JP2019210448A - Porous structure, manufacturing method of porous structure and data for 3d molding - Google Patents

Abstract

To provide a porous structure, a manufacturing method of the porous structure and data for 3D molding which can manufacture the porous structure with cushioning characteristics by 3D printer easily.SOLUTION: A porous structure 1 consists of flexible resin or rubber. The porous structure comprises a skeleton part 2 for the whole. The skeleton part consists of multiple bony parts 2B and multiple binding parts 2J binding ends of each bony part respectively. In the volume of the porous structure, ratio of the volume that the skeleton part accounts for is 3-10%.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a porous structure, a method for manufacturing a porous structure, and 3D modeling data.

  Conventionally, a porous structure with cushioning properties (for example, urethane foam) has been manufactured through a step of foaming by a chemical reaction in, for example, mold molding (for example, Patent Document 1).

JP, 2006-44292, A

  However, as described above, when producing a porous structure through a process of foaming by a chemical reaction, there is a problem that it takes time and labor for the production, and there is a possibility that the expected configuration may not be obtained. was there.

  Therefore, the inventors of the present invention newly paid attention to the fact that if a porous structure can be manufactured using a 3D printer, the manufacturing becomes simple and the desired configuration can be obtained. It came to make this invention.

  The present invention provides a porous structure, a method for manufacturing a porous structure, and data for 3D modeling, which can easily manufacture a porous structure with cushioning properties by a 3D printer. Objective.

The porous structure of the present invention is
A porous structure composed of a flexible resin or rubber,
The porous structure is provided with a skeleton part over the entire structure,
The skeleton part is
Multiple bones,
A plurality of joints each joining the ends of the plurality of bone parts;
Consists of
The ratio of the volume occupied by the skeleton in the volume of the porous structure is 3 to 10%.
Thereby, a porous structure with cushioning properties can be easily manufactured by the 3D printer.

In the porous structure of the present invention,
The skeleton has a first annular portion configured in an annular shape,
The first annular portion defines a first virtual surface by an inner peripheral side edge portion.
The first annular portion is preferably composed of a plurality of the bone portions and a plurality of the coupling portions.
Thereby, the characteristic as a cushioning material of a porous structure becomes more favorable.

In the porous structure of the present invention,
The skeleton has a first cell partition that partitions the first cell hole inside,
The first cell partition portion has a plurality of first annular portions each configured in an annular shape,
The plurality of first annular portions are connected to each other so that the first virtual surfaces defined by respective inner peripheral side edges do not intersect each other,
The first cell hole is partitioned by the plurality of first annular portions and the plurality of first virtual surfaces defined by the plurality of first annular portions,
The first annular portion is preferably composed of a plurality of the bone portions and a plurality of the coupling portions.
Thereby, the characteristic as a cushioning material of a porous structure becomes more favorable.

In the porous structure of the present invention,
The skeleton has a second cell partition that partitions the second cell hole inside,
The second cell partition portion has a plurality of second annular portions each configured in an annular shape,
The plurality of second annular portions are connected to each other such that the second virtual surfaces defined by the respective inner peripheral side edges intersect each other,
The second cell hole is partitioned by at least inner peripheral side edges of the plurality of second annular portions,
It is preferable that the second annular portion is composed of a plurality of the bone portions and a plurality of the coupling portions.
Thereby, the characteristic as a cushioning material of a porous structure becomes more favorable.

In the porous structure of the present invention,
The bone part is
A constant bone portion extending while maintaining a constant cross-sectional area; and
While changing the cross-sectional area gradually, extending from the bone constant part to the joint part, bone change part,
Have
It is preferable that the fixed bone portion has a smaller width than the bone changing portion and the connecting portion.
Thereby, the characteristic as a cushioning material of a porous structure becomes more favorable.

In the porous structure of the present invention,
The cross-sectional shape of the bone fixed portion is preferably a circular shape or a polygonal shape.
Thereby, the characteristic as a cushioning material of a porous structure becomes more favorable.

In the porous structure of the present invention,
The bone changing portion has an inclined surface,
It is preferable that the inclined surface is inclined with respect to the extending direction of the bone changing portion and gradually increases in width toward the coupling portion.
Thereby, the characteristic as a cushioning material of a porous structure becomes more favorable.

In the porous structure of the present invention,
The porous structure may be used for a seat pad.

In the porous structure of the present invention,
The porous structure may be formed by a 3D printer.

The method for producing the porous structure of the present invention comprises:
The above-mentioned porous structure is manufactured using a 3D printer.
Thereby, a porous structure with cushioning properties can be easily manufactured by the 3D printer.

The 3D modeling data of the present invention is
3D modeling data read by the control unit of the 3D printer when the modeling unit of the 3D printer performs modeling,
The said control part is comprised so that the said modeling part may model the above-mentioned porous structure.
Thereby, a porous structure with cushioning properties can be easily manufactured by the 3D printer.

  ADVANTAGE OF THE INVENTION According to this invention, the porous structure which can manufacture a cushioning porous structure easily with a 3D printer, the manufacturing method of a porous structure, and the data for 3D modeling are provided. be able to.

It is a top view which shows a mode when a part of porous structure which concerns on one Embodiment of this invention is seen from the direction of C arrow of FIGS. FIG. 5 is a side view showing the state of the porous structure of FIG. 1 when viewed from the direction of arrow A in FIGS. 1, 3, and 4. It is a perspective view which shows a mode when the porous structure of FIG. 1 is seen from the direction of the arrow D of FIG.1, FIG.2, FIG.4. It is a perspective view which shows a mode when the porous structure of FIG. 1 is seen from the direction of B arrow of FIG. 2, FIG. It is a perspective view which shows a mode when the unit part of the porous structure of FIG. 1 is seen from the direction of D arrow of FIG.1, FIG.2, FIG.4. It is a perspective view which shows a mode when a part of unit part of the porous structure of FIG. 5 is expanded and seen. It is a perspective view which shows a mode when the unit part of the porous structure of FIG. 5 is seen from the direction of the arrow E of FIG. 7 is the same drawing as FIG. 7, and only a part of reference numerals, broken lines and chain lines are different from FIG. 7. It is a perspective view which shows a mode when the unit part of the porous structure of FIG. 5 is seen from the direction of F arrow of FIG. 9. It is the same drawing as FIG. 9, and only a part of reference numerals and broken lines / chain lines are different from FIG. FIG. 11A is a perspective view showing a bone part of the porous structure of FIG. 1 in a state where no external force is applied, and FIG. 11B is a diagram of FIG. 11A in a state where an external force is applied. It is a perspective view which shows the bone part. FIG. 9 is a view corresponding to FIG. 8 for explaining a porous structure according to a first modification of the present invention. FIG. 9 is a view corresponding to FIG. 8 for explaining a porous structure according to a second modification of the present invention. FIG. 9 is a view corresponding to FIG. 8 for explaining a porous structure according to a third modification of the present invention. It is a perspective view showing a vehicular seat pad provided with a porous structure concerning one embodiment of the present invention. It is drawing for demonstrating the manufacturing method of the porous structure based on one Embodiment of this invention. It is drawing for demonstrating the manufacturing method of the porous structure based on one modification of this invention. FIG. 18A is a cross-sectional view showing an example of a cushion pad portion of a vehicle seat pad made of a porous structure according to an embodiment of the present invention by a cross section taken along line GG in FIG. FIG. 18 (b) is a cross-sectional view showing an example of a back pad portion of a vehicle seat pad made of a porous structure according to an embodiment of the present invention by a cross section taken along the line H-H in FIG. It is.

  The porous structure of the present invention and the porous structure manufactured using the porous structure of the present invention or the 3D modeling data are preferably used for a cushioning material and are used for sitting. It is more preferable to be used for a cushion material (such as a seat pad), and it is more preferable to be used for a vehicle seat pad.

Hereinafter, embodiments of a porous structure, a method for manufacturing a porous structure, and 3D modeling data according to the present invention will be described with reference to the drawings.
In each figure, the same code | symbol is attached | subjected to the common component.
In addition, in FIGS. 1 to 10 and FIGS. 12 to 14, the orientation of an XYZ orthogonal coordinate system fixed to the porous structure is displayed in order to facilitate understanding of the orientation of the porous structure.

First, a porous structure according to an embodiment of the present invention will be described with reference to FIGS.
1-4, the part cut | disconnected by the rectangular parallelepiped among the porous structures 1 which concern on this embodiment is seen from each different angle. FIG. 1 is a plan view of a certain surface of the portion of the porous structure 1, that is, the portion of the porous structure 1 is shown in the direction of the arrow C (−X in FIG. 2 to FIG. 4). From the direction). FIG. 2 is a plan view of the right side surface in FIG. 1 of the portion of the porous structure 1, that is, the portion of the porous structure 1 is shown in FIG. Watched from the direction of the arrow (-Y direction). FIG. 3 is an oblique view of the same surface as that of FIG. 1 in the portion of the porous structure 1, that is, the portion of the porous structure 1 is indicated by an arrow D in FIGS. 1, 2, and 4. Looking from the direction. 4 shows the surface of the porous structure 1 opposite to that in FIGS. 1 and 3 obliquely from above, that is, the portion of the porous structure 1 is shown in FIGS. Looking from the direction of the arrow B.

The porous structure 1 of the present embodiment is formed by a 3D printer. By producing a porous structure using a 3D printer, the production is simplified and a desired configuration can be obtained as compared with a case where a foaming process is performed by a chemical reaction as in the prior art. In addition, it can be expected that the 3D printer technology can be realized in a short time and at a low cost in the future due to the technical advancement of the 3D printer in the future.
The porous structure 1 is made of flexible resin or rubber. More specifically, the porous structure 1 includes a skeleton part 2 that forms the skeleton of the porous structure 1 and a large number of cell holes C partitioned by the skeleton part 2. The skeleton 2 exists over the entire porous structure 1 and is made of a flexible resin or rubber. In this example, portions of the porous structure 1 other than the skeleton portion 2 are voids.
Here, the “flexible resin” refers to a resin that can be deformed when an external force is applied. For example, an elastomeric resin is preferable, polyurethane is more preferable, and soft polyurethane is used. Further preferred. Examples of the rubber include natural rubber or synthetic rubber. Since the porous structure 1 is made of a flexible resin or rubber, it can be compressed and restored according to the addition / release of an external force, and can have cushioning properties.
In addition, from the viewpoint of ease of manufacture by a 3D printer, the porous structure 1 is more preferably configured from a flexible resin than from a rubber. .

The porous structure 1 of the present embodiment has a configuration in which a plurality of unit portions U each forming a cube are integrally connected in the X, Y, and Z directions. The portion shown in FIG. 1 to FIG. 4 of the porous structure 1 is composed of a total of 18 unit portions U in which three in the Z direction, three in the Y direction, and two in the X direction are arranged. In this example, the configuration, dimensions, and orientation of each unit portion U constituting the porous structure 1 are the same. For convenience, in FIGS. 1 to 4, only one unit portion U is colored with a darker gray color than the other unit portions U, and in FIGS. 1 and 2, it is further colored with a dark gray color. The outer edge of the unit portion U is indicated by a dotted line.
As in this example, when the outer edge (outer contour) of each unit portion U of the porous structure 1 forms a cube, it is possible to obtain mechanical characteristics equal to the respective directions of XYZ.
In addition, the outer edge (outer outline) of the unit part U may have a rectangular parallelepiped other than a cube or other shapes. Moreover, the structure and / or dimension of each unit part U which comprises the porous structure 1 may not be completely the same, and may differ little by little. When the outer edge (outer contour) of each unit portion U of the porous structure 1 forms a rectangular parallelepiped other than a cube, intentional anisotropy can be obtained as a function of the porous structure 1. For example, when the porous structure 1 is applied to a vehicle seat pad, the outer edge (outer contour) of each unit portion U is a rectangular parallelepiped other than a cube, so that it is soft in, for example, the Z direction (the direction in which a person sits). It is possible to improve the ride comfort.

  5 to 10 show one unit part U alone. 5 shows the unit part U from substantially the same direction as FIG. 3, that is, the unit part U is seen from the direction of the arrow D in FIGS. FIG. 6 is an enlarged view of a part of FIG. 7 and FIG. 8 are the same drawings, and the portion on the same side as FIG. 5 in the unit portion U is viewed from below, that is, the unit portion U is viewed from the direction of the arrow E in FIGS. I'm watching. 7 and 8 differ only in that different broken lines and chain lines are attached for the sake of easy viewing. 9 and 10 are the same drawings, and the portion of the unit portion U opposite to that of FIG. 5 is viewed from above, that is, the unit portion U is viewed from the direction of the arrow F in FIGS. I'm watching. FIG. 9 and FIG. 10 differ only in that different broken lines and chain lines are provided for easy viewing of the drawings. For reference, the arrows A, B, and C in FIGS. 1 to 4 are also shown in FIGS. 5 and 7 to 10.

As shown in FIGS. 1 to 10, the skeleton part 2 of the porous structure 1 includes a plurality of bone parts 2 </ b> B and a plurality of coupling parts 2 </ b> J, and the entire skeleton part 2 is configured integrally. Has been. In this example, each bone 2B is configured in a columnar shape, and in this example, each bone portion 2B extends linearly. Each coupling portion 2J is a portion where the end portions 2Be of a plurality of (2 to 6 in the illustrated example) bone portions 2B extending in different directions are adjacent to each other. Are combined.
In FIGS. 6, 7, and 9, a skeleton line O of the skeleton part 2 is shown in a part of the porous structure 1. The skeleton line O of the skeleton part 2 includes a skeleton line O of each bone part 2B and a skeleton line O of each joint part 2J. The skeleton line O of the bone part 2B is a central axis line of the bone part 2B, and includes a central axis line of the bone fixed part 2B1 and a central axis line of the bone changing part 2B2. The skeleton line O of the joint portion 2J is an extended line portion that is formed by smoothly extending the central axes of the bone portions 2B joined to the joint portion 2J into the joint portion 2J and connecting them together.
The extending direction of the bone part 2B is the extending direction of the skeleton line O of the bone part 2B (the part of the skeleton line O corresponding to the bone part 2B; the same applies hereinafter).
Since the porous structure 1 is provided with the skeleton portion 2 throughout, the porous structure 1 can be compressed / restored in accordance with the addition / release of an external force while ensuring air permeability. Become good. Moreover, the structure of the porous structure 1 becomes simple, and modeling with a 3D printer becomes easy.
In addition, some or all of the bone portions 2B of the bone portions 2B constituting the skeleton portion 2 may extend while being curved. In this case, because part or all of the bone part 2B is curved, when the load is input, the bone part 2B and thus the sudden change in the shape of the porous structure 1 is prevented, and local buckling is suppressed. be able to.
In each drawing, each edge part of the skeleton part 2 (side part where a pair of adjacent surfaces abut each other) is square, but each edge part of the skeleton part 2 is smoothly curved. Also good.

In this example, each bone 2B constituting the skeleton 2 has substantially the same shape and length. However, not limited to this example, the shape and / or length of each bone 2B constituting the skeleton 2 may not be the same, for example, the shape and / or length of some bones 2B. However, it may be different from other bone parts 2B. In this case, different mechanical characteristics can be intentionally obtained by making the shape and / or length of the bone part 2B of a specific part of the skeleton part 2 different from other parts. For example, as in the example of FIG. 18A described later, when the porous structure 1 is applied to a vehicle seat pad, the seat surface side (surface side) portion 11 of the main pad portion 311 improves riding comfort. Therefore, the portion 12 constituting the side pad portion 312 can be made hard to obtain a hold feeling.
FIG. 11 shows the bone 2B of this example alone. FIG. 11A shows a natural state where no external force is applied to the bone portion 2B, and FIG. 11B shows a state where an external force is applied to the bone portion 2B. FIG. 11 shows the central axis (skeleton line O) of the bone part 2B.
As shown in FIG. 11 (a), each bone part 2B has a cross-sectional area on both sides in the extending direction of the bone constant part 2B1 and the bone constant part 2B1 extending while keeping the cross-sectional area constant. It is composed of a pair of bone changing portions 2B2 extending from the bone constant portion 2B1 to the joint portion 2J while being gradually changed. In this example, each bone changing portion 2B2 extends from the fixed bone portion 2B1 to the joint portion 2J while gradually increasing the cross-sectional area. In addition, the same effect is acquired even if only some bone parts 2B satisfy | fill this structure among each bone part 2B which comprises not only this example but the skeleton part 2. FIG. Further, some or all of the bone parts 2B constituting the skeleton part 2 have a bone changing part 2B2 only at one end of the bone fixed part 2B1, and the bone fixed part 2B1. The other end may be directly coupled to the coupling portion 2J, and in this case, the same effect can be obtained although there may be a difference in degree.
Here, the cross-sectional areas of the fixed bone portion 2B1 and the bone changing portion 2B2 indicate cross-sectional areas of the cross sections perpendicular to the skeleton line O of the fixed bone portion 2B1 and the bone changing portion 2B2, respectively.
In this example, each bone part 2B constituting the porous structure 1 includes a bone constant part 2B1 and a bone change part 2B2, and the cross-sectional area of the bone change part 2B2 increases from the bone constant part 2B1 toward the coupling part 2J. Therefore, the bone portion 2B is constricted so as to become narrower toward the bone fixed portion 2B1 in the vicinity of the boundary between the bone fixed portion 2B1 and the bone changing portion 2B2. Therefore, when an external force is applied, the bone portion 2B is likely to buckle and deform at the constricted portion or an intermediate portion of the fixed bone portion 2B1, and as a result, the porous structure 1 is easily compressed and deformed. Thereby, a behavior and characteristics equivalent to those of a general polyurethane foam produced through a step of foaming by a chemical reaction can be obtained. Thereby, the touch feeling on the surface of the porous structure 1 becomes softer. For example, when the porous structure 1 is used as a cushioning material (seat pad or the like) for sitting, the seating person is given a softer feel, particularly at the timing of starting sitting. Such a soft feel is generally widely preferred, and is also preferred by a seat pad occupant of a luxury car (for example, a seat occupant who sits in the back seat when a driver is on the back seat). It is what

When the bone part 2B has the bone fixed part 2B1 in at least a part thereof as in this example, the cross-sectional area A1 (FIG. 11 (1)) of the end 2B21 on either side (preferably both sides) of the bone part 2B. The ratio A0 / A1 of the cross-sectional area A0 (FIG. 11 (a)) of the fixed bone portion 2B1 to a)) is
0.5 ≦ A0 / A1 ≦ 2.0
If it satisfies, it is preferable. As a result, the touch feeling on the surface of the porous structure 1 can be made not only too soft, not too hard, and moderately hard as a characteristic of the cushioning material and particularly as a characteristic of the cushioning material for sitting. For example, when the porous structure 1 is used as a cushioning material (seat pad or the like) for sitting, the seating person is given a feeling of moderate hardness especially when the seating starts. . The smaller the ratio A0 / A1, the softer the touch feeling on the surface of the porous structure 1 is. When the ratio A0 / A1 is less than 0.5, the touch feeling on the surface of the porous structure 1 becomes too soft, which may be undesirable as a characteristic of the cushion material. When the ratio A0 / A1 is more than 2.0, the touch feeling on the surface of the porous structure 1 becomes too hard, which may be undesirable as a characteristic of the cushion material.
More specifically, in this example, the bone portion 2B has a bone constant portion 2B1 and a pair of bone changing portions 2B2 continuous on both sides thereof, and each bone changing portion 2B2 gradually increases its sectional area. While increasing, the bone extends from the constant bone portion 2B1 to the joint portion 2J, and the ratio A0 / A1 is less than 1.0. Thereby, the touch feeling on the surface of the porous structure 1 can be made relatively soft as a characteristic of the cushioning material, and particularly as a characteristic of the cushioning material for sitting. Such a soft feel is generally widely preferred, and is also preferred by a seat pad occupant of a luxury car (for example, a seat occupant who sits in the back seat when a driver is on the back seat). It is what
In addition, each bone part 2B which comprises the skeleton part 2 may satisfy | fill this structure, or only some bone parts 2B among each bone part 2B which comprises the skeleton part 2 satisfy | fill this structure. In either case, the same effect can be obtained though there may be a difference in degree.

Instead of this example, the bone changing portion 2B2 may extend from the fixed bone portion 2B1 to the joint portion 2J while gradually reducing the cross-sectional area. In this case, the bone constant portion 2B1 has a larger (thicker) cross-sectional area than the bone changing portion 2B2. As a result, when an external force is applied, the fixed bone portion 2B1 is less likely to be deformed, and instead, a portion that is relatively easy to buckle becomes the bone changing portion 2B2 (particularly, the portion on the connecting portion 2J side), and thus has a porous structure. The body 1 becomes difficult to compress and deform. Thereby, the touch feeling on the surface of the porous structure 1 becomes harder and high mechanical properties can be obtained. For example, when the porous structure 1 is used as a cushioning material for sitting, a hard feeling is given to the seated person, particularly at the timing of starting sitting. Such a behavior cannot be obtained with a general polyurethane foam manufactured through a process of foaming by a chemical reaction. With such a configuration, it is possible to cope with a user who prefers a hard feel. Such a hard feeling is preferred by a seated person in a sports car seat pad that performs quick acceleration / deceleration or oblique line change, for example.
When the bone changing portion 2B2 extends from the fixed bone portion 2B1 to the joint portion 2J while gradually reducing the cross-sectional area, the ratio A0 / A1 exceeds 1.0.
In addition, each bone part 2B which comprises the skeleton part 2 may satisfy | fill this structure, or only some bone parts 2B among each bone part 2B which comprises the skeleton part 2 satisfy | fill this structure. In either case, the same effect can be obtained though there may be a difference in degree.

Or the bone part 2B may not be provided with the bone change part 2B2, but may consist only of the bone fixed part 2B1 as in the first modified example partially shown by a dotted line in FIG. In this case, the cross-sectional area of the bone part 2 is constant over its entire length. And the touch feeling of the surface of the porous structure 1 when an external force is applied becomes moderate hardness. With such a configuration, it is possible to cope with a user who prefers a medium hardness feel. Further, the present invention can be suitably applied to seat pads of all vehicle types such as luxury cars and sports cars.
In this case, the ratio A0 / A1 is 1.0.
In addition, each bone part 2B which comprises the skeleton part 2 may satisfy | fill this structure, or only some bone parts 2B among each bone part 2B which comprises the skeleton part 2 satisfy | fill this structure. In either case, the same effect can be obtained though there may be a difference in degree.

Returning to the examples of FIGS. 1 to 11, in this example, each bone part 2 </ b> B constituting the skeleton part 2 has a smaller bone cross-sectional area than the bone changing part 2 </ b> B <b> 2 and the joint part 2 </ b> J. More specifically, the cross-sectional area of the fixed bone portion 2B1 is the cross-sectional area of each portion of the bone changing portion 2B2 and the connecting portion 2J (excluding the boundary portion between the fixed bone portion 2B1 and the bone changing portion 2B2). Smaller than. That is, the fixed bone portion 2B1 is a portion having the smallest (thin) cross-sectional area in the skeleton portion 2. Thus, as described above, when an external force is applied, the fixed bone portion 2B1 is likely to be deformed, and as a result, the porous structure 1 is likely to be compressively deformed. Thereby, the touch feeling of the surface of the porous structure 1 becomes softer.
In addition, the cross-sectional area of the coupling part 2J refers to the cross-sectional area of the cross section perpendicular to the skeleton line O of the coupling part 2J.
In addition, not only in this example, only some of the bone parts 2B of the bone parts 2B constituting the skeleton part 2 may satisfy this configuration, and even in that case, although there may be a difference in degree, Similar effects can be obtained.

Similarly, in this example, in each bone part 2B constituting the skeleton part 2, the bone constant part 2B1 is smaller in width than the bone change part 2B2 and the joint part 2J. More specifically, the width of the fixed bone portion 2B1 is larger than the width of any portion of the bone changing portion 2B2 and the connecting portion 2J (excluding the boundary portion between the fixed bone portion 2B1 and the bone changing portion 2B2). ,small. That is, the fixed bone portion 2B1 is the smallest (thin) portion in the skeleton portion 2. This also makes it easier for the bone fixed portion 2B1 to be deformed when an external force is applied, thereby making the touch feeling on the surface of the porous structure 1 softer.
The widths of the fixed bone portion 2B1, the bone changing portion 2B2, and the connecting portion 2J are measured along the cross section perpendicular to the skeleton line O of the fixed bone portion 2B1, the bone changing portion 2B2, and the connecting portion 2J, respectively. It refers to the maximum width in the cross section. The skeleton line O of the coupling portion 2J is a portion of the skeleton line O corresponding to the coupling portion 2J. For reference, FIG. 11A shows the width W0 of the fixed bone portion 2B1 and the width W1 of the bone changing portion 2B2.
In addition, not only in this example, only some of the bone parts 2B of the bone parts 2B constituting the skeleton part 2 may satisfy this configuration, and even in that case, although there may be a difference in degree, Similar effects can be obtained.

In each example described above, from the viewpoint of simplification of the structure of the porous structure 1 and, hence, the ease of manufacture of the 3D printer, the width W0 (FIG. 11) of the bone fixed portion 2B1 is 0.05 mm or more. It is preferable that it is present, and more preferably 0.10 mm or more. When the width W0 is 0.05 mm or more, modeling can be performed with the resolution of a high-performance 3D printer, and when it is 0.10 mm or more, modeling can be performed with the resolution of a general-purpose 3D printer as well as a high-performance 3D printer.
On the other hand, from the viewpoint of improving the accuracy of the outer edge (outer contour) shape of the porous structure 1, from the viewpoint of reducing the gap (interval) between the cell holes C, and from the viewpoint of improving the characteristics as a cushioning material, The width W0 (FIG. 11) of the fixed bone portion 2B1 is preferably 0.05 mm or more and 2.0 mm or less.
It is preferable that each bone part 2B constituting the skeleton part 2 satisfies this configuration, but only a part of the bone parts 2B among the bone parts 2B constituting the skeleton part 2 satisfy this structure. Even in such a case, the same effect can be obtained although there may be a difference in degree.

As shown in FIG. 11, in this example, each bone part 2B constituting the skeleton part 2 has a bone changing part 2B2 having one or a plurality of (three in this example) inclined surfaces 2B23 on its side surface. The inclined surface 2B23 is inclined (inclined at less than 90 °) with respect to the extending direction of the bone changing portion 2B2, and the width W2 gradually increases from the bone fixed portion 2B1 toward the coupling portion 2J. Has increased.
This also makes it easier for the bone portion 2B to buckle and deform at the constricted portion near the boundary between the bone fixed portion 2B1 and the bone changing portion 2B2 when an external force is applied, and the porous structure 1 is compressed. It becomes easy to deform. Thereby, the touch feeling of the surface of the porous structure 1 becomes softer.
Here, the extending direction of the bone changing portion 2B2 is the extending direction of the central axis (skeleton line O) of the bone changing portion 2B2. Further, the width W2 of the inclined surface 2B23 of the bone changing portion 2B2 indicates the width of the inclined surface 2B23 when measured along a cross section perpendicular to the skeleton line O of the bone changing portion 2B2.
In addition, not only in this example, only some of the bone parts 2B of the bone parts 2B constituting the skeleton part 2 may satisfy this configuration, and even in that case, although there may be a difference in degree, Similar effects can be obtained.

In this example, in each bone part 2B constituting the skeleton part 2, the cross-sectional shapes of the bone constant part 2B1 and the bone changing part 2B2 are equilateral triangles.
Thereby, the structure of the porous structure 1 becomes simple, and it becomes easy to model with a 3D printer. Moreover, it is easy to reproduce the mechanical characteristics of a general polyurethane foam produced through a foaming process by a chemical reaction. In addition, by configuring the bone part 2B in a columnar shape in this way, it is possible to improve the durability of the porous structure 1 as compared with the case where the bone part 2B is replaced with a thin film-like part.
The cross-sectional shapes of the fixed bone portion 2B1 and the bone change portion 2B2 are shapes in cross sections perpendicular to the central axis (skeleton line O) of the fixed bone portion 2B1 and the bone change portion 2B2.
In addition, not only in this example, only some of the bone parts 2B of the bone parts 2B constituting the skeleton part 2 may satisfy this configuration, and even in that case, although there may be a difference in degree, Similar effects can be obtained.
Further, in all or some of the bone parts 2B constituting the bone part 2B, the bone constant part 2B1 and the bone changing part 2B2 are polygons other than regular triangles (regular triangles). Other than triangle, quadrangle, etc.) or a circle (true circle, ellipse, etc.), and in this case, the same effect as in this example can be obtained. Further, the fixed bone portion 2B1 and the bone changing portion 2B2 may have different cross-sectional shapes.

In the present embodiment, the ratio (VB × 100 / VS [%]) of the volume VB occupied by the skeleton 2 in the volume VS of the porous structure 1 is 3 to 10%. With this configuration, the reaction force generated in the porous structure 1 when an external force is applied to the porous structure 1, and thus the hardness of the porous structure 1, is used as a cushioning material, particularly a cushioning material for sitting. As a (seat pad etc.), it can be made more favorable as a seat pad for vehicles. Moreover, according to this structure, it becomes easy to model with a 3D printer.
Here, “volume VS of porous structure 1” means the entire internal space surrounded by the outer edge (outer contour) of porous structure 1 (the volume occupied by skeleton 2 and the film 3 described later). In this case, the total volume of the volume occupied by the film 3 and the volume occupied by the voids is indicated.
When the materials constituting the porous structure 1 are considered to be the same, the higher the proportion of the volume VB occupied by the skeleton 2 in the volume VS of the porous structure 1, the harder the porous structure 1 becomes. Further, the lower the volume ratio VB of the skeleton 2 in the volume VS of the porous structure 1, the softer the porous structure 1 is.
The reaction force generated in the porous structure 1 when an external force is applied to the porous structure 1, and thus the hardness of the porous structure 1 is good as a cushioning material, particularly as a cushioning material for sitting. From the viewpoint of making it, it is more preferable that the proportion of the volume VB occupied by the skeleton 2 in the volume VS of the porous structure 1 is 4 to 8%.
In addition, as a method of adjusting the ratio of the volume VB occupied by the skeleton part 2 in the volume VS of the porous structure 1, any method may be used. For example, each unit part U of the porous structure 1 may be used. Without changing the dimensions, the thickness (cross-sectional area) of a part or all of the bone part 2B constituting the skeleton part 2 and / or the size of the part or all of the joint part J constituting the skeleton part 2 The method of adjusting (cross-sectional area) is mentioned.
As an example, in the second modified example shown in FIG. 13, as indicated by the dotted line, the thickness (cross-sectional area) of each bone part 2 </ b> B constituting the skeleton part 2 and each connecting part J constituting the skeleton part 2. Of the volume VB occupied by the skeleton 2 in the volume VS of the porous structure 1 by increasing the size (cross-sectional area) of the porous structure 1 as shown by the solid line (example in FIG. 8). Is increasing.
When the porous structure 1 is used for a vehicle seat pad, the 25% hardness of the porous structure 1 is preferably 60 to 500N, and more preferably 100 to 450N. Here, the 25% hardness (N) of the porous structure 1 is obtained by compressing the porous structure by 25% in an environment of 23 ° C. and 50% relative humidity using an Instron type compression tester. The measured value is obtained by measuring the required load (N).

As shown in FIGS. 1 to 4, in the present embodiment, the porous structure 1 includes two types of cells: a first cell hole C <b> 1 and a second cell hole C <b> 2 having a smaller diameter than the first cell hole C <b> 1. It has a cell hole C. In this example, each cell hole C (first cell hole C1 and second cell hole C2) has a substantially polyhedral shape. More specifically, in this example, the first cell hole C1 has a substantially Kelvin tetrahedron shape (a truncated octahedron). The Kelvin tetrahedron (cut octahedron) is a polyhedron composed of six regular tetragonal component surfaces and eight regular hexagonal component surfaces. In the present example, the second cell hole C2 has a substantially octahedral shape. However, in the example of the figure, each bone part 2B has not only the fixed bone part 2B1 but also the bone change parts 2B2 on both sides thereof, so the shape of the first cell hole C1 and the second cell hole C2 is These are not mathematical (perfect) Kelvin tetrahedrons and octahedrons, respectively. Generally speaking, the cell holes C constituting the porous structure 1 are filled so as to fill the internal space surrounded by the outer edge (outer contour) of the porous structure 1 (gap between the cell holes C ( It is arranged with regularity so as to reduce the interval). The second cell holes C2 are arranged so as to fill a slight gap (interval) between the first cell holes C1. However, in this example, as can be seen from FIG. 4 and FIG. 9 in particular, a part of the second cell hole C2 is inside the first cell hole C1, that is, the first cell hole C1 and the first cell hole C1. The 2-cell hole C2 partially overlaps.
As in this example, a part or all (in this example, all) of the cell holes C of the porous structure 1 is substantially polyhedral so that the cell holes C constituting the porous structure 1 are formed between the cell holes C. The gap (interval) can be further reduced, and more cell holes C can be formed inside the porous structure 1. Thereby, the compression / restoration deformation behavior of the porous structure 1 according to the addition / release of the external force becomes better as a cushioning material, particularly as a cushioning material for sitting.
The shape of the polyhedron formed by the cell hole C is not limited to this example, and can be any shape. For example, when the shape of the first cell hole C1 is a substantially tetrahedron, a substantially octahedron, or a substantially dodecahedron, it is preferable from the viewpoint of reducing the gap (interval) between the cell holes C. Further, the shape of part or all of the cell holes C of the porous structure 1 may be a three-dimensional shape other than a substantially polyhedron (for example, a sphere, an ellipsoid, a cylinder, etc.). Further, the porous structure 1 may have only one type of cell hole C (for example, only the first cell hole C1), or may have three or more types of cell holes C. Good. In addition, when the shape of the 1st cell hole C1 was made into the substantially Kelvin tetrahedron (cut top octahedron) like this example, compared with other shapes, it was manufactured through the process of foaming by a chemical reaction. The characteristics of cushioning material equivalent to typical polyurethane foam are most easily reproduced.

In this example, one first cell hole C1 is composed of a total of eight unit portions U, each of which is arranged in two in each of the X, Y, and Z directions. One unit portion U constitutes a part of each of the plurality of first cell holes C1. On the other hand, two second cell holes C2 are arranged for each unit U.
However, not limited to this example, each cell hole C of the porous structure 1 may be configured by an arbitrary number of unit portions U, and each unit portion U may be configured by an arbitrary number. The cell hole C may be configured.

As shown in FIGS. 1-4, in this example, the frame | skeleton part 2 has the 1st cell division part 21 (only the number of 1st cell hole C1) which divides the 1st cell hole C1 inside. Yes.
As shown in FIGS. 1, 2, 5, and 7 to 10, each first cell partition portion 21 has a plurality (14 in this example) of first annular portions 211. . Each first annular portion 211 is formed in an annular shape, and a substantially flat first imaginary plane V1 is defined by each inner peripheral side edge portion 2111. The plurality of first annular portions 211 constituting the first cell partition portion 21 are connected to each other so that the first virtual planes V1 partitioned by the respective inner peripheral edge portions 2111 do not intersect each other.
The first cell hole C1 is partitioned by a plurality of first annular portions 211 that constitute the first cell partitioning portion 21, and a plurality of first virtual planes V1 that are partitioned by the plurality of first annular portions 211, respectively. Yes. Schematically speaking, the first annular portion 211 is a portion that divides a three-dimensional side formed by the first cell hole C1, and the first virtual plane V1 is a three-dimensional configuration surface formed by the first cell hole C1. It is a part which divides.
Each first annular portion 211 includes a plurality of bone portions 2B and a plurality of joint portions 2J that join end portions 2Be of the plurality of bone portions 2B.
A connecting portion between the pair of first annular portions 211 connected to each other is composed of one bone portion 2B shared by the pair of first annular portions 211 and a pair of coupling portions 2J on both sides thereof. ing.
Each of the first virtual surfaces V1 (excluding those that also constitute a second virtual surface V2 described later) is respectively a surface on one side of the first virtual surface V1 (the surface of the first virtual surface V1). A part of one first cell hole C1 is partitioned, and a part of another first cell hole C1 is defined by a surface on the other side of the first virtual surface V1 (the back surface of the first virtual surface V1). It is partitioned.
In the present example, each first virtual plane V1 is not covered with a film and is open, that is, constitutes an opening. For this reason, the cell holes C are communicated with each other through the first virtual plane V1, and ventilation between the cell holes C is made possible. As a result, the air permeability of the porous structure 1 can be improved, and the porous structure 1 can be easily compressed and restored according to the addition / release of external force.

As shown in FIGS. 1, 2, 5, and 7 to 10, in this example, a plurality (14 in this example) of first annular portions 211 that constitute the first cell partition portion 21 are respectively One or more (six in this example) first small annular part 211S and one or more (eight in this example) first macro annular part 211L are included. Each first small annular portion 211S defines the first small virtual surface V1S by its inner peripheral side edge portion 2111. Each first large annular portion 211L defines a first large virtual surface V1L having an area larger than that of the first small virtual surface V1S by an inner peripheral edge 2111 thereof.
7 and 9 show the skeleton line O of the portion constituting the first cell partition portion 21 in the unit portion U. FIG. As can be seen from FIGS. 7 and 9, in this example, the skeleton line O of the first large annular portion 211L is a regular hexagon, and accordingly, the first large virtual plane V1L is also a substantially regular hexagon. I am doing. Further, in the present example, the first small annular portion 211S has a skeleton line O forming a regular tetragon, and accordingly, the first small virtual plane V1S also forms a substantially regular tetragon. Thus, in this example, the first small virtual surface V1S and the first large virtual surface V1L differ not only in area but also in shape.
Each of the first macro-annular portions 211L includes a plurality (six in this example) of a plurality (six in this example) of bone parts 2B and ends 2Be of the plurality of bones 2B. And a connecting portion 2J. Each of the first small annular portions 211S has a plurality (four in this example) of a plurality of (four in this example) bone portions 2B and a plurality of (four in this example) that connect the end portions 2Be of the plurality of bone portions 2B. And a connecting portion 2J.
The plurality of first annular portions 211 constituting the first cell partitioning portion 21 include the first small annular portion 211S and the first large annular portion 211L having different sizes, thereby constituting the porous structure 1. It is possible to further reduce the gap (interval) between the one cell holes C1. Further, as in the present example, when the shapes of the first small annular portion 211S and the first large annular portion 211L are different, the gap (interval) between the first cell holes C1 constituting the porous structure 1 is further reduced. It becomes possible to do.
However, the plurality of first annular portions 211 constituting the first cell partition portion 21 may have the same size and / or shape. When the size and shape of each first annular portion 211 constituting the first cell partition portion 21 are the same, it is possible to obtain the same mechanical characteristics in the respective directions of XYZ.

As in this example, among the first virtual surfaces V1 constituting the first cell partition portion 21, a part or all (all in this example) of the first virtual surfaces V1 has a substantially polygonal shape. It becomes possible to make the space | interval of the cell holes C which comprise the porous structure 1 smaller. Further, the behavior of compression / decompression deformation of the porous structure 1 according to the addition / release of external force becomes better as a cushioning material, particularly as a cushioning material for sitting. In addition, since the shape of the first virtual surface V1 becomes simple, manufacturability and ease of adjustment of characteristics can be improved. In addition, when at least 1 1st virtual surface V1 is satisfy | filling this structure among each 1st virtual surface V1 which comprises the porous structure 1, although there may be a difference in a grade, the same effect is obtained. can get.
In addition, at least 1 1st virtual surface V1 among each 1st virtual surface V1 which comprises the porous structure 1 is arbitrary substantially polygonal shapes other than the substantially regular hexagon like this example, and a substantially regular tetragon. Alternatively, a planar shape other than a substantially polygonal shape (for example, a circle (perfect circle, ellipse, etc.)) may be formed. When the shape of the first virtual surface V1 is a circle (perfect circle, ellipse, etc.), the shape of the first virtual surface V1 becomes simple, so that it is possible to improve manufacturability and ease of adjustment of characteristics, and more Homogeneous mechanical properties can be obtained. For example, when the shape of the first virtual plane V1 is an ellipse that is long in a direction substantially perpendicular to the direction in which the load is applied (horizontal ellipse), an ellipse that is long in the direction substantially parallel to the direction in which the load is applied (vertically long) Compared to the case of an ellipse, the first annular portion 211 that defines the first virtual plane V1, and thus the porous structure 1 is easily deformed (softened) in response to an input of a load.

As shown in FIGS. 1-4, in this example, the frame | skeleton part 2 has the 2nd cell division part 22 (only the number of 2nd cell hole C2) which divides the 2nd cell hole C2 inside. Yes.
As shown in FIGS. 1, 2, 5 to 10 (particularly FIG. 6), each of the second cell partition portions 22 has a plurality (two in this example) of second annular portions 222. ing. Each of the second annular portions 222 is formed in an annular shape, and each inner peripheral edge 2221 defines a substantially flat second virtual surface V2. The second annular portions 222 constituting the second cell partitioning portion 22 are connected to each other so that the second virtual planes V2 partitioned by the respective inner peripheral edge portions 2221 intersect (orthogonal in this example). Yes.
The second cell hole C2 is formed by each inner peripheral edge 2221 of each second annular portion constituting the second cell partitioning part 22 and a virtual surface that smoothly connects the inner peripheral edges 2221. Is partitioned.
In FIG. 6, the skeleton line O of the part which comprises the 2nd cell division part 22 among the unit parts U is shown. As can be seen from FIG. 6, in the present example, each of the second annular portions 222 constituting the second cell partitioning portion 22 has a skeleton line O having a regular tetragon, and accordingly, the second virtual plane V2 is also a substantially square.
Each of the second annular portions 222 includes a plurality of (four in this example) bone portions 2B and a plurality of (four in this example) connecting end portions 2Be of the plurality of bone portions 2B. And a coupling portion 2J.
In this example, the connection part of each 2nd annular part 222 which comprises the 2nd cell division part 22 is comprised by the two coupling | bond part J shared by each 2nd annular part 222. FIG.
Moreover, in this example, the shape and area of each 2nd virtual surface V2 which comprises the 2nd cell division part 22 are mutually the same.
Note that the shape of each second virtual surface V2 constituting the second cell partitioning section 22 is not limited to this example, but any substantially polygonal shape other than a substantially regular quadrangle, or a planar shape other than a substantially polygonal shape (for example, , A circle (perfect circle, ellipse, etc.). When the shape of the second virtual surface V2 is a substantially polygonal shape or a circle (perfect circle, ellipse, etc.), the shape of the second virtual surface V2 becomes simple, so that manufacturability and ease of adjustment of characteristics are improved. it can. For example, when the shape of the second virtual plane V2 is an ellipse that is long in the direction substantially perpendicular to the direction in which the load is applied (horizontal ellipse), the ellipse that is long in the direction substantially parallel to the direction in which the load is applied (vertically long) Compared to the case of an ellipse), the second annular portion 222 that defines the second virtual plane V2, and thus the porous structure 1 is easily deformed (softened) with respect to the input of the load.
As shown in FIGS. 6 and 9, in this example, one of the two second annular parts 222 constituting the second cell partition part 22 is the first annular part 211 (more specifically, 1 small annular part 211S) is also constituted.
In the present example, each second virtual surface V2 is not covered with a film and is open, that is, constitutes an opening. For this reason, the cell holes C (particularly, the first cell hole C1 and the second cell hole C2) communicate with each other through the second virtual plane V2, and ventilation between the cell holes C is enabled. As a result, the air permeability of the porous structure 1 can be improved, and the porous structure 1 can be easily compressed and restored according to the addition / release of external force.

In each example described in this specification, it is preferable that the porous structure 1 has at least one cell hole C having a diameter of 5 mm or more. Thereby, manufacture of the porous structure 1 using a 3D printer becomes easy to implement | achieve. If the diameter of each cell hole C of the porous structure 1 is less than 5 mm, the structure of the porous structure 1 becomes too complicated, resulting in three-dimensional shape data (CAD) representing the three-dimensional shape of the porous structure 1. Data), or 3D modeling data generated based on the three-dimensional shape data may be difficult to generate on a computer, or even if they can be generated, 3D is generated according to the 3D modeling data. The printer may be difficult to model.
In addition, since the conventional porous structure which has cushioning property was manufactured through the process made to foam by a chemical reaction as mentioned above, the cell hole C whose diameter was 5 mm or more was not able to be formed. However, the inventor of the present invention has newly found that even when the porous structure has cell holes C having a diameter of 5 mm or more, the same characteristic as the conventional cushioning material can be obtained. Then, by making the porous structure have cell holes C having a diameter of 5 mm or more, it becomes easy to manufacture with a 3D printer.
Moreover, when the porous structure 1 has the cell holes C having a diameter of 5 mm or more, the air permeability and the ease of deformation of the porous structure 1 are easily improved.
As the diameter of the cell hole C increases, it becomes easier to produce the porous structure 1 using a 3D printer, and it becomes easier to improve air permeability and ease of deformation. From such a viewpoint, in the porous structure 1, the diameter of at least one cell hole C is more preferably 8 mm or more.
On the other hand, if the cell hole C of the porous structure 1 is too large, it becomes difficult to form the outer edge (outer contour) shape of the porous structure 1 cleanly (smoothly). When applied to the above, the shape accuracy may be reduced and the appearance may be deteriorated. Further, the characteristics as a cushioning material may not be sufficiently good. Therefore, from the viewpoint of improving the appearance and characteristics as a cushioning material, the diameter of each cell hole C of the porous structure 1 is preferably less than 30 mm, more preferably 25 mm or less, and even more preferably 20 mm or less. Good.
In addition, as the porous structure 1 has more cell holes C satisfying the above numerical range, the above-described effects are more easily obtained. From this point of view, it is preferable that at least the diameter of each first cell hole C1 among the plurality of cell holes C constituting the porous structure 1 satisfies at least one numerical range described above. Moreover, it is more preferable that the diameter of each cell hole C (each first cell hole C1 and each second cell hole C2) constituting the porous structure 1 satisfies at least one of the numerical ranges described above. .
Note that the diameter of the cell hole C indicates the diameter of the circumscribed sphere of the cell hole C when the cell hole C has a shape different from a strict spherical shape as in this example.

  If the cell hole C of the porous structure 1 is too small, it becomes difficult to manufacture the porous structure 1 using a 3D printer. From the viewpoint of facilitating the production of the porous structure 1 using a 3D printer, the cell hole C having the smallest diameter among the cell holes C constituting the porous structure 1 (in this example, the second cell) The diameter of the hole C2) is preferably 0.05 mm or more, and more preferably 0.10 mm or more. When the diameter of the cell hole C having the smallest diameter (in this example, the second cell hole C2) is 0.05 mm or more, it can be formed with the resolution of a high-performance 3D printer, and when the diameter is 0.10 mm or more, Modeling is possible not only with high-performance 3D printers but also with general-purpose 3D printer resolution.

As in the third modified example shown in FIG. 14, in the porous structure 1, at least one of the first virtual surfaces V <b> 1 constituting the porous structure 1 may be covered with the film 3. The membrane 3 is made of the same material as the skeleton part 2 and is configured integrally with the skeleton part 2. By the membrane 3, the two first cell holes C1 sandwiching the first virtual plane V1 are brought into a non-communication state, and as a result, the air permeability of the entire porous structure 1 is lowered. By adjusting the number of the first imaginary planes V1 constituting the porous structure 1 covered with the film 3, the overall air permeability of the porous structure 1 can be adjusted. Various breathability levels can be achieved. For example, when the porous structure 1 is used for a vehicle seat pad, by adjusting the air permeability of the porous structure 1, the effectiveness of the air conditioner in the vehicle can be improved, the resistance to stuffiness, Can be increased. When the porous structure 1 is used for a vehicle seat pad, each first virtual surface constituting the porous structure 1 is improved from the viewpoint of enhancing the effectiveness and squeeze resistance of the air conditioner in the vehicle and improving the ride comfort. It is not preferable that all of V1 is covered with the film 3, in other words, at least one of the first virtual surfaces V1 constituting the porous structure 1 is not covered with the film 3 and is open. It is preferable.
When the porous structure 1 is used for a vehicle seat pad, the air permeability of the porous structure 1 is 100 to 700 cc from the viewpoint of improving the effectiveness and stuffiness resistance of the air conditioner in the vehicle and improving the ride comfort. / Cm ² / sec is preferable, 150 to 650 cc / cm ² / sec is more preferable, and 200 to 600 cc / cm ² / sec is more preferable. Here, the air permeability (cc / cm ² / sec) of the porous structure 1 is measured according to JIS K 6400-7. When the porous structure 1 is used for a vehicle seat pad, the resonance magnification of the porous structure 1 is preferably 3 times or more and less than 8 times, and more preferably 3 times or more and 5 times or less. .
In addition, since the conventional porous structure was manufactured through the step of foaming by a chemical reaction as described above, the membrane in the communication hole that communicates each cell is formed at the position and number as expected. It was difficult to do. When the porous structure 1 is manufactured with a 3D printer as in this example, the information about the film 3 is included in advance in the 3D modeling data read by the 3D printer, so that the position as expected can be ensured. It is possible to form the film 3 in the same number.
From the same viewpoint, at least one of the first small virtual surfaces V1S constituting the porous structure 1 may be covered with the film 3. And / or at least one of the first large virtual surfaces V1L constituting the porous structure 1 may be covered with the film 3.

As described above, the porous structure of the present invention is preferably used for a cushioning material, more preferably used for a cushioning material for seating (such as a seat pad), and the vehicle seat pad. More preferably it is used.
As an example, FIG. 15 shows a vehicle seat pad 300 including the porous structure 1 of the example of FIG. The vehicle seat pad 300 in the example of FIG. 15 includes a cushion pad 310 for a seated person to sit on and a back pad 320 for supporting the back of the seated person.
In FIG. 15, the directions of “up”, “down”, “left”, “right”, “front”, and “rear” as viewed from a seated person sitting on the vehicle seat pad 300 are shown. Yes.
The cushion pad 310 includes a main pad portion 311 configured so that the buttocks and thighs of the seated person are placed, and a pair of side pad portions 322 located on both the left and right sides of the main pad portion 311.
In the example of FIG. 15, the cushion pad 310 and the back pad 320 are each composed of separate (as separate members) porous structures 1. The cushion pad 310 is configured integrally as a whole. Further, the entire back pad 320 is integrally formed.
The porous structures 1 constituting the cushion pad 310 and the back pad 320 are each formed by a 3D printer.

Next, a method for manufacturing a porous structure according to an embodiment of the present invention will be described with reference to FIG. FIG. 16 shows, as an example, how the porous structure 1 according to an embodiment of the present invention that constitutes the cushion pad 310 or the back pad 320 shown in FIG. 15 is manufactured by a 3D printer.
First, three-dimensional shape data (for example, three-dimensional CAD data) representing the three-dimensional shape of the porous structure 1 is created using a computer in advance.
Next, the three-dimensional shape data is converted into 3D modeling data 500 using a computer. The 3D modeling data 500 is read by the control unit 410 of the 3D printer 400 when the modeling unit 420 of the 3D printer 400 performs modeling, and the control unit 410 adds the porous structure 1 to the modeling unit 420. It is configured to be shaped. The 3D modeling data 500 includes, for example, slice data representing the two-dimensional shape of each layer of the porous structure 1.
Next, modeling of the porous structure 1 is performed by the 3D printer 400. The 3D printer 400 may perform modeling using an arbitrary modeling method such as an optical modeling method, a powder sintering lamination method, a hot-melt lamination method (FDM method), an inkjet method, or the like. FIG. 16 shows a state in which modeling is performed by a hot melt lamination method (FDM method).
The 3D printer 400 includes, for example, a control unit 410 configured by a CPU, a modeling unit 420 that performs modeling according to control by the control unit 410, and a modeled object to be modeled (that is, the porous structure 1). A support base 430; and a support body 440 in which the support base 430 and a modeled object are stored. When the hot melt lamination method (FDM method) is used as in this example, the modeling unit 420 is configured to discharge the main material MM that finally forms the modeled object (that is, the porous structure 1). It has a main material nozzle 421 and a support material nozzle 422 configured to discharge a support material SM that supports the main material MM during modeling. As the main material MM, it is preferable to use a flexible resin or rubber, but it is particularly preferable to use a flexible resin.
In the 3D printer 400 configured as described above, first, the control unit 410 reads the 3D modeling data 500, and the main unit MM is supplied to the modeling unit 420 based on the three-dimensional shape included in the read 3D modeling data 500. Each layer is sequentially shaped while controlling to discharge the support material SM. At this time, a portion of the porous structure 1 other than the voids (that is, the skeleton 2 and the film 3) is formed with the main material MM, and the void portion of the porous structure 1 is formed with the support material SM. .
After the modeling by the 3D printer 400 is completed, the support material SM is removed from the modeled object. Thereby, the porous structure 1 (as a result, the cushion pad 310 or the back pad 320) is finally obtained as a molded article.
In addition, when comprising the porous structure 1 with resin, after the modeling by the 3D printer 400 is completed, you may heat the porous structure 1 as a modeling thing in oven. In that case, since the coupling | bonding of each layer which comprises the porous structure 1 is strengthened and the anisotropy of the porous structure 1 can be reduced by it, the characteristic as a cushioning material of the porous structure 1 can further be improved. .
When the porous structure 1 is made of rubber, the porous structure 1 as a model may be vulcanized after the modeling by the 3D printer 400 is completed.

Note that, as in the modification shown in FIG. 17, a plurality of types of materials having different compositions may be used as the main material MM during modeling by the 3D printer 400. In that case, the 3D printer 400 may include a plurality of main material nozzles 421. As a result, for example, the porous structure 1 as a modeled object can be composed of materials having different blends depending on the part, and thus the characteristics (hardness, air permeability, etc.) can be varied depending on the part. become.
In a conventional manufacturing method using a mold or the like, it has been difficult to form a porous structure integrally with a material having a different composition depending on the part. Therefore, when it is composed of materials of different blends depending on the part, a plurality of separate porous structures made of materials of different blends are manufactured separately, and the resulting porous structures are separated from each other. It was necessary to bond them with an adhesive or the like. For this reason, it takes time and labor in manufacturing.
However, if the 3D printer 400 is used, it is possible to easily and in a short time configure the structure integrally with materials of different blends depending on the site.

FIG. 18A shows an example of a cross section taken along line GG parallel to the left-right direction of the cushion pad 310 of FIG. In the example of FIG. 18A, the porous structure 1 constituting the cushion pad 310 includes a first portion 11 constituting the surface side portion of the main pad portion 311 and a second portion 12 constituting the side pad portion 312. And a third portion 13 constituting the back side portion of the main pad portion 311, and these are integrally formed.
At this time, it is preferable that the second portion 12 is harder than the first portion 11. As a result, it is possible to obtain a sense that the seated person is firmly held by the side pad portions 312 on the left and right sides.
The first portion 11 is preferably harder than the third portion 13. Thereby, when a seated person sits down, a seated person can feel a seating feeling that the seated person is soft at the beginning of sitting and becomes hard at the back.
The second portion 12 and the third portion 13 may have the same hardness.
Moreover, the whole main pad part 311 may be comprised by the same hardness.
As a method of adjusting the hardness of the first portion 11, the second portion 12, and the third portion 13 of the porous structure 1 as described above, for example, by using the manufacturing method of the example of FIG. A method of changing the material constituting each of the first portion 11, the second portion 12, and the third portion 13 in the structure 1, or in addition to / alternatively, the first portion 11, the second portion in the porous structure 1 Configuration of each of the portion 12 and the third portion 13 (configuration of the skeleton 2 (diameter and shape of each cell hole, ratio A0 / A1 of each bone 2B, width W0 of each bone fixed portion 2B1, etc.), membrane 3 It is preferable to use a method in which the presence / absence and number, the ratio of the volume occupied by the skeleton 2 in the volume of each part, and the like are different.

FIG. 18B shows an example of a cross section taken along line HH parallel to the left-right direction of the back pad 320 of FIG. In the example of FIG. 18B, the porous structure 1 constituting the back pad 320 includes the first portion 11 constituting the main pad portion 321 and the second portion 12 constituting the side pad portion 322. These are configured integrally.
At this time, it is preferable that the second portion 12 is harder than the first portion 11. Thereby, the seated person can obtain a feeling of being firmly held by the left and right side pad portions 322.
As a method for adjusting the hardness of the first portion 11 and the second portion 12 of the porous structure 1 as described above, for example, as in the example of FIG. The method of making the material which comprises each of the part 11 and the 2nd part 12 different, or in addition to / alternatively, each structure of the 1st part 11 in the porous structure 1, and the 2nd part 12 (skeleton part 2) (The diameter and shape of each cell hole, the ratio A0 / A1 of each bone part 2B, the width W0 of each bone fixed part 2B1, etc.), the presence and number of membranes 3, and the volume of each part occupied by the skeleton part 2 It is preferable to use a method in which the volume ratio or the like is varied.

  Comparative examples and examples of the porous structure of the present invention were evaluated by analysis and experiment, and will be described below.

[Examples 1-2]
The 3D-CAD models of Examples 1-2 of the porous structure of the present invention were created on a PC. The models of the porous structures of Examples 1 and 2 all had the shapes of the examples shown in FIGS. 1 to 10, and the physical properties (rigidity, etc.) of the materials constituting each were the same. The volume of the models of the porous structures of Examples 1 and 2 was about 1000 cm ³ , equivalent to a general seat pad (more specifically, a vehicle seat pad). In the porous structure models of Examples 1 and 2, the sizes of the respective unit portions U are different from each other, and accordingly, the sizes of the first cell partition portions 21 and the second cell partition portions 22 and the skeleton portions 2 Thickness was different from each other. In any of the models of Examples 1 and 2, the ratio of the volume VB occupied by the skeleton 2 (VB × 100 / VS [%]) in the volume VS of the porous structure 1 is in the range of 3 to 10%. It was inside.
Table 1 shows the diameter of each first cell hole C1 and the width W0 of each bone fixed portion 2B1 in the models of Examples 1-2.
About each example of Examples 1-2, manufacturability and the shape precision at the time of applying to a seat pad were evaluated.
(Productivity evaluation)
In the evaluation of manufacturability, it was evaluated whether or not the load on the PC (personal computer) that processes the model of the porous structure in each example was realistic. If it can be processed by a general CAD PC in recent years, it is evaluated as “◯”, and if it can be processed in a PC having a relatively high specification in recent years, it is evaluated as “△”. Even if it is PC which has PC, it was evaluated as "x" when it cannot process (processing speed becomes extremely slow, freezes, etc.). The results are shown in Table 1. The higher the manufacturability evaluation, the more the computer processing capability in recent years is taken into consideration, and the three-dimensional shape data (CAD data) representing the three-dimensional shape of the porous structure and the three-dimensional shape data are generated. This means that 3D modeling data can be easily generated on a computer, and the 3D printer can easily model in accordance with the 3D modeling data.
(Evaluation of shape accuracy when applied to seat pads)
In the evaluation of the shape accuracy when applied to the seat pad, the outer edge (outer contour) shape of the porous structure model in each example is changed to the shape of the seat pad (more specifically, the vehicle seat pad). It was evaluated whether the required shape accuracy could be obtained. If the shape required for a general seat pad (minimum curvature radius is about 10mm) can be formed, evaluate as “○”, and if it is difficult to form the shape required for a general seat pad, “× " The results are shown in Table 1. The higher the evaluation of the shape accuracy when applied to the seat pad, the better the appearance when the porous structure is applied to the seat pad.

  As can be seen from Table 1, in Examples 1 and 2 having cell holes with a diameter of 5 mm or more, sufficiently good manufacturability is obtained, and the shape accuracy and the appearance when applied to a seat pad are also improved.

[Examples 3 to 5]
The 3D-CAD models of Examples 3 to 5 of the porous structure of the present invention were created on a PC. The model of the porous structure of Example 3 had the shape of the example shown in FIGS. The models of the porous structures of Examples 4 and 5 are different from Example 3 in the ratio A0 / A1 of the cross-sectional area A0 of the fixed bone portion 2B1 to the cross-sectional area A1 of the ends 2B21 on both sides of each bone portion 2B. Only was different. The models of the porous structures of Examples 3 to 5 had the same volume, dimensions of each unit portion U, and physical properties (rigidity, etc.) of the materials constituting each. The model of the porous structure of Example 4 had the shape of the example shown in part by dotted lines in FIG. In all the models of Examples 3 to 5, the ratio of the volume VB occupied by the skeleton 2 (VB × 100 / VS [%]) in the volume VS of the porous structure 1 is in the range of 3 to 10%. It was inside.
Table 2 shows the ratio A0 / A1 of each bone part 2B in the models of Examples 3 to 5.
About each example of Examples 3-5, the touch feeling of the surface was evaluated.
(Evaluation of touch feeling on the surface)
In the evaluation of the touch feeling on the surface, the load-deflection diagram was created by analysis for the model of the porous structure in each example, and the initial inclination (beginning of load application) of the created load-deflection diagram was It was evaluated as a touch feeling. The results are shown in Table 2. The softer the touch of the surface, the softer the touch is given to the seated person at the timing of sitting.

  As can be seen from Table 2, in Examples 3 to 5, the smaller the ratio A0 / A1, the softer the touch feeling on the surface. The touch feeling on the soft surface is preferred by a seated person on a luxury car (for example, a seated person sitting on the back seat when a driver is seated on the back seat). Has excellent applicability to luxury car seat pads. On the other hand, since the hard surface touch is preferred by sports car occupants who perform quick acceleration / deceleration and oblique line change, Example 5, which has the hardest surface touch, is applied to the seat pad of a sports car. The applicability of is excellent. Example 4 having a moderate touch feeling on the surface has good applicability to seat pads of both luxury cars and sports cars.

[Examples 6 to 8, Comparative Example 1]
Examples 6 to 8 and Comparative Example 1 of the porous structure according to the present invention were produced as prototypes. The porous structures of Examples 6 to 8 and Comparative Example 1 have the shapes of the examples shown in FIGS. 1 to 10, and the volume VB occupied by the skeleton 2 in the volume VS of the porous structure 1. Only the ratio (VB × 100 / VS [%]) was different from each other. The porous structures of Examples 6 to 8 and Comparative Example 1 had the same volume, dimensions of each unit U, and physical properties (rigidity, etc.) of the materials constituting each.
Table 3 shows the ratio (VB × 100 / VS [%]) of the volume VB occupied by the skeleton 2 in the volume VS of the porous structure 1 in Examples 6 to 8 and Comparative Example 1. .
About each example of Examples 6-8 and the comparative example 1, 25% hardness was evaluated.
(Evaluation of 25% hardness)
For the porous structure of each example, the load (N) required to compress the porous structure by 25% in an environment of 23 ° C. and 50% relative humidity was measured using an Instron type compression tester. The measured value was 25% hardness. The results are shown in Table 3.

  As can be seen from Table 3, in Examples 6 to 8 and Comparative Example 1, the higher the value of VB × 100 / VS, the higher the 25% hardness, and the harder the porous structure. The 25% hardness in Examples 6 to 8 is good as a cushioning material, particularly as a cushioning material for seating (such as a seat pad), and more particularly as a seat pad for a vehicle. The 25% hardness of 6-7 was better, and the 25% hardness of Example 7 was the best. The 25% hardness in Comparative Example 1 was as high as 700 N, and the cushioning property was poor.

[Examples 9 to 11]
Examples 9 to 11 of the porous structure according to the present invention were produced as prototypes. In the porous structures of Examples 9 to 11, the skeleton part 2 has the shape of the example shown in FIGS. 1 to 10, and each of the porous structures is configured as in the example of FIG. 14. Only the presence / absence and number of the films 3 on the first virtual plane V1 are different from each other, whereby the air permeability of the porous structure is different from each other. In each of Examples 9 to 11, a part of each first virtual plane V1 constituting the porous structure is covered with the film 3, and Example 10 is more preferable than Example 9 and In Example 11, the number of first virtual surfaces V1 covered with the film 3 (and hence the number of films 3) was smaller in Example 11 than in Example 10. The porous structures of Examples 9 to 11 had the same volume, dimensions of each unit portion U, and physical properties (rigidity, etc.) of the materials constituting each. In each of Examples 9 to 11, the ratio of the volume VB occupied by the skeleton 2 (VB × 100 / VS [%]) in the volume VS of the porous structure 1 is in the range of 3 to 10%. It was.
Table 4 shows the air permeability of each example of Examples 9-11. The air permeability shown in Table 4 was measured according to JIS K 6400-7.
About each example of Examples 9-11, the effect of the air-conditioner when applied to a seat pad and stuffiness resistance, and the riding comfort when applied to a seat pad were evaluated.
(Effectiveness and sag resistance of air conditioner when applied to seat pad)
In the evaluation of air conditioner effectiveness and sag resistance when applied to a seat pad, a seat pad (more specifically, a vehicle seat pad) was created from the porous structure of each example and installed in the vehicle. Above, the tester sat on the seat pad and comprehensively evaluated the effectiveness of the air conditioner in the vehicle and the resistance to stuffiness of the seat pad (dripping resistance) while the vehicle was running. The air conditioner was evaluated as “◯” when the effectiveness and sag resistance were good, “△” when it was moderate, and “X” when it was not good. The results are shown in Table 4.
(Ride comfort when applied to seat pads)
In the evaluation of ride comfort when applied to a seat pad, a seat pad (more specifically, a vehicle seat pad) is created from the porous structure of each example, and the resonance magnification of the seat pad is obtained by a vibration test. The ride comfort was evaluated from the obtained resonance magnification. Riding comfort here refers to the sitting comfort that the seat pad occupant feels while the vehicle is traveling after the seat pad is installed in the vehicle. If the resonance magnification is in the range of 3 times or more and 5 times or less, it is evaluated as “◯” in the sense that the riding comfort is good, and if the resonance magnification is in the range of more than 5 times and less than 8 times, It is evaluated as “△” in the sense that the application is limited, such as being suitable as a pad but not suitable as a cushion pad, and “×” in the sense that riding comfort is not good when the resonance magnification is 8 times or more. It was evaluated. The results are shown in Table 4.

  As can be seen from Table 4, Examples 9 to 11 had good applicability to the seat pad, and were good in both the air-conditioner effectiveness and sag resistance when applied to the seat pad, and the ride comfort. .

  The porous structure of the present invention and the porous structure manufactured using the porous structure of the present invention or the 3D modeling data are preferably used for a cushioning material and are used for sitting. It is more preferable to be used for a cushion material (such as a seat pad), and it is more preferable to be used for a vehicle seat pad.

1: porous structure, 2: skeletal part, 2B: bone part, 2Be: end part of bone part, 2B1: constant bone part, 2B2: bone change part, 2B21: end of joint part of bone change part, 2B22 : End of bone changing portion side of bone changing portion, 2B23: Inclined surface of bone changing portion, 2J: Joint portion, 3: Membrane, 11: First portion of porous structure, 12: Second portion of porous structure Part, 13: third part of porous structure, 21: first cell partition part, 22: second cell partition part, 211: first annular part, 211L: first macro annular part, 211S: first small annular part 2111: Inner peripheral edge of the first annular part 222: Second annular part 2221: Inner peripheral edge of the second annular part 300: Seat pad for vehicle 310: Cushion pad 311: Main Pad part, 312: Side pad part, 320: Back pad 321: Main pad part, 322: Side pad part, 400: 3D printer, 410: Control part, 420: Modeling part, 421: Main material nozzle, 422: Support material nozzle, 430: Support base, 440: Container, MM : Main material, SM: Support material, 500: Data for 3D modeling, C: Cell hole, C1: First cell hole, C2: Second cell hole, O: Skeletal line, U: Unit part of porous structure, V1: first virtual plane, V1L: first large virtual plane, V1S: first small virtual plane, V2: second virtual plane

Claims (11)

A porous structure composed of a flexible resin or rubber,
The porous structure is provided with a skeleton part over the entire structure,
The skeleton part is
Multiple bones,
A plurality of joints each joining the ends of the plurality of bone parts;
Consists of
The porous structure whose ratio of the volume which the said frame | skeleton part occupies is 3-10% among the volume of the said porous structure. The skeleton has a first annular portion configured in an annular shape,
The first annular portion defines a first virtual surface by an inner peripheral side edge portion.
The porous structure according to claim 1, wherein the first annular portion includes a plurality of the bone portions and a plurality of the coupling portions. The skeleton has a first cell partition that partitions the first cell hole inside,
The first cell partition portion has a plurality of first annular portions each configured in an annular shape,
The plurality of first annular portions are connected to each other so that the first virtual surfaces defined by respective inner peripheral side edges do not intersect each other,
The first cell hole is partitioned by the plurality of first annular portions and the plurality of first virtual surfaces defined by the plurality of first annular portions,
The porous structure according to claim 1 or 2, wherein the first annular portion is composed of a plurality of the bone portions and a plurality of the coupling portions. The skeleton has a second cell partition that partitions the second cell hole inside,
The second cell partition portion has a plurality of second annular portions each configured in an annular shape,
The plurality of second annular portions are connected to each other such that the second virtual surfaces defined by the respective inner peripheral side edges intersect each other,
The second cell hole is partitioned by at least inner peripheral side edges of the plurality of second annular portions,
The porous structure according to any one of claims 1 to 3, wherein the second annular portion includes a plurality of the bone portions and a plurality of the coupling portions. The bone part is
A constant bone portion extending while maintaining a constant cross-sectional area; and
While changing the cross-sectional area gradually, extending from the bone constant part to the joint part, bone change part,
Have
The porous structure according to any one of claims 1 to 4, wherein the fixed bone portion has a width smaller than that of the bone change portion and the joint portion.   The porous structure according to claim 5, wherein a cross-sectional shape of the fixed bone portion is a circle or a polygon. The bone changing portion has an inclined surface,
The porous structure according to claim 5 or 6, wherein the inclined surface is inclined with respect to an extending direction of the bone changing portion and gradually increases in width toward the connecting portion.   The porous structure according to any one of claims 1 to 7, wherein the porous structure is used for a seat pad.   The porous structure according to any one of claims 1 to 8, wherein the porous structure is formed by a 3D printer.   The manufacturing method of the porous structure which manufactures the porous structure as described in any one of Claims 1-8 using 3D printer. 3D modeling data read by the control unit of the 3D printer when the modeling unit of the 3D printer performs modeling,
Data for 3D modeling in which the control unit is configured to cause the modeling unit to model the porous structure according to any one of claims 1 to 8.