JP2012144631A - Cushioning body and method for producing cushioning body - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve the practicality of a cushioning body comprising a urethane gel and a urethane foam, and a method for producing the same.SOLUTION: Raw materials for the urethane foam containing a polyol, a polyisocyanate, a foaming agent, a foam stabilizer, and a catalyst are mixed, and raw materials for the urethane gel containing the polyol, polyisocyanate, a plasticizer, and catalyst are mixed in the raw materials for the urethane foam which are mixed during a foaming reaction produced in the mixing thereof, and composed so as to produce the cushioning body 22. Thus, the urethane gel 14 and urethane foam 16 can simultaneously be molded, and the urethane gel in a state sandwiched between a skin layer 18 and a foamed part 20 of the urethane foam and in a close contact state therewith can be included in the urethane foam. As a result, the production process can be simplified, and the cushioning body having a good load distribution property can be produced. Furthermore, the practicality of the cushioning body and method for production thereof can be improved.

Description

  The present invention relates to a cushion body constituted by urethane foam and urethane gel, and a manufacturing method for manufacturing the cushion body.

  As cushion bodies used in vehicle seats, household chairs, bedding, etc., many of those conventionally made of urethane foam have been conventionally employed. For example, Patent Document 1 listed below provides sitting comfort and function. A cushion body is described in which two types of urethane foams having different hardnesses are integrated to enhance the properties. However, the urethane foam absorbs the body pressure applied in the vertical direction well, but the effect of dispersing the load applied in the vertical direction in other directions is low. It has become difficult to do. On the other hand, urethane gel is known to be easily deformed and disperse a load in all directions, and various types of urethane gels have been developed such as urethane gels described in Patent Documents 2 and 3 below. For this reason, like the cushion body described in the following patent documents 4 and 5, the cushion body in which urethane foam and urethane gel are laminated, or the cushion body described in the following patent documents 6 and 7 Furthermore, development of a cushion body in which urethane gel is encapsulated in a urethane foam has been underway.

Japanese Patent Publication No.4-1684 Special table 2009-507969 JP-A-57-159847 JP-A-62-155849 JP 2001-198995 A JP-A-8-191966 Japanese Patent No. 4497883

  In the cushion body described in the said patent documents 4-7, it is possible to improve load dispersion | distribution performance by exhibiting each performance of a urethane foam and a urethane gel. However, in the cushion body in which the urethane foam and the urethane gel described in Patent Documents 4 and 5 are laminated, the urethane foam and the urethane gel are separately molded, and the molded urethane foam and urethane are molded separately. A product is manufactured by laminating with a gel. For this reason, a manufacturing process becomes comparatively many and manufacturing cost, manufacturing time, etc. will take much. And there exists a possibility that a level | step difference may arise in the surface of a cushion body by bonding of a urethane foam and urethane gel. Further, since the boundary between the urethane foam and the urethane gel is exposed on the surface of the cushion body, the feel is different at the boundary, and the user may feel uncomfortable. Furthermore, the surface of the urethane gel is usually sticky and sticky. For this reason, in the cushion body in which the urethane foam and the urethane gel are laminated, it is necessary to cover the urethane gel with a film such as a film, and a coating process for that purpose is further required.

  On the other hand, in the cushion body in which the urethane gel described in Patent Documents 6 and 7 is encapsulated in the urethane foam, problems such as a step due to bonding are eliminated, and a bonding process or the like becomes unnecessary. A process of wrapping urethane gel with urethane foam is required. Further, even in the cushion body described in Patent Documents 6 and 7, it is necessary to separately mold each of the urethane foam and the urethane gel, which still requires a lot of manufacturing costs and manufacturing time. Thus, the cushion body comprised by the urethane foam described in the said patent documents 4-7 and a urethane gel has left the room for improvement, and by giving various improvement, It is considered that the practicality of the cushion body composed of urethane foam and urethane gel is improved. This invention is made | formed in view of such a situation, and makes it a subject to provide the cushion body comprised by the highly practical urethane foam and urethane gel, and the manufacturing method of the cushion body.

  In order to solve the above problems, the cushion body manufacturing method of the present invention mixes a urethane foam raw material containing a polyol, a polyisocyanate, a foaming agent, a foam stabilizer, and a catalyst, and during the foaming reaction that occurs in the mixing In addition, in the state where the urethane gel raw material containing polyol, polyisocyanate, plasticizer, and catalyst is mixed, the cushion foam body in which the urethane gel is encapsulated in the urethane foam is mixed. Configured to manufacture.

  In order to solve the above-mentioned problem, the cushion body of the present invention mixes a urethane foam raw material containing polyol, polyisocyanate, foaming agent, foam stabilizer, and catalyst, and during the foaming reaction that occurs in the mixing, the polyol It is manufactured by mixing a urethane gel raw material containing polyisocyanate, a plasticizer and a catalyst into the mixed urethane foam raw material, and the urethane foam is included in the urethane foam. In addition, the cushion body of the present invention includes (a) a urethane foam having a skin layer having a relatively higher density than the urethane foam formed on the surface layer, and a foamed portion formed inside the skin layer; (B) Urethane gel, and the urethane gel is sandwiched between the skin layer and the foamed portion and is enclosed in the urethane foam in a state of being in close contact with the skin layer or the foamed portion. Configured.

  When the urethane foam is manufactured, a skin layer is formed on the surface layer, and a foamed portion is formed inside the skin layer. At this time, the foamed portion is formed while lowering the density by foaming. On the other hand, the urethane gel is formed without changing the density. For this reason, when the urethane gel raw material is mixed into the urethane foam raw material being foamed, the urethane gel raw material sinks into the urethane foam raw material and adheres to or closes to the urethane foam skin layer. It will be in the state. Incidentally, the state of being close to the skin layer refers to a state in which the urethane gel is approaching the bottom of the mold but is not in contact with the skin layer and is integrated with the foamed portion interposed. And since the foamed part of the urethane foam is formed in a state where the urethane gel raw material is in close contact with or close to the skin layer or both, the urethane gel is sandwiched between the skin layer or the foamed part of the urethane foam. And is enclosed in urethane foam in close contact with them.

  In this way, in the cushion body in which the urethane gel is encapsulated in the urethane foam, there is no step between the urethane foam and the urethane gel on the surface thereof, and there is no sense of discomfort in the surface touch. Further, since the surface layer of the urethane gel is not exposed on the surface of the cushion body, it is not necessary to cover the urethane gel. Furthermore, by mixing the urethane gel raw material into the urethane foam raw material being foamed, it becomes possible to form the urethane foam and the urethane gel at the same time, eliminating the need to separately form the urethane foam and the urethane gel. . Furthermore, the process etc. which bond the urethane foam and urethane gel shape | molded separately are also unnecessary. Since the urethane foam and the urethane gel are simultaneously molded while undergoing a urethane reaction, their adhesion is very good, and the skin layer is formed on the adhesive surface between the foamed portion of the urethane foam and the urethane gel. Since it does not occur, a highly flexible cushion body can be obtained. Therefore, according to the present invention, it is possible to provide a highly practical cushion body and a method for manufacturing a highly practical cushion body.

It is a figure which shows the flow of the manufacturing method of this invention. It is a figure which shows an example of the cushion body which can be manufactured with the manufacturing method of this invention. It is a figure which shows each compounding quantity of the urethane foam raw material and urethane gel raw material for manufacturing the cushion body of an Example, and the physical-property evaluation of the cushion body of an Example. It is a schematic sectional drawing which shows the cushion body of an Example.

  The “foam raw material mixing step” described in the present invention may be a step of mixing a urethane foam raw material containing polyol, polyisocyanate, foaming agent, foam stabilizer, and catalyst. For example, polyol, polyisocyanate, foaming Adopting various methods such as a method of mixing urethane foam raw materials including a sizing agent, foam stabilizer and catalyst at once, so-called one-shot method, method using isocyanate prepolymer obtained from polyisocyanate, so-called prepolymer method Is possible.

  The “gel raw material mixing step” described in the present invention is a step of mixing the urethane gel raw material into the urethane foam raw material during the foaming reaction in the mixed urethane foam raw material. The raw material is a mixture of polyol, polyisocyanate, plasticizer and catalyst. The method of mixing the urethane gel raw material is not particularly limited, and various methods such as a one-shot method and a prepolymer method can be employed in a usual method for producing a urethane gel. is there.

  The foaming reaction occurring in the foam raw material mixing step is a reaction in which carbon dioxide gas is generated in the reaction between polyisocyanate and water as a foaming agent, or foaming due to a temperature rise accompanying a chemical reaction between polyisocyanate and active hydrogen This is a reaction in which a gas is generated when the boiling point of the agent is exceeded, and a mixture of the urethane foam raw material is expanded by the generated gas in the foam raw material mixing step. That is, it can be said that the gel raw material mixing step is a step of mixing the urethane gel raw material into the mixed urethane foam raw material when gas is generated by mixing the urethane foam raw material. In other words, the gel raw material mixing step mixes the urethane gel raw material into the mixed urethane foam raw material when the mixed material swells by mixing the urethane foam raw material. It can be said that it is a process.

  Also, the time from the start of mixing all urethane foam materials in the foam material mixing step to the end of the foaming reaction that occurs in the foam material mixing step, the so-called rise time, is defined as the foaming reaction time. In this case, the gel raw material mixing step can be said to be a step of mixing the urethane gel raw material into the mixed urethane foam raw material before the foaming reaction time elapses. However, it takes a little time until the foaming reaction starts after all the urethane foam raw materials are mixed. Further, just before the end of the foaming reaction, the formation of the urethane foam may be affected in some way due to the mixing of the urethane gel raw material. For this reason, the urethane gel raw material is mixed into the mixed urethane foam raw material when a time corresponding to 15 to 85% of the foaming reaction time has elapsed since all mixing of the urethane foam raw material has started. It is preferable. Furthermore, when a time corresponding to 35 to 70% of the foaming reaction time has elapsed after all the mixing of the urethane foam raw material has started, the urethane gel raw material is mixed into the mixed urethane foam raw material. It is preferable to do.

  The “polyol” described in the present invention is a compound having two or more hydroxyl groups in one molecule, and each raw material may be contained in any of the urethane foam raw material and the urethane gel raw material. Anything that is normally employed may be used. For example, a polyester polyol, a polyether polyol, etc. are mentioned. Some polyester polyols are obtained by a condensation reaction between a polyhydric alcohol and a polycarboxylic acid. Examples of the polyhydric alcohol include ethylene glycol, propylene glycol, butanediol, butylene glycol, glycerin, trimethylolpropane, and the like, and these can be used alone or in combination of two or more. Examples of the polyvalent carboxylic acid include glutaric acid, adipic acid, maleic acid, terephthalic acid, and isophthalic acid, and these can be used alone or in combination of two or more. Furthermore, the polyester polyol obtained by ring-opening condensation of caprolactone, methylvalerolactone, etc. is mentioned.

  Examples of polyether polyols include addition polymerization of oxides such as ethylene oxide, propylene oxide, trimethylene oxide, and butylene oxide to polyhydric alcohols such as ethylene glycol, propylene glycol, diethylene glycol, glycerin, trimethylolpropane, and sorbitol. Can be mentioned. Those used in combination of one or more of these various polyols can be used as the urethane foam raw material or the urethane gel raw material. Further, the polyol of the urethane foam raw material and the polyol of the urethane gel raw material may be the same type or different types.

  Incidentally, the weight average molecular weight, the number of functional groups, and the hydroxyl value of the polyol are not particularly limited as long as they are numerical values that can form a good urethane foam and urethane gel. If it is a weight average molecular weight, it is preferable that it is 3000-7000, if it is the number of functional groups, it is preferable that it is 2-4, and if it is a hydroxyl value, it is preferable that it is 27-56.

  The “polyisocyanate” described in the present invention is a compound having two or more isocyanate groups in one molecule, and each of them may be contained in either the urethane foam raw material or the urethane gel raw material. What is necessary is just to employ | adopt normally as a raw material. For example, aromatic isocyanate, aliphatic isocyanate, alicyclic isocyanate, etc. are mentioned. Examples of the aromatic isocyanate include tolylene diisocyanate (TDI), 4,4′-diphenylmethane diisocyanate (MDI), polymeric MDI (crude MDI), xylylene diisocyanate, 1,5-naphthalene diisocyanate, and the like. Examples of the aliphatic isocyanate include hexamethylene diisocyanate, isopropylene diisocyanate, and methylene diisocyanate. Examples of the alicyclic isocyanate include cyclohexane-1,4-diisocyanate, isophorone diisocyanate, and hydrogenated MDI. A combination of one or more of these various polyisocyanates can be used as the urethane foam material or the urethane gel material. Further, the polyol of the urethane foam raw material and the polyol of the urethane gel raw material may be the same type or different types. It is also possible to use an isocyanate prepolymer obtained from these polyisocyanates.

  The ratio of the blend amount of polyol and polyisocyanate in each of the urethane foam raw material and the urethane gel raw material is a percentage of the equivalent ratio of the isocyanate group concentration in the polyisocyanate to the total active hydrogen group concentration in the polyol, so-called , Can be indicated by the isocyanate index. The isocyanate index in the urethane foam raw material is not particularly limited, but if it is too low, foaming is not suitably performed, and if it is too high, good cushioning properties cannot be obtained, so 50 or more and 130 or less. It is preferable. Furthermore, it is preferably 90 or more and 110 or less. In addition, the isocyanate index in the urethane gel raw material is not particularly limited, but if it is too low, it is not molded into a gel shape, and if it is too high, good stress dispersibility cannot be obtained, so 65 or more and 85 or less. It is preferable that Furthermore, it is preferably 70 or more and 75 or less.

  The “catalyst” described in the present invention may be any of the urethane foam raw material and the urethane gel raw material, as long as it is normally employed as each raw material. Examples include catalysts and organometallic catalysts. Examples of the amine catalyst include triethylenediamine, diethanolamine, dimethylaminomorpholine, N-ethylmorpholine, and the like. Examples of the organometallic catalyst include star octoate, dibutyltin dilaurate, lead octenoate, potassium octylate and the like. A combination of one or more of these various catalysts can be used as the urethane foam raw material or the urethane gel raw material. Further, the catalyst of the urethane foam raw material and the catalyst of the urethane gel raw material may be of the same type or different types, but as the catalyst of the urethane foam raw material, It is preferable to employ one that has a high effect of promoting the foaming reaction. In addition, it is preferable that the compounding quantity of the catalyst in each raw material is 0.05-3 weight part, when the total amount of the polyol in each raw material is 100 weight part.

  The “foaming agent” described in the present invention is not particularly limited as long as it is normally employed as a raw material for urethane foam, and examples thereof include water, pentane, cyclopentane, methylene chloride, carbon dioxide, and the like. It can be used in combination of two or more species. When water is used as the foaming agent, the amount is preferably 1 to 5 parts by weight when the total amount of polyol in the urethane foam raw material is 100 parts by weight.

  The “foam stabilizer” described in the present invention is not particularly limited as long as it is usually employed as a raw material for urethane foam, and examples thereof include silicone compounds and nonionic surfactants. As said foam stabilizer, it is preferable that it is 0.1-5 weight part when the total amount of the polyol in the said urethane foam raw material is 100 weight part.

  The “plasticizer” described in the present invention is not particularly limited as long as it is usually employed as a raw material for urethane gels. Examples thereof include phthalic acid esters, adipic acid esters, trimellitic acid esters, and phosphoric acid esters. When the total amount of polyol in the urethane gel raw material is 100 parts by weight, the plasticizer is preferably 50 to 200 parts by weight.

  In addition, it is possible to add an additive suitably to the said urethane foam raw material or the said urethane gel raw material as needed. Examples of the additive include a chain extender, a colorant, an antioxidant, an ultraviolet absorber, and a filler.

  As the “manufacturing method” of the present invention and the method of manufacturing the “cushion body” of the present invention, it is preferable to employ a method of molding a cushion body using a mold, a so-called molding method. By adopting the molding method, a cushion body having a complicated three-dimensional structure can be formed. A specific manufacturing method will be described with reference to FIG. First, a mold release agent such as wax or silicone is applied to the inside of the mold, and the mold is heated. When the temperature of the mold is low, reactivity such as resinification is lowered, so that it is preferably heated to 55 to 65 ° C. And the said urethane foam raw material which mixed and stirred the said urethane foam raw material previously is put in a metal mold | die (FIG. 1 (a)). A foaming reaction occurs in the mold, and foaming begins (FIG. 1 (b)). Next, the urethane gel raw material that has been mixed and stirred in advance during foaming is placed in the mold (FIG. 1 (c)). Then, the mold is covered. The urethane foam is formed while lowering the density by foaming, but the urethane gel is formed without changing the density. For this reason, the urethane gel raw material sinks inside the urethane foam raw material (FIG. 1 (d)). However, the urethane gel raw material is in close contact with or close to the urethane foam skin layer formed along the inner side of the mold, and in that state, the foamed portion of the urethane foam is formed. . For this reason, the urethane gel is encapsulated in the urethane foam in a state where it is sandwiched between either the skin layer or the foamed portion of the urethane foam and is in close contact with the skin layer or the foamed portion. And after 10 minutes or more have passed since the mixing and stirring of the urethane foam, the cushion is removed from the mold. Thereby, the cushion body by which urethane gel was included in the inside of a urethane foam is manufactured. By being manufactured as described above, a flexible urethane foam can be obtained without causing a skin layer having a higher density than the foamed portion on the adhesive surface of the urethane foam in the foamed portion, and as a cushion body. It is possible to ensure flexibility.

  In addition, since the urethane foam material and the urethane gel material have fluidity, it is possible to manufacture a cushion body having a complicated shape by devising a shape of a mold used for manufacturing. Specifically, for example, by using the mold 10 having a shape as shown in FIG. 2, the cushion body 12 having a complicated shape can be manufactured.

  The following examples illustrate the present invention more specifically. However, the present invention is not limited to this embodiment, and can be implemented in various modes with various modifications and improvements based on the knowledge of those skilled in the art.

The cushion body of the Example was manufactured by the molding method from the urethane foam raw material and urethane gel raw material of the mixing | blending shown in FIG. Details of the urethane foam material and the urethane gel material in FIG. 3 are shown below.
Polyol (urethane foam material and urethane gel material); polypropylene glycol, trade name: FA-703, manufactured by Sanyo Chemical Industries, Ltd., weight average molecular weight: 4800, hydroxyl number: 3, hydroxyl value: 35
Polyisocyanate (urethane foam raw material); TDI (2,4-TDI: 2,6-TDI = 80: 20): Crude MDI = 80: 20, trade name: Coronate 1306, Nippon Polyurethane Industry Co., Ltd.
Catalyst (urethane foam raw material); dipropylene glycol: triethylenediamine = 67: 33, trade name: 33LX, Air Products Japan Co., Ltd.
・ Foaming agent; water / foam stabilizer; silicone foam stabilizer, trade name: B8738LF2, Eponic Degussa Japan Co., Ltd.
Polyisocyanate (urethane gel raw material); polyisocyanate prepolymer, isocyanate group content: 23%, trade name: F-1180B, BASF INOAC Polyurethane Co., Ltd.
・ Catalyst (urethane gel raw material); Starnas Octoate, trade name: MRH-110, Johoku Chemical Industry Co., Ltd.
・ Plasticizer; diisononyl adipate, trade name: DINA, Daihachi Chemical Industry Co., Ltd.

  In all the examples, the isocyanate index of the urethane gel raw material is the same, but Examples 1, 2 and 3 to 8 and Examples 9 to 11 differ in the isocyanate index of the urethane foam raw material. It is an example.

  A manufacturing method in each of all the examples will be described. First, a wax release agent is applied inside the mold. And the metal mold | die is heated at 55-65 degreeC. This process is an example of a mold heating process. Next, a polyol, a catalyst, a foaming agent, and a foam stabilizer, which are urethane foam raw materials, are mixed in another container, and the mixed product is put into a mold. Subsequently, the urethane foam raw material isocyanate is charged into the mold, and all the raw materials of the urethane foam raw material are mixed and stirred by mixing. Specifically, the mixture is stirred for 10 seconds at 1500 rpm using a mixer. This step is an example of the foam material mixing step.

  The urethane gel raw material put into the mold is mixed and stirred in advance, or is mixed and stirred in parallel with or before and after the mixing and stirring of the urethane foam raw material. Specifically, a polyol (65 parts by weight) of a urethane gel raw material, a catalyst (1 part by weight), and a plasticizer (35 parts by weight) are mixed and stirred to prepare a mixed solution A, and an isocyanate (3. 57 parts by weight) and a plasticizer (25 parts by weight) are mixed and stirred to prepare a mixed solution B. Then, by mixing and stirring the mixed liquid A and the mixed liquid B, a mixture in which all urethane gel raw materials are mixed and stirred is prepared. All the urethane gel raw materials are mixed and stirred, and the foaming reaction is taking place in the mold while it is put into the mold. This step is an example of the gel raw material mixing step.

  In the gel raw material mixing step, the timing of introducing the urethane gel raw material into the mold is indicated by the elapsed time since the start of mixing all the urethane foam raw materials in the foam raw material mixing step, and the elapsed time is shown in FIG. In the “input time” column. In other words, “input time” indicates the time from the start of mixing of all urethane foam raw materials in the foam raw material mixing step until the urethane gel raw material is charged into the mold in the gel raw material mixing step. It is.

  Also, in order to make it easier to understand when the urethane gel raw material is introduced during the foaming reaction, the rise time and the introduction of the urethane gel raw material with respect to the rise time are shown as an indication of the timing of the urethane gel raw material introduction. The percentage of time is shown in FIG. By the way, the rise time is the time from the start of mixing of all urethane foam materials in the foam material mixing step to the end of the foaming reaction that occurs in the foam material mixing step. It is equivalent.

  After all of the urethane foam material and the urethane gel material are put into the mold, the mold is sealed. Then, after 10 minutes have passed since the mixing of the urethane foam raw material was started, the cushion body is removed from the mold. The physical properties of the demolded cushion body were evaluated by the following methods.

  First, it was evaluated whether or not urethane gel was exposed on the surface of the cushion body. That is, it was evaluated whether the urethane gel was included in the urethane foam. The urethane foam is usually composed of a skin layer formed on the surface layer and a foamed portion formed inside the skin layer. When a cushion body is manufactured by the above method, the surface of the urethane gel is urethane. Covered by the foam skin layer and foam. More specifically, as shown in FIG. 4 which is a cross-sectional view of the cushion body manufactured by the above method, the urethane gel 14 is sandwiched between the skin layer 18 and the foamed portion 20 of the urethane foam 16. The skin layer 18 and the foamed portion 20 are in close contact with each other. That is, in the cushion body 22 manufactured by the above method, the urethane gel 14 can be included in the urethane foam 16, and the stickiness of the urethane gel on the cushion body surface can be eliminated. Therefore, in order to evaluate whether the urethane gel is included in the urethane foam, the surface of the cushion manufactured by the above method is touched, and when there is no stickiness, it is evaluated as `` ○ '', and when it is sticky Evaluated as “x”. The results of this evaluation are shown in the “Skin layer formation” column in FIG.

  Incidentally, in the gel raw material mixing step, since the urethane gel raw material sinks into the urethane foam raw material, the urethane gel 14 is positioned below the cushion body 22 in the cushion body 22 in FIG. However, it is desirable to use the cushion body 22 so that the urethane gel 14 is positioned upward. That is, it is desirable to use the cushion body 22 in FIG. 4 upside down.

  Next, in the cushion body manufactured by the above method, it was evaluated whether or not the urethane foam and the urethane gel were integrated. If the urethane foam and the urethane gel are mixed too much, the gel characteristics deteriorate, so it is desirable that the boundary between the urethane foam and the urethane gel is clear to some extent. Then, the cushion body manufactured by the said method was divided | segmented, and it evaluated by visually observing the boundary of the urethane foam and urethane gel in the division | segmentation surface. When the boundary between the urethane foam and the urethane gel was clear, it was evaluated as “◯”, and when the boundary was stagnant, it was evaluated as “x”. The result of this evaluation is shown in the column “Separability” in FIG.

  Furthermore, in the cushion manufactured by the above method, the state of the foamed portion of the urethane foam was evaluated. Specifically, the cushion body manufactured by the above method was divided, and the foamed portion of the urethane foam on the divided surface was visually observed to confirm the presence or absence of cavities and cracks. If there is no cavity etc. and the foamed part is in good condition, it is evaluated as “◯”, and the foamed part is in poor condition, such as the presence of a cavity, cell coalescence and cell diameter becoming larger. In some cases, it was evaluated as “x”. Further, when the state of the foamed portion was slightly good, it was evaluated as “◯ △”, and when the state of the foamed portion was slightly poor, it was evaluated as “Δx”. The result of this evaluation is shown in the “form state” column in FIG.

  As is clear from the column of “skin layer formation” shown in FIG. 3, in all the cushion bodies of Examples 1 to 11, the urethane gel is not exposed on the surface, and the stickiness of the urethane gel is eliminated. . In Examples 1 to 11, the percentage of the charging time of the urethane gel raw material with respect to the rise time is set to 15 to 81%, and the urethane gel is added to the urethane foam raw material at such timing. The cushion body included in the urethane foam can be manufactured by the above method.

  Further, as is clear from the column of “Separability” shown in FIG. 3, in the cushion bodies of Examples 1, 3, 4, and 9, the urethane foam and the urethane gel are excessively mixed, and the gel characteristics are deteriorated. is doing. On the other hand, in the cushion bodies of Examples 2, 5 to 8, 10, and 11, the urethane foam and the urethane gel are separated to some extent, and the gel properties are good. In Examples 2, 5 to 8, 10, and 11, the percentage of the time for introducing the urethane gel material with respect to the rise time is 37 to 81%, and the urethane gel material is charged into the urethane foam material at such timing. Thereby, it is possible to make the gel characteristic of the cushion body manufactured by the said method favorable.

  Further, as is apparent from the “foam state” column shown in FIG. 3, in the cushion bodies of Examples 1, 3, 4, and 9, the state of the foamed portion of the urethane foam was not good, and Examples 5 and 8 Even in the cushion body, the state of the foamed portion is not so good. On the other hand, in the cushion bodies of Examples 7 and 11, the state of the foamed portion is good, and in the cushion bodies of Examples 2, 6, and 10, the state of the foamed portion is good to some extent. In Examples 2, 6, 7, 10, and 11, the percentage of the urethane gel raw material charging time relative to the rise time is 37 to 69%, and the urethane gel raw material is charged into the urethane foam raw material at such timing. Thus, it is possible to improve the state of the foamed portion of the cushion body manufactured by the above method.

  From the result of the physical property evaluation described above, the percentage of the time for introducing the urethane gel raw material to the rise time is preferably 15 to 85%, and more preferably 35 to 70%. And more specifically, if the percentage of the urethane gel raw material input time relative to the rise time is 65 to 70%, all evaluations of “skin layer formation”, “separability” and “foam state” are good. Can be.

  Hereinafter, various aspects of the present invention will be listed.

(1) a foam material mixing step of mixing a urethane foam material containing a polyol, a polyisocyanate, a foaming agent, a foam stabilizer, and a catalyst;
The urethane foam raw material mixed in the foam raw material mixing step in a state in which a urethane gel raw material containing polyol, polyisocyanate, plasticizer and catalyst is mixed during the foaming reaction occurring in the foam raw material mixing step A method for producing a cushion body comprising a urethane foam encapsulated in a urethane foam.

(2) The time from the start of all the mixing of the urethane foam raw material in the foam raw material mixing step to the end of the foaming reaction occurring in the foam raw material mixing step is defined as the foaming reaction time. In case
The gel raw material mixing step,
In the step of mixing the urethane gel raw material when a time corresponding to 15 to 85% of the foaming reaction time has elapsed since the start of mixing all of the urethane foam raw material in the foam raw material mixing step. A manufacturing method of a cushion object given in a certain (1) term.

(3) The gel raw material mixing step includes
In the step of mixing the urethane gel raw material when a time corresponding to 35 to 70% of the foaming reaction time has elapsed since the start of mixing all of the urethane foam raw material in the foam raw material mixing step. A manufacturing method of a cushion object given in a certain (2) term.

(4) The method for manufacturing a cushion body according to any one of (1) to (3), wherein the cushion body is manufactured inside a mold.

(5) The cushion body according to any one of (1) to (4), further including a mold heating step in which the mold is heated before the polyurethane foam raw material is charged. Manufacturing method.

(6) Urethane gel containing polyol, polyisocyanate, plasticizer and catalyst during the foaming reaction that occurs during mixing of the urethane foam raw material containing polyol, polyisocyanate, foaming agent, foam stabilizer and catalyst. A cushion body produced by mixing a raw material into the mixed urethane foam raw material, and urethane foam encapsulated in the urethane foam.

(7) The urethane foam is
Having a skin layer formed on the surface layer, and a foamed portion formed inside the skin layer;
The urethane gel is
The cushion body according to (6), wherein the cushion body is included in the urethane foam in a state of being sandwiched between the skin layer and the foamed portion and in close contact with the skin layer or the foamed portion.

(8) The urethane gel is
The cushion body according to item (7), which is sandwiched between the skin layer and the foamed portion and is enclosed in the urethane foam in a state of being in close contact with the skin layer and the foamed portion.

(9) a urethane foam having a skin layer formed on the surface layer and a foamed portion formed inside the skin layer;
A cushion body comprising urethane gel contained in the urethane foam in a state of being sandwiched between the skin layer and the foamed portion and in close contact with the skin layer or the foamed portion.

(10) The urethane gel is
The cushion body according to item (9), which is sandwiched between the skin layer and the foamed portion and is enclosed in the urethane foam in a state of being in close contact with the skin layer and the foamed portion.

(11) The urethane foam is
Produced by urethane foam raw material containing polyol, polyisocyanate, foaming agent, foam stabilizer, catalyst,
The urethane gel is
The cushion body according to (9) or (10), which is produced from a urethane gel raw material containing a polyol, a polyisocyanate, a plasticizer, and a catalyst.

10: Mold 12: Cushion body 14: Urethane gel 16: Urethane foam 18: Skin layer 20: Foam part 22: Cushion body

Claims (5)

A foam raw material mixing step of mixing a urethane foam raw material containing a polyol, a polyisocyanate, a foaming agent, a foam stabilizer, and a catalyst;
The urethane foam raw material mixed in the foam raw material mixing step in a state in which a urethane gel raw material containing polyol, polyisocyanate, plasticizer and catalyst is mixed during the foaming reaction occurring in the foam raw material mixing step A method for producing a cushion body comprising a urethane foam encapsulated in a urethane foam. In the case where the foaming reaction time is defined as the time from the start of all the mixing of the urethane foam raw material in the foam raw material mixing step to the end of the foaming reaction occurring in the foam raw material mixing step,
The gel raw material mixing step,
In the step of mixing the urethane gel raw material when a time corresponding to 15 to 85% of the foaming reaction time has elapsed since the start of mixing all of the urethane foam raw material in the foam raw material mixing step. The method for manufacturing a cushion body according to claim 1. The gel raw material mixing step,
In the step of mixing the urethane gel raw material when a time corresponding to 35 to 70% of the foaming reaction time has elapsed since the start of mixing all of the urethane foam raw material in the foam raw material mixing step. A method for manufacturing a cushion body according to claim 2.   While mixing the urethane foam raw material containing polyol, polyisocyanate, foaming agent, foam stabilizer, catalyst, during the foaming reaction that occurs in the mixing, the urethane gel raw material containing polyol, polyisocyanate, plasticizer, catalyst, A cushion body, which is manufactured by mixing in the urethane foam raw material being mixed, and in which urethane gel is included in the urethane foam. A urethane foam having a skin layer formed on the surface layer and a foamed portion formed inside the skin layer;
A cushion body comprising urethane gel contained in the urethane foam in a state of being sandwiched between the skin layer and the foamed portion and in close contact with the skin layer or the foamed portion.

Images