JP2018135498A - Functional open-cell foam and method for producing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a heat-resistant continuous open-cell foam which uses a conventional continuous open-cell foam, is not blended with a special raw material, does not accompany any trouble in production caused by changes in blending ratios of a raw material, a foaming agent, a crosslinking agent and the like, and has heat resistance.SOLUTION: A continuous open-cell foam having heat resistance includes: a step of impregnating a fluororubber resin coating material or a solution containing the fluororubber resin coating material with a continuous open-cell foam, drying the continuous open-cell foam containing the fluororubber resin coating material and removing a solvent, and curing the continuous open-cell foam by heating.SELECTED DRAWING: None

Description

  The present invention relates to a functional open-cell foam having enhanced or added functions such as heat resistance as compared with conventional ones, and a method for producing the same.

  Conventionally, an EPDM-based open-cell foam has been widely used. This type of open-cell foam was significantly shrunk when exposed to a high temperature environment exceeding 120 ° C., and could not be said to have heat resistance.

  On the other hand, as a method of adding a function to this type of open-cell foam, there are many cases where the blending ratio of raw materials, foaming agents, crosslinking agents, etc. is changed or new materials are selected (for example, see Patent Document 1). ).

  However, changes in the blending ratio of raw materials, foaming agents, cross-linking agents, etc., and the use of special raw materials may be accompanied by increased manufacturing costs and manufacturing difficulties.

  The above-mentioned problems are not limited to heat resistance, and even when other functions such as flame retardancy and oil resistance are strengthened or added, and the open cell foam as the main part is other than EPDM. Even if it exists, it exists as well.

  Therefore, there is a demand to form an open-cell foam in which raw materials, foaming agents, cross-linking agents, etc. that have been widely used are blended at a blending ratio that has been widely employed, and to enhance or add functions by other methods. Exists.

JP 2007-21111 A

  The present invention pays attention to the above points and utilizes conventional open-cell foams, without blending special raw materials, and by changing the blending ratio of raw materials, foaming agents, crosslinking agents, etc. It is an object of the present invention to provide a functional open-cell foam capable of enhancing or adding various functions such as heat resistance without the above difficulties, and a method for producing the same.

  The functional open-cell foam, which is a heat-resistant open-cell foam according to the invention of claim 13, has a main part formed of the open-cell foam, and fluorocarbon rubber on the inner surface of the bubbles not exposed to the outside A layer containing a resin paint is formed.

  The method for producing a functional open-cell foam according to the invention of claim 10 comprises the steps of impregnating the open-cell foam in a fluororubber resin paint or a solution containing the fluororubber resin paint, and the open-cell foam containing the fluororubber resin paint. A functional open-cell foam which is a heat-resistant open-cell foam having heat resistance is obtained by drying the body to remove the solvent and curing it by heating.

  If it is such, while using the open-cell foam of the conventional structure (the main part was formed of the EPDM open-cell foam) as it is, open-cell in the fluororubber resin paint (including solution) By impregnating the foam, a layer containing a fluororubber resin coating is formed on the inner surface of the bubbles not exposed to the outside, and heat resistance can be added to such open-cell foam. Therefore, without using special raw materials in the formation of open-cell foams, and without accompanying manufacturing difficulties and cost increases by changing the blending ratio of raw materials, foaming agents, crosslinking agents, etc., heat resistance The functional open-cell foam which is a heat-resistant open-cell foam which has can be obtained.

  In addition, if the content of the fluororubber resin coating with respect to the open-cell foam is less than 100 g / l (gram per liter), sufficient heat resistance may not be obtained, and the content may be 300 g / l. When it exceeds, performance represented by cushioning properties as an open-cell foam may be impaired, whereas in the method for producing a functional open-cell foam that is a heat-resistant open-cell foam according to the invention of claim 10 If present, since the content of the fluororubber resin coating with respect to the open cell foam is 100 to 300 g / l, sufficient heat resistance can be obtained without impairing the performance typified by cushioning as the open cell foam. it can.

  And as an example of the open cell foam which forms the said principal part, EPDM open cell foam is mentioned.

  On the other hand, the functional open-cell foam according to the invention of claim 1 includes a main part having open cells and a layer formed of a material different from the main part and formed on the inner surface of the air bubbles constituting the open-cells. It comprises.

  In the method for producing a functional open-cell foam according to the invention of claim 8, the open-cell foam as a main part is immersed in a solution containing a material different from the main part, and the solution is put into the open-cell foam. By impregnating the foam, drying the open-cell foam, removing the solvent, and curing by heating, a layer made of the material is formed on the inner surface of the bubbles constituting the open-cell of the open-cell foam. The formed functional open-cell foam is obtained.

  Furthermore, in the method for producing a functional open-cell foam according to the invention of claim 9, a solution containing a material different from that of the main part is sprayed on the open-cell foam which is the main part, and the solution is used as the open-cell foam. By impregnating the foam, drying the open-cell foam, removing the solvent, and curing by heating, the material is provided over substantially the entire inner surface of the cell constituting the open-cell of the open-cell foam. A functional open-cell foam in which a layer is formed is obtained.

  If it is something like these, it will be difficult and costly to manufacture without changing the ingredients and manufacturing method of the main part, that is, by changing the blending ratio of raw materials, foaming agents, crosslinking agents, etc. Thus, it is possible to obtain a functional open-cell foam in which a desired function is expressed by selecting a material to be a layer.

  As a suitable physical parameter for indicating such a functional open cell foam, the volume of voids due to the open cells is 60% to 80% (more desirably about 70%) with respect to the total volume. In addition, the main part has an expansion ratio of 6 to 40 times, and the material forming the layer with respect to the open cell foam has a content of 20 to 300 g / l.

  Examples of a suitable main part of such a functional open-cell foam include an open-cell foam made of synthetic rubber and an open-cell foam made of chemically crosslinked polyethylene resin.

  As an example of a material suitable for the layer formed on the inner surface of the bubble constituting the open cell in such a functional open cell foam, fluororubber resin paint (heat resistance, flame resistance, oil resistance, Chemical resistance, UV resistance, abrasion resistance, cold resistance, weather resistance, ozone resistance, stain resistance), colored fluororubber resin paint (designed in addition to the characteristics of the fluororubber resin paint described above), silicone resin Paint (heat resistance), colored silicone resin paint (heat resistance, designability), epoxy resin (adhesion, moldability, electrical performance, insulation), electromagnetic wave shielding paint (radio wave absorption), UV curable resin (weather resistance) , Ozone resistance, UV resistance, adhesiveness), FRP (increased strength, increased rigidity), phenolic resin (increased strength, increased rigidity), waterproof coating agent (oil resistance, waterstop), thermal barrier paint (thermal barrier properties) ) And aqueous Lil resin emulsion paints (sound insulating property) and the like.

  The “open cell foam” in the present invention includes not only a so-called open cell foam in a narrow sense but also a so-called “semi-open cell foam” that prevents air permeability during compression.

  According to the present invention, the conventional open-cell foam can be used without blending special raw materials, and the manufacturing difficulties due to changing the blending ratio of raw materials, foaming agents, crosslinking agents, etc. Without being accompanied, it is possible to provide a functional open-cell foam capable of reinforcing or adding various functions such as heat resistance and a method for producing the same.

1 is a schematic view of a functional open-cell foam according to an embodiment of the present invention. The figure which shows the sound absorptivity of the functional open cell foam which concerns on one Example of this invention.

«First embodiment» (the main part is an open-cell foam made of synthetic rubber)
A first embodiment of the present invention will be described below.

  In this embodiment, as shown in FIG. 1, a main part 2 having an open cell BB and a layer 3 made of a material different from the main part 2 and formed on the inner surface of the bubble B constituting the open cell BB. In which the main part 2 is an open-cell foam made of synthetic rubber. The open-cell foam made of synthetic rubber includes EPDM open-cell foam (manufactured by Sanwa Kako Co., Ltd., model numbers OP-130, OP-130FR # 2 and OP-180) and the like. The produced open cell foam is obtained by adding and kneading at least an auxiliary material for foaming to a resin which is a raw material of synthetic rubber such as ethylene propylene rubber resin, and heating and foaming.

  Examples of functions to be added or strengthened include heat resistance, flame resistance, oil resistance, UV resistance, sound absorption, chemical resistance, wear resistance, cold resistance, weather resistance, ozone resistance, stain resistance, and adhesiveness. , Moldability, electrical performance, insulation, radio wave absorptivity, mechanical strength, rigidity, water stoppage, heat insulation, sound insulation, and the like. In order to add or reinforce these functions, in this embodiment, the material to be the layer 3 is selected without changing or modifying the components and manufacturing method of the main part 2 that is an open-cell foam made of synthetic rubber. Thus, a desired function is expressed. That is, it constitutes layer 3 for adding or strengthening heat resistance, flame resistance, oil resistance, ultraviolet resistance, sound absorption, chemical resistance, wear resistance, cold resistance, weather resistance, ozone resistance or contamination resistance. As the material to be used, fluororubber resin paint is suitable. In particular, if it is a colored fluororubber resin paint, the design can be added or enhanced. A silicone resin paint is also suitable as a material constituting the layer 3 for adding or reinforcing heat resistance. In particular, if it is a colored silicone resin paint, the design can be added or enhanced. An epoxy resin is suitable as a material constituting the layer 3 for adding or reinforcing adhesiveness, moldability, electrical performance, or insulation. As a material constituting the layer 3 for adding or enhancing the radio wave absorbability, an electromagnetic wave shielding paint is suitable. As a material constituting the layer 3 for adding or reinforcing ultraviolet resistance, weather resistance, ozone resistance or adhesiveness, an ultraviolet curable resin is suitable. As a material constituting the layer 3 for enhancing mechanical strength or rigidity, FRP and phenol resin are suitable. A waterproof coating agent is suitable as a material constituting the layer 3 for adding or reinforcing oil resistance or water-stopping property. As a material constituting the layer 3 for adding or reinforcing the heat shielding property, a heat shielding paint is suitable. A water-based acrylic resin emulsion-based paint is suitable as a material constituting the layer 3 for adding or reinforcing sound insulation.

  Hereinafter, the case where a fluororubber resin paint is used as the material of the layer 3 for adding heat resistance, flame retardancy or oil resistance will be specifically described as Examples 1 and 2 and Comparative Examples 1 and 2. The case where a fluororubber resin paint is used as the material of the layer 3 for adding ultraviolet resistance will be specifically described as Example 3 and Comparative Example 3. The case where a fluororubber resin paint is used as the material of the layer 3 for adding sound absorption will be specifically described as Examples 4 to 8 and Comparative Example 3. The case where a silicone resin paint is used as the material of the layer 3 for adding heat resistance will be specifically described as Example 9 and Comparative Example 1.

  Here, the outline of the functional open-cell foam (hereinafter referred to as the heat-resistant open-cell foam 1) having the EPDM open-cell foam as the main part 2 and added or strengthened heat resistance is as follows. is there. That is, as shown in FIG. 1, the heat-resistant open-cell foam 1 has a main portion 2 formed of an EPDM open-cell foam, and a fluororubber resin on the inner surface of the bubble B that is not exposed to the outside. A layer 3 containing paint is formed. In other words, as is well known, the main part 2 which is this EPDM open-cell foam is a continuous structure in which a large number of bubbles B formed inside and bubbles exposed on the surface of the foam (not shown) are continuously formed. A large number of bubbles BB are provided. The layer 3 is formed not only in the surface of the foam (not shown) and the inner surface of the bubble exposed outside (not shown) but also in the main part 2 and constitutes the open cell BB to communicate with the outside air. It is also formed on the inner surface of B.

  The EPDM open-cell foam constituting the main part 2 is a well-known EPDM open-cell foam of this type, for example, an EPDM open-cell foam manufactured and sold by the applicant as model No. OP-130FR # 2. Certainly, the raw materials, the blending ratio of the foaming agent, the cross-linking agent, and the production method thereof are not specifically described.

  The EPDM open cell foam is an auxiliary raw material for adding flame retardancy to ethylene propylene rubber resin, decabromodiphenyl ether, aluminum hydroxide, magnesium hydroxide, antimony trioxide, red phosphorus, softener, foam An agent and a vulcanizing agent are added and kneaded and heated and foamed.

  In addition, the air bubbles B that are not exposed to the outside in the heat-resistant open cell foam 1, that is, the inner surface of the air bubbles B that are formed inside the main portion 2 and constitute the open cell BB and communicate with the outside air, The layer 3 containing the fluororubber resin paint is formed by the method described below.

  First, the EPDM open cell foam constituting the main part 2 is impregnated in a solution containing a fluororubber resin paint. Here, the fluororubber resin paint in the solution so that the content after drying of the fluororubber resin paint with respect to the EPDM open-cell foam constituting the main part 2 is 100 to 300 g / l, more preferably 200 g / l. The concentration and impregnation time are set. Examples of the fluororubber resin paint include, for example, vinylidene fluoride / tetrafluoroethylene / hexafluoropropylene copolymer 15 to 25% by weight, carbon black 3 to 15% by weight, other fillers 1 to 10% by weight, methyl isobutyl Examples include 30 to 50% by weight of ketone, 20 to 30% by weight of methyl ethyl ketone, and 3 to 10% by weight of methanol. As a more specific example, for example, Perflon (registered trademark) paint manufactured by Kinyo Co., Ltd. can be mentioned, but any paint containing fluororubber resin can be used.

  Next, the open-cell foam containing the fluororubber resin paint is dried to remove the solvent. More specifically, the solvent is volatilized by blowing air on the open-cell foam taken out of the solution.

  Then, the process of hardening this open cell foam is performed. More specifically, the open-cell foam that has been impregnated in the solution containing the fluororubber resin paint is placed in an environment of 100 ° C. for 3 to 4 hours. The open cell foam may be placed in an environment at a temperature lower than 100 ° C. until the open cell foam is sufficiently cured, for example, in a room temperature environment for 7 to 10 days. When this step is completed, the layer 3 containing the fluororubber resin coating is also formed on the inner surface of the bubbles B not exposed to the outside, and the heat-resistant open-cell foam 1 having heat resistance is obtained.

An example of the heat-resistant open-cell foam 1 thus formed will be described below.
<Example 1> (heat resistance, flame resistance, oil resistance)
EPDM open cell foam (manufactured by Sanwa Kako Co., Ltd., model number OP-130FR # 2) has a fluororubber resin paint, more specifically, the content of Perflon (registered trademark) paint manufactured by Kinyo Co., Ltd. is 200 g / l. It is impregnated with fluororubber resin paint.

A comparative example for Example 1 will be described below.
<Comparative Example 1>
EPDM open cell foam (manufactured by Sanwa Kako Co., Ltd., model number OP-130FR # 2).

  That is, the open cell foam according to Comparative Example 1 is impregnated with the fluororubber resin paint in the procedure as described above, and the layer 3 containing the fluororubber resin paint is formed on the inner surface of the bubbles B not exposed to the outside. What was made to do is the heat-resistant open-cell foam according to Example 1. The expansion ratio of the open-cell foam according to Comparative Example 1 and the open-cell foam constituting the main part 2 of Example 1 is about 11 times.

  Here, the following tests were conducted on the heat resistance, that is, thermal stability, of the heat-resistant open-cell foam according to Example 1 and the open-cell foam according to Comparative Example 1. Specifically, after measuring the tensile strength of the sample by the method specified in JIS K6767, the sample is placed in an environment of 200 ° C. for 22 hours, and then the dimensional change rate and the volume change rate are measured and the sample is again measured. The tensile strength was measured and the elongation was measured. The results are shown in Table 1 below.

Moreover, as an example of another functional open cell foam according to the present embodiment, the main part 2 is constituted by an EPDM open cell foam manufactured and sold by the applicant as model number OP-130. The thing based on the following Example 2 produced by the procedure similar to the thing based on Example 1 mentioned above except the structure of this is mentioned.
<Example 2> (Heat resistance, flame retardancy, oil resistance)
EPDM open cell foam (manufactured by Sanwa Kako Co., Ltd., model number OP-130), fluororubber resin paint, more specifically, the content of Perflon (registered trademark) paint manufactured by Kinyo Co., Ltd. is 200 g / l. Impregnated with the fluororubber resin paint.

A comparative example for Example 2 will be described below.
<Comparative example 2>
EPDM open cell foam (manufactured by Sanwa Kako Co., Ltd., model number OP-130).

  That is, the open-cell foam according to Comparative Example 2 is impregnated with the fluororubber resin paint in the procedure described above, and the layer 3 containing the fluororubber resin paint is formed on the inner surface of the bubble B not exposed to the outside. This is the heat-resistant open-cell foam according to Example 2. Further, the expansion ratio of the open-cell foam according to Comparative Example 2 and the open-cell foam constituting the main part 2 of Example 2 is about 11 times.

  Here, the heat resistance, that is, the thermal stability of the heat-resistant open-cell foam according to Example 2 and the open-cell foam according to Comparative Example 2 shown below is described in Example 1 and Comparative Example 1 described above. Tests similar to those performed on such open cell foams were performed. The results are shown in Table 2 below.

  Here, “2 mm”, “5 mm”, and “10 mm” in Tables 1 and 2 are the thicknesses of the samples. The unit of tensile strength is MPa. The elongation percentage of the 10 mm thick sample after heating in Comparative Example 2 was not measurable because one end of the sample was damaged when measuring the elongation percentage after heating.

  According to the above, the heat-resistant open-cell foam 1 of Example 1 is compared with the open-cell foam of Comparative Example 1, and the heat-resistant open-cell foam 1 of Example 2 is the open-cell of Comparative Example 2. Compared to a foam, it can be said that the dimensions are less likely to change even after being exposed to a high-temperature environment, and there is no decrease in tensile strength, indicating that it has thermal stability. That is, a desired function is expressed by selecting the material to be the layer 3 without changing or modifying the components and manufacturing method of the main part 2. In Example 1 and Example 2, by impregnating the open cell foam constituting the main part 2 with the fluororubber resin paint, problems in manufacturing the open cell foam constituting the main part 2 are caused. It can be said that thermal stability can be added without any.

  Further, regarding the flame retardancy of the heat-resistant open-cell foam according to Example 1 and the open-cell foam according to Comparative Example 1, the vertical combustion test defined in “UL-94” and the oxygen defined in JIS K7201. The index (oxygen concentration necessary for combustion) was measured. The results are shown in Table 3 below.

  Here, “UL94 V-0” in Table 3 indicates whether or not the flame retardant class “UL94 V-0” is satisfied in the vertical combustion test defined in “UL-94”. Yes.

  According to the above, the heat-resistant open-cell foam of Example 1 satisfies the standard of the flame-retardant class “UL94 V-0”, whereas the open-cell foam of Comparative Example 1 has the flame-retardant class “ The standard of “UL94 V-0” is not satisfied, and the heat-resistant open-cell foam of Example 1 has a larger oxygen index than the open-cell foam of Comparative Example 1. Therefore, it can be said that the heat-resistant open-cell foam of Example 1 has flame retardancy compared to the open-cell foam of Comparative Example 1. That is, the manufacturing of the open cell foam constituting the main part 2 by impregnating the open cell foam of the main part 2 with the fluororubber resin paint without changing or modifying the components and manufacturing method of the main part 2 It can be said that flame retardancy can be added without incurring the above problems.

  Furthermore, regarding the flame retardancy of the heat-resistant open-cell foam according to Example 2 and the open-cell foam according to Comparative Example 2 shown below, the horizontal combustion test specified in “UL-94” and JIS K7201 The specified oxygen index was measured. The results are shown in Table 4 below.

  Here, “UL94 HF” in Table 4 indicates which class of criteria is satisfied in the horizontal combustion test defined in “UL-94”. Here, the flame retardancy class in the horizontal combustion test is “UL94 HF-1”, “UL94 HF-2”, and “UL94 HBF” in descending order. In Table 4, “UL94 HF-1” and “UL94 HBF” are abbreviated as “HF-1” and “HBF”, respectively.

  According to the above, the heat-resistant open-cell foam of Example 2 satisfies the standards of the flame-retardant class “UL94 HF-1”, whereas the open-cell foam of Comparative Example 2 has lower flame resistance. Only the standard of class “UL94 HBF” is satisfied, and the heat-resistant open-cell foam of Example 2 has a larger oxygen index than the open-cell foam of Comparative Example 2. Therefore, it can be said that the heat-resistant open-cell foam of Example 2 has flame retardancy compared to the open-cell foam of Comparative Example 2. That is, also from this, the main part 2 is comprised by impregnating the open cell foam which comprises the main part 2 with a fluororubber resin coating material, without adding a change and a device to the component and manufacturing method of the main part 2. It can be said that flame retardancy can be added without causing problems in the production of open-cell foams.

  In addition, the following tests were conducted on the oil resistance of the heat-resistant open-cell foam according to Example 1 and the open-cell foam according to Comparative Example 1. Specifically, after being immersed in JIS designated oils IRM901 (low swelling oil), IRM902 (medium swelling oil) or IRM903 (high swelling oil) for 24 hours, taken out from the oil and allowed to stand for 48 hours to determine the dimensional change rate. It was measured. The results are shown in Table 5 below. In Table 5, Experiment 1, Experiment 2 and Experiment 3 are the results when immersed in IRM901, IRM902 and IRM903, respectively.

  According to the above, the heat-resistant open-cell foam of Example 1 has a smaller dimensional change rate before and after being immersed in oil than the open-cell foam of Comparative Example 1. Therefore, it can be said that the heat-resistant open-cell foam of Example 1 has oil resistance compared to the open-cell foam of Comparative Example 1.

  And the test similar to what was mentioned above was done also about the oil resistance of the heat resistant open-cell foam which concerns on Example 2, and the open-cell foam which concerns on the comparative example 2. FIG. The results are shown in Table 6 below.

  According to the above, the heat-resistant open-cell foam of Example 2 has a smaller dimensional change rate before and after being immersed in oil than the open-cell foam of Comparative Example 2. Therefore, it can be said that the heat-resistant open-cell foam of Example 2 has oil resistance compared to the open-cell foam of Comparative Example 2.

  From the above, the open cells constituting the main part 2 can be obtained by impregnating the open cell foam constituting the main part 2 with the fluororubber resin paint without changing or modifying the components and manufacturing method of the main part 2. It can be said that oil resistance can be added without causing problems in the production of the foam.

Furthermore, as an example of another functional open cell foam according to the present invention, the main part 2 is constituted by an EPDM open cell foam manufactured and sold by the applicant as model number OP-180. Examples according to Example 3 below, which are made by the same procedure as that according to Example 1 described above, except for the configuration, can be mentioned.
<Example 3> (UV resistance)
EPDM open cell foam (manufactured by Sanwa Kako Co., Ltd., model number OP-180) so that the content of the fluororubber resin paint is 47.5 g / l, more specifically, Kinyo Co., Ltd. Impregnated with Perflon paint.

A comparative example for Example 3 will be described below.
<Comparative Example 3>
EPDM open cell foam (manufactured by Sanwa Kako Co., Ltd., model number OP-180).

  That is, the open-cell foam according to Comparative Example 3 is impregnated with the fluororubber resin paint in the procedure described above, and the layer 3 containing the fluororubber resin paint is formed on the inner surface of the bubble B not exposed to the outside. Is a functional open-cell foam according to Example 3. The expansion ratio of the open-cell foam according to Comparative Example 3 and the expansion ratio of the open-cell foam constituting the main part 2 of Example 3 are about 16 times.

  Here, the following tests were conducted on the ultraviolet resistance of the functional open-cell foam according to Example 3 and the open-cell foam according to Comparative Example 3. Specifically, after measuring the tensile strength of the sample by the method prescribed in JIS K6767, the sample was irradiated with an ultraviolet lamp (made by Toshiba: Mercury lamp of model number SHL-100UVQ-2) for a predetermined period, and the next day A dumbbell punching operation was performed, and the tensile strength of the sample was measured again the next day, and the elongation was measured. The results are shown in Table 7 below. In Table 7, Experiment 1, Experiment 2, and Experiment 3 are the results when ultraviolet rays were irradiated for 10 days, 20 days, and 30 days, respectively.

  Here, the unit of tensile strength in Table 7 is MPa. The thickness of the sample is 10 mm in all experiments.

  The functional open-cell foam of Example 3 maintains the tensile strength when irradiated with ultraviolet rays for 10 days, and the tensile strength is enhanced when irradiated with ultraviolet rays for 20 days or more. On the other hand, the tensile strength of the open cell foam of Comparative Example 3 is reduced when irradiated with ultraviolet rays. Therefore, it can be said that the functional open-cell foam of Example 3 has ultraviolet resistance compared to the open-cell foam of Comparative Example 3. That is, without adding or modifying the components and manufacturing method of the main part 2, the open-cell foam constituting the main part 2 is impregnated with the fluororubber resin paint into the open-cell foam constituting the main part 2. It can be said that ultraviolet resistance can be added without incurring manufacturing problems.

In addition, as an example of another functional open-cell foam according to the present invention, the main part 2 is constituted by an EPDM open-cell foam manufactured and sold by the applicant as model number OP-180. Examples according to the following Examples 4 to 8 made by the same procedure as that according to Example 1 described above are included.
<Example 4> (Sound absorption)
EPDM open cell foam (manufactured by Sanwa Chemical Co., Ltd., model number OP-180) has a fluororubber resin paint, more specifically, 46.4 g / l of Perflon (registered trademark) paint manufactured by Kinyo. It is impregnated with fluororubber resin paint.
<Example 5> (Sound absorption)
EPDM open-cell foam (manufactured by Sanwa Chemical Co., Ltd., model number OP-180) has a fluororubber resin paint, more specifically, the content of Perflon (registered trademark) paint by Kinyo Co., Ltd. is 50.2 g / l. It is impregnated with fluororubber resin paint.
<Example 6> (Sound absorption)
EPDM open cell foam (manufactured by Sanwa Kako Co., Ltd., model number OP-180) has a fluororubber resin paint, more specifically, a content of 55.7 g / l of Perflon (registered trademark) paint manufactured by Kinyo Co., Ltd. It is impregnated with fluororubber resin paint.
<Example 7> (Sound absorption)
EPDM open cell foam (manufactured by Sanwa Kako Co., Ltd., model number OP-180) has a fluororubber resin paint, more specifically, a content of Perflon (registered trademark) paint by Kinyo Co., Ltd. of 85.5 g / l. It is impregnated with fluororubber resin paint.
<Example 8> (Sound absorption)
EPDM open-cell foam (manufactured by Sanwa Chemical Co., Ltd., model number OP-180) has a fluororubber resin paint, more specifically, the content of Perflon (registered trademark) paint by Kinyo Co., Ltd. is 112.4 g / l. It is impregnated with fluororubber resin paint.

  The functional open-cell foams according to Examples 4 to 8 are all exposed to the outside by impregnating the open-cell foam according to Comparative Example 3 with the fluororubber resin paint in the procedure described above. The layer 3 containing the fluororubber resin paint is formed on the inner surface of the bubbles B that are not formed.

  Here, the sound absorption properties of the functional open-cell foams according to Examples 4 to 8 and the open-cell foam according to Comparative Example 3 were tested by a method based on JIS A1405-2: 2007. The results are shown in Table 8 below. Moreover, the result of the said test in the functional open cell foam which concerns on the said Example 4 and the open cell foam which concerns on the said comparative example 3 is shown in FIG.

Here, the thicknesses of the samples of Examples 4 to 8 are 10.7 mm, 10.4 mm, 10.9 mm, 10.3 mm, and 9.7 mm, respectively, in order. On the other hand, the thickness of the sample of Comparative Example 3 is 10.5 mm. The density of the sample of Example 4-8, 107 kg / m ³ in order, ^{respectively, 115kg / m 3, 110kg /} m 3, 134kg / m 3, is 175 kg / m ^3. The density of the sample of Comparative Example 3 is 47 kg / m ³ . Moreover, the numerical value in Table 8 and the vertical axis | shaft of FIG. 2 are the sound absorption rate in each data and each frequency. The sound absorption rate is a ratio of sound applied to the sample that is absorbed without rebounding. Specifically, the sound absorption rate when a sound at a frequency of 1600 Hz is applied to the sample of Example 4 is 0.79. In other words, 79% of the sound applied to the sample is absorbed and the remaining 21% is absorbed. It bounces back without being absorbed.

  According to the above, as is clear from Table 8 and FIG. 2, the functional open-cell foams of Examples 4 to 8 have a frequency range of 400 to 1600 Hz compared to the open-cell foam of Comparative Example 3. Therefore, it can be said that the sound absorption is excellent. That is, without adding or modifying the components and manufacturing method of the main part 2, the open-cell foam constituting the main part 2 is impregnated with the fluororubber resin paint into the open-cell foam constituting the main part 2. It can be said that sound absorption in the frequency range of 400 to 1600 Hz can be enhanced without causing problems in manufacturing.

  The material for forming the layer on the inner surface of the bubble is not limited to the fluororubber resin paint. Hereinafter, on the inner surface of the bubble B of the open-cell foam described in Comparative Example 1 (EPDM open-cell foam (manufactured by Sanwa Chemical Co., Ltd., model number OP-130FR # 2)), a layer 3 made of a silicone resin paint is applied. Examples of the formed functional open-cell foam are described below.

  This is made by a method substantially similar to the method for producing the functional open-cell foam described in Example 1, but the EPDM open-cell foam constituting the main part 2 is not a fluororubber resin paint. It differs in that it is impregnated in a solution containing a silicone resin paint.

An example of the functional open-cell foam formed as described above will be described below.
<Example 9> (Heat resistance)
Silicone resin paint, more specifically Taiho Paint Co., Ltd., so that the content of the silicone resin paint is 200 g / l with respect to EPDM open cell foam (manufactured by Sanwa Chemical Co., Ltd., model number OP-130FR # 2). Impregnated with Santomo (registered trademark) DHX paint.

  Here, the following tests were conducted on the heat resistance, that is, the thermal stability of the functional open-cell foam according to Example 9 and the open-cell foam according to Comparative Example 1. Specifically, the sample was placed in a 200 ° C. environment for 22 hours, and then the dimensional change rate was measured. The results are shown in Table 9 below.

  Here, “2 mm”, “5 mm”, and “10 mm” in Table 9 are the thicknesses of the samples.

  According to the above, it can be said that the functional open-cell foam of Example 9 has a smaller dimensional change rate than the open-cell foam of Comparative Example 1, and thus has thermal stability. That is, manufacturing the open-cell foam constituting the main part 2 by impregnating the open-cell foam constituting the main part 2 with a silicone resin paint without changing or modifying the components and manufacturing method of the main part 2 It can be said that the thermal stability can be enhanced without causing the above problems.

  The functional open-cell foam 1 according to the present embodiment described above preferably has physical properties as described below. That is, it is desirable that the functional open cell foam 1 has a void volume of 60% to 80% (more preferably about 70%) with respect to the total volume of the open cell BB. This is because if the void volume is 60 to 80% (more preferably about 70%) of the total volume, basic functions such as flexibility as an open-cell foam can be maintained. Moreover, it is desirable that the expansion ratio of the main portion 2 is in the range of 6 to 40 times. This is because it is difficult to produce an open-cell foam having an expansion ratio of 40 times or more. On the other hand, if the expansion ratio is less than 6, the functions such as flexibility as the open-cell foam are impaired. The content of the material forming the layer 3 with respect to the open-cell foam forming the main portion 2 is preferably in the range of 20 to 300 g / l. When the content of the material is less than 20 g / l, the desired effect is often not obtained. On the other hand, when the content of the material is more than 300 g / l, the majority of the bubbles inside the layer 3 This is because it is occupied by the material to be formed, and basic functions such as flexibility as an open-cell foam are impaired.

As an open cell foam constituting the main part 2 according to the present embodiment, an EPDM open cell foam other than those used in the examples described above may be used.
«Second embodiment» (main part is cross-linked polyolefin open-cell foam)
Next, a second embodiment of the present invention will be described below.

  In this embodiment, a cross-linked polyolefin open-cell foam is used as the open-cell foam forming the main portion 2 instead of the EPDM open-cell foam.

  Examples of functions to be added or strengthened include heat resistance, flame resistance, oil resistance, UV resistance, sound absorption, chemical resistance, wear resistance, cold resistance, weather resistance, ozone resistance, stain resistance, and adhesiveness. , Moldability, electrical performance, insulation, radio wave absorptivity, mechanical strength, rigidity, water stoppage, heat insulation, sound insulation, and the like. In order to add or reinforce these functions, the present embodiment is realized by selecting the material to be the layer 3 without changing or modifying the main part 2. That is, in order to add or enhance heat resistance, flame resistance, oil resistance, chemical resistance, ultraviolet resistance, wear resistance, cold resistance, weather resistance, ozone resistance or contamination resistance, fluororubber resin coatings are used. Is suitable. In particular, if it is a colored fluororubber resin paint, the design can be added or enhanced. Silicone resin paints are also suitable for adding or enhancing heat resistance. In particular, if it is a colored silicone resin paint, the design can be added or enhanced. Epoxy resins are suitable for adding or reinforcing adhesion, moldability, electrical performance, or insulation. In order to add or enhance the radio wave absorptivity, an electromagnetic wave shielding paint is suitable. In order to add or enhance weather resistance, ozone resistance, ultraviolet resistance or adhesiveness, an ultraviolet curable resin is suitable. FRP and phenol resin are suitable for enhancing mechanical strength or rigidity. A waterproof coating agent is suitable for adding or strengthening oil resistance or water-stopping property. Thermal barrier coatings are suitable for adding or enhancing thermal barrier properties. An aqueous acrylic resin emulsion-based paint is suitable for adding or enhancing sound insulation.

  Hereinafter, the case where a fluororubber resin paint is used as the material of the layer 3 to add heat resistance will be specifically described as Example 10 and Comparative Example 4.

  The cross-linked polyolefin open-cell foam constituting the main part 2 is a cross-linked polyolefin open-cell foam known as this type of cross-linked polyolefin open-cell foam, for example, a cross-link manufactured and sold by the applicant under the trade name “Super Opcell LC3001 # 2”. It is a polyolefin open-cell foam, and the specific description of the raw materials, the blending ratio of the foaming agent, the cross-linking agent, and the production method thereof is omitted.

  The cross-linked polyolefin open-cell foam is obtained by adding and kneading a foaming agent and an auxiliary raw material for adding functions such as flame retardancy to a polyolefin resin, and heating and foaming.

Here, as an example of a functional open-cell foam in which the main part 2 is composed of a chemically-crosslinked polyethylene open-cell foam, a chemically-crosslinked polyethylene open-cell manufactured and sold by the applicant under the trade name “Super Opcel LC3001 # 2” The main part 2 is comprised with the foam, The thing which concerns on the following Example 10 made by the procedure similar to the thing which concerns on Example 1 mentioned above except the structure of the main part 2 is mentioned.
<Example 10> (Heat resistance)
Chemically cross-linked polyethylene open cell foam (manufactured by Sanwa Kako Co., Ltd., trade name “Super Opcell (registered trademark) LC3001 # 2”) with fluororubber resin paint, more specifically, Perflon (registered trademark) manufactured by Kinyo What the said fluororubber resin coating material was impregnated so that the content of a paint might be about 100 g / l.

A comparative example for Example 10 will be described below.
<Comparative Example 4>
Chemically crosslinked polyethylene open cell foam (manufactured by Sanwa Kako Co., Ltd., trade name “Super Opcell (registered trademark) LC3001 # 2”).

  That is, the open-cell foam according to Comparative Example 4 is impregnated with the fluororubber resin paint in the procedure as described above, and the layer 3 containing the fluororubber resin paint is formed on the inner surface of the bubble B not exposed to the outside. Is a functional open-cell foam according to Example 10. The expansion ratio of the open-cell foam according to Comparative Example 4 and the expansion ratio of the open-cell foam constituting the main part 2 of Example 10 are both about 21 times.

  Here, the following tests were conducted on the heat resistance, that is, the thermal stability of the functional open-cell foam according to Example 10 and the open-cell foam according to Comparative Example 4. Specifically, the sample was placed in a 160 ° C. environment or a 170 ° C. environment for 22 hours, and then the dimensional change rate and the volume change rate were measured. The results are shown in Table 10 below.

  Here, the thickness of the sample is 2 mm. The dimensional change rate during heating at 170 ° C. in Comparative Example 4 was not measurable because the sample was melted and the original pattern was hardly retained.

  In addition, the sample of Example 10 is defined in JIS K6767 before the sample is placed in a 160 ° C environment or 170 ° C environment and after the sample is placed in a 160 ° C environment or 170 ° C environment for 22 hours. The tensile strength of the sample was measured by this method. Table 10 also shows the measurement results of the tensile strength. The unit of tensile strength is MPa. Regarding the sample of Comparative Example 4, after being placed in a 160 ° C. environment for 22 hours, a size sufficient to measure the tensile strength does not remain, and in a 170 ° C. environment, 22 hours. After placing, the sample was melted as described above and the original pattern was not substantially retained, so the measurement of the tensile strength was omitted.

  According to the above, the functional open-cell foam of Example 10 changes greatly in size after being exposed to a high-temperature environment of 160 ° C. to 170 ° C. compared to the open-cell foam of Comparative Example 4. It can be said that it has thermal stability without being melted and not retaining the original shape, and further, the tensile strength is not greatly reduced. That is, the open cell which comprises the main part 2 by impregnating the chemically crosslinked polyethylene open cell foam which comprises the main part 2 with a fluororubber resin coating without adding a change or a device to the component and manufacturing method of the main part 2 It can be said that the thermal stability can be enhanced without causing problems in the production of the foam.

  Further, the functional open-cell foam 1 according to the present embodiment described above is also preferably one having the following physical properties for the same reason as the first embodiment described above. . That is, it is desirable that the functional open cell foam 1 has a void volume of 60% to 80% (more preferably about 70%) with respect to the total volume of the open cell BB. Moreover, it is desirable that the expansion ratio of the main portion 2 is in the range of 6 to 40 times. The content of the material forming the layer 3 with respect to the open-cell foam forming the main portion 2 is preferably in the range of 20 to 300 g / l.

Of course, a cross-linked polyolefin open-cell foam other than the one used in Example 10 described above may be used as the open-cell foam constituting the main part 2 according to the present embodiment.
<< Other Embodiments >>
The present invention is not limited to the first and second embodiments described above.

  For example, the main part is not limited to the one configured using an open-cell foam other than the open-cell foam made of synthetic rubber or the open-cell foam made of chemically cross-linked polyethylene resin. You may comprise using other open cell foams, such as a cellular foam, a urethane foam, a PVC foam, an acrylic rubber foam.

  Various functions can be added to or strengthened with respect to main parts other than those described in the first and second embodiments by a method according to the method of the first and second embodiments described above. In other words, examples of functions to be added or strengthened include heat resistance, flame resistance, oil resistance, ultraviolet resistance, sound absorption, chemical resistance, wear resistance, cold resistance, weather resistance, ozone resistance, contamination resistance, Adhesiveness, moldability, electrical performance, insulation, radio wave absorptivity, mechanical strength, rigidity, water stoppage, heat insulation, sound insulation, design, etc. are mentioned. Suitable layer materials for realizing each function are as described below.

  That is, it constitutes a layer for adding or strengthening heat resistance, flame resistance, oil resistance, ultraviolet resistance, sound absorption, chemical resistance, wear resistance, cold resistance, weather resistance, ozone resistance or contamination resistance. As the material, fluororubber resin paint is suitable. In particular, if it is a colored fluororubber resin paint, the design can be added or enhanced. A silicone resin paint is also suitable as a material constituting the layer for adding or reinforcing the heat resistance. In particular, if it is a colored silicone resin paint, the design can be added or enhanced. An epoxy resin is suitable as a material constituting the layer for adding or reinforcing adhesiveness, moldability, electrical performance or insulation. An electromagnetic wave shielding paint is suitable as a material constituting the layer for adding or enhancing the radio wave absorptivity. As a material constituting the layer for adding or reinforcing ultraviolet resistance, weather resistance, ozone resistance or adhesion, an ultraviolet curable resin is suitable. As a material constituting the layer for enhancing mechanical strength or rigidity, FRP or phenol resin is suitable. A waterproof coating agent is suitable as a material constituting the layer for adding or reinforcing oil resistance or water-stopping property. As a material constituting the layer for adding or reinforcing the heat shielding property, a heat shielding paint is suitable. A water-based acrylic resin emulsion-based paint is suitable as a material constituting the layer for adding or reinforcing the sound insulation. Colored fluororubber resin paints and colored silicone resin paints are suitable as materials constituting the layer for adding or reinforcing the design properties.

  The functional open-cell foam described above is preferably one having the following physical properties for the same reason as that of the first embodiment described above. That is, in such a functional open cell foam, it is desirable that the void volume due to the open cells is 60% to 80% (more preferably about 70%) with respect to the total volume. Moreover, it is desirable that the expansion ratio of the main part is in the range of 6 to 40 times. And as for content of the material which forms the said layer with respect to the open-cell foam which forms the said main part, what is in the range of 20-300 g / l is desirable.

  In Examples 1 and 2 of the first embodiment described above, characteristics such as heat resistance and oil resistance when the content of the material for forming a layer, such as fluororubber for the open cell foam, is less than 100 g / l. In view of the fact that if the content exceeds 300 g / l, the performance represented by the cushioning property as an open-cell foam is impaired, the content is set in the range of 100 to 300 g / l. Like to do. However, depending on the main component of the open-cell foam, the properties such as heat resistance and oil resistance can be sufficiently obtained even when the content is less than 100 g / l, or as in Examples 3 to 8, Other properties such as UV resistance and sound absorption may be obtained sufficiently, and even when the content exceeds 300 g / l, the performance typified by cushioning as an open cell foam is not impaired. There is also. In that case, it is not always necessary to set the content within the range of 100 to 300 g / l. In the first and second embodiments described above, the expansion ratio of the main part constituting the functional open-cell foam is set in the range of 6 to 40 times. It may be changed according to the desired effect and the type of open-cell foam constituting the main part.

  In addition, it is not necessary that a layer is formed on the entire inner surface of the open cell, and a layer may be formed only on a part thereof.

  And after forming the layer by one material in the inner surface of an open cell, you may of course form the layer by a material different from said one material on this layer. In this case, an operation of impregnating the open cell foam with the solution is performed a plurality of times.

  Further, instead of the method of immersing the open-cell foam constituting the main part in the solution containing the material constituting the layer and impregnating the open-cell foam with the solution, the solution containing the material constituting the layer is used as the main part. Alternatively, a method may be adopted in which a layer is formed on substantially the entire inner surface of the bubbles constituting the open cells by spraying the open cell foam constituting the bubbles and impregnating the open cell foam with the solution.

  In addition, various changes may be made without departing from the spirit of the present invention.

DESCRIPTION OF SYMBOLS 1 ... Open-cell foam 2 ... Main part 3 ... Layer containing fluororubber resin paint

The functional open-cell foam, which is a heat-resistant open-cell foam according to the invention of claim 5 , has a main part formed of the open-cell foam and a fluororubber on the inner surface of the bubbles not exposed to the outside It has heat resistance and oil resistance in which a layer containing a resin coating is formed.

The method for producing a functional open-cell foam according to the first aspect of the present invention includes an open-cell foam containing a fluororubber resin paint by impregnating the open-cell foam in a fluororubber resin paint or a solution containing the fluororubber resin paint. A functional open-cell foam that is a heat-resistant open-cell foam having heat resistance and oil resistance is obtained by drying the body, removing the solvent, and curing it by heating.

If it is such, while using the open-cell foam of the conventional structure (the main part was formed of the EPDM open-cell foam) as it is, open-cell in the fluororubber resin paint (including solution) By impregnating the foam, a layer containing a fluororubber resin coating is formed on the inner surface of the bubbles not exposed to the outside, and heat resistance and oil resistance can be added to such open-cell foam. Therefore, without using special raw materials in the formation of open-cell foams, and without accompanying manufacturing difficulties and cost increases by changing the blending ratio of raw materials, foaming agents, crosslinking agents, etc., heat resistance In addition , a functional open-cell foam that is a heat-resistant open-cell foam having oil resistance can be obtained.

Moreover, what contains a vinylidene fluoride / tetrafluoroethylene / hexafluoropropylene copolymer as an example of the said fluororubber resin coating material is mentioned.

Further, even when a layer is formed on the inner surface of the bubble with a material other than the fluororubber resin paint, an effect similar to that of the present invention may be obtained. Hereinafter, as an example of such, on the inner surface of the bubble B of the open-cell foam described in Comparative Example 1 (EPDM open-cell foam (manufactured by Sanwa Chemical Co., Ltd., model number OP-130FR # 2)) An example of a functional open-cell foam in which the layer 3 made of silicone resin paint is formed will be described below.

An example of the functional open-cell foam formed as described above will be described below.
< Reference Example 1 > (Heat resistance)
Silicone resin paint, more specifically Taiho Paint Co., Ltd., so that the content of the silicone resin paint is 200 g / l with respect to EPDM open cell foam (manufactured by Sanwa Chemical Co., Ltd., model number OP-130FR # 2). Impregnated with Santomo (registered trademark) DHX paint.

Here, the following tests were conducted on the heat resistance, that is, the thermal stability of the functional open-cell foam according to Reference Example 1 and the open-cell foam according to Comparative Example 1. Specifically, the sample was placed in a 200 ° C. environment for 22 hours, and then the dimensional change rate was measured. The results are shown in Table 9 below.

According to the above, it can be said that the functional open-cell foam of Reference Example 1 has a smaller dimensional change rate than the open-cell foam of Comparative Example 1, and thus has thermal stability. That is, manufacturing the open-cell foam constituting the main part 2 by impregnating the open-cell foam constituting the main part 2 with a silicone resin paint without changing or modifying the components and manufacturing method of the main part 2 It can be said that the thermal stability can be enhanced without causing the above problems.

As an open cell foam constituting the main part 2 according to the present embodiment, an EPDM open cell foam other than those used in the examples described above may be used.
<< Reference Embodiment >> (main part is crosslinked polyolefin open-cell foam)
Next, one of the reference embodiments capable of obtaining an effect similar to that of the present invention will be described below.

Here, as an example of a functional open-cell foam in which the main part 2 is composed of a chemically-crosslinked polyethylene open-cell foam, a chemically-crosslinked polyethylene open-cell manufactured and sold by the applicant under the trade name “Super Opcel LC3001 # 2” The main part 2 is comprised with the foam, The thing which concerns on the following reference examples 2 made by the procedure similar to the thing which concerns on Example 1 mentioned above except the structure of the main part 2 is mentioned.
< Reference Example 2 > (Heat resistance)
Chemically cross-linked polyethylene open cell foam (manufactured by Sanwa Kako Co., Ltd., trade name “Super Opcell (registered trademark) LC3001 # 2”) with fluororubber resin paint, more specifically, Perflon (registered trademark) manufactured by Kinyo What the said fluororubber resin coating material was impregnated so that the content of a paint might be about 100 g / l.

A comparative example with respect to this reference example 2 will be described below.
<Comparative Example 4>
Chemically crosslinked polyethylene open cell foam (manufactured by Sanwa Kako Co., Ltd., trade name “Super Opcell (registered trademark) LC3001 # 2”).

That is, the open-cell foam according to Comparative Example 4 is impregnated with the fluororubber resin paint in the procedure as described above, and the layer 3 containing the fluororubber resin paint is formed on the inner surface of the bubble B not exposed to the outside. Is a functional open-cell foam according to Reference Example 2 . The expansion ratio of the open-cell foam according to Comparative Example 4 and the expansion ratio of the open-cell foam constituting the main part 2 of Reference Example 2 are both about 21 times.

Here, the following tests were conducted on the heat resistance, that is, the thermal stability of the functional open-cell foam according to Reference Example 2 and the open-cell foam according to Comparative Example 4. Specifically, the sample was placed in a 160 ° C. environment or a 170 ° C. environment for 22 hours, and then the dimensional change rate and the volume change rate were measured. The results are shown in Table 10 below.

Moreover, it is prescribed | regulated to JISK6767 before putting a sample in a 160 degreeC environment or a 170 degreeC environment with respect to the sample of the reference example 2 , and after putting a sample in a 160 degreeC environment or a 170 degreeC environment for 22 hours. The tensile strength of the sample was measured by this method. Table 10 also shows the measurement results of the tensile strength. The unit of tensile strength is MPa. Regarding the sample of Comparative Example 4, after being placed in a 160 ° C. environment for 22 hours, a size sufficient to measure the tensile strength does not remain, and in a 170 ° C. environment, 22 hours. After placing, the sample was melted as described above and the original pattern was not substantially retained, so the measurement of the tensile strength was omitted.

According to the above, the functional open-cell foam of Reference Example 2 is greatly changed in size even after being exposed to a high temperature environment of 160 ° C. to 170 ° C., compared with the open-cell foam of Comparative Example 4. It can be said that it has thermal stability without being melted and not retaining the original shape, and further, the tensile strength is not greatly reduced. That is, the open cell which comprises the main part 2 by impregnating the chemically crosslinked polyethylene open cell foam which comprises the main part 2 with a fluororubber resin coating without adding a change or a device to the component and manufacturing method of the main part 2 It can be said that the thermal stability can be enhanced without causing problems in the production of the foam.

Of course, a cross-linked polyolefin open-cell foam other than that used in the above-mentioned Reference Example 2 may be used as the open-cell foam constituting the main part 2 according to the present embodiment.
<< Other Embodiments >>
The present invention is not limited to the first embodiment described above.

The functional open-cell foam, which is a heat-resistant open-cell foam according to the invention of claim 5 , has a main part formed of the open-cell foam and a fluororubber on the inner surface of the bubbles not exposed to the outside A layer containing a resin paint is formed, and the content of the fluororubber resin paint with respect to the open-cell foam is 100 to 300 g / l, and the fluororubber resin paint is cured at room temperature. The open cell foam has a void volume of 60 to 80% of the total volume of the open cell foam or the expansion ratio of the open cell foam is 6 to 40 times, and is heat resistant. And oil resistance.

The method for producing a functional open-cell foam according to the first aspect of the present invention includes an open-cell foam containing a fluororubber resin paint by impregnating the open-cell foam in a fluororubber resin paint or a solution containing the fluororubber resin paint. the body is dried removed the solvent, by performing the step of curing by heating, there is obtained a functional open-cell foam is a heat-resistant open-cell foam having heat resistance and oil resistance, the open-celled The content of the fluororubber resin paint with respect to the foam is 100 to 300 g / l, the fluororubber resin paint can be cured at room temperature, and the void volume due to the open cells of the open cell foam Is 60 to 80% of the total volume, and the curing step is performed at a temperature of 100 ° C. or lower .
According to a second aspect of the present invention, there is provided a method for producing a functional open-cell foam, wherein the open-cell foam is impregnated in a fluororubber resin paint or a solution containing the fluororubber resin paint, and the continuous foam containing the fluororubber resin paint is contained. A functional open-cell foam that is a heat-resistant open-cell foam having heat resistance and oil resistance is obtained by drying the cell foam to remove the solvent and curing it by heating. The content of the fluororubber resin coating with respect to the open cell foam is 100 to 300 g / l, the fluororubber resin paint can be cured at room temperature, and the foaming ratio of the open cell foam is 6 The step of curing is performed at a temperature of 100 ° C. or lower .

In addition, if the content of the fluororubber resin coating with respect to the open-cell foam is less than 100 g / l (gram per liter), sufficient heat resistance may not be obtained, and the content may be 300 g / l. When it exceeds, performance represented by cushioning properties as an open-cell foam may be impaired, whereas production of a functional open-cell foam that is a heat-resistant open-cell foam according to the invention of claim 1 or 2 If it is a functional open-cell foam which is a heat-resistant open-cell foam concerning the method and invention of Claim 5 , content of the fluororubber resin coating material with respect to the open-cell foam is 100-300 g / l. Therefore, sufficient heat resistance can be obtained without impairing the performance typified by cushioning as an open-cell foam.

Claims (14)

A functional open-cell foam comprising a main part having open cells and a layer made of a material different from that of the main part and formed on the inner surface of the air bubbles constituting the open-cells. The functional open-cell foam according to claim 1, wherein the volume of voids due to the open cells is 60% to 80% with respect to the total volume. The functional open-cell foam according to claim 1, wherein the main part has a foaming ratio of 6 to 40 times. The functional open-cell foam according to claim 1, wherein the content of the material forming the layer with respect to the open-cell foam is 20 to 300 g / l. The functional open-cell foam according to claim 1, 2, 3, or 4, wherein the main part is an open-cell foam made of synthetic rubber. The functional open-cell foam according to claim 1, 2, 3, or 4, wherein the main part is an open-cell foam made of a chemically cross-linked polyethylene resin. The layer formed on the inner surface of the bubble constituting the open cell is a fluororubber resin paint, a colored fluororubber resin paint, a silicone resin paint, a colored silicone resin paint, an epoxy resin, an electromagnetic wave shielding paint, an ultraviolet curable resin, an FRP The functional open-cell foam according to claim 1, 2, 3, 4, 5 or 6, which is any one of a phenol resin, a waterproof coating agent, a thermal barrier paint and a water-based acrylic resin emulsion paint. The open-cell foam that is the main part is immersed in a solution containing a material different from the main part, and the open-cell foam is impregnated with the solution,
Dry the open cell foam to remove the solvent,
By performing the step of curing by heating,
A method for producing a functional open-cell foam, comprising: obtaining a functional open-cell foam in which a layer of the material is formed on an inner surface of a cell constituting the open-cell foam. Spraying a solution containing a material different from the main part to the open-cell foam as the main part to impregnate the open-cell foam with the solution,
Dry the open cell foam to remove the solvent,
By performing the step of curing by heating,
A method for producing a functional open-cell foam, characterized in that a functional open-cell foam is obtained in which a layer of the material is formed on substantially the entire inner surface of a cell constituting the open-cell foam. Fluorine rubber resin paint, or impregnated with open cell foam in a solution containing fluororubber resin paint,
Dry the open cell foam containing fluororubber resin paint to remove the solvent,
By performing the step of curing by heating,
A method for producing a functional open-cell foam, which is a heat-resistant open-cell foam, characterized by obtaining a heat-resistant open-cell foam having heat resistance. The method for producing a functional open-cell foam which is a heat-resistant open-cell foam according to claim 10, wherein the content of the fluororubber resin coating with respect to the open-cell foam is 100 to 300 g / l. The method for producing a functional open-cell foam as a heat-resistant open-cell foam according to claim 10 or 11, wherein the open-cell foam is an EPDM open-cell foam. Functional open-cell foam, which is a heat-resistant open-cell foam in which the main part is formed by open-cell foam and a layer containing fluororubber resin paint is formed on the inner surface of the foam not exposed to the outside body. The functional open-cell foam which is a heat-resistant open-cell foam according to claim 13, wherein the open-cell foam forming the main part is an EPDM open-cell foam.

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