JP2017065194A - Metal mold for molding foamed polyurethane - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a method capable of readily engaging a reinforcement base cloth on a surface of a metal mold for molding foamed polyurethane without adopting a method of adhering a magnetic material on a surface of the reinforcement base cloth made of a nonwoven fabric or the like.SOLUTION: The present invention relates to a metal mold for molding foamed polyurethane, in which a reinforcement base cloth engagement member is partially arranged on a surface of the metal mold for molding foamed polyurethane and a method of manufacturing the foamed polyurethane molded body using the metal mold.SELECTED DRAWING: Figure 1

Description

  The present invention provides a foamed polyurethane molding mold suitable for molding a foamed polyurethane molded body having a nonwoven fabric laminated on the back surface, a method for producing a foamed polyurethane molded body using the mold, and a method suitable for the manufacturing method. The present invention relates to a nonwoven fabric for foam molding.

  As a cushioning material for a vehicle seat or the like, a foam molded body such as soft foamed polyurethane is used. A reinforcing base fabric is disposed at the bottom of such a foam molded product in order to increase the rigidity of the foamed polyurethane molded product and to prevent the polyurethane from seeping out from the back surface. A combination of cold water and slab urethane or a coarse blanket is used as the reinforcing base fabric, but the improvement of the rigidity of the polyurethane molded product is insufficient, or the prevention of seepage from the back of the polyurethane is insufficient. There is a risk of it.

As a method for improving such drawbacks, as a reinforcing base fabric, a method of using the basis weight 10 to 30 g / m ² of the thin dense layer and the basis weight 40 to 100 g / m nonwoven fabric integrating the bulky layer ² of the crude ( Japanese Utility Model Publication No. 62-26193: Patent Document 1), a method using a high-weight nonwoven fabric having a basis weight of 110 to 800 g / m ² and a fiber diameter of 1 to 16d (Japanese Patent Laid-Open No. Hei 2-258332: Patent Document 2), or dense Various methods such as a method using a melt blown nonwoven fabric having a fiber diameter of 10 μm or less as a layer (Japanese Patent Laid-Open No. 2004-353153: Patent Document 3) have been proposed.

  On the other hand, the reinforcing base fabric made of non-woven fabric is rich in flexibility and has no adhesiveness, so that it is difficult to install it at a predetermined location of the foamed polyurethane molding die. A method of attaching a magnetic material to the surface and adsorbing it on the surface of the mold by magnetic force (Japanese Patent Laid-Open No. 2002-120236: Patent Document 4) is employed.

  However, the method of sticking a magnetic material on the surface of a reinforcing base fabric made of nonwoven fabric takes time and, if the mold is aluminum, embeds a metal that can adsorb the magnetic substance on a part of the mold. In any case, there is a problem that the molding of the polyurethane foam becomes complicated.

Japanese Utility Model Publication No. 62-26193 JP-A-2-258332 JP 2004-353153 A JP 2002-120236 A

  The present invention provides a method capable of easily locking a reinforcing base fabric to the surface of a foamed polyurethane molding die without adopting a method of sticking a magnetic material on the surface of a reinforcing base fabric made of nonwoven fabric. With the goal.

  The present invention relates to a foamed polyurethane molding die, wherein a reinforcing base cloth locking member is disposed on a part of the surface of the foamed polyurethane molding die, and foamed polyurethane molding using the die It relates to a method of manufacturing a body.

  In the foamed polyurethane molding die of the present invention, since the reinforcing base cloth engaging member is disposed on a part of the surface of the mold, the reinforcing base fabric can be accurately placed on the surface of the mold. . Further, since no special installation tool is required on the surface of the reinforcing base fabric, it is excellent in economic efficiency.

FIG. 1 is a perspective view showing an example of a foamed polyurethane molding die of the present invention. FIG. 2 is a cross-sectional view of a foamed polyurethane molded product produced using the foamed polyurethane molding die shown in FIG. 1 of the present invention. FIG. 3 is a perspective view showing another example of the foamed polyurethane molding die of the present invention.

<Mold for polyurethane foam molding>
The mold for molding polyurethane foam of the present invention will be described with reference to the drawings.
Since the foaming polyurethane molding die of the present invention is injected and foamed with a foaming urethane raw material liquid, the foaming polyurethane molding die 1 is usually composed of an upper die 1a as shown in FIG. It consists of the lower mold 1b.

In FIG. 1, a reinforcing base cloth locking member 2 for installing the reinforcing base cloth 3 is disposed on the surface of the upper mold 1 a.
FIG. 3 is a diagram in which a reinforcing base cloth locking member 2 for installing the reinforcing base cloth 3 is disposed on the surface of the lower mold 1b of the foamed polyurethane molding die of the present invention.

  As shown in FIGS. 1 and 3, the reinforcing base cloth locking member 2 can be attached to the upper mold 1 a of the foamed polyurethane molding die 1 depending on where the reinforcing base cloth 3 is laminated on the foamed polyurethane molded body. Or it arrange | positions on the surface of the lower mold | type 1b.

  In the foamed polyurethane mold of the present invention, the reinforcing base cloth locking member 2 is disposed on a part of the surface of the mold 1, so that the reinforcing base cloth 3 is wrinkled or loosened at a desired position on the mold surface. It can be installed accurately.

The reinforcing base cloth locking member 2 is not particularly limited as long as the reinforcing base cloth 3 is disposed at a position where the reinforcing base cloth 3 can be locked to the mold surface 11 without shifting. Depending on the situation, it is appropriately arranged.
As a means for disposing the reinforcing base cloth engaging member 2 according to the present invention on the mold surface 11, the foamed polyurethane molding mold can be disposed by, for example, a double-sided adhesive tape.

The material of the foamed polyurethane molding die 1 of the present invention is not particularly limited, and various known metals or alloys can be used. The material of the foamed polyurethane molding die of the present invention is not limited to a generally used alloy such as iron or nickel that can adsorb a magnetic material, and aluminum or the like can also be used.
FIG. 2 shows a cross-sectional view of a foamed polyurethane molded product produced using the foamed polyurethane molding die of the present invention shown in FIG.

<Reinforcing base cloth locking member>
The reinforcing base cloth locking member disposed on a part of the surface of the foamed polyurethane molding die of the present invention is not particularly limited as long as it is a member capable of locking the reinforcing base cloth, and various known ones. The locking member, specifically, a locking member including a plurality of hook elements, for example.

  The locking member including a plurality of hook elements according to the present invention can be manufactured from various known materials. Specifically, it can be manufactured from a metal material, a thermoplastic resin such as nylon, polyester, polypropylene, or a combination thereof.

  The hook element according to the present invention may have various known shapes, specifically, any shape such as a hook shape, a T shape, and a mushroom shape. Other suitable hook elements include an array of protrusions formed from a thermoplastic material.

  Also, hot melt adhesive thermoplastic polymers, particularly hot melt adhesives such as polyesters and polyamides, are particularly suitable for forming protrusions on hook elements. In one embodiment, the protrusions are printed in a manner that allows the thermoplastic polymer in a molten state to be printed on the substrate in discrete units and stretched before a portion of the thermoplastic polymer molding is cut. It can also be made by using a modified gravure printing process by cutting thermoplastic polymer moldings and “freezing” the stretched molten material so that the protrusions result.

《Reinforcing base fabric》
The reinforcing base fabric according to the present invention may be usually a single layer nonwoven fabric, a laminate in which other layers are laminated on a single layer nonwoven fabric, or a laminate in which two or more layers of nonwoven fabric are laminated.
In addition, when a laminate is used as the reinforcing base fabric according to the present invention, other layers may be laminated as long as the layer in contact with the surface of the foamed polyurethane molding die is a nonwoven fabric.

  As the nonwoven fabric according to the present invention, various known nonwoven fabrics such as spunbond nonwoven fabric, melt blown nonwoven fabric, wet nonwoven fabric, dry nonwoven fabric, dry pulp nonwoven fabric, flash spun nonwoven fabric, spread nonwoven fabric, etc. Nonwoven fabrics can be mentioned. Among these nonwoven fabrics, a long fiber nonwoven fabric such as a spunbond nonwoven fabric is preferable because of its excellent locking force with the locking member, and a crimped long fiber nonwoven fabric is particularly preferable because of its excellent locking force with the locking member.

  The thermoplastic polymer used as the raw material for the nonwoven fabric according to the present invention is not particularly limited as long as it is a thermoplastic polymer capable of forming a nonwoven fabric, and various known thermoplastic polymers, specifically ethylene, propylene. 1-butene, 1-hexene, 4-methyl-1-pentene, 1-octene and other α-olefin homopolymers or copolymers, high-pressure low-density polyethylene, linear low-density polyethylene (so-called LLDPE), high Density polyethylene (so-called HDPE), polypropylene (propylene homopolymer), polypropylene random copolymer, poly 1-butene, poly 4-methyl-1-pentene, ethylene / propylene random copolymer, ethylene / 1-butene random copolymer Polymers, polyolefins such as propylene / 1-butene random copolymer, polyesters (polyethylene Phthalate, polybutylene terephthalate, polyethylene naphthalate, etc.), polyamide (nylon-6, nylon-66, polymetaxylene adipamide, etc.), polyvinyl chloride, polyimide, ethylene / vinyl acetate copolymer, ethylene / vinyl acetate / Examples thereof include vinyl alcohol copolymers, ethylene / (meth) acrylic acid copolymers, ethylene-acrylic acid ester-carbon monoxide copolymers, polyacrylonitrile, polycarbonate, polystyrene, ionomers, and mixtures thereof. Among these, high-pressure method low-density polyethylene, linear low-density polyethylene (so-called LLDPE) and ethylene-based polymers such as high-density polyethylene, propylene-based polymers such as polypropylene and polypropylene random copolymers, or polyethylene terephthalate, Polyamide and the like are more preferable.

If the fiber constituting the nonwoven fabric according to the present invention is a synthetic fiber, a single fiber selected from the thermoplastic polymers, or a core-sheath structure (concentric or composed of two or more thermoplastic polymers) is used. It may be a composite fiber such as eccentricity) or side-by-side structure.
The shape of the fiber may be an irregular cross section such as a V shape, a cross shape, or a T shape in addition to a round cross section.

  As the crimped long fiber nonwoven fabric according to the present invention, as long as the long fibers forming the nonwoven fabric are crimped, various known crimped long fiber nonwoven fabrics, specifically, for example, the melting point described in WO02 / 061912 A non-woven fabric of crimped composite fibers comprising a first propylene polymer component and a second propylene polymer component having a difference of 20 ° C. or more, the cross section described in Japanese Patent No. 528959 is (a) and ( b) a crimped composite fiber having a crimpable cross-sectional shape having at least two regions of the part, wherein the mass ratio of the part (a) to the part (b) [(a) :( b)] 10:90 to 55:45, the part (a) is composed of the propylene polymer (A), the part (b) is composed of the propylene polymer (B), and the propylene polymer. Mz / Mw (A) of (A) and the propylene system The difference [Mz / Mw (A) −Mz / Mw (B): ΔMz / Mw] of Mz / Mw (B) of the combined body (B) is 0.30 to 2.2, and the propylene polymer ( The absolute value of the difference between the melting point [Tm (A)] of A) and the melting point [Tm (B)] of the propylene polymer (B) is 0 to 10 ° C., and the MFR of the propylene polymer (A) A crimped continuous fiber non-woven fabric made of crimped composite fibers having a ratio of (A) to MFR (B) of the propylene polymer (B) of 0.8 to 1.2 can be used.

The nonwoven fabric according to the present invention is preferably embossed. By embossing, the locking force with the locking member is further improved.
Moreover, when heat-sealing by hot embossing, the embossed area ratio is usually 5 to 30%, preferably 10 to 25%, more preferably 15 to 25%.

Examples of the embossed marking shape include a circle, an ellipse, an ellipse, a square, a rhombus, a rectangle, a square, a quilt, a lattice, a turtle shell, and a continuous shape based on these shapes. The non-embossed unit area is preferably 0.5 mm ² or more, more preferably 4 mm ² or more, further preferably 10 mm ² or more, and most preferably 100 mm ² or more. Here, the non-embossed unit area refers to the maximum area of a quadrilateral inscribed in the embossed portion in the smallest unit non-embossed portion surrounded by the embossed portions on all four sides. When embossing is performed under the conditions in this range, it is possible to obtain a bulkier nonwoven fabric while maintaining the required nonwoven fabric strength. The emboss area ratio and the non-emboss unit area can be changed by changing the emboss pattern.

  When the periphery of the non-embossed portion is discontinuous or surrounded by a continuous embossed portion, the fibers do not rise significantly between adjacent non-embossed portions via the embossed section, and the fuzz resistance is excellent. This is preferable.

  Specifically, the embossment in which continuous linear inscriptions described in JP 2009-527257 A are formed in a zigzag pattern, or the embossment in which continuous linear inscriptions are formed in a wavy pattern Since the fibers are difficult to fall off, the locking force of the locking member is further improved, which is preferable.

<< Method for producing foamed polyurethane molding >>
The manufacturing method of the foaming polyurethane molding of this invention is demonstrated based on FIG.
After the reinforcing base cloth 3 is placed on the reinforcing base cloth engaging member 2 disposed on the surface of the upper mold 1a of the foamed polyurethane molding die 1 of the present invention, the foamed polyurethane raw material is injected into the lower mold 1b. Then, the lower mold 1a on which the reinforcing base fabric 3 is installed is closed, the foamed polyurethane raw material is foamed, and the foamed polyurethane base material is laminated with the reinforcing base fabric on the surface as shown in FIG. A polyurethane molded product can be produced.

  In the method for producing a foamed polyurethane molded article of the present invention, since the reinforcing base cloth locking member 2 is disposed on a part of the surface of the foamed polyurethane mold 1, the reinforcing base cloth 3 is desired on the mold surface. Since there is no wrinkle or slack in the position, it can be installed accurately, and therefore, a foamed polyurethane molded product in which a reinforcing base fabric without wrinkles or slack is laminated can be manufactured.

EXAMPLES Hereinafter, although this invention is demonstrated further more concretely based on an Example, this invention is not limited to these Examples.
[Example 1]
A locking tape 2 (male material, length 13 mm × width 25 mm) was attached to the surface 11 of the upper mold 1a of the foamed polyurethane molding die shown in FIG. This locking tape is made of polypropylene and has an average height of 0.4 mm, an average tip size of 0.2 mm × 0.3 mm, and hooks of about 220 hooks / cm ² .

A nonwoven fabric of crimped composite fibers composed of a first propylene polymer component and a second propylene polymer component having a melting point difference of 20 ° C. or more described in WO 02/061192 was measured in accordance with JIS L1906. The basis weight was adjusted to 80 g / m ² . Next, the nonwoven fabric was passed between an embossing roll engraved with a zigzag pattern in which continuous linear inscriptions described in JP-T-2009-527257 and a roll with a smooth surface were heated. The reinforcing base fabric 3 was obtained by pressure treatment. At this time, the embossing roll temperature and the smoothing roll temperature were both 125 ° C. and a linear pressure of 30 N / mm.

  The reinforcing base fabric 3 is arranged on the surface 11 of the upper mold 1a so as not to have wrinkles or slack. After the foamed polyurethane raw material is injected into the lower mold 1b, the upper mold 1a is closed to form the foamed polyurethane 4. . In the obtained foamed polyurethane molded article, the reinforcing base fabric 3 and the foamed polyurethane 4 were integrated, and the reinforcing base fabric 3 was free from wrinkles and slack, and could be suitably used as a cushioning material for a vehicle seat or the like.

  In the foamed polyurethane molding die of the present invention, the reinforcing base cloth locking member is disposed on a part of the surface of the mold, so that it is troublesome to arrange a special installation tool on the surface of the reinforcing base fabric. It is possible to save the reinforcing base fabric accurately on the mold surface.

DESCRIPTION OF SYMBOLS 1 ... Mold for foaming polyurethane molding 1a ... Upper mold 1b for foaming polyurethane molding die ... Lower die of foaming polyurethane molding die 2 ... Reinforcement base cloth locking member 3 ... Reinforcement Base fabric 4 ... Polyurethane foam molded body

Claims (7)

  A foamed polyurethane molding die comprising a reinforcing base cloth engaging member disposed on a part of the surface of a foamed polyurethane molding die.   The foaming polyurethane molding die according to claim 1, wherein the reinforcing base cloth locking member is a locking member including a plurality of hook elements.   The mold for polyurethane foam molding according to claim 1, wherein the reinforcing base cloth locking member is disposed using a double-sided adhesive tape.   The mold for polyurethane foam molding according to claim 1, wherein the reinforcing base cloth locked to the reinforcing base cloth locking member is a crimped long fiber nonwoven fabric. The crimped long fiber nonwoven fabric can be locked to a plurality of locking elements of the locking member, and comprises a receiving side member having a vertical axis and a horizontal axis.
a) The first bond line and the second bond line extending in the first direction, and the second bond line is adjacent to the first bond line so that a part of the second bond line overlaps a part of the first bond line. The overlap is substantially parallel to the second direction, and the first direction is substantially perpendicular to the second direction,
b) a bond band surrounding the first bond line and the second bond line;
c) a plurality of successive sweep regions disposed within the coupling band, each of the sweep regions having a length and a width, the length of the sweep region being equal and substantially parallel to the vertical axis, the width of the sweep region being Equally parallel to the horizontal axis, at least one sweep region includes portions of both the first and second coupled lines, and the remaining sweep regions of the plurality of sweep regions are at least portions of the first coupled line. Or at least a portion of the second coupling line, each sweep region including a coupling region, wherein the receiver member is a coupling between two sweep regions greater than or equal to 1 and less than or equal to 20. The mold for molding polyurethane foam according to claim 4, which is a nonwoven fabric having a ratio.   After the reinforcing base cloth is locked to the reinforcing base cloth locking member arranged on the surface of the foamed polyurethane molding die, the foamed polyurethane raw material is injected into the mold to foam the foamed polyurethane raw material. A method for producing a foamed polyurethane molded article comprising laminating a reinforcing base fabric and foamed polyurethane.   The method for producing a foamed polyurethane molded article according to claim 6, wherein the reinforcing base fabric is a crimped continuous fiber nonwoven fabric.

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