JP2008080627A - Pad and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a pad allowing sufficient prevention or control of evaporation of VOCs even with a small amount of a used catcher agent and having high production efficiency and its manufacturing method. <P>SOLUTION: The method comprises arranging a subsidiary material 3 applied with a catcher agent 4 on the surface coming in contact with the body 2 of the pad on the inside surface of an upper mold 10b in such a way that the contact surface lies on the side of the cavity 11, joining the lower mold 10a with the upper mold 10b and supplying a raw material for soft foam to the cavity 11 to foam and mold, and carrying out mold removal to take out a molding integrated with the subsidiary material 3 from the mold 10 in order to obtain a seat pad 1 for vehicles. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a pad such as a vehicle seat pad made of a flexible foam such as polyurethane foam, and more particularly to a pad in which the emission of volatile organic compounds such as formaldehyde is suppressed. The present invention also relates to a method for manufacturing the pad.

  Since volatile organic compounds (VOC) such as formaldehyde cause sick house syndrome and chemical hypersensitivity, it is required that various compounds used indoors do not emit these compounds as much as possible. This situation is the same in the interior of a vehicle such as an automobile, and it is expected that such demand will increase further in the future.

  By the way, in general, a seat pad made of a flexible polyurethane foam having a high cushioning property is used for an automobile seat, but these are contained in a polyurethane foam raw material or generated during a urethane reaction. Some volatile organic compounds such as formaldehyde and acetaldehyde diffuse from the pad after foam molding, and countermeasures are required.

  Japanese Patent No. 3625141 describes that VOC volatilization is prevented by blending a catcher agent in this urethane composition.

Japanese Patent No. 3069845 describes that a deodorant component-containing liquid is coated on the surface of building materials, textile products, etc., and a hydrazide compound having an aldehyde decomposition action is described as the deodorant component.
Japanese Patent No. 3625141 Patent 3069845

  When a catcher agent is blended in the urethane composition, most of the catcher agent is incorporated into the urethane matrix of the pad product or reacts with the raw materials. Therefore, the catcher is incorporated in order to obtain a sufficient VOC emission prevention effect. The amount of the agent increases and the cost increases.

  In addition, when a deodorant coating agent is applied to the pad surface, the next process cannot be started until the coating agent is dried, resulting in low pad manufacturing efficiency.

  The present invention solves the above-mentioned conventional problems, can sufficiently prevent or suppress (hereinafter referred to as prevention) VOC volatilization even if the amount of catcher agent used is small, and has a high production efficiency, It aims at providing the manufacturing method.

  The pad of claim 1 is a pad having a pad main body made of a flexible foam and a sheet-like auxiliary material bonded to the outer surface of the pad main body, wherein a catcher agent is attached to the auxiliary material. To do.

The pad of claim 2 is characterized in that, in claim 1, the amount of solid content of the catcher agent is 0.5 to 15 g / m ² .

  The pad of claim 3 is characterized in that, in claim 1 or 2, the catcher agent is applied to an adhesive surface with the pad of the auxiliary material.

  The pad according to claim 4 is the pad according to any one of claims 1 to 3, wherein the pad main body is made of polyurethane foam.

  The pad of claim 5 is characterized in that, in any one of claims 1 to 4, the auxiliary material is a cloth support material, a chip agent or a slab foam.

  The pad according to claim 6 is the pad according to any one of claims 1 to 5, wherein the pad is fixed to the frame, and the auxiliary material is disposed at least in a portion in contact with the frame. It is what.

  A pad according to a seventh aspect is characterized in that in any one of the first to sixth aspects, the pad is a vehicle seat pad.

  The pad manufacturing method according to claim 8 is a method for manufacturing the pad according to claims 1 to 7, wherein the auxiliary material is coated with the catcher agent and placed in the mold, and the pad is manufactured in the mold. And a step of integrating the pad main body and the auxiliary material by injecting a foam stock solution for flexible foam and performing foam molding.

  The pad manufacturing method according to claim 9 is characterized in that, in claim 8, the integration step is started in a state where the catcher agent is undried.

  The pad manufacturing method according to claim 10 is characterized in that, in claim 8 or 9, a catcher agent is applied to a surface of the auxiliary material to be bonded to the pad.

The pad manufacturing method according to claim 11 is a method for manufacturing the pad according to claims 1 to 7, wherein the pad main body is manufactured by injecting a stock solution for a flexible foam into the mold and performing foam molding. And a step of attaching the auxiliary material to which the catcher agent is attached to the pad main body.

  A pad manufacturing method according to a twelfth aspect of the present invention is the pad manufacturing method according to the eleventh aspect, wherein a catcher agent is applied to a surface of the auxiliary material bonded to the pad.

  In the pad of the present invention, since the catcher agent adheres to the auxiliary material, VOC volatilization is sufficiently achieved with a small amount of catcher agent used compared to the case where the catcher agent is blended in the composition of the pad body. Can be prevented or suppressed.

  In addition, since the catcher agent is attached to the auxiliary material, the manufacturing efficiency is higher than the case where the catcher agent is attached to the pad body. That is, in the case where the catcher agent is attached to the pad body, it is necessary to hold the catcher agent sideways until the catcher agent is dried after the pad body is attached to the pad body after the pad body is manufactured. Time, labor, and space for drying are required. On the other hand, in the pad of the present invention, since the catcher agent is attached to the secondary material, the catcher agent attached to the secondary material can be dried before or during manufacture of the pad main body.

  In the present invention, the catcher agent is preferably applied to the adhesive surface with the auxiliary material pad. In this case, even if the powder is deposited on the bonding surface of the pad when the catcher agent is dried, the powder is not visible from the outside, and the appearance of the pad is not impaired.

  In the present invention, when the pad is fixed to the frame, the auxiliary material may be disposed at least in a portion in contact with the frame. In this case, since secondary materials are interposed between the pad and frame made of flexible foam, it is possible to prevent these pads and the frame from coming into direct contact with each other and rubbing to generate abnormal noise (friction noise). Is done.

  The pad of the present invention is obtained by applying a catcher agent to a secondary material and placing it in a molding die, injecting a flexible foam stock solution into the molding die and performing foam molding, thereby integrating the pad main body and the secondary material. Can be manufactured.

  In this manufacturing method, it is preferable to start the integration step in a state where the catcher agent is not dried. In this case, the catcher agent is dried during the integration step, so that the pad manufacturing efficiency is further improved.

The pad of the present invention can also be produced by injecting a flexible foam stock solution into a mold and foam-molding it to produce a pad body, and then attaching a secondary material to which a catcher agent is attached to the pad body. Can be manufactured.
Be controlled.

  Hereinafter, embodiments will be described with reference to the drawings. FIG. 1 is a cross-sectional view of a vehicle seat pad 1 according to an embodiment.

  The vehicle seat pad 1 includes a pad main body 2 and a sheet-like auxiliary material 3 formed on the back surface of the pad main body 2. A catcher agent 4 is attached to the adhesive surface of the auxiliary material 3 with the pad main body 2.

  In the vehicle seat pad 1, the catcher agent 4 is attached to the auxiliary material 3. For this reason, when manufacturing the vehicle seat pad 1, the catcher agent 4 can be attached and dried before foam molding of the pad body 2 or during foam molding. Manufacturing efficiency can be improved. Moreover, the volatilization of VOC can be prevented with a small amount of catcher agent compared with the case of mix | blending in the composition of the pad main body 2. FIG.

  In this vehicle seat pad 1, a catcher agent 4 is applied to an adhesive surface of the auxiliary material 3 with the pad body 2. For this reason, even if the powder is deposited on the adhesion surface when the catcher agent 4 is dried, the powder is not visible from the outside, and the appearance of the pad is not impaired.

The back surface of the vehicle seat pad 1 is fixed to a metal frame (not shown). At this time, since the auxiliary material 3 is interposed between the pad main body 2 and the metal frame, the pad main body 2 and the metal frame are in direct contact with each other and rub against each other to generate abnormal noise (friction noise). It is prevented.
Next, a method for manufacturing the vehicle seat pad 1 will be described.

<First Production Example>
FIG. 2 is a cross-sectional view for explaining an example of a method for manufacturing the vehicle pad 1. In FIG. 2, the mold 10 is composed of a lower mold 10a and an upper mold 10b. In the figure, reference numeral 11 denotes a cavity.

  The auxiliary material 3 in which the catcher agent 4 is applied to the surface in contact with the pad main body 2 is disposed on the inner surface of the upper mold 10b so that the contact surface is on the cavity side. Next, the lower mold 10a and the upper mold 10b are matched with each other, and the flexible foam raw material is supplied into the cavity 11 for foam molding. Thereafter, the vehicle seat pad 1 is obtained by removing the mold and taking out the molded body integrated with the auxiliary material 3 from the mold 10.

  In this production example, even if the foam molding is started with the catcher agent 4 applied to the auxiliary material 3 in an undried state, the catcher agent is subjected to the steps of foam molding, demolding, finishing, and inspection. 4 can be sufficiently dried. For this reason, after foaming the pad main body 2 as in the past, the catcher agent 4 is applied to the surface, and compared with the case where the pad main body 2 is held sideways until dry, time and labor are omitted, Space for drying can be omitted.

  However, foam molding may be started after the catcher agent 4 applied to the auxiliary material 3 is dried.

<Second Production Example>
The pad main body 2 is manufactured by supplying the raw material for flexible foam into the cavity 11 and foam-molding it without arranging the auxiliary material 3 in the upper mold 10b.

  Next, the auxiliary material 3 in which the catcher agent 4 is applied to the surface in contact with the pad main body 2 is bonded to the surface of the pad main body 2 using an adhesive. In this way, the vehicle seat pad 1 is obtained.

  Next, the pad main body 2, the auxiliary material 3, and the catcher agent 4 will be described.

<Pad body 2>
The pad body 2 is preferably made of polyurethane foam. This polyurethane foam is obtained by foam-molding a polyurethane foam blend mainly composed of polyol and isocyanate.

  Examples of the polyol include dihydric to hexavalent polyhydric alcohols, polyoxyalkylene polyols (polyether polyols), polyester polyols, polymer polyols, and the like. Of these, polyether polyols and polyester polyols are preferably used, and polyether polyols are particularly preferably used. These polyols may be used alone or in combination of two or more.

  Known isocyanates can be used as the isocyanate. For example, tolylene diisocyanate, diphenylmethane diisocyanate, triphenyl diisocyanate, xylene diisocyanate, polymethylene polyphenylene polyisocyanate, hexamethylene diisocyanate, isophorone diisocyanate and the like can be mentioned, and these can be used alone or in combination of two or more. May be.

  Among these, in the present invention, it is preferable to use tolylene diisocyanate (TDI) and / or diphenylmethane diisocyanate (MDI) as the isocyanate from the viewpoint of the molding density region. Here, the TDI is not particularly limited, but is a mixture having a blending ratio of 2,4-TDI and 2,6-TDI of 80/20 to 50/50 (mass ratio). A mixture of 80/20 to 65/35 (mass ratio) is particularly preferable. The MDI is not particularly limited, and can be used regardless of its molecular weight distribution. For example, pure (Pure) MDI (4,4'-MDI), polymeric MDI, crude MDI, etc. It can be used suitably.

  When the TDI and MDI are used in combination, the mixing ratio of the two is usually 20/80 to 90/10 (mass ratio) as the value of TDI / MDI (mass ratio), preferably 50/50 to 80/20 ( Mass ratio).

  The isocyanate equivalent of the isocyanate is preferably 70 to 120, particularly 80 to 110.

  Although the compounding quantity of the said isocyanate is not restrict | limited in particular, It is 20-100 mass parts normally with respect to 100 mass parts of all polyols, Preferably it is 25-60 mass parts. If the amount of isocyanate is too small, the resinification reaction proceeds too much, resulting in closed cells and a suitable sheet may not be obtained. On the other hand, if the amount is too large, curing of the polyurethane foam may be delayed.

  From the viewpoint of adjusting (increasing) the hardness of the polyurethane foam molded article, a crosslinking agent can also be blended in the polyurethane foam blend. Examples of such a crosslinking agent include trimethylolpropane, diethylene glycol, sucrose (sugar), pentaerythritol, 1,4-butanediol, dipropylene glycol, ethylenediamine, glycerin, etc., and PO or EO added thereto. And alkylene oxide homopolymers (EO homopolymers and PO homopolymers). In particular, when an EO homopolymer is used as a cross-linking agent, it is possible to moderately suppress the initial reaction when the polyurethane foam compound is foam-cured, and the liquid spreads and foams to every corner in the mold. As a result of the stock solution being easily spread, abnormalities in the outer shape of the molded product (such as “chips” at the corners) are less likely to occur.

  A commercial item can be used as said crosslinking agent, For example, Takeda Pharmaceutical Co., Ltd. product T-880, the company GR-04, Dow polyurethane Japan Co., Ltd. XQ82211 etc. can be mentioned.

  Although it does not specifically limit as a compounding quantity of the said crosslinking agent, It is 0.1-10 mass parts normally with respect to 100 mass parts of all polyols, Preferably it is 1-5 mass parts.

  In the polyurethane foam formulation, a foaming agent, a catalyst, a foam stabilizer and the like can be blended as necessary in the same manner as in a normal polyurethane foam formulation.

  The foaming agent can be appropriately blended as necessary. For example, water can be suitably used, but a compound having a low boiling point such as methylene chloride and monofluorotrichloromethane can also be used. The blending amount of the foaming agent is appropriately adjusted, but is usually 0 to 15 parts by mass, preferably 1 to 5 parts by mass with respect to 100 parts by mass of the total polyol.

  As the catalyst, for example, amine-based and tin-based catalysts are preferably used. Examples of amine catalysts include tetramethylhexamethylenediamine, pentamethyldiethylenetriamine, dimethylcyclohexylamine, bis- (dimethylaminoethyl) ether, tetramethylpropylenediamine, trimethylaminoethylpiperazine, tetramethylethylenediamine, dimethylbenzylamine, methylmorpholine, Examples of tin-based catalysts such as ethylmorpholine and triethylenediamine include stannous octate and dibutyltin dilaurate. These may be used alone or in combination of two or more. Among them, triethylenediamine is suitably used for promoting resinification, and diethanolamine is suitably used for controlling the breathability of the resulting foam. As a compounding quantity of a catalyst, it is 0-5 mass parts normally with respect to 100 mass parts of all the polyols, Preferably it is 0.1-1 mass part.

  Examples of the foam stabilizer include organopolysiloxanes, alkyl carboxylates, and alkylbenzene sulfonates. As a compounding quantity of a foam stabilizer, it is 0-5 mass parts normally with respect to 100 mass parts of all the polyols, Preferably it is 0.5-2 mass parts.

  Furthermore, various additives can be added to the polyurethane foam formulation as necessary. For example, colorants such as pigments, fillers such as calcium carbonate, antioxidants, flame retardants, and UV absorbers. , A light stabilizer, a conductive substance such as carbon black, an antibacterial agent, and the like can be blended.

  The polyurethane foam molded article is obtained by foam-curing the above polyurethane foam composition. As the foaming method, for example, a one-shot method or a prepolymer method can be employed. The foaming temperature is usually 0 to 40 ° C., preferably 15 to 25 ° C., and the value of (specific gravity of foam molded product) / (specific gravity of raw material before foaming) is usually 1/10 to 1/50. is there.

<Sub-material 3>
The secondary material 3, fabric support member, for example, Toyobo "polyester spunbond borane scan CRE3080" (basis weight 80 g ^{/ m} 2), manufactured by Mitsui Chemicals "Tufnell ESE323" (basis weight 80 g ^{/ m} 2), Aoyama Sangyo ( Nonwoven fabrics such as “Finelite W” manufactured by Co., Ltd. (400 g / m ² per unit area) can be used. Moreover, although a chip agent and a slab foam can also be used, it is not limited to these.

<Catcher agent 4>
As the catcher agent 4, various substances that capture VOC can be used. For example, amines, imines, amidines, amides, carbamides, hydrazides, azoles, azines that capture formaldehyde and acetaldehyde. Nitrogen-containing organic compounds that chemically react with aldehyde gas and exhibit a trapping action, such as amino acids and amino acids.

  When the pad body 2 is a polyurethane foam molded body, aldehydes such as acetaldehyde and formaldehyde in the molded body are reduced by thiosulfate, so that sodium thiosulfate, potassium thiosulfate, and the like can also be used.

  Commercially available products can be used as the catcher agent. For example, Air Wash SPU3 (Idemitsu Techno Fine), Air Wash SPU3 (Idemitsu Techno Fine), Chemcatch S5000SP04E (Otsuka Chemical), Kesmon KS220 (Toagosei), Poly Fix FAI5 (Showa High Polymer), Air Wash SPU4 (Idemitsu Technofine), Efnica PM-W (Nanban Efnica), Efnica T-Sol (Nanban Efnica), etc. can be mentioned.

It is preferable that the solid content of the catcher agent is 0.5 to 15 g / m ² , particularly 1 to 12 g / m ² . If it is 1 g / m ² or more, this catcher agent captures the volatile organic compound (VOC) in the pad main body 2 more reliably. Moreover, it is preferable that it is 12 g / m < ² > or less for the cost reduction of a catcher agent.

  Furthermore, you may mix | blend adsorbents, such as activated carbon, as needed.

  Hereinafter, the present invention will be described more specifically with reference to examples and comparative examples.

Example 1
The vehicle seat pad 1 was manufactured according to the first manufacturing example. That is, as shown in FIGS. 1 and 2, the auxiliary material 3 in which the catcher agent 4 is applied to the surface that contacts the pad main body 2 is disposed on the inner surface of the upper mold 10b so that the contact surface is on the cavity 11 side. . Next, the lower mold 10a and the upper mold 10b were combined, and the flexible foam raw material was supplied into the cavity 11 for foam molding. Then, the vehicle seat pad 1 was obtained by removing the mold and taking out the molded body integrated with the auxiliary material 3 from the mold 10.

In addition, Tafnel ESE323 (weight per unit area 80g / m < ² >) was used as an auxiliary material.

As the catcher agent, “Air Wash SPU3 Kai” manufactured by Idemitsu Techno Fine Co., Ltd. was used, and the amount applied to the auxiliary material was 50 g / m ² .

  As a light foam raw material, a mixture of 100 parts by mass of the mixture shown in Table 1 and 35 parts by mass of isocyanate shown below was used.

Isocyanate: Tolylene Diisocyanate (TDI) / Diphenylmethane Diiso
Cyanate (MDI) = 80/20. Isocyanate equivalent 100.

  Further, in foam molding, the liquid temperature of this raw material was 25 ° C., and the temperature of the mold 10 was maintained at 60 ° C.

Example 2
A vehicle seat pad 1 was obtained in the same manner as in Example 1 except that the amount of the catcher agent applied to the auxiliary material was 100 g / m ² .

Comparative Example 1
A vehicle seat pad was obtained in the same manner as in Example 1 except that the catcher agent and the auxiliary material were omitted.

Comparative Example 2
A vehicle seat pad was obtained in the same manner as in Example 1 except that the auxiliary material was omitted and the pad main body was manufactured and then a catcher agent was applied to the surface of the pad main body and dried for 4 hours.

  Note that the application area of the catcher agent was the same as the area of the auxiliary material in Example 1, and the type and application amount of the catcher agent were the same as in Example 1.

Example 3
A vehicle seat pad was obtained in the same manner as in Example 1 except that the type and application amount of the catcher agent were as follows.

Type of catcher agent: “Kesmon KP240” manufactured by Toagosei
Application amount of catcher agent: 30 g / m ² .

Example 4
A vehicle seat pad was obtained in the same manner as in Example 3 except that the amount of the catcher agent applied was 50 g / m ² .

Comparative Example 3
The auxiliary material was omitted, and after manufacturing the pad main body, a vehicle seat pad was obtained in the same manner as in Example 3 except that the surface of the pad main body was coated with a catcher agent and dried for 3 hours.

  Note that the application area of the catcher agent was the same as the area of the auxiliary material in Example 3, and the type and application amount of the catcher agent were the same as in Example 3.

<Measurement of formaldehyde emission>
About the obtained vehicle seat pad, the emission amount of formaldehyde was measured as follows. That is, a test piece cut out to a length of 10 cm, a width of 8 cm, and a thickness of 7 cm was put in a Tedora bag, and the inside of the bag was replaced with 4 L of nitrogen gas or dry air. Heating was performed in an oven at 65 ° C. for 2 hours, and the total amount of gas in the bag was collected in a DNPH cartridge (GL Pak mini AERO: manufactured by GL Sciences Inc.). The solution eluted with 4 mL of acetonitrile was quantified by HPLC method. The results are shown in Table 2.

<Acetaldehyde emission measurement>
About the obtained vehicle seat pad, the amount of acetaldehyde diffused simultaneously with formaldehyde was measured in the same manner as in the case of formaldehyde. The results are shown in Table 2.

<Observation of appearance>
The appearance of the obtained vehicle seat pad was visually observed. The results are shown in Table 2. In addition, the case where the powder deposited when the catcher agent was dried was not visible from the outside was indicated as ◯, and the case where it was visible was indicated as ×.

  As is clear from Table 2, the vehicle seat pads of Examples 1 to 4 have a small amount of formaldehyde and acetaldehyde diffused and have a good appearance.

It is typical sectional drawing of the vehicle seat pad which concerns on embodiment. It is sectional drawing explaining an example of the manufacturing method of the vehicle seat pad of FIG.

Explanation of symbols

1 Vehicle seat pad 2 Pad body 3 Auxiliary material 4 Catcher agent

Claims (12)

In a pad having a pad body made of flexible foam and a sheet-like auxiliary material bonded to the outer surface of the pad body,
A pad, wherein a catcher agent is attached to the auxiliary material. The pad according to claim 1, wherein the catcher agent has a solid content of 0.5 to 15 g / m ² .   3. The pad according to claim 1, wherein the catcher agent is applied to an adhesive surface with the pad of the auxiliary material.   4. The pad according to any one of claims 1 to 3, wherein the pad body is made of polyurethane foam.   5. The pad according to claim 1, wherein the auxiliary material is a cloth support material, a chip agent, or a slab foam.   The pad according to any one of claims 1 to 5, wherein the pad is fixed to a frame, and the auxiliary material is disposed at least in a portion in contact with the frame.   The pad according to any one of claims 1 to 6, wherein the pad is a vehicle seat pad. A method of manufacturing a pad according to claim 1, comprising:
Applying the catcher agent to the auxiliary material and placing it in a mold;
A method for producing a pad, comprising the step of integrating the pad main body and the auxiliary material by injecting a stock solution for a flexible foam into the mold and performing foam molding.   The pad manufacturing method according to claim 8, wherein the integration step is started in a state where the catcher agent is not dried.   The method for manufacturing a pad according to claim 8, wherein a catcher agent is applied to a surface of the auxiliary material bonded to the pad. A method of manufacturing a pad according to claim 1, comprising:
A step of producing the pad main body by injecting a flexible foam stock solution into the mold and foam-molding;
And a step of attaching the auxiliary material to which the catcher agent is attached to the pad body.   The method for manufacturing a pad according to claim 11, wherein a catcher agent is applied to a surface of the auxiliary material to be bonded to the pad.

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