JP2002306283A - Cushion material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a cushion material having low repulsion performance and high air permeability. SOLUTION: This cushion material 1 is provided with a granular material formed body 2 formed by connecting granular materials of low-repulsive polyurethane foam together with a binder.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a low resilience and high air permeability suitable for a pillow, a bedding, a mattress for preventing pressure ulcer, a cushion material for a sofa, a cushion material for office use, a small cushion material for office use, and the like. The present invention relates to a cushion material having:

[0002]

2. Description of the Related Art A cushioning material using a low resilience polyurethane foam is very comfortable because when the load is applied, the cushioning material follows the same and disperses the pressure so that the pressure does not concentrate locally. Although it has an excellent feature of being able to obtain a proper use state, it has a drawback that heat from body temperature is easily stored due to low air permeability of the material, which causes stuffiness and heat feeling.

[0003] For this reason, in the past, processing such as providing air holes in the low resilience polyurethane foam or wrapping the low resilience polyurethane foam with a highly breathable polyurethane foam has been performed. Effect was not obtained, and depending on the processing method, the original low resilience performance of the low resilience polyurethane foam was sometimes impaired.

[0004]

SUMMARY OF THE INVENTION An object of the present invention is to solve the above-mentioned conventional problems and to provide a cushioning material having low resilience and high air permeability.

[0005]

The cushioning material of the present invention is characterized in that it has a granule formed by bonding granules of a low resilience polyurethane foam with a binder.

[0006] In the granular molded product obtained by binding the particles of the low resilience polyurethane foam with a binder, voids are formed between the particles of the low resilience polyurethane foam, and due to the presence of these voids, good ventilation is achieved. Sex can be obtained. In addition, since the granular material is made of a low resilience polyurethane foam, the original resilience of the low resilience polyurethane foam is hardly impaired.

The particle size of the low resilience polyurethane foam of the present invention is preferably 1 to 50 mm.

[0008] Further, the air permeability of the granule formed by combining such granules is 30 to 300 cc / cm ² / s.
ec is preferred.

As the binder for binding the particulate matter, a urethane-based adhesive is preferable, and the amount of the binder used is 3 to 3 parts by weight based on 100 parts by weight of the particulate matter of the low resilience polyurethane foam.
It is preferably 0 parts by weight.

It is preferable that the rebound resilience of the low resilience polyurethane foam constituting the granular material is 15% or less.

[0011] The cushioning material of the present invention may be composed of only a granular molded product, or may be a combination (for example, integrated) of a granular molded product and a polyurethane foam.

In the present invention, the density (g / c)
m ³ ), hardness (kgf), air permeability (cc / cm ² / se)
c), rebound resilience (%) and compression set (%) are as follows:
The value measured according to JISK6400 is shown.

[0013]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of the cushioning material of the present invention will be described below in detail with reference to the drawings.

FIGS. 1A to 1D are cross-sectional views showing an embodiment of the cushioning material of the present invention.

The cushioning material of the present invention has a granular material formed by binding particles of a low resilience polyurethane foam with a binder. As shown in FIG. Cushion material 1 consisting of only 2
A, or as shown in FIG. 1 (b), may be a cushion material 1B in which a granular material forming layer 2 and a normal soft or hard polyurethane foam layer 3 are laminated. FIG.
As shown in FIG. 1 (c), a cushion material 1C in which a granular material forming layer 2 is interposed between ordinary soft or hard polyurethane foam layers 3 and 3, or as shown in FIG.
An ordinary soft or hard polyurethane foam layer 3 may be interposed between the two.

The granules of the low resilience polyurethane foam constituting the granule forming layer 2 can be obtained by crushing a mass or mat or sheet of ordinary low resilience polyurethane foam with a rotary blade crusher or the like. it can.

The shape of the granular material is not particularly limited, and may be spherical, cubic, rectangular, cylindrical (including elliptical), triangular,
It may be a quadrangular prism (including a trapezoidal column or the like), a polygonal prism, other irregular shaped objects, or a mixture thereof.

If the size of the particles of the low resilience polyurethane foam is too small or too large, a void portion effective for improving air permeability cannot be formed between the particles. Has an average particle diameter of 1 to 50 mm, particularly 5 to 30 mm.
mm. Here, the particle diameter of the granular material means the minimum value of the length of one side of a square mesh through which the granular material can pass.

The low-resilience polyurethane foam constituting the granular material has a density of 20 to 150 g / cm ³ , a hardness of 1.0 to 30.0 kgf, and a gas permeability of 0.5 to 300 cc / cm ³ .
cm ² / sec, rebound resilience 15% or less, especially 0 to 10
% And a compression residual strain of about 0 to 5.0% are preferable. Such a low-rebound polyurethane foam can be produced by a conventional method, for example, by blending the following raw materials. [Low resilience polyurethane foam compounding (parts by weight)] Polyol (polyol A and polyol B): 100 Polyisocyanate: 25 to 70 Blowing agent: 0.5 to 5.0 Catalyst: 0.01 to 1.0 Foam stabilizer : 0.3 to 2.0

As the polyol, those usually used for polyurethane can be used, and examples thereof include polyether polyols and polymer polyols obtained by polymerizing vinyl monomers in the polyol. Examples of the polyether polyol include those obtained by adding an alkylene oxide to an initiator such as water, alcohols, amines, and ammonia. Examples of the alcohols include monohydric alcohols (eg, methanol and ethanol), dihydric alcohols (eg, ethylene glycol and propylene glycol), and trihydric alcohols (eg, glycerin,
Trimethylolpropane, etc.), tetrahydric alcohols (D-
Sorbitol), polyhydric alcohols such as hexahydric alcohols and octahydric alcohols. As the amines, monovalent amines (dimethylamine, diethylamine, etc.), divalent amines (methylamine, ethylamine, etc.), trivalent amines (monoethanolamine, diethanolamine, triethanolamine, etc.), tetravalent amines And other polyvalent amines. Examples of the alkylene oxide include ethylene oxide (EO), propylene oxide (PO), 1,2-, 1,4- and 2,3-butylene oxide, and a combination of two or more thereof. Of these, preferred are propylene oxide and / or ethylene oxide, and when used in combination, the addition form may be either block or random.

Preferred as polyol A are polyether polyols and / or polymer polyols. The average number of functional groups of the polyol A is usually 2 to 5,
It is preferably from 2.5 to 3.5, and the hydroxyl value is usually 20
-60 mg-KOH / g, preferably 30-60 mg-
KOH / g. When the hydroxyl value is less than 20 mg-KOH / g, it is difficult to produce a polyurethane foam, and it is also difficult to obtain a polyether polyol as a commercial product. If the hydroxyl value exceeds 60 mg-KOH / g, the resin formed by the polyurethane foam becomes hard,
Moist feel cannot be obtained. The ethylene oxide content of this polyol A is usually 5 to 30% by weight, preferably 10 to 25% by weight, and the percentage of terminal primary hydroxyl groups is usually 5 to 80%, preferably 60 to 75%.

The average number of functional groups of the polyol B is usually 1.
5 to 4.5, preferably 2 to 3, and the hydroxyl value is usually 200 to 300 mg-KOH / g, preferably 240 to 300 mg-KOH / g.
280 mg-KOH / g. 200mg hydroxyl value
If it is less than -KOH / g, the rebound resilience of the foam increases, and if it exceeds 300 mg-KOH / g, the temperature dependence of the foam increases.

Examples of the polyol A include polyoxyalkylene polyester block copolymer polyol (average number of functional groups: about 3, hydroxyl value: 56 mg-KOH / g) and polyoxyalkylene polyol (average number of functional groups: about 3, hydroxyl value: 56 mg-KOH / g). g) etc., specifically, GP-300
0 (manufactured by Sanyo Chemical Industries, Ltd.) and the like. As the polyol B, a polyoxyalkylene polyol (average number of functional groups: about 3, hydroxyl value 250 mg-KOH /
g), using polyoxyalkylene polyol (average number of functional groups: about 3, hydroxyl value: 280 mg-KOH / g), specifically, Boranol 2070 (manufactured by Dow) or G-700 (manufactured by Asahi Denka Kogyo KK). Can be.

The mixing ratio of the polyol A and the polyol B is preferably 30 to 80% by weight of the polyol B to 70 to 20% by weight of the polyol A.

As the polyisocyanate, a known polyisocyanate conventionally used for producing a low resilience polyurethane foam, for example, tolylene diisocyanate (TDI),
Obtained by reacting aromatic polyisocyanates such as diphenylmethane diisocyanate (MDI), phenylene diisocyanate (PDI), and naphthalene diisocyanate (NDI), modified TDI, crude MDI and modified MDI, and excess polyisocyanate with low molecular polyol. A free isocyanate-containing prepolymer and the like can be mentioned, and these can be used alone or in combination of two or more. As the polyisocyanate, specifically, Takenate T-80 (Takeda Pharmaceutical Co., Ltd.)
Co., Ltd.), Coronate T-65 (Nippon Polyurethanes Inc.)
Manufactured) can be used.

Examples of the blowing agent include water and / or halogen-substituted aliphatic hydrocarbon-based blowing agents such as trichlorofluoromethane, dichlorodifluoromethane, trichloroethane, trichloroethylene, tetrachloroethylene, methylene chloride, trichlorotrifluoroethane, and dibromotetrafluoroethane. , Carbon tetrachloride and the like. Among these blowing agents, water is preferred.

As the catalyst, known catalysts usually used in the production of polyurethane, for example, tertiary amines (triethylamine, triethylenediamine, N-methylmorpholine, etc.), quaternary ammonium (tetraethylhydroxylammonium, etc.), imidazoles ( Imidazole, 2
Amine catalysts such as -ethyl-4-methylimidazole, etc., organic tin compounds (tin acetate, tin octylate, dibutyltin dilaurate, dibutyltin chloride, etc.), organic lead compounds (lead octylate, lead naphthenate),
An organic metal-based catalyst such as an organic nickel compound (nickel naphthenate) may be used. Of these, tertiary amines and imidazoles are preferred.

As the foam stabilizer, for example, a silicone-based surfactant which can be generally used for conventional polyurethanes such as a siloxane-oxyalkylene block copolymer is used. As the foam stabilizer, specifically, F-242T (manufactured by Shin-Etsu Chemical Co., Ltd.), SH-192 (manufactured by Dow Corning Toray Silicone Co., Ltd.) or the like can be used.

In addition, in the present invention, for example, known additives such as a crosslinking agent, a flame retardant, a coloring agent, a plasticizer, and an internal mold release agent used in the production of ordinary polyurethane foam may be blended as required. May be.

The low-resilience polyurethane foam according to the present invention is prepared by mixing a mixture of a polyol, a foam stabilizer, a catalyst, a foam stabilizer, and other additives with a polyisocyanate at a predetermined ratio, stirring and mixing the mixture. It can be produced by foaming according to the method.

In order to produce a molded article from such a low resilience polyurethane foam, the low resilience polyurethane foam is pulverized to a predetermined particle size to obtain a granule, which is mixed with a binder, and the mixture is mixed. What is necessary is just to fill in a type | mold, shape | mold and harden on the hardening conditions of a binder.

The binder used here is preferably a polyurethane-based adhesive. The amount of the binder is 3 parts per 100 parts by weight of the binder of the low-rebound polyurethane foam.
The amount is preferably from 30 to 30 parts by weight, particularly preferably from 5 to 15 parts by weight. If the amount of the binder is too small, the particles cannot be sufficiently bonded to each other, and if the amount is too large, a sufficient amount of voids effective for improving air permeability cannot be formed between the particles.

[0033] The thus obtained granular compact is
Density 25 to 300 g / cm ³ , hardness 1.0 to 40.0 k
gf, breathability of 30 to 300 cc / cm ² / sec, rebound resilience of 0 to 15%, and compression residual strain of about 0.5 to 10% are preferably used. The mixing ratio of the granular material and the binder, the filling amount in the mold, and the like may be appropriately adjusted with respect to the particle size and physical properties of the granular material.

The cushioning material 1A shown in FIG. 1 (a) can be manufactured by filling a mixture of a particulate material of a low resilience polyurethane foam and a binder into a mold, molding and curing as described above. However, FIG.
As shown in (d), the cushioning materials 1B to 1D having a structure in which the granular material forming layer 2 and the polyurethane foam layer 3 are laminated,
In molding the granular material, it can be easily manufactured by arranging the polyurethane foam layer 3 molded in advance at a predetermined position in the mold. However, the molded polyurethane foam layer 3 and the granular material molding layer 2 may be adhered with an adhesive or the like. Further, when inserted into a cover or the like, the polyurethane foam layer 3 and the granular material forming layer 2 do not necessarily need to be joined.

The polyurethane foam constituting the polyurethane foam layer 3 is not particularly limited, and various properties may be used according to the intended use of the cushioning material, and a low resilience polyurethane foam may be used. .
Further, the arrangement of the polyurethane foam layer and the granular material forming layer is not limited to the illustrated one. However, in order to secure air permeability and low resilience by the granular material forming layer 2, the cushion material of the present invention is a composite with a polyurethane foam layer as shown in FIGS. 1 (b) to (d). Preferably, 50% or more of the total volume of the cushion material is the granular material forming layer.

Such a cushioning material of the present invention is usually used by covering with a cover such as cloth, leather, synthetic resin, etc. It is preferable because air permeability can be obtained.

The cushioning material of the present invention has the low resilience of the low resilience polyurethane foam and the good air permeability due to the gap between the granular materials, and provides a pillow, a bedding, and a mattress for pressure ulcer prevention. , Sofa cushioning material,
An extremely comfortable use feeling and a good use state can be obtained as office cushion materials, small office cushion materials and the like.

[0038]

The present invention will be described more specifically below with reference to examples and comparative examples.

In the following, as the low resilience polyurethane foam, a low resilience polyurethane foam or a low resilience polyurethane foam obtained by foaming and molding a foam material having the following composition in a mold was used.

[0040]

[Table 1]

In Table 1, the materials used are as follows. Polyol A: Actoda 3 manufactured by Takeda Pharmaceutical Co., Ltd.
P56B "polyoxyalkylene polyester book copolymer polyol average number of functional groups: about 3, hydroxyl value: 56 mg-KOH / g Polyol B:" G-700 "polyoxyalkylene polyol manufactured by Asahi Denka Kogyo Co., Ltd. average number of functional groups: about 3, hydroxyl group Value: 280 mg-KOH / g Polyisocyanate: Takeda T-80 manufactured by Takeda Pharmaceutical Co., Ltd. Catalyst C: DABC033 manufactured by Sankyo Air Products Co., Ltd.
LV "Catalyst D:" Stanoct "manufactured by Yoshitomi Pharmaceutical Co., Ltd. Foam stabilizer:" F-242T "manufactured by Shin-Etsu Chemical Co., Ltd.

Examples 1-4 A low rebound polyurethane foam shown in Table 2 was pulverized by a rotary blade type pulverizer so as to have an average particle size shown in Table 2 to obtain a granular material. A urethane-based adhesive (“R-1000” manufactured by Token Resin Chemical Co., Ltd.) is used as a binder for the granular material.
M ") were mixed at the ratios shown in Table 2, and the resulting mixture was filled into a mold, cured, and molded to obtain a granular molded product. The physical properties of the granular molded product are as shown in Table 2, and the air permeability is improved without significantly impairing the low resilience as compared with the physical properties of the raw material low resilience polyurethane foam shown in Table 1. In particular, in Examples 3 and 4, it was confirmed that the air permeability was significantly improved with little effect on the low resilience.

[0043]

[Table 2]

Each of the cushioning materials of Examples 1 to 4 was processed to a thickness of 60 cm × 60 cm × 8 cm and placed on a seat of a wooden chair. A man weighing about 70 kg was seated on the chair, and pressure distribution after about 30 seconds. Was measured using a seat pressure distribution system (BIG-MAT) manufactured by Nitta Corporation. As a result, the pressure was sufficiently dispersed in each case, and there was no portion to which pressure was applied locally.

In addition, each of the cushion materials has a temperature of 22.
Even when used for 6 hours in a room at a temperature of 50 ° C. and a humidity of 50%, the user could comfortably use without feeling stuffy or hot.

[0046]

As described above in detail, according to the present invention, it is possible to provide a cushioning material having low resilience, high air permeability, and a comfortable feeling of use.

[Brief description of the drawings]

FIG. 1 is a sectional view showing an embodiment of a cushioning material of the present invention.

[Explanation of symbols]

 1A, 1B, 1C, 1D Cushion material 2 Granular material molding layer 3 Polyurethane foam layer

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) B32B 27/40 B32B 27/40 B68G 11/04 B68G 11/04 F term (Reference) 3B096 AD07 3B102 AB07 4F100 AK51A AK51B BA02 BA03 BA06 BA07 BA10A BA10B BA16 CB00A DE01A DJ01A DJ01B JD02 JD02A YY00A

Claims (6)

[Claims] 1. A cushioning material comprising a granular material formed by binding particles of a low resilience polyurethane foam with a binder. 2. The cushion material according to claim 1, wherein the particle size of the low resilience polyurethane foam is 1 to 50 mm. 3. The cushion material according to claim 1, wherein the granular material has an air permeability of 30 to 300 cc / cm ² / sec. 4. The method according to claim 1, wherein the binder is a urethane-based adhesive, and the binder is used in an amount of 3 to 30 parts by weight based on 100 parts by weight of the granular material of the low-rebound polyurethane foam. A cushioning material characterized by being: 5. The low rebound polyurethane foam according to claim 1, wherein the low rebound polyurethane foam has a rebound resilience of 15 or less.
% Or less. 6. A cushioning material according to claim 1, wherein the cushioning material comprises the granular material and a polyurethane foam.