JP2012206341A - Urethane foam molding, method for manufacturing the same, and urethane foam molding apparatus - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a urethane foam molding thin and low in density with less defects such as underfill, a method for easily manufacturing such a urethane foam molding, and a urethane foam molding apparatus.SOLUTION: The method for manufacturing the urethane foam molding includes a raw material arranging process for arranging a liquid urethane foam resin raw material U1 containing magnetic particles S, between a first base material 30 and a second base material 31 that are arranged facing each other, and a foam molding process for foam-molding the urethane foam resin raw material U1 while intercepting the flow of the urethane foam resin raw material U1 by a magnetic force line concentration region M which is formed in at least a part around the urethane foam resin raw material U1 between the first base material 30 and the second base material 31 and in which magnetic force lines L are concentrated in a direction to intersect the flow direction of the urethane foam resin raw material U1.

Description

  The present invention relates to a urethane foam molded body used as, for example, a sound absorbing material or a vibration absorbing material, a manufacturing method thereof, and a urethane foam molded apparatus.

  A urethane foam molded body is usually produced by foam molding a liquid material containing a polyol and a polyisocyanate in a mold. During foam molding, gas generated by foaming of the liquid raw material or remaining air may stay in the cavity of the mold. When a gas such as air is present in the cavity, the liquid material is difficult to reach every corner of the cavity. As a result, defects such as lacking and voids occur in the urethane foam molded article obtained. In order to suppress the occurrence of defects such as lacking, for example, the input amount of the liquid material into the cavity may be increased. However, in this case, the density of the obtained urethane foam molded article is increased. For this reason, desired performance (for example, sound absorption property, elasticity, etc.) cannot be obtained. Moreover, when manufacturing a thin urethane foam molded object with a small amount of liquid raw material, the expansion pressure of the liquid raw material is smaller. For this reason, it is easy to be influenced by the staying gas. As described above, the retention of the gas in the cavity becomes a problem particularly when a thin low-density sheet-like urethane foam molded article is manufactured.

  On the other hand, a slab method is known as a method for producing a low-density urethane foam molded article. According to the slab method, the liquid raw material is injected into the mold in an open system and spontaneously foams as it is under atmospheric pressure. The obtained bulk urethane foam molding is used after being cut into a predetermined shape (see, for example, Patent Document 1).

JP 2010-136914 A JP 2003-33925 A JP-A-6-339935

  However, according to the slab method, there is a limit to the thickness of the urethane foam molded article obtained due to restrictions such as cutting. In the slab method, the liquid raw material is naturally foamed in an open system. For this reason, for example, it is not possible to manufacture a urethane foam molded body having an uneven shape on the upper surface. Thus, according to the slab method, the thickness and shape of the urethane foam molding which can be manufactured are restrict | limited.

  This invention is made | formed in view of such a situation, and makes it a subject to provide a urethane foam molded object with few defects, such as a lack of thickness, and being thin and low density. It is another object of the present invention to provide a production method and a urethane foam molding apparatus that can easily produce such a urethane foam molding.

  (1) In order to solve the above-mentioned problem, the method for producing a urethane foam molded article of the present invention is a production of a urethane foam molded article for producing a urethane foam molded article by foaming a liquid foamed urethane resin material containing magnetic particles. It is a method, Comprising: The raw material arrangement | positioning process which arrange | positions the said urethane foam resin raw material between the 1st base material and 2nd base material which were arrange | positioned facing, This 1st base material and this 2nd base material The flow of the foamed urethane resin raw material is caused by a magnetic field line concentration region formed in at least a part of the periphery of the foamed urethane resin raw material between which the magnetic force lines are concentrated in a direction intersecting the flow direction of the foamed urethane resin raw material. A foam molding step of foam-molding the foamed urethane resin raw material while being damped.

  According to the manufacturing method of the present invention, the foamed urethane resin raw material is foam-molded between the first base material and the second base material arranged to face each other. The shapes of the first substrate and the second substrate are not particularly limited, and may be the same or different from each other. Moreover, the 1st base material and the 2nd base material may respectively be the 1st type | mold and 2nd type | mold which comprise a metal mold | die.

  The foamed urethane resin raw material is in a liquid state and is disposed between the first base material and the second base material. The foamed urethane resin material expands by foaming and flows while growing in three dimensions. At this time, the flow in the thickness direction is regulated by the first base material and the second base material. When the flow in the thickness direction is regulated by the first base material and the second base material, the foamed urethane resin raw material flows in the extending direction of the first base material and the second base material. Here, when the foamed urethane resin raw material is disposed on the surface of the first base material, the second base material and the foamed urethane resin raw material may or may not be in contact before foaming. In this case, for example, the foamed urethane resin raw material may be foam-molded while being pressed through the second base material.

  A magnetic field line concentration region is formed at least part of the periphery of the foamed urethane resin material between the first base material and the second base material. In the line of magnetic force concentration, the lines of magnetic force are concentrated in the direction intersecting with the flow direction of the urethane foam raw material. Here, the foamed urethane resin raw material includes magnetic particles. The magnetic particles have a property of moving and staying in a region where the magnetic flux density is larger. For this reason, when the flow front of a foaming urethane resin raw material reaches | attains a magnetic force line concentration area | region between a 1st base material and a 2nd base material, a magnetic body particle will be restrained by magnetic flux. Thereby, the foamed urethane resin raw material does not flow any more. That is, the flow of the urethane foam resin raw material is stopped by the magnetic field line concentration region. Therefore, for example, even when the mold surface is not arranged in the flow direction of the foamed urethane resin raw material, it is possible to form the foamed urethane resin raw material into a predetermined shape by acting as a mold surface as if the magnetic field line concentration region. it can.

  As described above, according to the manufacturing method of the present invention, it is possible to manufacture a urethane foam molded body even if it is not a sealed space like a conventional mold (of course, even if a mold mode is adopted). The aspect of the mold will be described later in the configuration of (5)). When foam molding is performed in an open system, stagnation of gas in the cavity is not a problem. For this reason, there is little possibility that defects, such as lacking and a void, will arise. For this reason, it is easy to manufacture a low density urethane foam molded article. Moreover, a thin sheet-like urethane foam molding can be easily manufactured by adjusting the space | interval of a 1st base material and a 2nd base material. Furthermore, when at least one opposing surface of the first base material and the second base material has an uneven shape, the unevenness is transferred to the surface of the urethane foam molded article. Therefore, by forming the opposing surfaces of the first base material and the second base material in desired shapes, urethane foam molded articles having various surface shapes can be easily produced.

  (2) Preferably, in the configuration of (1), the magnetic force line concentration region is formed by a magnetic force line concentration region forming unit having a magnetic member disposed on at least one of the first base material and the second base material. It is better to have a configuration.

  In this configuration, the magnetic force line concentration region is formed by the magnetic force line concentration region forming means. The magnetic force line concentration region forming means has a magnetic member. The magnetic member may be formed of a magnetic material or a mixed material obtained by adding another material to the magnetic material. Further, the magnetic member may be a member that can form a magnetic force line concentration region alone, such as a permanent magnet, or may be a member that can form a magnetic force line concentration region together with other members. For example, when a magnetic member is formed from a material having a high magnetic permeability such as iron, if a magnet is disposed in the vicinity of the magnetic member, the lines of magnetic force from the magnet are concentrated on the magnetic member. By utilizing this, the magnetic force line concentration region may be formed by a magnetic member and a magnet.

  (2-1) Preferably, in the configuration of (2) above, the urethane foam resin raw material is disposed on the surface of the first base material, and the magnetic member is disposed at least on the first base material. Is better. According to this structure, it is easy to form a magnetic force line concentration area | region on the 1st base material side by which a foaming urethane resin raw material is arrange | positioned. Thereby, the flow of a foaming urethane resin raw material can be reliably stopped in the early stage of foaming.

  (3) Preferably, in the configuration of (2) above, the magnetic member is preferably arranged so as to face both the first base material and the second base material.

  According to this structure, a magnetic force line concentration area | region can be formed from both sides of a 1st base material and a 2nd base material. Thereby, a magnetic force line concentration area | region can be formed reliably between a 1st base material and a 2nd base material.

  (4) Preferably, in any one of the constitutions (1) to (3), at least one of the first base material and the second base material is a component integrally formed with the foamed urethane resin raw material. It is better to have a configuration.

  In general, a soundproof cover such as an engine cover includes a cover body and a urethane foam molded body (sound absorbing material) fixed to the back surface of the cover body. Such a soundproof cover can be manufactured, for example, by integrally molding a cover body and a urethane foam molded body. In the integral molding, the cover body (core material) is placed in a mold, and a foamed urethane resin material is injected into the cavity to perform foam molding. For example, the cover body of the engine cover appears in the engine room. For this reason, the design of the cover body of the engine cover is required. However, in the case of integral molding, the cover body is pressed by clamping to ensure the sealing performance of the mold. Thereby, there exists a possibility that a cover main body may be damaged. The cover body is provided with an attachment hole for attachment to an engine or the like. In this case, the foamed urethane resin raw material may wrap around the mounting hole during molding, and burrs may be formed.

  In this regard, in this configuration, a part such as a cover body that is integrally formed with the foamed urethane resin raw material is employed as at least one of the first base material and the second base material. Thereby, it can integrally mold by an open system and components are not pressed by mold clamping. Therefore, the parts are hardly damaged. In addition, if the magnetic field line concentration region is formed around the attachment hole, it is possible to suppress the foamed urethane resin material from entering the attachment hole. Thereby, formation of the burr | flash around a mounting hole can be suppressed.

  (5) Preferably, in the configuration of (2) or (3), the first base material is a lower mold, the second base material is an upper mold, and the lower mold and the upper mold are combined. Thus, a mold cavity is formed, the mold has a gas vent passage communicating from the cavity to the outside, and the magnetic member is disposed near the cavity side of the gas vent path. Better to do.

  In this configuration, the foamed urethane resin raw material is foam-molded in a cavity of a mold formed of a first base material (lower mold) and a second base material (upper mold). As described above, in foam molding using a normal mold, gas generated by foaming of the foamed urethane resin material and remaining air are likely to stay in the mold cavity. Therefore, in order to discharge the gas in the cavity to the outside, a gas vent passage communicating from the cavity to the outside is formed (for example, see Patent Documents 2 and 3). However, depending on the amount of gas, foaming pressure, etc., the foamed urethane resin material may leak from the gas vent passage and a burr may be formed. On the other hand, if the gas vent passage is too small, the gas discharge becomes insufficient. As described above, when the gas vent passage is formed, it is difficult to achieve both gas discharge and mold sealing performance.

  In this regard, in this configuration, the magnetic member constituting the magnetic force line concentration region forming means is disposed in the vicinity of the cavity side of the gas vent passage. Thereby, a magnetic field line concentration region is formed near the entrance of the gas vent passage. For this reason, the foamed urethane resin raw material in the cavity cannot flow through the gas vent passage beyond the magnetic field line concentration region. That is, the flow of the urethane foam resin raw material is blocked by the magnetic field line concentration region. Therefore, only the gas can be selectively discharged from the gas vent passage.

  (5-1) The gas vent passage is preferably formed on at least one of the mating surfaces of the lower mold and the upper mold. According to this configuration, the gas vent passage can be formed relatively easily by forming the groove on at least one mating surface. Further, the gas in the cavity tends to stay above the cavity as the foamed urethane resin material expands. Therefore, in this configuration, it is particularly easy to discharge gas when the mating surface of the lower mold and the upper mold is flush with the upper end of the cavity.

  (6) Preferably, in any one of the configurations (1) to (5), the foam molding step includes an orientation step of orienting the magnetic particles by applying a magnetic field to the foamed urethane resin raw material. Better to do.

  When a foamed urethane resin material containing magnetic particles is foam-molded while applying a magnetic field, the magnetic particles are oriented along the lines of magnetic force. When the magnetic particles in the urethane foam molded body are oriented, the heat applied to one end of the urethane foam molded body is transmitted to the other end in the orientation direction via the magnetic body particles and is quickly released. Therefore, the thermal conductivity of the urethane foam molding is improved. In the orientation step, the magnitude of the magnetic field and the timing for applying the magnetic field may be controlled in consideration of the viscosity of the foamed urethane resin material and the like so as not to hinder the flow of the foamed urethane resin material.

  (7) The urethane foam molding apparatus of the present invention includes a first base material on which a liquid foamed urethane resin material containing magnetic particles is disposed, and is disposed to face the first base material, and the foamed urethane resin material. A magnetic field line concentration region in which magnetic field lines are concentrated between the first base material and the second base material in a direction intersecting the flow direction of the foamed urethane resin raw material. And a foamed urethane resin material is foam-molded while the flow of the foamed urethane resin material is blocked by the formed magnetic field line concentrated region.

  In the urethane foam molding apparatus of the present invention, the foamed urethane resin material is foam-molded between the first base material and the second base material that are arranged to face each other. The shapes of the first substrate and the second substrate are not particularly limited, and may be the same or different from each other. Moreover, the 1st base material and the 2nd base material may respectively be the 1st type | mold and 2nd type | mold which comprise a metal mold | die.

  The foamed urethane resin raw material is in a liquid state and is disposed on the surface of the first substrate. The foamed urethane resin material expands by foaming and flows while growing in three dimensions. At this time, the flow in the thickness direction is regulated by the second base material. When the flow in the thickness direction is regulated by the second base material, the urethane foam raw material flows in the extending direction of the first base material and the second base material. Here, the second base material and the urethane foam resin raw material may or may not be in contact before foaming. Further, the foamed urethane resin raw material may be subjected to foam molding while being pressed through the second base material.

  The magnetic force line concentration region forming means forms a magnetic force line concentration region between the first base material and the second base material. In the line of magnetic force concentration, the lines of magnetic force are concentrated in the direction intersecting with the flow direction of the urethane foam raw material. Here, the foamed urethane resin raw material includes magnetic particles. For this reason, when the flow front of a foaming urethane resin raw material reaches | attains a magnetic force line concentration area | region between a 1st base material and a 2nd base material, a magnetic body particle will be restrained by magnetic flux. Thereby, the foamed urethane resin raw material does not flow any more. That is, the flow of the urethane foam resin raw material is stopped by the magnetic field line concentration region. Therefore, for example, even when the mold surface is not arranged in the flow direction of the foamed urethane resin raw material, it is possible to form the foamed urethane resin raw material into a predetermined shape by acting as a mold surface as if the magnetic field line concentration region. it can.

  Thus, according to the urethane foam molding apparatus of the present invention, it is possible to produce a urethane foam molded body even if it is not a sealed space like a conventional mold (of course, adopting a mold mode). May be) When foam molding is performed in an open system, stagnation of gas in the cavity is not a problem. For this reason, there is little possibility that defects, such as lacking and a void, will arise. For this reason, it is easy to manufacture a low density urethane foam molded article. Moreover, a thin sheet-like urethane foam molding can be easily manufactured by adjusting the space | interval of a 1st base material and a 2nd base material. Furthermore, when at least one opposing surface of a 1st base material and a 2nd base material has uneven | corrugated shape, the said uneven | corrugated shape is transcribe | transferred to the surface of a urethane foam molded object. Therefore, by forming the opposing surfaces of the first base material and the second base material in desired shapes, urethane foam molded articles having various surface shapes can be easily produced.

  (8) The urethane foam molded article of the present invention is a sheet-like urethane foam molded article containing magnetic particles, and the magnetic particles are unevenly distributed in at least a part of the peripheral edge of the urethane foam molded article. It is characterized by that.

  The urethane foam molded article of the present invention is produced by the production method of the present invention having the constitution (1) above. As described above, according to the manufacturing method of the present invention, in the foam molding step, at least a part of the flow front of the foamed urethane resin raw material is blocked by the magnetic force line concentration region. At this time, the magnetic particles in the foamed urethane resin material are restrained and stay in the magnetic force line concentration region. Therefore, according to the urethane foam molded article obtained, the density of the magnetic particles is high in at least a part of the portion hardened in the magnetic force line concentration region, that is, the peripheral portion. In other words, magnetic particles are unevenly distributed on at least a part of the peripheral edge of the urethane foam molded article. The uneven distribution site of the magnetic particles is harder than other sites that hardly contain the magnetic particles. Moreover, the uneven distribution site | part of a magnetic body particle is excellent in heat conductivity compared with the other site | part which hardly contains a magnetic body particle. Moreover, conveyance can be facilitated by magnetizing the uneven distribution site of the magnetic particles with a magnet or the like. As described above, the urethane foam molded article of the present invention can be used for various applications by utilizing properties such as the hardness of the peripheral edge and thermal conductivity.

  (9) Preferably, in the configuration of (8) above, the content of the magnetic particles is 0.5 volume% or more and 5 volume% or less when the volume of the urethane foam molded article is 100 volume%. Is better.

  The magnetic particles contained in the foamed urethane resin raw material mainly play a role of blocking at least a part of the flow front of the foamed urethane resin raw material in the magnetic field line concentration region. In order to fulfill this role, the content of the magnetic particles is preferably 0.5% by volume or more when the volume of the urethane foam molded product is 100% by volume. On the other hand, the excessive magnetic particles harden the urethane foam molded article and increase the cost. For this reason, from the viewpoint of stopping the flow of the foamed urethane resin material, the content of the magnetic particles is desirably 5% by volume or less when the volume of the urethane foam molded product is 100% by volume. In addition, for reasons such as improving the thermal conductivity of the urethane foam molded article, the content of the magnetic particles may be increased. In this case, the content of the magnetic particles is desirably 30% by volume or less.

(10) Preferably, in the above configuration (8) or (9), the density is 100 kg / m ³ or less and the thickness is 1 mm or less.

  According to the urethane foam molded article of the present invention, a thin and low density urethane foam molded article that is difficult to produce by the slab method can be realized.

  (11) Preferably, in any one of the configurations (8) to (10), it is better to have a configuration having at least one of a convex portion and a concave portion on the surface in the thickness direction.

  The urethane foam molded article of this configuration has at least one of a convex part and a concave part on the surface. Thereby, the heat dissipation of a urethane foam molded object improves, for example. Moreover, the positioning at the time of attaching to another member can be facilitated.

  According to the present invention, it is possible to provide a thin and low-density urethane foam molded article with few defects such as lack of thickness. Moreover, the simple manufacturing method of such a urethane foam molding and a urethane foam molding apparatus can be provided.

It is a perspective view of the urethane foam molding apparatus of a first embodiment. It is a perspective exploded view of the same device. (A) is III-III sectional drawing of FIG. 1, (b) is a top view of the apparatus. (A) is sectional drawing of the apparatus of the state by which the foaming urethane resin raw material is arrange | positioned, (b) is a top view of the apparatus. It is an enlarged view of the area | region V enclosed with the dashed-dotted line of FIG. (A) is sectional drawing of the apparatus at the time of completion | finish of foam molding, (b) is a top view of the apparatus. (A) is sectional drawing of the urethane foam molding apparatus of 2nd embodiment, (b) is a top view of the apparatus. (A) is sectional drawing of the urethane foam molding apparatus of 3rd embodiment, (b) is a top view of the apparatus. (A) is sectional drawing of the urethane foam molding apparatus of 4th embodiment, (b) is a top view of the apparatus. It is an enlarged view of the area | region X enclosed with the dashed-dotted line of FIG. (A) is sectional drawing of the urethane foam molding apparatus of 5th embodiment, (b) is a top view of the apparatus. It is a perspective view of the urethane foam molding apparatus of 6th embodiment. It is sectional drawing of the same apparatus. It is a perspective exploded view of the metal mold | die which comprises the apparatus.

  Hereinafter, embodiments of the urethane foam molded article, the manufacturing method thereof, and the urethane foam molding apparatus of the present invention will be described.

<First embodiment>
[Configuration of urethane foam molding equipment]
First, the structure of the urethane foam molding apparatus of this embodiment is demonstrated. In FIG. 1, the perspective view of a urethane foam molding apparatus is shown. FIG. 2 shows a perspective exploded view of the apparatus. FIG. 3A shows a cross-sectional view taken along the line III-III in FIG. FIG. 3B shows a top view of the apparatus. For convenience of explanation, FIG. 3B shows the upper magnet and the upper plate in a transparent manner (hereinafter, FIG. 4B, FIG. 6B, FIG. 7B, FIG. 11B). The same). As shown in FIGS. 1 to 3, the urethane foam molding apparatus 1 includes a frame body 2 and a molding portion 3.

  The frame body 2 includes a lower plate 20, an upper plate 21, and four support columns 22. The lower plate 20 and the upper plate 21 are both made of aluminum and have a square plate shape. The four struts 22 are all made of aluminum and have a cylindrical shape. The four struts 22 are fixed to the four corners of the lower plate 20, respectively. The upper plate 21 is placed on the four support columns 22 and is disposed so as to face the lower plate 20.

  The molding unit 3 includes a lower base material 30, an upper base material 31, a wire 32, a lower magnet 33, and an upper magnet 34. The lower magnet 33 has a square plate shape. The lower magnet 33 is bonded to the upper surface of the lower plate 20. The upper surface of the lower magnet 33 is magnetized to the N pole, and the lower surface is magnetized to the S pole. The upper magnet 34 has a square plate shape. The upper magnet 34 is bonded to the lower surface of the upper plate 21. The upper surface of the upper magnet 34 is magnetized to the N pole, and the lower surface is magnetized to the S pole.

  The lower base material 30 is made of an acrylic resin and has a square plate shape. The lower base material 30 is disposed on the upper surface of the lower magnet 33. The size of the lower substrate 30 is the same as the size of the lower magnet 33. The lower base material 30 is included in the first base material in the present invention.

  The upper base material 31 is made of an acrylic resin and has a square plate shape. The upper base material 31 is bonded to the lower surface of the upper magnet 34. The size of the upper substrate 31 is the same as the size of the upper magnet 34. The upper substrate 31 is included in the second substrate in the present invention.

  The wire 32 is made of iron and has an endless annular shape. The wire 32 is embedded in the lower base material 30. The thickness of the wire 32 in the vertical direction is the same as the thickness of the lower substrate 30. The wire 32 is disposed in a rectangular shape along the peripheral edge of the lower base material 30. As will be described later, the wire 32 forms a magnetic force line concentration region M together with the lower magnet 33 and the upper magnet 34. The wire 32 is included in the magnetic member in the present invention. Moreover, the wire 32, the lower magnet 33, and the upper magnet 34 are included in the magnetic force line concentration region forming means in the present invention.

[Method for producing urethane foam molding]
Next, the manufacturing method of the urethane foam molding of this embodiment using the urethane foam molding apparatus 1 is demonstrated. The manufacturing method of the urethane foam molding of this embodiment has a raw material arrangement | positioning process and a foam molding process. FIG. 4A shows a cross-sectional view of a urethane foam molding apparatus in which a foamed urethane resin raw material is disposed. FIG. 4B shows a top view of the apparatus. FIG. 5 shows an enlarged view of a region V surrounded by a one-dot chain line in FIG. FIG. 6A shows a cross-sectional view of the urethane foam molding apparatus at the end of foam molding. FIG. 6B shows a top view of the apparatus.

  First, a raw material arrangement | positioning process is demonstrated. As shown in FIG. 4, the foamed urethane resin raw material U <b> 1 is placed on the upper surface of the lower base material 30. The foamed urethane resin raw material U1 is prepared by mixing a polyol component, an isocyanate component, stainless steel powder (magnetic particles), and predetermined additives such as a foaming agent and a catalyst. The blending amount of the stainless steel powder is 4% by volume when the volume of the urethane foam molding to be manufactured is 100% by volume.

  Next, the foam molding process will be described. The foamed urethane resin raw material U1 spreads while expanding as the foaming reaction proceeds. That is, as shown by the white arrow in FIG. 4, the urethane foam raw material U <b> 1 flows three-dimensionally (up / down / left / right / front / rear direction) between the lower base material 30 and the upper base material 31. And after foaming urethane-resin raw material U1 arrives at the lower surface of the upper side base material 31, it flows in the left-right front-back direction so that it may spread concentrically.

  Here, the magnetic permeability of the wire 32 is large. Therefore, as shown in an enlarged view in FIG. 5, the magnetic lines of force L radiated from both the magnets 33 and 34 pass through the wire 32 in the upper region of the wire 32 between the lower magnet 33 and the upper magnet 34. By concentrating in an attempt, a magnetic force line concentration region M (indicated by the alternate long and short dashed lines in FIG. 5) is formed. In the magnetic force line concentration region M, magnetic force lines extending in the direction (vertical direction) substantially perpendicular to the flow direction (left / right front / rear direction) of the urethane foam resin raw material U1 are concentrated. Therefore, when the flow front end U1 'of the foamed urethane resin raw material U1 reaches the magnetic field line concentration region M, the stainless steel particles S in the foamed urethane resin raw material U1 are restrained by the magnetic flux. For this reason, the foamed urethane resin raw material U1 does not flow any more. That is, the flow of the urethane foam resin raw material U1 is blocked by the magnetic force line concentration region M. In this state, the urethane foam resin body U1 is cured to produce a urethane foam molded body U2 as shown in FIG.

[Urethane foam molding]
Next, the urethane foam molded article of this embodiment will be described. As shown in FIG.6 (b), the urethane foam molded object U2 is exhibiting the substantially square thin sheet form. The urethane foam molded body U2 has a thickness of about 1 mm and a density of 100 kg / m ³ . In the urethane foam molded body U2, the density of the stainless steel particles S at the peripheral edge portion (shown by dotted line cross-hatching in FIG. 6B) hardened in the magnetic force line concentration region M is higher than that of other portions. That is, the stainless steel particles S are unevenly distributed on the peripheral edge of the urethane foam molded body U2.

[Function and effect]
Next, the operation effect of the urethane foam molding of this embodiment, its manufacturing method, and a urethane foam molding apparatus will be described. According to the urethane foam molding apparatus 1 and the manufacturing method of the present embodiment, the urethane foam molded body U2 can be manufactured even if it is not a sealed space like a conventional mold. Since foam molding can be performed in an open system, stagnation of gas in the cavity is not a problem. For this reason, in urethane foam molded object U2, there is little possibility that defects, such as lack of thickness and a void, will arise. For this reason, it is easy to manufacture a low-density urethane foam molded body U2. In addition, by adjusting the distance between the lower base material 30 and the upper base material 31, a thin urethane foam molded body U2 having a thickness of 1 mm or less that is difficult to manufacture by the slab method can be easily manufactured.

  In the urethane foam molding apparatus 1 of the present embodiment, the magnetic force line concentration region M is formed by the wire 32, the lower magnet 33, and the upper magnet 34. That is, according to the urethane foam molding apparatus 1 of the present embodiment, it is possible to produce a urethane foam molded body U2 having a simple configuration, low cost, few defects such as lack of wall, and thin and low density. Moreover, the wire 32 (magnetic member) is arrange | positioned at the lower base material 30 side in which the foaming urethane resin raw material U1 is mounted. Thereby, the flow of the foaming urethane resin raw material U1 can be reliably stopped at the early stage of foaming.

  In the urethane foam molded body U2 of the present embodiment, the stainless steel particles S are unevenly distributed at the peripheral edge. The uneven distribution site of the stainless steel particles S is harder than other sites. Moreover, the uneven distribution site | part of the stainless steel particle S is excellent in thermal conductivity compared with the other site | part. Moreover, conveyance can be made easy by magnetizing the uneven distribution site | part of the stainless steel particle | grains S with a magnet. As described above, the urethane foam molded body U2 can be used for various applications by utilizing properties such as the hardness of the peripheral edge and thermal conductivity.

<Second embodiment>
The difference between the urethane foam molding apparatus of this embodiment and the urethane foam molding apparatus of the first embodiment is that a groove is formed on the upper surface of the lower substrate. Therefore, only the differences will be described here.

  FIG. 7A shows a cross-sectional view of the urethane foam molding apparatus of the present embodiment (corresponding to the III-III cross section of FIG. 1). FIG. 7B shows a top view of the apparatus. In each of FIGS. 7A and 7B, portions corresponding to FIGS. 3A and 3B are denoted by the same reference numerals.

  As shown in FIG. 7A, four grooves 300 are formed on the upper surface of the lower base material 30. The four groove portions 300 are arranged inside the wire 32 embedded in the lower base material 30. The bottom surfaces of the groove portions 300 each have a curved surface shape. The groove portions 300 each extend in the front-rear direction. The grooves 300 are arranged in parallel to each other in the left-right direction.

  The manufacturing method of the urethane foam molding of this embodiment is the same as 1st embodiment. Therefore, the description is omitted. In addition, the bottom surface of the urethane foam molding to be manufactured is provided with a concave and convex shape that is symmetrical with the grooves 300 on the top surface of the lower substrate 30.

  The urethane foam molded body, the manufacturing method, and the urethane foam molding apparatus of the present embodiment are the same as the urethane foam molded body, the manufacturing method, and the urethane foam molding apparatus of the first embodiment with respect to the parts having the same configuration. Has a working effect. Moreover, according to the urethane foam molding apparatus of this embodiment, the urethane foam molding which has an uneven | corrugated shape on the lower surface can be manufactured simply. Moreover, in the urethane foam molded body of the present embodiment, the surface area of the lower surface is larger than when the lower surface is flat. Therefore, the urethane foam molding of this embodiment is excellent in heat dissipation.

<Third embodiment>
The difference between the urethane foam molding apparatus of this embodiment and the urethane foam molding apparatus of the first embodiment is that a rubber magnet is disposed as a magnetic member instead of a wire. Further, the upper magnet and the lower magnet are not arranged. Therefore, only the differences will be described here.

  First, the structure of the urethane foam molding apparatus of this embodiment is demonstrated. FIG. 8A shows a cross-sectional view of the urethane foam molding apparatus of the present embodiment (corresponding to the III-III cross section of FIG. 1). FIG. 8B shows a top view of the apparatus. In each of FIGS. 8A and 8B, portions corresponding to FIGS. 3A and 3B are denoted by the same reference numerals. For convenience of explanation, in FIG. 8B, a member above the upper base material is shown through.

  As shown to Fig.8 (a), the shaping | molding part 3 is provided with the lower side base material 30, the upper side base material 31, the lower side strip | belt material 35a, and the upper side strip | belt material 35b. The lower base material 30 is disposed on the upper surface of the lower plate 20 via the lower belt member 35a. The upper base material 31 is bonded to the lower surface of the upper plate 21 via the upper belt member 35b.

  The lower belt member 35a is composed of four rubber magnets and has an endless annular shape. The rubber magnet is made of a mixed material of ferrite magnet powder and rubber. The lower band member 35 a is bonded to the lower surface of the lower substrate 30. The lower band member 35 a is disposed along the peripheral edge portion of the lower surface of the lower substrate 30. N poles and S poles are alternately arranged in the extending direction of the lower belt member 35a. Thereby, a loop-shaped magnetic field that flows from the N pole adjacent to each other to the S pole is formed on the surface of the lower band member 35a.

  Similarly, the upper band member 35b is composed of four rubber magnets and has an endless annular shape. The upper band member 35 b is bonded to the upper surface of the upper substrate 31. The upper band member 35b is disposed along the peripheral edge of the upper surface of the upper substrate 31 so as to face the lower band member 35a. N poles and S poles are alternately arranged in the extending direction of the upper band member 35b. As a result, a loop-shaped magnetic field that flows from the N pole adjacent to each other to the S pole is formed on the surface of the upper band member 35b.

  Between the lower belt member 35a and the upper belt member 35b, that is, between the lower base member 30 and the upper base member 31, due to the magnetic lines radiated from the lower belt member 35a and the upper belt member 35b, the magnetic force line concentration region. Is formed. In the magnetic force line concentration region, magnetic force lines extending in the direction (vertical direction) substantially perpendicular to the flow direction (left / right front / rear direction) of the foamed urethane resin material are concentrated. In this way, the lower belt member 35a and the upper belt member 35b each form a magnetic force line concentration region. The lower belt member 35a and the upper belt member 35b are included in the magnetic member and the magnetic force line concentration region forming means in the present invention.

  About the manufacturing method of the urethane foam molding of this embodiment, it is the same as 1st embodiment except the point in which the formation method of a magnetic force line concentration area | region differs. Moreover, it is the same as that of 1st embodiment also about the urethane foam molded object manufactured. Therefore, the description is omitted.

  The urethane foam molded body, the manufacturing method, and the urethane foam molding apparatus of the present embodiment are the same as the urethane foam molded body, the manufacturing method, and the urethane foam molding apparatus of the first embodiment with respect to the parts having the same configuration. Has a working effect. Moreover, according to the urethane foam molding apparatus 1 of this embodiment, the magnetic field line concentration area | region is formed of the lower side strip | belt material 35a and the upper side strip | belt material 35b. As described above, according to the urethane foam molding apparatus 1 of the present embodiment, a thin and low density urethane foam molded body can be manufactured with a simple configuration and low cost, with few defects such as lack of thickness. In addition, magnetic members are disposed on both the lower base material 30 and the upper base material 31. Thereby, a magnetic force line concentration region can be formed from both sides of the lower base material 30 and the upper base material 31. Therefore, a magnetic force line concentration region can be reliably formed between the lower base material 30 and the upper base material 31.

<Fourth embodiment>
The difference between the urethane foam molding apparatus of this embodiment and the urethane foam molding apparatus of the first embodiment is that a coil member is arranged instead of the upper magnet and the lower magnet. Therefore, only the differences will be described here.

  First, the structure of the urethane foam molding apparatus of this embodiment is demonstrated. FIG. 9A shows a cross-sectional view of the urethane foam molding apparatus of the present embodiment (corresponding to the III-III cross section of FIG. 1). FIG. 9B shows a top view of the apparatus. In each of FIGS. 9A and 9B, portions corresponding to FIGS. 3A and 3B are denoted by the same reference numerals. For convenience of explanation, FIG. 9B shows the upper plate in a transparent manner.

  As shown in FIG. 9A, the molding unit 3 includes a lower base material 30, an upper base material 31, a wire 32, and a coil member 36. The lower base material 30 is disposed on the upper surface of the lower plate 20. The upper base material 31 is bonded to the lower surface of the upper plate 21.

  The coil member 36 is composed of an air-core coil in which a conducting wire is wound spirally. The coil member 36 is annularly arranged along the side surface of the lower base material 30. The coil member 36 is connected to a power source (not shown) for causing a current to flow through the coil member 36.

  Next, a method for forming the magnetic force line concentration region will be described. FIG. 10 shows an enlarged view of a region X surrounded by a one-dot chain line in FIG. First, a current is passed through the coil member 36. Then, a magnetic field is formed outside the coil member 36. Here, the wire rod 32 is disposed along the coil member 36. For this reason, as shown in FIG. 10, the lines of magnetic force L radiated from the coil member 36 are concentrated so as to pass through the wire 32. Thereby, the magnetic force line concentration area | region M (it shows by hatching of the dashed-dotted line in FIG. 10) is formed. In the magnetic force line concentration region M, magnetic force lines extending in the direction (vertical direction) substantially perpendicular to the flow direction (left / right front / rear direction) of the urethane foam resin raw material U1 are concentrated. Thus, the wire 32 forms the magnetic force line concentration region M together with the coil member 36. The wire 32 is included in the magnetic member in the present invention. Moreover, the wire 32 and the coil member 36 are included in the magnetic force line concentration region forming means in the present invention.

  About the manufacturing method of the urethane foam molding of this embodiment, it is the same as 1st embodiment except the point in which the formation method of a magnetic force line concentration area | region differs. Moreover, it is the same as that of 1st embodiment also about the urethane foam molded object manufactured. Therefore, the description is omitted.

  The urethane foam molded body, the manufacturing method, and the urethane foam molding apparatus of the present embodiment are the same as the urethane foam molded body, the manufacturing method, and the urethane foam molding apparatus of the first embodiment with respect to the parts having the same configuration. Has a working effect. Further, according to the urethane foam molding apparatus 1 of the present embodiment, the magnetic force line concentration region M is formed by the wire 32 and the coil member 36. Therefore, it is possible to manufacture a urethane foam molded body having a simple structure and low cost, with few defects such as thinning, and a thin and low density. Moreover, according to the urethane foam molding apparatus 1 of this embodiment, a magnetic field is formed only around the foamed urethane resin raw material U1. For this reason, the initial flow due to foaming of the foamed urethane resin raw material U1 is not easily disturbed. Therefore, the magnetic field concentration region can be formed with a relatively large magnetic flux density from the start of foam molding.

<Fifth embodiment>
The difference between the urethane foam molding apparatus of this embodiment and the urethane foam molding apparatus of the first embodiment is that, in place of the upper base material, a part that is integrally molded with the foamed urethane resin raw material is used. It is. Therefore, only the differences will be described here.

  First, the structure of the urethane foam molding apparatus of this embodiment is demonstrated. FIG. 11A shows a cross-sectional view of the urethane foam molding apparatus of this embodiment. FIG. 11B shows a top view of the apparatus. In each of FIGS. 11A and 11B, portions corresponding to FIGS. 3A and 3B are denoted by the same reference numerals.

  As shown in FIG. 11A, the urethane foam molding apparatus 1 includes a frame body 2 and a molding portion 4. The frame 2 includes a lower plate 23, an upper plate 24, and four struts 22. The lower plate 23 and the upper plate 24 are both made of aluminum and have a rectangular plate shape. The configuration of the frame 2 other than the shapes of the lower plate 23 and the upper plate 24 is the same as the configuration of the frame 2 of the first embodiment.

  The molding unit 4 includes a lower base 40, a cover main body 41, a wire 42, a lower magnet 43, and an upper magnet 44. The lower substrate 40, the lower magnet 43, and the upper magnet 44 all have a rectangular plate shape. The shapes of the lower substrate 40, the lower magnet 43, and the upper magnet 44, and the configuration of the molding unit 4 other than the cover body 41 described later are the same as the configuration of the molding unit 3 of the first embodiment. That is, the wire 42 forms a magnetic force line concentration region together with the lower magnet 43 and the upper magnet 44. The wire 42 is included in the magnetic member in the present invention. The wire 42, the lower magnet 43, and the upper magnet 44 are included in the magnetic force line concentration region forming means in the present invention.

  The cover body 41 is made of resin and has a rectangular convex plate shape. The cover body 41 is disposed between the lower base material 40 and the upper magnet 44. The cover body 41 is disposed below the upper magnet 44 so as to be spaced apart. Both end portions in the left-right direction of the cover body 41 are stacked on the upper surface of the lower base material 40. The left and right ends of the cover body 41 and the left and right ends of the lower substrate 40 are fixed by jigs (not shown). The cover main body 41 is spaced apart above the lower base material 40 except for both ends in the left-right direction. The cover main body 41 is included in the second base material in the present invention.

  About the manufacturing method of the urethane foam molding of this embodiment, it is the same as 1st embodiment. Moreover, it is the same as that of 1st embodiment also about the urethane foam molded object manufactured. Therefore, the description is omitted.

  The urethane foam molded body, the manufacturing method, and the urethane foam molding apparatus of the present embodiment are the same as the urethane foam molded body, the manufacturing method, and the urethane foam molding apparatus of the first embodiment with respect to the parts having the same configuration. Has a working effect. Moreover, according to the urethane foam molding apparatus 1 of the present embodiment, the urethane foam molding can be integrally formed on the lower surface of the cover body 41 in an open system. For this reason, unlike the case of using a mold, the cover main body 41 is not pressed by mold clamping. Therefore, the cover main body 41 is hardly damaged. Further, the cover body 41 serves as a sound insulation layer. The urethane foam molded body integrally formed with the cover body 41 plays a role as a sound absorbing layer. Therefore, the cover main body 41 with the urethane foam molded body of the present embodiment is suitable as a soundproof cover.

<Sixth embodiment>
The difference between the urethane foam molding apparatus of this embodiment and the urethane foam molding apparatus of the first embodiment is that a mold is constituted by the upper base material and the lower base material. Further, an electromagnet portion is arranged instead of the lower magnet and the upper magnet. Therefore, only the differences will be described here.

[Configuration of urethane foam molding equipment]
First, the structure of the urethane foam molding apparatus of this embodiment is demonstrated. In FIG. 12, the perspective view of a urethane foam molding apparatus is shown. FIG. 13 shows a sectional view of the apparatus. FIG. 14 shows a perspective exploded view of a mold constituting the apparatus. In FIG. 13, for convenience of explanation, hatching of the yoke part and the core part is omitted. As illustrated in FIGS. 12 and 13, the urethane foam molding apparatus 5 includes a gantry 50, an electromagnet portion 52, and a mold 6.

  The electromagnet portion 52 is placed on the upper surface of the gantry 50. The electromagnet portion 52 and the gantry 50 are fixed by screwing the bracket 51 to each. The electromagnet portion 52 includes yoke portions 53U and 53D, coil portions 54L and 54R, and pole pieces 55U and 55D.

  The yoke portion 53U is made of iron and has a flat plate shape. Similarly, the yoke portion 53D is made of iron and has a flat plate shape. The yoke portions 53U and 53D are arranged to face each other in the vertical direction.

  The coil portion 54L is interposed between the yoke portions 53U and 53D. The coil part 54 </ b> L is disposed on the left side of the mold 6. Two coil portions 54L are arranged in the vertical direction. Each of the coil portions 54L includes a core portion 540L and a conductive wire 541L. The core portion 540L is made of iron and has a columnar shape extending in the vertical direction. The conducting wire 541L is wound around the outer peripheral surface of the core portion 540L. The conducting wire 541L is connected to a power source (not shown).

  The coil portion 54R is interposed between the yoke portions 53U and 53D. The coil portion 54 </ b> R is disposed on the right side of the mold 6. Two coil portions 54R are arranged in the vertical direction. Each of the coil portions 54R has a configuration similar to that of the coil portion 54L. That is, the coil part 54R includes a core part 540R and a conducting wire 541R. The conducting wire 541R is wound around the outer peripheral surface of the core portion 540R. The conducting wire 541R is connected to a power source (not shown).

  The pole piece 55U is made of iron and has a flat plate shape. The pole piece 55U is disposed at the center of the lower surface of the yoke portion 53U. The pole piece 55U is interposed between the yoke portion 53U and the mold 6. The pole piece 55D is made of iron and has a flat plate shape. The pole piece 55D is disposed at the center of the upper surface of the yoke portion 53D. The pole piece 55D is interposed between the yoke portion 53D and the mold 6.

  The mold 6 is disposed between the coil portion 54L and the coil portion 54R. As shown in FIG. 14, the mold 6 includes an upper mold 60U and a lower mold 60D. The upper mold 60U is included in the second base material in the present invention. Lower mold 60D is included in the first substrate in the present invention. The upper mold 60U is made of aluminum and has a square plate shape. The lower mold 60D is made of aluminum and has a rectangular parallelepiped shape. A cavity recess 610 and a gas vent passage recess 620 are formed on the upper surface of the lower mold 60D. The cavity recess 610 has a rectangular parallelepiped shape that opens upward. The recess 620 for the gas vent passage has a rectangular slit shape that opens upward. The gas vent passage recess 620 is formed continuously from the upper right end of the cavity recess 610.

  A wire 63 is disposed near the boundary between the cavity recess 610 and the gas vent passage recess 620. The wire 63 is made of iron. The wire 63 is embedded so as to surround the front, rear, and lower sides of the left end of the recess 620 for the gas vent passage. As will be described later, the wire 63 forms a magnetic force line concentration region together with the electromagnet portion 52. The wire 63 is included in the magnetic member in the present invention. Moreover, the wire 63 and the electromagnet part 52 are contained in the magnetic force line concentration area | region formation means in this invention.

  Returning to FIG. 13, the upper die 60U and the lower die 60D are combined to partition a rectangular parallelepiped cavity 61 and a gas vent passage 62 connected thereto. The cavity 61 communicates with the outside through a gas vent passage 62. The cavity 61 is filled with a foamed urethane resin raw material. The foamed urethane resin raw material is prepared by mixing a polyol component, an isocyanate component, stainless steel powder (magnetic particles), and predetermined additives such as a foaming agent and a catalyst. The blending amount of the stainless steel powder is 16% by volume when the volume of the urethane foam molding to be produced is 100% by volume.

[Method for producing urethane foam molding]
Next, the manufacturing method of the urethane foam molding of this embodiment using the urethane foam molding apparatus 5 is demonstrated. First, when both the power source connected to the conducting wire 541L and the power source connected to the conducting wire 541R are turned on, the upper end of the core portion 540L of the coil portion 54L is magnetized to the N pole and the lower end is magnetized to the S pole. For this reason, a magnetic force line L (indicated by a dotted line in FIG. 13) is generated in the core portion 540L from below to above. Similarly, the upper end of the core portion 540R of the coil portion 54R is magnetized to the N pole and the lower end is magnetized to the S pole. For this reason, lines of magnetic force L are generated in the core portion 540R from below to above.

  The lines of magnetic force L emitted from the upper end of the core portion 540L of the coil portion 54L flow into the cavity 61 of the mold 6 through the yoke portion 53U and the pole piece 55U. Then, it flows into the lower end of the core part 540L through the pole piece 55D and the yoke part 53D. Similarly, the lines of magnetic force L radiated from the upper end of the core portion 540R of the coil portion 54R flow into the cavity 61 of the mold 6 through the yoke portion 53U and the pole piece 55U. Then, it flows into the lower end of the core part 540R through the pole piece 55D and the yoke part 53D.

  Here, the magnetic permeability of the wire 63 is large. Therefore, a part of the lines of magnetic force L flowing into the cavity 61 concentrates in the vicinity of the wire 63 while trying to pass through the wire 63. Thereby, a magnetic force line concentration region is formed near the boundary between the cavity 61 and the gas vent passage 62. In the magnetic force line concentration region, magnetic force lines L extending in the direction (vertical direction) substantially perpendicular to the flow direction of the urethane foam raw material (the direction of flowing out from the cavity 61 to the gas vent passage 62) are concentrated. Accordingly, the outflow of the urethane foam resin raw material is blocked by the magnetic field line concentration region. Further, a part of the stainless steel powder (magnetic particles) contained in the foamed urethane resin raw material is oriented along the magnetic field lines L other than the magnetic field line concentration region. Thereby, the urethane foam molding which has the oriented stainless steel particle is manufactured.

[Function and effect]
The urethane foam molded body, the manufacturing method, and the urethane foam molding apparatus of the present embodiment are the same as the urethane foam molded body, the manufacturing method, and the urethane foam molding apparatus of the first embodiment with respect to the parts having the same configuration. Has a working effect. Further, according to the urethane foam molding apparatus 5 of the present embodiment, the magnetic force line concentration region is formed near the entrance of the gas vent passage 62. Thereby, the outflow of the foamed urethane resin material can be stopped near the entrance of the gas vent passage 62. Therefore, only the gas in the cavity 61 can be selectively discharged from the gas vent passage 62.

  The gas vent passage 62 is formed on the upper surface of the lower mold 60D (the mating surface with the upper mold 60U). Therefore, it is easy to form a gas vent passage. The mating surface of the lower mold 60D and the upper mold 60U is flush with the upper end of the cavity 61. Therefore, in this configuration, the gas staying above the cavity 61 can be reliably discharged.

  Moreover, in the manufactured urethane foam molded body, the stainless steel particles are oriented from one end to the other end. For this reason, the heat applied to one end of the urethane foam molded article is transmitted to the other end via the stainless steel particles and quickly released. Therefore, the urethane foam molded article of this embodiment is excellent in thermal conductivity.

<Others>
The embodiments of the urethane foam molded body, the manufacturing method thereof, and the urethane foam molding apparatus of the present invention have been described above. However, the embodiment is not particularly limited to the above embodiment. Various modifications and improvements that can be made by those skilled in the art are also possible.

  For example, the material, shape, and the like of the first base material (lower base material) and the second base material (upper base material) are not limited to the above embodiment. The material of the first substrate and the second substrate may be a nonmagnetic material. Moreover, in 5th embodiment, the cover main body integrally molded with the foaming urethane resin raw material was used as a 2nd base material. In this case, the type of parts to be integrally molded is not particularly limited.

  The material of the magnetic member for forming the magnetic force line concentration region is not limited to the above embodiment. For example, in addition to iron, iron-based alloys such as stainless steel and ferromagnetic materials such as nickel and cobalt may be used as materials having a high magnetic permeability. The shape of the magnetic member may also be a sheet material or the like in addition to the wire material. The material of the magnetic member may be different for each location. Further, a plurality of magnetic members having different materials, shapes, etc. may be arranged in combination. For example, you may use together the iron wire of 1st embodiment, and the rubber magnet of 3rd embodiment.

  In 1st-5th embodiment, the magnetic member was arrange | positioned so that the circumference | surroundings of a foaming urethane resin raw material may be enclosed. However, the arrangement of the magnetic members may be appropriately determined in consideration of the magnetic field concentration region to be formed. For example, you may arrange | position a magnetic member only to a part of circumference | surroundings of a foaming urethane resin raw material. Further, the magnetic members may be scattered at predetermined intervals. In the first to fifth embodiments, the magnetic members are arranged in a rectangular shape. However, the magnetic member may be arranged in a circular shape, a star shape, or the like.

  In the said embodiment, the magnetic field concentration area | region was formed by concentrating a magnetic force line in the direction substantially orthogonal to the flow direction of a foaming urethane resin raw material. However, the magnetic field lines in the magnetic field concentration region do not necessarily have to be orthogonal to the flow direction of the foamed urethane resin raw material. The direction of the magnetic field lines in the magnetic field concentration region only needs to intersect the flow direction of the foamed urethane resin raw material. Further, it is desirable to adjust the magnetic flux density in the magnetic field concentration region, the timing for forming the magnetic field concentration region, and the like so as not to hinder the flow of the foamed urethane resin material.

  When the magnetic field line concentration region is formed by a combination of a magnetic member and another member, a permanent magnet or an electromagnet is preferable as the other member. When an electromagnet is used, on / off of magnetic field formation can be switched instantaneously, and control of the strength of the magnetic field is easy. For example, in place of the mold of the sixth embodiment, the urethane foam molding apparatus may be configured by arranging the molding parts of the first to third and fifth embodiments. In the sixth embodiment, coil portions are arranged in the left-right direction of the mold. However, the configuration of the electromagnet portion may be appropriately determined according to the magnetic field to be formed. For example, you may arrange | position a coil part to the up-down direction of a metal mold | die. Moreover, in 1st, 2nd, 5th embodiment, you may arrange | position an upper magnet and a lower magnet only in the part corresponding to a magnetic member (wire).

The foamed urethane resin raw material may be prepared from already known raw materials such as polyol, polyisocyanate, foaming agent, catalyst and the like other than the magnetic particles. Further, the magnetic particles only need to have excellent magnetization characteristics, for example, ferromagnetic materials such as iron, nickel, cobalt, gadolinium, stainless steel, magnetite, maghemite, manganese zinc ferrite, barium ferrite, strontium ferrite, Antiferromagnetic materials such as MnO, Cr ₂ O ₃ , FeCl ₂ , and MnAs, and particles of alloys using these are preferable. Among these, iron, nickel, cobalt, and powders of these iron-based alloys (including stainless steel) are preferable from the viewpoint of easy availability as fine particles and high saturation magnetization.

  The urethane foam molded article of the present invention can be used as a sound absorbing material and a vibration absorbing material in various fields such as vehicles, electronic devices, and electric products. For example, it is suitable for an engine cover and a side cover arranged in an engine room of a vehicle to reduce engine noise, an OA (Office Automation) device, a sound absorbing material for motors of home appliances, and the like.

1: urethane foam molding device 2: frame 20, 23: lower plate 21, 24: upper plate 22: support column 3: molded part 30: lower substrate (first substrate) 31: upper substrate (second substrate) Material)
32: Wire rod (magnetic member) 33: Lower magnet (magnetic force line concentration region forming means)
34: Upper magnet (magnetic line concentration region forming means) 35a: Lower belt member (magnetic member)
35b: Upper band member (magnetic member) 36: Coil member (magnetic line concentration region forming means)
300: Groove part 4: Molding part 40: Lower base material (first base material) 41: Cover body (second base material)
42: Wire rod (magnetic member) 43: Lower magnet (magnetic force line concentration region forming means)
44: Upper magnet (magnetic line concentration region forming means)
5: Urethane foam molding apparatus 50: stand 51: bracket 52: electromagnet part (magnetic force line concentration region forming means) 53D, 53U: yoke part 54L, 54R: coil part 55D, 55U: pole piece 540L, 540R: core part 541L, 541R : Conductor 6: Mold 60D: Lower mold (first substrate) 60U: Upper mold (second substrate) 61: Cavity 62: Gas vent passage 63: Wire rod (magnetic member) 610: Cavity recess 620: Gas vent Recess for passage L: Magnetic field line M: Magnetic field line concentration area S: Stainless steel particle (magnetic particle)
U1: Foamed urethane resin raw material U1 ': Flow front of the foamed urethane resin raw material U2: Urethane foam molded article

Claims (11)

It is a method for producing a urethane foam molded article by producing a urethane foam molded article by foaming a liquid foamed urethane resin raw material containing magnetic particles,
A raw material placement step of placing the foamed urethane resin raw material between the first base material and the second base material arranged to face each other,
Magnetic field lines formed between at least a part of the periphery of the foamed urethane resin raw material between the first base material and the second base material and having magnetic field lines concentrated in a direction intersecting the flow direction of the foamed urethane resin raw material. A foam molding step of foam-molding the foamed urethane resin raw material while blocking the flow of the foamed urethane resin raw material by a concentrated area;
A method for producing a urethane foam molded article comprising:   The method for producing a urethane foam molded article according to claim 1, wherein the magnetic force line concentration region is formed by a magnetic force line concentration region forming unit having a magnetic member disposed on at least one of the first base material and the second base material. .   The said magnetic member is a manufacturing method of the urethane foam molding of Claim 2 arrange | positioned so that each may face both said 1st base material and said 2nd base material.   The method for producing a urethane foam molded body according to any one of claims 1 to 3, wherein at least one of the first base material and the second base material is a part integrally molded with the foamed urethane resin raw material. The first base is a lower mold, the second base is an upper mold, and a mold cavity is formed by combining the lower mold and the upper mold,
The mold has a gas vent passage communicating from the cavity to the outside,
The method for producing a urethane foam molded article according to claim 2 or 3, wherein the magnetic member is disposed in the vicinity of the cavity side of the gas vent passage.   The method for producing a urethane foam molded article according to any one of claims 1 to 5, wherein the foam molding process includes an orientation process in which a magnetic field is applied to the foamed urethane resin raw material to orient the magnetic particles. A first base material on which a liquid foamed urethane resin material containing magnetic particles is disposed;
A second substrate that is disposed to face the first substrate and regulates the flow direction of the foamed urethane resin raw material;
A magnetic force line concentration region forming means capable of forming a magnetic force line concentration region in which magnetic force lines are concentrated in a direction intersecting the flow direction of the foamed urethane resin raw material between the first base material and the second base material. ,
A urethane foam molding apparatus, wherein the foamed urethane resin material is foam-molded while the flow of the foamed urethane resin material is blocked by the formed magnetic field line concentration region. It is a sheet-like urethane foam molded body containing magnetic particles,
The magnetic foam particles are unevenly distributed in at least a part of the peripheral edge of the urethane foam molded article.   The urethane foam molded article according to claim 8, wherein the content of the magnetic particles is 0.5 volume% or more and 5 volume% or less when the volume of the urethane foam molded article is 100 volume%. The urethane foam molded article according to claim 8 or 9, wherein the density is 100 kg / m ³ or less and the thickness is 1 mm or less.   The urethane foam molded article according to any one of claims 8 to 10, which has at least one of a convex part and a concave part on a surface in a thickness direction.

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