JP2006315324A - Molded polyurethane foam material and method for preparing molded polyurethan foam material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a molded polyurethane foam material having sufficient porosity and air permeability and a method for preparing the molded polyurethane foam material. <P>SOLUTION: The method for preparing the molded polyurethane foam material comprises: preparing a polyurethan foam material; reticulating the polyurethane foam material to substantially remove cell membranes of the polyurethane foam; disposing the reticulated polyurethane foam material in a preheated molding part; applying pressure to close the molding part to form a compressed polyurethane foam material in a cavity formed by the molding part so as to deform the compressed polyurethane foam material to a configuration defined by the cavity; opening the molding part and removing the molded polyurethane foam material from the molding part. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a novel method for preparing polyurethane foam, and more particularly to a method for preparing molded polyurethane foam for chest pads, cups, fronts and other similar items used in brassieres and other garments and the present invention. It relates to breast pads, cups, anterior parts and the like prepared by the method according to the invention. The present invention is particularly useful in a method for forming a seamless brassiere cup molded from a soft polyurethane foam produced by polymerization of an aliphatic isocyanate and a polyol.

  Elasticity that can adapt to various positions and wearer's movements in the manufacturing method of brassiere and other garments, including molded chest pads, cups, front parts and other similar items, always maintaining the original shape A certain material is required. Furthermore, the shape and elasticity should not be affected by washing and machine washing. Furthermore, the bra pad needs to be porous and breathable in order to improve the comfort of the wearer.

  Bra pads made from different thickness fiberfill materials have long been used. Conventional processes have a thin top, which results in poor shape stability after washing or machine washing. To solve this thinning problem, sewing the top is a common solution. However, it does not meet the demands of seamless bra cups for sewing and current fashion.

  Improvements in the formation of brassiere pads are described in a patent issued to Sawamoto Kosi on May 24, 1977 (see Patent Document 1). This invention includes molding an elastic fibrous material mixed with a thermoplastic resin with a mold, and heating the mold to a temperature at which the resin softens. However, this process requires a uniform distribution of the thermoplastic resin in the fibrous material, which makes it difficult to produce a flexible and elastic brass cup using this process. Another disadvantage of the present invention is that an accurate resin content is required. In addition, the resin makes the brassiere cup less elastic. Bra cups with insufficient amounts of resin binding tend to be affected by washing and lack shape stability.

  Another method of manufacturing brassiere cups involves the thermoforming of polyurethane foam according to a patent published on Feb. 10, 1981 to Walter Riedler, promulgated (see Patent Document 2). The polyurethane foam sheet peeled from the polyurethane slabstock foam block is placed between the heated female molded part and the heated male molded part of the molded part. Then, hydraulic pressure is implemented to press the foam sheet at the molding part. According to the description of the invention, the molded part is heated from 350 to 450 degrees Fahrenheit. The pressure applied to the polyurethane foam is about 60 pounds per square inch of molding, the heat applied to the polyurethane foam is about 400 degrees Fahrenheit, and heat and pressure are applied simultaneously for about 60 seconds. The actual process cycle time depends on the thickness of the polyurethane foam sheet. In order to allow sufficient cell strut deformation at the center of the polyurethane foam, due to the low temperature conductivity of the polyurethane foam, a thick foam sheet usually requires significantly longer process cycle times. Such heat treatment causes separation of the chemical bonds of the polyurethane, resulting in a lack of physical properties and accelerated yellowing during the use of the polyurethane foam.

  An important drawback of the results of using aromatic polyurethane foam is the discoloration nature. It is well known that aromatic polyurethane foams become yellowish when exposed to light, particularly ultraviolet light. In order to solve this problem, Kiyotake invented a method of forming a polyurethane foam using an aliphatic isocyanate (see Patent Document 3). In the present invention, an isocyanate-terminated prepolymer obtained by adding a polyol to an aliphatic isocyanate having a hydroxyl equivalent of 1.4 to 2.6 times is reacted with 0.4 to 5 times water in the presence of a catalyst. Including. Aliphatic polyurethane foams that do not turn yellow are produced by this method. However, aliphatic polyurethane foams have closed cells in almost every part of the structure because of the low reactivity due to the slow reactivity of the aliphatic isocyanate functional group. Closed cell structures in polyurethane foam require higher formation temperatures and longer process times due to slower heat dissipation and process difficulties. The resulting brassiere pad has limited breathability due to the residual cell membrane.

  Another problem with thermoformed polyurethane bra pads is the limited breathability resulting from the reduced porosity after thermal deformation. Chen, a patent promulgated on October 23, 2001, describes a method of forming a polyurethane bra pad having a number of air holes conducting to upper and lower surfaces to improve air permeability (see Patent Document 4). ). However, these air holes adversely affect the smoothness of the finished brassiere cup. As a result, such pad structures are only acceptable in a limited market.

United States Patent No. 4,025,597 United States Patent No. 4,250,137 European Patent Application Publication No. 0,473,107 United States Patent No. 6,306,006

  The problems of the prior art are solved by the present invention, and a molded brassiere cup with sufficient porosity and breathability is formed. A brassiere cup formed from an aliphatic polyurethane foam having excellent color fastness to ultraviolet light is also obtained.

The present invention provides an economical solution for maintaining the smoothness of a brassiere cup and forming a brassiere pad with improved breathability.
The object of the present invention is to provide a novel method for preparing polyurethane foam suitable for seamless breast pads, cups, fronts and the like for use in brassieres and other garments.

  Another object of the present invention is to provide a novel method for improving heat dissipation in foam and reducing the molding temperature and the process time of the thermoforming process. The method of the present invention helps to prevent degradation of the polymer at very high temperatures and protects workers from exposure to harmful hydrogen cyanide gas resulting from pyrolysis.

  Furthermore, it is an object of the present invention to provide a method for molding brassiere cups with shorter production cycle times. As the production cycle time decreases, the production capacity of the brass cup molding line increases significantly.

  It is a further object of the present invention to provide a molding process for a brassiere cup comprising a polyurethane foam formed from heat sensitive fibers or aliphatic isocyanates. The brassiere cup needs to maintain its original color during the period of use. Any polyurethane foam formed from aromatic isocyanates will appear in color and gradually turn from yellow to dark brown. A common way to solve this problem with the prior art is to add UV stabilizers to the polyurethane foam formulation. UV stabilizers only slow down the yellowing in a short period of time, and the foam still turns dark during use. Polyurethane foams formed from aliphatic isocyanates are suitable for brassiere cup materials. Urethanes formed from aliphatic isocyanates have a lower chemical bond strength stability than aromatic urethane polymers and tend to separate at a lower chemical bond temperature. Therefore, the conventional thermoforming process cannot be used for molding a molded polyurethane foam formed from aliphatic isocyanate. Therefore, the improvement of the present invention has improved the molding method of polyurethane foam formed from aliphatic isocyanate.

  While the preferred embodiment has been illustrated and described, it will be appreciated that various modifications and alternatives can be made without departing from the spirit and scope of the invention. Accordingly, the present invention is illustrated by way of example and not limitation. Aliphatic polyurethane foam is used as an example to illustrate this example, however, aromatic polyurethane foam is also used in the present invention.

  The present invention relates to a novel process for preparing polyurethane foam suitable for seamless breast pads, cups, fronts and the like for use in brassieres and other garments. The present invention is particularly useful for the formation of seamless brassiere cups molded from soft polyurethane foam produced by the polymerization of aliphatic isocyanates and polyols. The aliphatic polyurethane foam is reticulated to remove all cell membranes and cut into a sheet that is thicker than the wall of the finished bra. Seamless molded brassiere cups have walls that are thicker at the exterior or top than at the periphery. The cut aliphatic polyurethane foam sheet is pressed between the female part and the male part of the molding part. The molding part is closed and pushed by hydraulic pressure. Aliphatic polyurethane foam is molded into the exact shape of the mold groove. Molded aliphatic polyurethane foam is used for seamless breast pads, cups, fronts and other similar items in brassieres and other garments. The molded aliphatic polyurethane bra pad has excellent yellowing properties compared to the aromatic polyurethane bra pad and has improved heat dissipation due to improved breathability and porosity.

  In general, polyurethane foams are (1) polyols, (2) water, (3) cross-linked materials or materials with extended chains, (4) silicon-based foam stabilizers, (5) Produced using formulations consisting of various other additives such as amine and organometallic catalysts, (6) isocyanates with multiple functional populations, (7) auxiliary blowing agents, fillers and flame suppressants. . Examples of materials that can be applied to the mixture are well known to those skilled in the art. Therefore, detailed description is omitted.

  In the preparation of commercially available polyurethane foam, it is considered that the exchange of two properties of gelation and foaming is important in the process. Gelation indicates a reaction in isocyanate, polyol and cross-linked materials in urethane polymer formation. Foaming indicates the reaction of isocyanate with water, thereby producing carbon dioxide. If the foaming reaction proceeds very fast or if the gelling reaction is very slow, the foam will eventually collapse. On the other hand, if the foaming reaction proceeds very slowly, or if the gelling reaction is very fast, the foam will have a cellular structure in a capsule where almost all cells are filled with hot air heated by reaction external heat. Have. Therefore, when the produced foam material is cooled, it shrinks after curing.

  In order to produce a commercially available flexible polyurethane foam with good quality and suitable porosity, the balance between gelation and foaming reaction during the production process can be adjusted by adjusting the content of amine and organometallic catalyst in the reaction mixture. Controlled. The porosity or openness of a resilient polyurethane foam is explained by the airflow. Airflow is the volume of air through a 1.0 inch thick foam specimen, and a standard pressure differential is performed on both sides of the foam specimen and is recorded in units of cfm representing cubic feet per minute. . A detailed test method is shown in ASTM D3574 and is referenced in the present invention.

  Commercially resilient polyurethane foams usually have airflow values from 0.5 cfm to 4.0 cfm. Foams with low airflow values are at risk of shrinking and as a result the material is discarded. On the other hand, foams with higher airflow values have severe internal splitting if they do not collapse overall. Both result in production problems and material disposal.

  The cell size of the foam material is indicated in units of ppi representing pores per inch. Commercially resilient polyurethane foams generally have cell sizes from 20 ppi to 100 ppi, and state-of-the-art foaming devices produce polyurethane foams with cell sizes from 3 ppi to 140 ppi.

  In the present invention, different cell sizes and porous foams are considered to form thermoformed polyurethane foam bra pads with improved breathability. Surprisingly, it can be seen that the networking of the polyurethane foam prior to the thermoforming of the brassiere pad significantly improves the breathability. A similar trend is seen regardless of the cell size of the foam, but the larger cell size foam therefore has a lower ppi value and improvement is more important.

  The present invention provides an ideal method for forming brassiere pads from aliphatic isocyanates. Aliphatic polyurethane foams formed from aliphatic isocyanates usually have a fairly tight structure due to the lower reactivity of aliphatic isocyanates. Aliphatic polyurethane foam usually needs to be broken after the foaming process to prevent sieve shrinkage. It is a very tedious process because the failure is only performed if the foam slab has sufficient strength. Breaking is not performed immediately after foaming and when the foam slab is under cure and has a weak cellular structure that is broken in the breaking process and an adhesive skin that makes breakage difficult. Commercially broken foam materials usually have airflow values greater than 0.5 cfm. This value is considered low, but is sufficient to prevent shrinkage of the foam.

  It can be seen that after the thermoforming of the polyurethane foam, the porosity of the foam is significantly reduced by the residual cell membrane of the polyurethane foam, whether aliphatic or aromatic. It can be easily understood that the cell membrane residue is smooth, contains many small air passages in the thermoformed polyurethane foam, and the breathability of the foam is significantly reduced after thermoforming.

  The polyurethane foam so prepared is then reticulated. Surprisingly, it can be seen that the reticulation process prior to thermal deformation used in the present invention improves the heat dissipation in the foam during the thermal deformation process. As a result, the foam is molded or thermally deformed at a low molding temperature and a short molding time. This is an important feature of the present invention and helps to reduce cycle time and improve productivity.

  Several methods are used to produce reticulated foam. An example is John J. On January 2, 1973. Winchcombe et al. 3,708,362, which is a method for reticulating a spongy material such as polyurethane foam. According to Winchcombe's invention, the foam sheet is placed between the platens. The tight cellular air in the sheet is replaced by a flammable gaseous medium that is subsequently ignited to generate foam reticulation.

  There are other methods of reticulating polyurethane foam. For example, an eat-out cell membrane by immersing a foam material in a strong caustic or acid aqueous solution for a certain time. Then immerse the foam in the wash water several times. Strong caustic or acid solutions will corrode certain skins of the membrane and struts. The disadvantage of such a process is that it is difficult to remove all caustic or acid residues from the finished foam. Such residues begin to hydrolyze and deteriorate in months after reticulation. Such a reticulated foam has only a limited service life.

  Another important advantage of lowering the molding temperature is an improved working environment. In the prior art, the molded part is heated from 350 degrees to 450 degrees during the thermal deformation process. The pressure applied to the polyurethane foam is about 60 pounds per square inch of molding, the heat applied to the polyurethane foam is about 400 degrees Fahrenheit, and the heat and pressure are applied simultaneously for about 60 seconds. . The actual process cycle time depends on the thickness of the polyurethane foam sheet. Due to the low thermal conductivity and porosity of conventional polyurethane foams, thicker foam sheets usually require longer process cycle times, so that sufficient cell strut deformation occurs in the middle of the polyurethane foam. Done. An important problem with conventional processes is the separation of biuret, urea and urethane bonds in the polyurethane foam. The long thermal deformation cycle time of thicker polyurethane foams usually has severe separation problems, especially at the surface of the polyurethane foam sheet. Their chemical bonds undergo thermal separation in the temperature range of 212 to 395 degrees Fahrenheit. Harmful hydrogen cyanide gas is generated from such chemical bond separation. Accordingly, the reticulated polyurethane foam of the present invention is improved in thermal deformation due to improved heat dissipation, so that the temperature required for molding is lowered. Therefore, harmful hydrogen cyanide gas emissions are reduced.

  Lower molding temperatures are more important in the thermal deformation of aliphatic polyurethane foams. Urethanes formed from aliphatic isocyanates are less stable in chemical bond strength than aromatic urethane polymers and tend to separate at lower temperatures. For this reason, the conventional thermal deformation process cannot be used for a molded polyurethane foam formed from an aliphatic isocyanate. The improvement of the present invention shows a novel method for molding polyurethane foams formed from aliphatic isocyanates.

(Summary of Invention)
The present invention relates to a novel method of adjusting polyurethane foam suitable for seamless breast pads, cups, fronts and the like for use in brassieres and other garments. The method is particularly useful for the formation of seamless brassiere cups molded from soft polyurethane foam produced by the polymerization of aliphatic isocyanates and polyols. The aliphatic polyurethane foam is reticulated to remove all cell membranes and cut into a sheet that is thicker than the wall of the finished bra. Molded seamless brassiere cups have walls that are thicker at the exterior or top than at the periphery. The cut aliphatic polyurethane foam sheet is pressed between the female part and the male part of the molding part. The molding part is closed and pressed by hydraulic pressure. Therefore, the aliphatic polyurethane foam is molded into the exact shape of the mold groove. Molded aliphatic polyurethane foam is used for seamless breast pads, cups, fronts and other similar items in brassieres and other clothing. The molded aliphatic polyurethane bra pad has superior non-yellowing properties to the aromatic polyurethane bra pad and has improved body temperature dissipation due to improved breathability and porosity.

  According to a preferred embodiment of the present invention, the aliphatic polyurethane foam is obtained by reaction of an aliphatic isocyanate and a polyol directly in the presence of water and a catalyst. A few days after curing, the thicker skin of the polyurethane foam bundle is peeled off. The polyurethane foam bundle is then reticulated to remove all cell membranes in the foam so as to have a substantially skeletal network.

  After reticulation, the polyurethane foam is then cut to twice the thickness of the thickest wall of the finished brassiere cup. The cut polyurethane foam sheet is then thermally deformed between the female mold part and the male mold part of the molded part heated. The molding part is closed and pressed by hydraulic pressure. The pressure applied to the polyurethane foam is about 60 pounds per square inch of molding. Therefore, the polyurethane foam is molded into the shape of the groove of the molded part. Molded polyurethane foam is used for seamless breast pads, cups, fronts and the like in brassieres and other garments. Molded seamless brassiere cups have walls that are thicker at the exterior or top than at the periphery.

The following examples are intended to illustrate the purpose of the examples without having to complete the disclosure of the present invention.
(Example 1 to Example 4)
As shown in Table 1, the foam material 1 to the foam material 4 are the foam materials produced by the present embodiment, and are prepared as follows. A sample 3 inches thick and 10 inches wide by 10 inches wide was placed in a 3 liter autoclave reactor in a separation experiment. In all experiments, the contents of the autoclave are aspirated at about 1 torr for 5 minutes, then the aspiration is stopped and about 250 torr of oxygen is injected into the autoclave. After oxygen injection, hydrogen is injected until the internal pressure is 650 Torr. The explosive gaseous content is then ignited by a spark device located inside the autoclave. After this step, the foam specimen is inspected. This process is repeated until all cell membranes are completely burned out. As shown in Table 1, the foam specimens for each experiment were designated as foam 5 to foam 8. The foamed material 5 to the foamed material 8 were immersed in purified methylene chloride in order to remove a separation product that could be generated by reticulation. The foam specimen was dried in an oven at 50 degrees Celsius for 20 minutes and then cooled for subsequent testing.

The airflow value of the polyurethane foam is measured according to ASTM D-3574. An airflow meter made by Amcor (Texas, USA) is used in the test. Airflow values are reported in units of cfm. Foam density is measured according to ASTM D-3574 and is reported in kg / m ³ .

(Example 5 to Example 12)
Foam 1 to foam 8 were placed between aluminum plates heated to a suitable temperature and pressed with a hydraulic cylinder. The foam was thermally deformed to a suitable thickness (foam 9 to foam 16).

  The molding part equipped with the built-in electric heater is installed in a hydraulic press device manufactured by Shenling Industries Co., Ltd. (Hong Kong). The apparatus can apply a pressure of about 60 psi to the mold. The surface temperature of the mold is measured and recorded using a K-type thermocoupler and a digital thermo recorder manufactured by Shimadzu (Japan). A 3-inch thick foam sheet is thermoformed in 100 seconds with a set of aluminum plates preheated to 180 degrees Celsius by built-in electric heater plates. The gap between the two molded parts is 1 inch. The final thickness of the resulting foam material is measured 30 minutes after the foam material has cooled. The molding state and final foam thickness were recorded.

  The advantages of the reticulation pretreatment step are shown by analysis of experimental results.

(Example 13 to Example 20)
The air permeability of the foamed material specimen 9 to the foamed material specimen 16 was measured by the following process. The foam specimen was placed on top of the beaker and then sealed in a moisture controlled jar. The entire assembly was stored in an oven at 38 degrees Celsius to ensure temperature control. The weight of the beaker assembly was measured at the end of every hour for 24 consecutive hours.

The water vapor transmission rate is measured to show the breathability of the produced polyurethane foam. Thermoformed polyurethane foam is tested according to ISO 1663. A desiccant calcium chloride is placed at the bottom of the glass beaker. The foam specimen is sealed using a circular template on top of the glass beaker to ensure that the renewable portion of the foam surface is exposed to moisture adjusted to 88.5% humidity at 38 ° C. Is done. The assembly was exposed to a conditioned atmosphere for 24 consecutive hours and weighed at each exposure until the rate of change was approximately constant. When the rate of weight increase is constant, the water vapor permeability that permeates the unit portion of the sample per unit time is recorded as an index of air permeability.
The results are shown in Table 3 below.

As can be clearly seen from Table 3, the reticulation treatment of the present invention can significantly improve the breathability of the thermoformed polyurethane foam.
The present invention is particularly useful for forming breast pads, cups, fronts and the like for use in brassieres and other garments. However, other products that require elasticity and shape stability are also produced by the methods and products of the present invention. The scope of the invention is limited only by the claims.

Claims (34)

(A) preparing a polyurethane foam;
(B) reticulate the polyurethane foam to substantially remove cell membranes from the polyurethane foam;
(C) placing the reticulated polyurethane foam in a preheated molded part;
(D) In order to form a compressed polyurethane foam material in the groove formed by the molded part, the pressure for closing the molded part is performed,
(E) transforming the compressed polyurethane foam into a shape defined by the groove of the molded part;
(F) A method for preparing a molded polyurethane foam material, comprising the step of opening the molded part and removing the deformed polyurethane foam material from the molded part.   The method for preparing a molded polyurethane foam material according to claim 1, wherein the polyurethane foam material comprises a reaction product of an aliphatic isocyanate and a polyol in the presence of a foaming agent and a catalyst.   The method for preparing a molded polyurethane foam material according to claim 1, wherein the polyurethane foam material comprises a reaction product of an aromatic isocyanate and a polyol in the presence of a foaming agent and a catalyst.   The method for preparing a molded polyurethane foam material according to claim 2, wherein the aliphatic isocyanate is 1,6-hexane diisocyanate.   The method for preparing a molded polyurethane foam material according to claim 2, wherein the aliphatic isocyanate is isophorone diisocyanate.   2. The method for preparing a molded polyurethane foam material according to claim 1, wherein the polyurethane foam material is thicker than a thick wall of the finished deformed polyurethane foam material.   7. The method for preparing a molded polyurethane foam material according to claim 6, wherein the polyurethane foam material is about twice as thick as a thick wall of the finished deformed polyurethane foam material.   The method for preparing a molded polyurethane foam material according to claim 1, wherein the polyurethane foam material is a polyurethane foam material sheet obtained by cutting from a polyurethane foam material block.   The method for preparing a molded polyurethane foam material according to claim 1, wherein the polyurethane foam material has a network structure substantially in the polyurethane matrix after the reticulation.   The method for preparing a molded polyurethane foam material according to claim 1, further comprising a step of performing a fibrous laminate on the polyurethane foam material before placing the polyurethane foam material in the molding part.   The method for preparing a molded polyurethane foam material according to claim 1, wherein the pressure for closing the molded portion and pressing the polyurethane foam material is implemented by a hydraulic pressure mechanism.   2. The method for preparing a molded polyurethane foam material according to claim 1, wherein the pressure for closing the molded part and pressing the polyurethane foam is about 30 pounds to 90 pounds per square inch of the molded part. .   The method for preparing a molded polyurethane foam material according to claim 1, wherein the thermoforming of the pressed polyurethane foam material is continued for about 45 seconds to 100 seconds.   The method for preparing a molded polyurethane foam material according to claim 1, wherein the molded part is preheated to about 150 to 210 degrees Celsius.   2. The method for preparing a molded polyurethane foam material according to claim 1, wherein the deformed polyurethane foam material has a cell size of 3 to 120 ppi.   16. The method for preparing a molded polyurethane foam material according to claim 15, wherein the deformed polyurethane foam material has a cell size of 5 ppi to 70 ppi. (A) preparing a polyurethane foam;
(B) in order to substantially remove the cell membrane in the polyurethane foam, the polyurethane foam is reticulated,
(C) placing the reticulated polyurethane foam in a preheated molded part;
(D) In order to form a compressed polyurethane foam material in the groove formed by the molded part, the pressure for closing the molded part is performed,
(E) transforming the compressed polyurethane foam into a shape defined by the groove of the molded part;
(F) A molded polyurethane foam material prepared by a step of opening the molded part and removing the deformed polyurethane foam from the molded part.   The molded polyurethane foam material according to claim 17, wherein the polyurethane foam material comprises a reaction product of an aliphatic isocyanate and a polyol in the presence of a foaming agent and a catalyst.   The molded polyurethane foam material according to claim 17, wherein the polyurethane foam material comprises a reaction product of an aromatic isocyanate and a polyol in the presence of a foaming agent and a catalyst.   The molded polyurethane foam material according to claim 17, wherein the aliphatic isocyanate is 1,6-hexane diisocyanate.   The molded polyurethane foam material according to claim 18, wherein the aliphatic isocyanate is isophorone diisocyanate.   The molded polyurethane foam material according to claim 17, wherein the polyurethane foam material is thicker than a thick wall of the finished deformed polyurethane foam material.   23. The molded polyurethane foam material of claim 22, wherein the polyurethane foam material is about twice as thick as the thick wall of the finished deformed polyurethane foam material.   The molded polyurethane foam material according to claim 17, wherein the polyurethane foam material is a polyurethane foam material sheet obtained by cutting from a polyurethane foam material block.   The molded polyurethane foam material according to claim 17, wherein the polyurethane foam material has a substantially net-like structure in a polyurethane substrate after the reticulation.   The molded polyurethane foam material according to claim 17, further comprising a step of performing a fibrous laminate on the polyurethane foam material before the polyurethane foam material is disposed in the molding portion.   18. The molded polyurethane foam material according to claim 17, wherein the pressure for closing the molded portion and pressing the polyurethane foam material is implemented by a hydraulic pressing mechanism.   18. The molded polyurethane foam material of claim 17, wherein the pressure for closing the molded part and pressing the polyurethane foam is about 30 pounds to 90 pounds per square inch of the molded part.   18. The molded polyurethane foam material of claim 17, wherein the thermoforming of the pressed polyurethane foam material lasts from about 45 seconds to 100 seconds.   The molded polyurethane foam material according to claim 17, wherein the molded part is preheated to about 150 to 210 degrees Celsius.   The molded polyurethane foam material according to claim 17, wherein the deformed polyurethane foam material has a cell size of 3 ppi to 120 ppi.   32. The molded polyurethane foam of claim 31, wherein the deformed polyurethane foam has a cell size of 5 ppi to 70 ppi.   32. A molded polyurethane foam material according to claim 31, wherein the deformed polyurethane foam material has a cell size of 3 ppi to 40 ppi.   The molded polyurethane foam material according to claim 33, wherein the molded polyurethane foam material is a brassiere pad.