surfaces.

Here, when used as a cleaner, a prepolymer obtained by using a compound having MDI (diphenylmethane diisocyanate) and a hydroxyl as a urethane prepolymer, for example, allows the coated portion to have an appropriate strength and hardness. , Elasticity and abrasiveness are preferable. On the other hand, other isocyanates such as TDI (toluene diisocyanate)
When using a urethane prepolymer obtained by a compound having a hydroxyl, the coated portion becomes too hard,
The lack of adequate elasticity makes them unsuitable as cleaners. However, it may be appropriate for other uses.

According to a third aspect of the present invention, an impregnated layer made of a urethane prepolymer is formed on at least one surface of the soft or semi-rigid urethane foam, and the urethane prepolymer is provided with scattered spots or partial gaps thereon. So that it was painted.

If the impregnated layer is formed by the urethane prepolymer in this manner, the rigidity of the surface layer is increased and the shape retention is improved, and the durability is improved. And so on. By the way,
When used as a cleaner, the impregnated layer may make it impossible to include a cleaning liquid or the like in the inner foam, but when cleaning without using a cleaning liquid or the like, durability and polishing properties are improved. Sometimes it is convenient.

According to a fourth aspect of the present invention, there is provided a method for producing a urethane resin product in which a urethane prepolymer is applied to the surface of a flexible or semi-rigid urethane foam in a scattered manner or with a partial gap. A punching plate is superimposed on the treated surface of a soft or semi-rigid urethane foam in a shape, and is put into a roll coater, and a viscous liquid urethane prepolymer is applied by the roll coater,
Thereafter, it was cured.

That is, as a method of applying a urethane prepolymer to the surface of a soft or semi-rigid urethane foam in a scattered manner or partially with a gap, a design is applied to a rotary screen system or a roll itself. A method of directly applying the form to the form with a roller using a scattered point is also conceivable, but this method increases the equipment cost, and the design of the scattered form is limited to one rotation of the roll and is not limited to the second rotation. From the same design will be repeated,
Moreover, there is a problem that when changing the design or the like, it takes time and effort to replace the roll.

Therefore, if the punching plates are superposed and applied by a roll coater, the design can be changed only by changing the punching plates, and the equipment cost can be reduced. Here, the material of the punching plate is optional,
It may be made of metal, resin, paper, or other materials.

The procedure from application of the viscous liquid urethane prepolymer to curing is optional,
For example, if unreacted isocyanate groups are present in the urethane prepolymer to react with atmospheric moisture, atomized water is sprayed on the treated impregnation layer, which is generally performed conventionally. And hardening work can be omitted. Although such a viscous liquid urethane prepolymer varies depending on various conditions, it usually cures sufficiently in about 1 to 3 hours when left naturally, so that drying equipment is not required. Of course, you may make it harden using a drying equipment.

By the way, if a soft or semi-rigid urethane foam and a punching plate are superimposed and put into a roll coater, the urethane foam is compressed in the thickness direction and the urethane foam slightly protrudes from the punched portion of the punching plate. Even urethane prepolymers having a high level can be applied neatly and reliably.

[0021]

Embodiments of the present invention will be described with reference to the accompanying drawings. Here, FIG. 1 and FIG. 2 show an example of the urethane resin product according to the present invention.
Is a perspective view, (b) is a cross-sectional view, FIG. 3 is an explanatory view showing an example of a cleaner, FIG. 4 is an explanatory view of a manufacturing method, and FIG. 5 is a configuration example of another urethane resin product.

The urethane resin product according to the present invention is obtained by partially varying the surface properties of a soft or semi-rigid urethane foam, for example, a cleaner for polishing the surface of various materials, a shoe insole, a health mattress, If it is used as an anti-slip sheet, it will be developed as a suitable product, it will not be necessary to separate it in disposal or recycling, etc., and it will be noted that equipment costs can be reduced, and the design can be expanded easily. It is noted.

That is, as shown in FIGS. 1 and 2, the urethane resin product 1 is applied to a sheet-like soft or semi-rigid urethane foam 2 and at least one surface of the urethane foam 2 in a scattered manner. The urethane prepolymer coating portion 3 is provided, and the urethane prepolymer coating portion 3 may be formed in a raised convex shape as shown in FIG. 1, and as shown in FIG. It may be formed in a shape.

Here, as shown in FIG. 1, when the coating portion 3 is formed in a raised convex shape, a high-viscosity urethane prepolymer is used, and as shown in FIG. 2, it is formed in a flat shape. In this case, impregnation is performed using a low-viscosity urethane prepolymer, and applied to the surface of the urethane foam 2 and cured in the manner described below. While being integrated, the hardness, robustness, strength, elasticity, and the like of the coated portion 3 are increased from the peripheral portion, and when used as a cleaner, the polishing properties are improved, and in the portion where the urethane foam 2 is exposed, The impregnating action of the cleaning liquid etc. is not impaired.

When used as a cleaner, it is preferable to use a prepolymer obtained from MDI (diphenylmethane diisocyanate) and a compound having a hydroxyl as the urethane prepolymer. Appropriate strength, hardness, elasticity and abrasiveness can be provided.

When used as a cleaner, the urethane resin product 1 is attached to the tip of a handle 4 as shown in FIG. 3A, for example, or a predetermined size as shown in FIG. 3B. It can be used in the form of a spongy scourer.

Of course, it can be used for various purposes other than the cleaner, for example, a health mattress which can provide a local acupressure effect, an anti-slip sheet for preventing slipping, a shoe insole, and the like. The raised shape and hardness of the wearing part 3,
Make the elasticity etc. appropriate.

Next, a method for producing the urethane resin product 1 as described above will be described with reference to FIG. The urethane resin product 1 includes a coater 10 and a feed roll 1 as shown in FIG.
1, a soft or semi-rigid urethane foam 2 and a punching plate 12 are superposed and charged, and a viscous liquid urethane prepolymer P supplied by a guide roll 13 and a coater 10 is applied and cured. We are going to manufacture. At this time, the punching plate 12
Any material such as metal, resin, paper, or the like can be selected as the material.

Further, for example, the size of the urethane foam 2 is about 1 to 1.5 m in width and about 2 m in length, and thereafter, it is cut into a product size, so that the urethane foam 2 is coated on the urethane foam 2 of this size. The work is completed in only a few seconds, and the design change of the punching plate 12 can be dealt with only by replacing the punching plate 12, so that no equipment cost is required and the efficiency is high. On the other hand, for example, in the case of a rotary screen method or a method of applying a design to a roll itself, the capital investment amount rises, and it is difficult to set up a design change or the like.

Further, when the urethane foam 2 passes through the coater 10, it is compressed in the thickness direction and slightly protrudes from the punched portion of the punching plate 12, so that even if the urethane prepolymer P has a high viscosity, it is surely applied. I can do it.

Further, as the urethane prepolymer P,
By containing unreacted isocyanate groups, it reacts with moisture in the air, and is sprayed and hardened by spraying mist on the impregnated part after treatment, which is generally performed Such work can be omitted. Moreover,
The urethane prepolymer P is naturally dried sufficiently for about 1 to 3 hours, although it depends on the outside air temperature and the kind of the prepolymer, and therefore, no drying equipment is required.

FIG. 5 is a cross-sectional view of a urethane resin product 1A of another configuration example. In this case, the impregnated layer 5 is formed with a low-viscosity urethane prepolymer over the entire treated surface of the urethane foam 2, and thereafter. In addition, a raised protrusion 6 is formed on the impregnated layer 5 by a urethane prepolymer having a relatively high viscosity.

Such a urethane resin product 1A increases the rigidity of the surface layer to improve the shape retention and the durability and the like, and is suitable for, for example, shoe insoles and health mattresses. Needless to say, although the ability to penetrate the cleaning liquid is somewhat inferior, it can be used as a cleaner.

The present invention is not limited to the above embodiment. Those having substantially the same configuration as those described in the claims of the present invention and exhibiting the same operation and effect belong to the technical scope of the present invention. For example, the design pattern or the like of the urethane prepolymer applied in a scattered manner or the like is arbitrary, and the application of the urethane resin product is an example. Further, although the embodiment shows an example in which the urethane prepolymer coating portion 3 is formed on only one surface, it may be formed on a plurality of surfaces. Further, when curing, a drying facility may be used.

[0035]

As described above, the present invention provides a urethane resin product in which at least one surface of a sheet-like flexible or semi-rigid urethane foam is provided with a urethane prepolymer in the form of scattered spots or partial gaps. Because it was made to apply, it is possible to partially change the surface properties of the urethane foam, for example, cleaners, health mattresses, shoe insoles, and products suitable for anti-slip sheets, etc. In addition, since they are a combination of the same materials, disposal and recycling are easy.

At this time, when the present invention is used for a cleaner for cleaning the surface of various materials, it is suitable for a cleaning method in which polishing is performed while containing a cleaning liquid or the like. Further, as in claim 3, an impregnated layer of a low-viscosity urethane prepolymer is formed on the treated surface of the urethane foam, and a relatively high-viscosity urethane prepolymer is applied over the impregnated layer. If the rigidity of the surface layer increases, the shape retention is improved, and the durability is improved.
For example, it is suitable for shoe insoles, health mattresses, and the like. If the manufacturing method is used, the manufacturing can be efficiently performed with inexpensive equipment, and the design can be easily changed.

[Brief description of the drawings]

FIG. 1 is an example of a urethane resin product according to the present invention,
(A) is a perspective view, (b) is a sectional view.

FIG. 2 is another example of the urethane resin product according to the present invention,
(A) is a perspective view, (b) is a sectional view.

FIG. 3 is an explanatory view showing an example of a cleaner.

FIG. 4 is an explanatory view of a manufacturing method.

FIG. 5 is a cross-sectional view showing a configuration example of another urethane resin product.

[Explanation of symbols]

1, 1A: urethane resin product, 2: urethane foam,
3: Coating part, 10: Coater, 12: Punching plate, P: Urethane prepolymer.

Continuing on the front page F-term (reference) 3B074 AA03 AB02 BB01 CC03 3B096 AB02 AB09 AD07 3B120 AB15 BA02 CA01 DB01 DB02 EB21 4F050 EA05 HA56 4F100 AK51A AK51B AK51C BA02 BA03 BA10B BA10C BA16 DC21B DC21C DJ01BJ12E08 GBE EJB12J08E JL00 JL02

Claims (4)

[Claims] 1. A urethane resin product wherein a urethane prepolymer is applied to at least one side of a sheet-like flexible or semi-rigid urethane foam in a scattered manner or with a partial gap. . 2. The urethane resin product according to claim 1, wherein the urethane resin product is used for a cleaner for cleaning the surface of various materials. 3. The urethane resin product according to claim 1, wherein an impregnated layer of a urethane prepolymer is formed on at least one surface of the soft or semi-rigid urethane foam, and the urethane prepolymer is formed thereon. A urethane resin product, wherein the polymer is applied in a scattered manner or partially with a gap. 4. A method for producing a urethane resin product in which a urethane prepolymer is applied to at least one surface side of a sheet-like flexible or semi-rigid urethane foam in a scattered manner or with a partial gap. Then, a punching plate is superimposed on the treated surface of the sheet-like soft or semi-rigid urethane foam, and is put into a roll coater, and a viscous liquid urethane prepolymer is applied by the roll coater and then cured. Method for producing a urethane resin product.