JP2017100433A - Compressed melamine foam product and method for producing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To solve the problem that a heat compression time in a melamine foam is long as understood from a patent literature and the like, in a daily supply and an oral cavity supply that are distributed in the market, the long heat compression time causes an increase in cost and it is difficult to manufacture a product, and thus only a reduction in the cost is described based on mass production and stabilization of a product by paying attention to a change in a method for cutting the melamine foam and enhancement of a compressive force.SOLUTION: A heat conduction process of a melamine foam is known which is a thermosetting resin foam and is excellent not only a heat insulating material but also a heat reserving material, the melamine foam is cut and divided parallel to a compression surface so as to efficiently progress heat compression and a repulsive force of a constitution wall is reduced, and a compressive force is enhanced by utilizing the melamine foam itself and mass production of the melamine foam is enabled.SELECTED DRAWING: Figure 1

Description

The present invention relates to a compressed melamine foam product and a method for producing the same.

For melamine foam, manufactured and sold by BASF in Germany has the majority of the domestic market share. Each company purchases the original fabric and sells it as a kitchen cleaning product at home centers after cutting. Patent documents related to the above are listed.

Japanese Patent Application Laid-Open No. 11-128137. Utility model registration No. 3065215. JP2003-250818A. The literature which listed the increase in tensile strength and tear strength by applying heat compression as secondary processing is listed in the next section.

JP-A-5 301291. Japanese Patent Application Laid-Open No. 2002 201299. Japanese Patent No. 3675907. Japanese Patent No. 4963552. [Patent Document 4] is a document related to a heat insulating jig, [Patent Document 5] and [Patent Document 6] are documents related to cleaning supplies, and [Patent Document 7] is a living body attached to a tooth surface. This document aims to remove colored stains originating from outside. In addition,
JP 2000-288482 A Japanese Patent No. 63-8976 [Patent Document 8] is a document for the purpose of cleaning a denture, and [Patent Document 9] is a document regarding a method for producing a melamine foam. In addition, there are documents for which the inventor has applied for a patent.

Problems to be solved by the inventor

There are a number of documents related to heat compression of melamine foam. However, detailed description on the method and conditions is limited. Yuichi, Japanese Patent Application Laid-Open No. 2002-201239 describes the time required for heating and compression, but it is only 2 minutes and 15 minutes. In this manufacturing time, life in the general market and oral products rebound to cost, and it can be said that commercialization in domestic manufacturing is hopeless. The present inventor has applied for a document on melamine foam so far, but this time, the quality of compressed melamine foam products and cost reduction due to mass production are reduced from the thickness of melamine foam (dimension suitable for heat compression) and the cutting method. Considered and made the issue of shortening the manufacturing time.

Means for solving the problem

Melamine foam is a thermosetting resin foam, and at the same time is an excellent heat insulating material and heat insulating material, so that suitable conditions are naturally essential for heat compression. The heat conduction mechanism of melamine foam is known from experiments, and the pressure of the melamine foam, which is efficiently heated and compressed, and the repulsive force of each other as a cushioning material by dividing into parallel and several steps with respect to the compression surface. At the same time as applying an equal pressure to the melamine foam compression surface, we considered and implemented a means to reduce the repulsive force of the constituent walls by cutting and dividing into several stages.

Effect of the invention

By knowing the preferred melamine foam thicknesses shown in Tables 3 and 4 in the heat compression process and by dividing the cut into parallel and several steps with respect to the compression surface, the time required for heat compression became an average of 6 seconds. . This shortening also reduced discoloration of the melamine foam surface and reduced the defect rate. In addition, by forming a shape that connects parts when the melamine foam is cut in parallel and in several steps, the melamine foam is stacked accurately, and the surroundings are poorly compressed due to minute differences in melamine foam cut dimensions. In addition to eliminating the cutting process, the product is simply cut and divided into a bellows shape in a shape that is partially connected to the compression surface, and then becomes a product only by packaging. With this series of process reductions, labor costs, which account for the majority of costs, have also been reduced, enabling mass production.

BEST MODE FOR CARRYING OUT THE INVENTION The best mode for carrying out the present invention will be described in order based on the physical properties of the melamine foam used, the conventional heat compression method and range, and the form of the present invention based on the figures and the tables and graphs showing the results of implementation.

According to the literature, the production method of melamine foam is “a thermosetting plastic molding agent containing at least 50% by weight of melamine and formaldehyde and containing 50% by weight or less of amino-, amide-, hydroxyl- or carboxyl groups”. And an elastic foam based on the aldehyde condensation product. ”The physical properties are“ density according to JISK6401 is 5 to 50 kg / m ³ , tensile strength according to JISK6301 is 0.6 to 1.6 kg / m ² , JISK6301. The elongation at break by 8 to 20% is 80 to 300 cells / 25 mm as measured by JISK6402. "

The physical properties of a popular melamine foam that is currently marketed are shown in more detail. Thermosetting resin foam having a density of 10 kg / m ³ or less (8 to 10 kg / m ³ ) and 150 to 200 cells / mm. It is rich in elasticity and has a strong repulsive force. In addition, heat compression is not easy because of its excellent heat insulation and heat retention.

This melamine foam was cut into a 200 mm × 200 mm square, and the experiment was advanced by changing the thickness in the range of 8 to 20 mm. The press machine at that time can adjust the temperature from 180 to 250 ° C. from above and below, and the compression force applied to the above dimensions is 500 kg at the maximum.

The temperature of the upper and lower plate surfaces in this press machine is heated to about 210 ° C., the compression force is set to about 400 kg, and the melamine foam-shaped product is applied to the surface with a heating compression time of 30 seconds at each thickness of 2 to 20 mm. A case where no discoloration was observed and an accurate compression ratio was obtained was indicated as ◯, and a case where discoloration was observed or a change in thickness could be confirmed with the naked eye after standing for 24 hours was not achieved. The case is shown as x in Table 1.

Next, Table 2 shows the compression state when the press conditions are the same and the heating compression time is set to 10 seconds. (The contents of ○ △ × are the same.)

（表１）で記載したメラミンフォーム厚さ２０ｍｍは、加熱圧縮時間１０秒では所定の圧縮比の実現は不可能であるため省略した。

The melamine foam thickness of 20 mm described in (Table 1) was omitted because a predetermined compression ratio could not be achieved with a heating compression time of 10 seconds.

Under the above-described heating temperature and compression conditions, the heating and compression range is determined as can be understood from (Tables 1 and 2). The current implementation conditions and melamine foam shape are as described above, and the thickness 8-10 mm is heated and compressed to 4 mm, the compression ratio is 1 / 2-1 / 2.5, and the heating compression time is 10 seconds. It has been commercialized because it can achieve almost accurate dimensions.

However, each condition is required for the above high compression. 1. Increase the heating temperature. 2. Increase the pressure required for compression. In other words, reducing the volume of the melamine foam. When the heating temperature is set to 230 ° C. or higher as in 1, the time required for compression is shortened. However, heat accumulates in the vicinity of the surface due to the physical properties (moisturizing properties) of melamine foam, and since it does not penetrate into the interior due to heat insulation, only the surface turns yellow and does not become a product. When the pressure is increased as in 2, when the thickness is 8 mm or less, since the melamine foam is an elastic foam, the upper and lower surfaces of the pressing machine come into contact with each other and the pressure cannot be accurately transmitted. The compression ratios obtained in the thickness range of 8 to 2 mm in Tables 1 and 2 are almost the same. This is because when the thickness is 8 mm, the thickness of the melamine foam during compression is set to 0.5 to 1 mm, and when the thickness is 5 mm or less, the upper and lower surfaces of the press are in contact with each other and the pressure is not transmitted accurately.

Therefore, the present inventor cuts the melamine foam 1 in parallel and several steps with respect to the compression surface, and a part of the melamine foam 1 is connected, and is shown in an oblique view in FIG. The part where a part is connected is described as a parallel connection part 3. The results of heat compression under the same conditions described above are shown in Table 3 for the case of two stages and Table 4 for the case of three stages.

In Table 3, two cases in the case of 8 mm (4 mm × 2) and 10 mm (5 mm × 2) can obtain a compression ratio of 1/10 in a short time of 6 seconds, and 24 hours after heat compression. No change in dimensions (backlash phenomenon) was observed even when left as above. At 4 mm (2 mm × 2) and 6 mm (3 mm × 2), as described above, the pressure disperses as the upper and lower plates of the press machine are in contact with each other, so there is a slight change in dimensions and an increase in heating temperature. Discoloration was also observed due to lack of heat insulation and heat retention due to its thinness. In the case of 12 mm (6 mm × 2), a compression ratio of 1/10 can be obtained by setting the heat compression time to 12 seconds. In the case of 16 mm (8 mm × 2), only the compression ratio of 1/5 could be obtained even if the heating compression time was 12 seconds under the above conditions.

Next, in Table 4, three cases of 9 mm (3 mm × 3) and 12 mm (4 mm × 3) can obtain a compression ratio of 1/10 at a heating compression time of 6 seconds, and no backlash phenomenon is observed. It was. At 6 mm (2 mm × 3), a compression ratio of 1/10 could not be obtained for the same reason as above. Also, at 15 mm (5 mm × 3), the compression ratio of 1/7 is obtained by extending the heat compression time to 12 seconds, and in the case of a compression ratio of 1/10, the heat compression time is only extended to 12 seconds. Then, it is impossible and the pressure rise is also necessary. However, the extension of the heat compression time causes discoloration (decrease in quality) and cost (not mass production), and an increase in pressure also causes discoloration of the surface layer. For 18 mm (6 mm × 3), 1/5 is the limit under the above conditions, and for 24 mm (8 mm × 3), even if heated from above and below, heat conduction does not proceed to near the center of melamine foam 1 and compression of 1/2 The ratio was the limit.

In the case of two stages of 4 mm (2 mm × 2) and 6 mm (3 mm × 2) or three stages of 6 mm (2 mm × 3), more heat compression is performed once by overlapping the melamine foam 1. It becomes possible. Of course, the cutting blade can be modified to have four or more stages.

The shape of the compressed melamine foam 1A heated and compressed by the above method is shown in FIG. The cut part when this compressed melamine foam 1A is cut to a size and quantity suitable for the intended use of the product (daily necessities, cleaning products, oral products, nail polish products, nail polish products, etc.) 4, the connecting portion is shown as a vertical connecting portion 5.

FIG. 3 shows a shape in which the compressed melamine foam 1 </ b> A shown in FIG. 2 is folded in a bellows shape from the vertical division portion 4. In FIG. 3, it is connected at the vertical connecting portion 5 and, when used, there is no need for scissors or a cutter, so it becomes 9 pieces easily, and by separating from the parallel connecting portion 5, it becomes 12 pieces together with 3 pieces. At the same time as the convenience for the manufacturer, there is no need to stack and package one by one accurately, which is advantageous for the manufacturer side.

Next, it is about cutting of melamine foam. The inventor has filed a patent application on June 5, 2015 (Japanese Patent Application No. 2015-140849), although it has not yet been disclosed. In this cutting method, a commercially available cutter blade is connected, a jig is used to divide a compressed melamine foam having a thickness of 4 mm × 200 mm × 200 mm into 10 parts, and a compressed melamine having a thickness of 4 mm × 8 mm × 40 mm. This was a method of manufacturing 10 sets of products having 11 connected foams in 2 steps. Although this method is currently used exclusively for the oral cavity, a cutter and a jig were manufactured by using this method as a hint of a cutting blade.

The shape of the cutting blade is shown in FIGS. FIG. 4 shows a straight-type cutting blade 6, and FIG. 5 shows a corrugated cutting blade 7. The total length of each cutter must be at least 250 mm. The reason is to cut and divide a 200 mm × 200 mm square melamine foam as described above. The surface to be used for cutting is required to be 210mm or more, and both ends are 20mm for the purpose of stretching each cutting blade to the left and right with a pull hole like this on the bow and its inner part (cut blade thickness plus 0.1-0.5mm) Jigs with gaps for moving the cutting blades are provided at both ends, and the straight cutting blade 6 or corrugated cutting blade 7 moves to the left and right accurately to cut the melamine foam parallel to the compression surface and in several steps. Can be divided. In the case of two stages, a single cutting blade was used. If the dimensions of 5 mm each are required in 3 steps, it can be divided into 3 parts by using 15 mm thick melamine foam and cutting it in parallel, then turning the melamine foam upside down and performing the same process. If a higher speed is required, it is possible to divide into three parts in one process if the cutting blade has two stages with the same dimensions. In the case of two stages, the frictional stress applied to the cutting blade naturally increases, but it was possible to process with the dimensions of the cutting blade described below in the dimensions up to dividing the melamine foam thickness of 18 mm into 6 mm.

The detailed dimensions and overall length of the cutting blade are preferably 270 mm, width 25 mm, and thickness 1.5 mm or less. Either a single blade or both pieces may be used, but preferably both pieces are cut surfaces with respect to the upper and lower melamine foams. Because of the same pressure (friction stress), dimensional displacement is unlikely to occur. It is preferable to use the cut blade by pulling it like a bow saw through the pull hole 8, but if the blade itself has a certain thickness, it can be said that only the blade is sufficient. The displacement of the cut thickness dimension can be easily adjusted by changing the dimension of the jig described above.

The idea of the corrugated cutting blade 7 shown in FIG. 5 is that the melamine foam is an elastic foam and is flexible, and is associated with bread from the shape having cells (bubbles). This was because it was corrugated, and it was possible to easily and accurately cut and divide. However, the melamine foam itself seems to be flexible because it has elasticity, but the particles themselves are at the Hv150 level of the metal equivalent value, and the blade must be replaceable or easily sharpened.

From the above description, the best mode for carrying out the invention has been described up to the cutting method, the compression method, and the packaging of the product. The results are shown in Table 5 showing the comparison of each working time.

(Graph 1)

The solid line shows the limit of the compression ratio according to thickness in the melamine foam of Table 1 (heat compression time 30 seconds), and the result of Table 2 (heat compression time 10 seconds under the same conditions as Table 1) is a dotted line on the compression surface On the other hand, the result of heat-compressing the melamine foam (in the case of two stages), which is cut and divided in parallel, and partly connected under the same conditions (heat compression time 6 seconds) is a single diagonal line, in the case of three stages at the same time Is indicated by two-point diagonal lines.

In the graph 1, the case where the thickness is 8 mm (3 steps is 9 mm) will be described. The case of one conventional sheet is indicated by a solid line (Table 1) and a dotted line (Table 2). The solid line shows a limit of 1/5 for the heat compression time and the compression ratio is 1/5, and the dotted line shows the limit for the compression ratio of 1/3 for the heat compression time of 10 seconds. On the other hand, the case of 2 stages (2 divisions of 8 mm) is indicated by a single oblique line (Table 3), but the compression ratio becomes 1/10 when the heating and compression time is 6 seconds, and the case of 3 stages (3 divisions of 9 mm). As indicated by the two-point diagonal lines (Table 4), the compression ratio was the same as 1/10. In other words, in the case of two stages with a thickness of 8 mm, one sheet was about 0.4 mm, and in the case of three stages with a thickness of 9 mm, one sheet was about 0.3 mm and finished in a cloth-like shape.

This method was filed as patent application No. 2015-140850 by the inventor on June 5, 2015 as the name of the invention “melamine foam and its compression method”. In order to improve the above, it is a method in which a melamine foam that has been heated and compressed in advance is placed on the lower surface of the press and used as a jig. The hint that follows is that the pressure is transmitted to the entire surface accurately and maximally by using a cushioning material when printing. However, in the case of a cushion jig, it is not necessary to change it by heating and compressing several hundred sheets and it will not be mass-produced. In addition, when pre-cut melamine foam is stacked and heated and compressed, the surroundings of the melamine foam cannot be accurately heated and compressed due to individual differences during cutting (cut size error) even if the stacking is performed accurately. It is necessary to cut the film in a later process, and it takes a long time for packaging, and the efficiency is remarkably lowered. Table 5 shows the comparison of processing time between the compressed melamine foam processed into the final product one by one and the product of the present invention.

The explanation in Table 5 is that the melamine foam having a thickness of 9 mm × 200 mm × 200 mm is divided into parallel and three-stage cut parts, and a part of the shape is connected to the present invention, and the thickness is 3 mm × 200 mm × 200 mm in advance. The cut product was used as a conventional product. The product of the present invention was cut and divided in one step using a two-blade. Even for those skilled in the art who cut the melamine foam from the raw fabric for the conventional product, a cut order with a thickness of 8 mm or less cannot be made, so the inventor randomly cut using a different cutting jig, so the dimensional difference is somewhat Although produced, it was cut to a thickness of 3 mm and used. Since the time used for cutting was the same as 10 seconds per sheet, it was tripled to 30 seconds. Next, the pre-compression process for accurately stacking the melamine foam on the lower surface of the press machine took at least 30 seconds in the conventional case where three sheets had to be stacked, compared with 5 seconds in the present invention which was simply placed. The heat compression time was 6 seconds for both. However, even if the melamine foam is cut individually, even if it is fine, a dimensional difference occurs and a surrounding cut is necessary, and the time required for it is at least 180 seconds. In FIG. 2, in the case of the present invention, it takes 45 seconds since three melamine foams are required to produce the same number for 15 seconds in the case of the present invention. In the present invention, as shown in FIG. 3, the final packaging process is completed in 20 seconds just by folding the bellows from the vertical dividing section 4. Conventionally, however, the packaging process is performed accurately one by one. Takes 180 seconds.

When all processes are combined, 471 seconds are required in the case of the conventional product, whereas in the case of the present invention, the efficiency is 56 times or more, and the efficiency is more than 7 times. The accuracy of the product has also improved since there is no such thing.

When melamine foam was born in Germany, the cells (bubbles) of melamine foam, which are suitable for building wall materials (fireproof, soundproof, heat-resistant, heat-retaining), were crushed to improve the tensile strength and tear strength. The use of a bridge) as a cleaning product can be considered to go against the superiority of the physical properties, unlike the original physical properties. However, it is natural that the colored dirt removing power is as excellent as any other, and is attracting attention as a cleaning product. Then, it is a well-known fact that the thickness (1 mm or less) is suitable as a cleaning article or the like like the shape of a cloth or non-woven fabric, and the strength is increased by heating and compression. If the compression ratio is increased, each strength is also increased. If there is no change in the cleaning power, naturally, it is necessary to consider a method for easily realizing high compression and to develop the product, and this is shown in the present invention.

The melamine foam is fine (1-10 μm) at the same time as its constituent walls (bridges), and at the same time is brittle, and dust particles (0.1-08 μm) enter the colored and dirty recesses, and sand eraser (sand perper) Remove the dirt with the principle of. The method to make the melamine foam itself flexible (reducing the load required for bending and compression) is to immerse it in a liquid with a biased PH value, or to rotate with a dehydrator after washing with water. Stress is instantaneously reduced by applying a “repetitive load” with a roller or the like. However, there is almost no change in the repulsive force (elasticity), and even if it is immersed in water and compressed, it is restored at the same time as drying, and the same applies to suction (vacuum). In order to lose the repulsive force (elasticity) of the melamine foam without discoloration, it is necessary to infiltrate a suitable temperature in order to lose the repulsive force (elasticity) throughout the inside of the melamine foam excellent in heat insulation and heat retention. In addition, it was effective to apply a uniform pressure to the entire melamine foam, and to cut the constituent walls short for the purpose of reducing the repulsive force (elasticity).

An oblique view of a melamine foam that is cut and divided in parallel to the compression surface and connected partially. An oblique view of a compressed melamine foam that has been cut and divided in parallel to the compression surface and heat-compressed with a part of the melamine foam connected to the compression surface, and then cut and divided perpendicularly in a shape of a part of the compression surface connected. The melamine foam, which is cut and divided in parallel to the compression surface and partly connected, is heated and compressed, and then the compressed melamine foam that is cut and divided vertically in the shape that is partly connected to the compression surface is An oblique view of the product before packaging folded from the cut dividing plane. The oblique view which showed the shape of the straight type cutting blade for melamine foam and compression melamine foam in this invention. The oblique view which showed the shape of the wave type cutting blade for melamine foam and compression melamine foam in this invention.

Explanation of sign

1. Melamine foam.
1A, compressed melamine foam.
2. Parallel division (with respect to the compression surface).
3. Parallel connection part.
4. Vertical division (for parallel division).
5. Vertical connecting part.
6. Straight type cutting blade.
7. Corrugated cutting blade.
8. Pull hole.

Claims (4)

A melamine foam product characterized by heat-compressing a melamine foam that is cut and divided into several steps parallel to the compression surface and connected in part. The melamine foam product according to claim 1, wherein the melamine foam product is cut and divided vertically in a shape in which a part is connected to the compression surface. The shape of a part connected to the compression surface is cut and divided perpendicularly, and the part of the compression surface connected to the part is cut to form a goodwill shape. Melamine foam products. Cut and split in several steps parallel to the heat-compressed surface, heat-compress the melamine foam partly connected to the part, and cut vertically into a part partly connected to the heat-compressed surface The manufacturing method of the melamine foam product of Claim 1 characterized by the above-mentioned.

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