JP2020189070A - Porous structure, porous structure manufacturing method, and 3d modeling data - Google Patents

Abstract

To provide a porous structure capable of enhancing the durability, a porous structure manufacturing method capable of providing the porous structure capable of enhancing the durability, and 3D modeling data capable of providing the porous structure capable of enhancing the durability.SOLUTION: A porous structure 1 of the present invention is formed from a flexible resin or rubber. The porous structure is provided with: a skeleton part 2 which demarcates a plurality of cell holes C; and a skin part 6 which covers at least a portion of an imaginary outer contour surface of the skeleton part and is formed integrally with the skeleton part. The skin part has: a plurality of column parts 6C extending along the imaginary outer contour surface VC of the skeleton part; a plurality of column connecting parts 6J connecting end portions of the plurality of column parts; and a plurality of skin imaginary surfaces V6 demarcated between the plurality of column parts. The skin part has a non-uniform unit area ratio, the unit area ratio being the ratio of the total area of the column parts and the column connecting parts per 1 cm2.SELECTED DRAWING: Figure 2

Description

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

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

Japanese Unexamined Patent Publication No. 2016-44292

However, in the above-mentioned porous structure, since the skeleton portion of the porous structure is exposed to the outside, the vicinity of the outer surface (virtual outer contour surface) of the skeleton portion due to interference with people or objects or the like. The part may be easily damaged.

The present invention obtains a porous structure capable of improving durability, a method for producing a porous structure capable of obtaining a porous structure capable of improving durability, and a porous structure capable of improving durability. The purpose is to provide 3D modeling data that can be used.

A porous structure made of flexible resin or rubber.
The porous structure is
The skeleton that separates multiple cell holes,
An epidermis portion that covers at least a part of the virtual outer contour surface of the skeleton portion and is integrally formed with the skeleton portion.
Is equipped with
The epidermis is
A plurality of pillars extending along the virtual outer contour surface of the skeleton, and
A plurality of column joints, each of which connects the ends of the plurality of columns,
A plurality of epidermis virtual surfaces partitioned between the plurality of pillars, and
Have and
The skin portion has a non-uniform unit area ratio, which is the ratio of the total area of the pillar portion and the pillar joint portion within 1 cm ² .
Durability can be improved by the porous structure of the present invention.

In the porous structure of the present invention,
The epidermis is
Large radius of curvature part and
A small radius of curvature portion having a smaller radius of curvature than the large radius of curvature portion,
Have and
The small area ratio, which is the ratio of the total area of the column portion and the column joint portion in the small radius of curvature portion, is the ratio of the total area of the column portion and the column joint portion in the large radius of curvature portion. It is preferable that the area ratio is higher than the majority area ratio.
As a result, flexural rigidity and torsional rigidity can be improved while obtaining good cushioning properties.

In the porous structure of the present invention,
The porous structure is used as a cushioning material and is used as a cushioning material.
The porous structure is
With a load receiving surface configured to receive the load from the user,
A side surface continuous from the load receiving surface,
Have and
The load receiving surface of the porous structure is composed of the large radius of curvature portion of the skin portion.
It is preferable that the edge portion between the load receiving surface and the side surface of the porous structure is formed by the small radius of curvature portion of the skin portion.
As a result, flexural rigidity and torsional rigidity can be improved while obtaining good cushioning properties.

In the porous structure of the present invention,
The epidermis is
Low area ratio part and
A high area ratio portion having a higher unit area ratio than the low area ratio portion,
Have and
It is preferable that the average value of the area of the epidermis virtual surface in the high area ratio portion is smaller than the average value of the area of the epidermis virtual surface in the low area ratio portion.
As a result, the characteristics of the porous structure as a cushioning material can be improved while improving the durability.

In the porous structure of the present invention,
The epidermis is
Low area ratio part and
A high area ratio portion having a higher unit area ratio than the low area ratio portion,
Have and
It is preferable that the average value of the lengths of the pillars in the high area ratio portion is shorter than the average value of the lengths of the pillars in the low area ratio portion.
As a result, the characteristics of the porous structure as a cushioning material can be improved while improving the durability.

In the porous structure of the present invention,
The epidermis is
Low area ratio part and
A high area ratio portion having a higher unit area ratio than the low area ratio portion,
Have and
The average value of the width of the pillar portion in the high area ratio portion may be larger than the average value of the width of the pillar portion in the low area ratio portion.

In the porous structure of the present invention,
The epidermis is
Low area ratio part and
A high area ratio portion having a higher unit area ratio than the low area ratio portion,
Have and
The number density of said post coupling portion of the number density and 1cm ² per the column portion per 1cm ² in the high area ratio portion, respectively, the number density and 1cm of the pillar portion per 1cm ² in the low area ratio portion It is preferable based on the number density of the column joints per ^two .
As a result, the characteristics of the porous structure as a cushioning material can be improved while improving the durability.

In the porous structure of the present invention,
It is preferable that each of the portions of the skeleton portion located on the virtual outer contour surface is connected to any one of the pillar connecting portions.
Thereby, the durability can be further improved.

In the porous structure of the present invention,
It is preferable that each of the plurality of pillars extends while maintaining a constant cross-sectional area.
As a result, the structure of the epidermis can be simplified, and the production of the porous structure by the 3D printer becomes easy.

In the porous structure of the present invention,
The porous structure is preferably used for a seat pad.

In the porous structure of the present invention,
The skeleton is
With multiple bones
A plurality of bone joints, each of which connects the ends of the plurality of bones,
Consists of
The skeleton portion has a plurality of cell partition portions that internally partition the cell holes.
It is preferable that the cell compartment has a plurality of annular portions each formed in an annular shape.
As a result, the characteristics of the porous structure as a cushioning material are improved.

In the porous structure of the present invention,
It is preferable that the annular portion is shared by the pair of cell compartments adjacent to the annular portion.
As a result, the characteristics of the porous structure as a cushioning material are improved.

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

The method for producing a porous structure of the present invention is
The above-mentioned porous structure is manufactured by using a 3D printer.
According to the method for producing a porous structure of the present invention, a porous structure capable of improving durability can be obtained.

The 3D modeling data of the present invention is
This is 3D modeling data that is read into the control unit of the 3D printer when the modeling unit of the 3D printer performs modeling.
The control unit is configured to cause the modeling unit to model the above-mentioned porous structure.
According to the 3D modeling data of the present invention, it is possible to obtain a porous structure capable of improving durability.

According to the present invention, a porous structure capable of improving durability, a method for producing a porous structure capable of obtaining a porous structure capable of improving durability, and a porous structure capable of improving durability are provided. It is possible to provide the data for 3D modeling that can be obtained.

FIG. 5 is a perspective view schematically showing a vehicle seat provided with a seat pad capable of comprising the porous structure according to any embodiment of the present invention. It is a perspective view which shows the porous structure which concerns on one Embodiment of this invention which can form the seat pad of FIG. It is a perspective view which shows the B part of the porous structure of FIG. 2 in an enlarged manner. It is a perspective view which shows the appearance of the porous structure of FIG. 2 seen from the side opposite to FIG. It is a cross-sectional view of AA which shows the porous structure of FIG. 2 by the cross section along the line AA of FIG. It is sectional drawing which shows the D part of the porous structure of FIG. 5 enlarged. It is a perspective view which shows the appearance of the part of the porous structure shown in FIG. 6 viewed from an angle. It is a perspective view which shows a part of the skeleton part which has the same cell structure as the skeleton part of FIG. It is a G arrow view which shows the state when the skeleton part of FIG. 8 is seen from the direction of the G arrow of FIG. It is an H arrow view which shows the state when the skeleton part of FIG. 8 is seen from the direction of the H arrow of FIG. It is a perspective view which shows the cell section part of the skeleton part of FIG. It is a drawing corresponding to FIG. 11, and is a drawing for explaining the first modification example of a skeleton part. It is a drawing for demonstrating the 2nd modification of a skeleton part. FIG. 14 (a) is a perspective view showing the bone portion of the skeleton portion of FIG. 13 in a state where no external force is applied, and FIG. 14 (b) is a perspective view showing the bone portion of FIG. 14 (a) in a state where an external force is applied. It is a perspective view which shows the part. It is a drawing for demonstrating the manufacturing method of the porous structure which concerns on one Embodiment of this invention. It is a drawing for demonstrating the manufacturing method of the porous structure which concerns on one modification of this invention.

The porous structure of the present invention and the porous structure produced by using the method for producing the porous structure of the present invention or the data for 3D modeling are preferably used as a cushioning material, and are suitable for sitting. It is more preferable to use it as a cushioning material (seat pad or the like), and it is more preferable to use it as a vehicle seat pad.

Hereinafter, the porous structure according to the present invention, the method for producing the porous structure, and the embodiment of the data for 3D modeling will be illustrated and described with reference to the drawings.
The components common to each figure are designated by the same reference numerals.

First, a suitable use example of the porous structure 1 according to any embodiment of the present invention will be described with reference to FIG.
In the example of FIG. 1, the porous structure 1 is configured to be used as a cushion material, and specifically, to be used for a seat pad (more specifically, a vehicle seat pad) 302. It is configured. FIG. 1 shows an example of a vehicle seat 300 provided with a seat pad (more specifically, a vehicle seat pad) 302 capable of comprising the porous structure 1 according to any embodiment of the present invention. ing. As will be described later, the porous structure 1 has a plurality of cell holes C (FIGS. 6 and 7) partitioned therein, and is formed by a 3D printer.

In the description of the seat pad 302 in the present specification, the terms "top", "bottom", "left", "right", "front", and "rear" are from the user (seat person) seated on the seat pad 302. Refers to "top", "bottom", "left", "right", "front", and "rear" when viewed. In FIG. 1, each direction of “top”, “bottom”, “left”, “right”, “front”, and “rear” when viewed from a seated person seated on the seat pad 302 is shown.

In the example of FIG. 1, the vehicle seat 300 includes a frame 301 and a seat pad 302 attached to the frame 301. The frame 301 is preferably made of, for example, metal or resin. The seat pad 302 includes a cushion pad portion 310 for seating the seated person, a back pad portion 320 for supporting the back of the seated person, and a headrest portion 340 for supporting the head of the seated person. ing.

The cushion pad portion 310 is located on both the left and right sides of the main pad portion 311 configured to support the buttocks and thighs of the seated person from below, and the buttocks and thighs of the seated person. It has a pair of side pad portions 312, which are configured to support from both the left and right sides. The main pad portion 311 has a lower buttock 311h configured to support the buttocks of the seated person from below, and a lower thigh 311t configured to support the thighs of the seated person from below. There is. In the example of FIG. 1, the main pad portion 311 and the side pad portion 312 are configured as separate bodies from each other, and each is configured as a separate porous structure 1. However, any part or all of the main pad portion 311 and any part or all of the side pad portion 312 may be integrated with each other. Further, in the example of FIG. 1, the lower buttock 311h and the lower thigh 311t are configured as separate bodies from each other, and each is configured as a separate (separate body) porous structure 1. However, a part or all of the lower buttock 311h and a part or all of the lower thigh 311t may be integrated with each other. Further, in the example of FIG. 1, the lower thigh 311t is divided into two in the left-right direction, in other words, a pair of left and right lower thighs 311t are provided, and these pair of lower thighs 311t are each having different porous properties. It is composed of the structure 1. However, the lower thigh 311t may be integrally formed as a whole.

The back pad portion 320 is located on both the left and right sides of the main pad portion 321 configured to support the back of the seated person from behind and the main pad portion 321, and is configured to support the back of the seated person from both the left and right sides. It has a pair of side pad portions 322 and the like. In the example of FIG. 1, the main pad portion 321 and the side pad portion 322 are configured as separate bodies from each other, and each is configured as a separate porous structure 1. However, any part or all of the main pad portion 321 and any part or all of the side pad portion 322 may be integrally configured with each other. Further, in the example of FIG. 1, the main pad portion 321 is divided into two in the vertical direction, in other words, a pair of upper and lower main pad portions 321 are provided, and the pair of main pad portions 321 are separated from each other. It is composed of the porous structure 1 of. However, the main pad portion 321 may be integrally formed as a whole. Further, although the back pad portion 320 is configured separately from the cushion pad portion 310 in the example of FIG. 1, any part or all of the back pad portion 320 is an arbitrary one of the cushion pad portions 310. It may be integrally formed with a part or all.

The headrest portion 340 is located on both the left and right sides of the main pad portion 341 and the main pad portion 341, which are configured to support the seated person's head from the rear, and supports the seated person's head from both the left and right sides. It has a pair of side pad portions 342 that are configured. In the example of FIG. 1, the main pad portion 341 and the side pad portion 342 are configured as separate bodies from each other, and specifically, each is configured as a separate porous structure 1. However, any part or all of the main pad portion 341 and any part or all of the side pad portion 342 may be integrated with each other. Further, the headrest portion 340 does not have to have the side pad portion 342. Further, in the example of FIG. 1, the main pad portion 341 of the headrest portion 340 is a part of the main pad portion 321 of the back pad portion 320 (specifically, the upper main pad of the pair of upper and lower main pad portions 321). It is integrally configured with the unit 321). However, any part or all of the headrest portion 340 may be integrally formed with any part or all of the backpad portion 320, or may be configured separately from the backpad portion 320. You may. Further, the seat pad 302 does not have to include the headrest portion 340.

As described above, the seat pad 302 of FIG. 1 is composed of a plurality of parts configured separately from each other, and each component is composed of a separate porous structure 1. However, the seat pad 302 may be composed of one component by being integrally configured as a whole, and may be composed of one porous structure 1 as a whole.
In the following, for convenience of explanation, the parts constituting the seat pad 302 may be simply referred to as "seat pad 302".

When the porous structure 1 is used as a cushioning material as in the example of FIG. 1, the porous structure 1 has a load receiving surface FS configured to receive a load from a user (seat). It is preferable to have a side surface SS continuous from the load receiving surface FS and a back surface BS continuous from the side surface SS and facing the side opposite to the load receiving surface FS. More specifically, when the porous structure 1 is used for the seat pad (particularly the vehicle seat pad) 302, the load receiving surface FS, the side surface SS, and the back surface of the porous structure 1 are as shown in the example of FIG. It is preferable that the BS constitutes the load receiving surface FS, the side surface SS, and the back surface BS of the seat pad 302, respectively. The load receiving surface FS of the seat pad 302 (and by extension, the porous structure 1) is a surface (the surface on the seated side) configured to face the user (seat) side seated on the seat pad 302.

In the example of FIG. 1, the back surface BS of the seat pad 302 (and thus the porous structure 1) is fixed to the frame 301. The back surface BS of the seat pad 302 (and thus the porous structure 1) may be removably fixed to the frame 301 via a hook-and-loop fastener or the like. Alternatively, the back surface BS of the seat pad 302 (and by extension, the porous structure 1) may be fixed to the frame 301 so as not to be removable via an adhesive or the like.

In the example of FIG. 1, the vehicle seat 300 does not have a skin covering the seat pad 302 (and thus the porous structure 1). Therefore, the load receiving surface FS and the side surface SS of the seat pad 302 (and by extension, the porous structure 1) are exposed to the outside, in other words, the outer surface of the vehicle seat 300 (specifically, the load receiving surface FS). And side surface SS). As will be described later, since the porous structure 1 includes the epidermis portion 6 (FIG. 2), it is not necessary to cover the porous structure 1 with a separate epidermis.
However, the vehicle seat 300 may include a skin covering the seat pad 302 (and thus the porous structure 1).

In the example of FIG. 1, each of the plurality of parts constituting the seat pad 302 is composed of the porous structure 1.
However, in each of the one or more parts constituting the seat pad 302, only an arbitrary part of each part may be composed of the porous structure 1. In that case, the remaining portion of the parts constituting the seat pad 302 may be manufactured through a step of foaming by a chemical reaction in mold molding or the like.
Further, only some of the plurality of parts constituting the seat pad 302 may be composed of the multi-rigid structure 1 in a part or all of each. In that case, the remaining parts among the plurality of parts constituting the seat pad 302 may be manufactured through a step of foaming by a chemical reaction in mold molding or the like.

The porous structure 1 may be used for a seat pad having a structure different from that of the seat pad 302 described above with reference to FIG. Further, the porous structure 1 may be used for any cushion material other than the seat pad.

[Porous structure]
Next, the porous structure 1 according to various embodiments of the present invention will be described with reference to FIGS. 2 to 14.
2 to 7 show the porous structure 1 according to the embodiment of the present invention. The porous structure 1 shown in FIGS. 2 to 7 is configured to be used for the side pad portion 342 of the headrest portion 340 in the seat pad 302 of the example of FIG. However, the configuration of the porous structure 1 of each example described in the present specification is preferably used for the seat pad 302 of the example of FIG. 1, any other seat pad, and other types of cushioning materials. be able to.
FIG. 2 is a perspective view showing a state in which the porous structure 1 according to the embodiment of the present invention is viewed from the load receiving surface FS side. FIG. 3 shows an enlarged portion B of the porous structure of FIG. FIG. 4 is a perspective view showing a state in which the porous structure 1 of FIG. 2 is viewed from the side opposite to that of FIG. 2 (back surface BS side). FIG. 5 is a cross-sectional view taken along the line AA of FIG. 2 showing the porous structure 1 of FIG. 2 by a cross section taken along the line AA of FIG. FIG. 6 shows an enlarged portion D of the porous structure 1 of FIG. FIG. 7 is a perspective view showing a state in which the portion of the porous structure 1 shown in FIG. 6 is viewed from an angle.

As shown in FIGS. 5 to 7, the porous structure 1 of each example described in the present specification has a skeleton portion 2 for partitioning a plurality of cell holes C and a virtual outer contour surface VC of the skeleton portion 2. It includes an epidermis portion 6 that covers at least a part of the skin and is integrally formed with the skeleton portion 2. The entire porous structure 1 is integrally formed.
Here, the "virtual outer contour surface (VC)" of the skeleton portion 2 is a virtual outer surface forming the outer contour of the skeleton portion 2, as shown by a broken line in FIGS. 5 and 6, and is of the skeleton portion 2. It is a virtual surface that smoothly connects the outermost parts (flesh parts).
The configuration of the skeleton portion 2 and the epidermis portion 6 will be described in detail later.

The porous structure 1 of each example described in the present specification is modeled by a 3D printer. By producing the porous structure 1 using a 3D printer, the production becomes simpler and the desired configuration can be obtained as compared with the case where the porous structure 1 is foamed by a chemical reaction as in the conventional case. In addition, since the degree of freedom in designing the porous structure 1 can be greatly expanded, it is possible to meet a wider range of required characteristics. In addition, it is expected that future technological advances in 3D printers will make it possible to realize manufacturing with 3D printers in a shorter time and at lower cost.
Further, by manufacturing the porous structure 1 using a 3D printer, the porous structure 1 provided with the skin portion 6 integrally formed with the skeleton portion 2 can be easily and as expected in one step. Can be obtained. In addition, when the step of foaming by a chemical reaction is performed as in the conventional case, it is not possible to obtain the porous structure 1 having the skin portion 6 integrally formed with the skeleton portion 2.

The porous structure 1 of each example described herein is made of a flexible resin or rubber. That is, the skeleton portion 2 and the flesh portion of the epidermis portion 6 of the porous structure 1 are made of a flexible resin or rubber, and are formed by the cell holes C partitioned by the skeleton portion 2 and the epidermis portion 6. The through hole 66, which will be described later, is a void.
Here, the "flexible resin" refers to a resin that can be deformed when an external force is applied. For example, an elastomer-based resin is preferable, and polyurethane is more preferable. Examples of rubber include natural rubber and synthetic rubber. Since the porous structure 1 is made of a flexible resin or rubber, it can be compressed / restored and deformed according to the application / release of an external force, and can have cushioning properties.
From the viewpoint of ease of manufacture by a 3D printer, the porous structure 1 is more preferably made of a flexible resin than it is made of rubber. ..
The composition of the material (flexible resin or rubber) constituting the porous structure 1 may be the same throughout the porous structure 1, or may be different for each portion of the porous structure 1. May be good. From the viewpoint of ease of production by a 3D printer, it is preferable that the composition of the materials constituting the porous structure 1 is the same throughout the porous structure 1.

<Epidermis>
Hereinafter, the skin portion 6 of the porous structure 1 according to various embodiments of the present invention will be described in more detail with reference to FIGS. 2 to 7.
The skin portion 6 covers at least a part of the virtual outer contour surface VC of the skeleton portion 2 and is integrally formed with the skeleton portion 2. In the examples of FIGS. 2 to 7, the skin portion 6 covers the entire virtual outer contour surface VC of the skeleton portion 2, but the skin portion 6 is an arbitrary part of the virtual outer contour surface VC of the skeleton portion 2. Only may be covered. The epidermis portion 6 is the outermost portion of the porous structure 1. Therefore, in the region of the porous structure 1 in which the epidermis 6 is provided, the epidermis 6 constitutes the outer surface of the porous structure 1.
The entire epidermis portion 6 extends along the virtual outer contour surface VC of the skeleton portion 2.
As shown enlarged in FIGS. 3 and 6, the skin portion 6 has a plurality of pillar portions 6C, a plurality of pillar connecting portions 6J, and a plurality of epidermis virtual surfaces V6. Each of the pillar portions 6C is formed in a columnar shape, and extends along the virtual outer contour surface VC of the skeleton portion 2. Each of the pillar connecting portions 6J connects the end portions 6Ce of the pillar portions 6C to each other at a position where the extending direction end portions 6Ce of the plurality of pillar portions 6C extending in different directions are adjacent to each other. ing. The pillar portion 6C and the pillar connecting portion 6J of the epidermis portion 6 are located outside the virtual outer contour surface VC of the skeleton portion 2 (opposite to the skeleton portion 2) and the virtual outer contour surface VC of the skeleton portion 2. Is in contact with the skeleton and is not located inside the skeleton 2. Each of the epidermis virtual surfaces V6 is partitioned between the plurality of pillar portions 6C. More specifically, the outer edge of each epidermis virtual surface V6 is formed on the inner peripheral side of three or more pillars (three in the example of FIG. 3) connected to each other via the pillar joint 6J so as to form an annular shape. It is partitioned by the edges. Each skin virtual surface V6 may be provided with a through hole 66 penetrating the skin portion 6 in the thickness direction thereof, or may be provided with a surface film 65 covering the skin virtual surface V6. .. The surface film 65 is integrated with the column portion 6C and the column connecting portion 6J that surround the surface film 65, and is thinner than the column portion 6C. From the viewpoint of improving the air permeability of the porous structure 1, as shown in the example of FIG. 3, at least a part (preferably all) of the epidermis virtual surfaces V6 of the plurality of epidermis virtual surfaces V6 of the epidermis portion 6 , Each of which is preferably provided with a through hole 66. Since the skin portion 6 has the through hole 66, ventilation to the inside and outside of the skeleton portion 2 is possible through the through hole 66 of the skin portion 6. However, when the epidermis portion 6 covers only a part of the virtual outer contour surface VC of the skeleton portion 2, the ventilation to the inside and outside of the skeleton portion 2 is the epidermis portion of the virtual outer contour surface VC of the skeleton portion 2. Since it is possible to secure the skin through a portion where the skin 6 is not provided, the skin portion 6 does not have to have the through hole 66, that is, each skin virtual surface V6 of the skin portion 6 has a surface coating. It may be covered by 65.

As described above, in the porous structure 1 of the present embodiment, in addition to the skeleton portion 2 that partitions the plurality of cell holes C, the skin portion 6 that covers at least a part of the virtual outer contour surface VC of the skeleton portion 2 is provided. The skin portion 6 is provided with a plurality of pillars 6C that connect a plurality of pillar portions 6C extending along the virtual outer contour surface VC of the skeleton portion 2 and end portions 6Ce of the plurality of pillar portions 6C, respectively. It has a connecting portion 6J and a plurality of epidermis virtual surfaces V6 partitioned between the plurality of pillar portions 6C. As a result, the skeleton portion 2 can be prevented from being exposed to the outside of the porous structure 1 by the epidermis portion 6. Since the outer surface of the epidermis portion 6 has far less unevenness than the outer surface of the skeleton portion 2, the epidermis portion 6 is less likely to be damaged by interference with people, objects, or the like than the skeleton portion 2. Since the skin portion 6 can prevent a person or an object from directly interfering with the skeleton portion 2, the vicinity of the virtual outer contour surface VC of the skeleton portion 2 that may occur when a person or an object directly interferes with the skeleton portion 2. Damage to the portion can be suppressed. Therefore, the durability of the porous structure 1 can be improved.
Further, since the porous structure 1 of the present embodiment includes the skin portion 6 having less unevenness than the skeleton portion 2, the user can apply a load to the porous structure 1. You can reduce the feeling of strangeness. This is particularly suitable when the porous structure 1 is used as a cushion material (for example, a seat pad, particularly a vehicle seat pad).
Further, since the porous structure 1 of the present embodiment includes the skin portion 6 having less unevenness than the skeleton portion 2, the porous structure 1 is a cushioning material (for example, a seat pad) as in the example of FIG. In particular, when it is used for a vehicle seat pad), it is possible to reduce the need to cover the porous structure 1 with a skin that is separate from the porous structure 1. Therefore, it is possible to reduce the number of parts of the product (vehicle seat 300 in the example of FIG. 1) using the cushion material and simplify the manufacturing. From this point of view, when the porous structure 1 is used as a cushioning material and has a load receiving surface FS and a side surface SS, the skin portion 6 has a skin portion 6 as in the example of FIG. , It is preferable that the outer surface of the porous structure 1 constitutes a part or all of the load receiving surface FS, and the skin portion 6 is the load receiving surface of the outer surface of the porous structure 1. It is more preferable that a part or all of the FS and a part or all of the side surface SS are formed.
Further, since the porous structure 1 of the present embodiment includes the skin portion 6 having less unevenness than the skeleton portion 2, the skin portion of the porous structure 1 as shown in the examples of FIGS. 1 and 2. When the surface provided with 6 (back surface BS in the example of FIG. 1) is fixed to another member (frame 301 in the example of FIG. 1), the skeleton portion 2 of the porous structure 1 is temporarily fixed to another member. It is possible to increase the contact area of the porous structure 1 with the other member as compared with the case where the porous structure 1 is formed, and by extension, the porous structure 1 is more reliably connected via a surface fastener, an adhesive, or the like. In addition, it becomes possible to fix it to the separate member. From this point of view, in the porous structure 1, as in the examples of FIGS. 1 and 2, the skin portion 6 is a part of the outer surface of the porous structure 1 which is fixed to another member. Alternatively, it is preferable that all of them are configured. From the same viewpoint, when the porous structure 1 is used as a cushioning material and has a load receiving surface FS, a side surface SS, and a back surface BS, as in the examples of FIGS. 1 and 2. In addition, the skin portion 6 constitutes a part or all of the back surface BS and / or a part or all of the side surface SS which can be a fixing surface to another member in the outer surface of the porous structure 1. It is preferable to have it.
Further, in the porous structure 1 of the present embodiment, the epidermis portion 6 has a plurality of pillar portions 6C, a plurality of column connecting portions 6J, and a plurality of epidermis virtual surfaces V6, and by extension, a mesh. It is structured like a figure. As a result, it is possible to suppress the reduction of the cushioning property of the porous structure 1 by providing the skin portion 6, as compared with the case where the skin portion 6 is formed in the form of a sheet having a constant thickness.

In the porous structure 1 of the present embodiment, as shown in FIGS. 1 and 2, the skin portion 6 has a unit area ratio UAR which is a ratio of the total area UTA of the column portion 6C and the column connecting portion 6J within 1 cm ² . (Hereinafter, simply referred to as "unit area ratio UAR") is non-uniform. Here, in calculating the unit area ratio UAR, first, the epidermis portion 6 is developed on a plane, and then the epidermis portion 6 is viewed in a plane, and the epidermis portion 6 is a 1 cm ² square unit. It is divided into each area UA, and the unit area ratio UAR is calculated for each unit area UA. In FIGS. 2 and 3, a part of the unit area UA is shown by a broken line. Unit area ratio UAR is
UAR [%] = UTA [cm ² ] x 100 / (1 [cm ² ])
Calculated by.
In the present specification, "the unit area ratio (UAR) of the epidermis portion 6 is non-uniform" means that the unit area ratio (UAR) of the epidermis portion 6 is uniform (constant) over the entire epidermis portion 6. It refers to all unit area ratio distributions except for, in other words, it means that the skin portion 6 is at least one place and the unit area ratio (UAR) is different from the other parts. Therefore, if the unit area ratio UAR of each unit area UA is the same (including substantially the same), the unit area ratio UAR of the skin portion 6 is uniform. On the other hand, if the unit area ratio UARs of at least two unit region UAs are different from each other, the unit area ratio UARs of the skin portion 6 will be non-uniform.
The flexural rigidity and torsional rigidity of the porous structure 1 depend on the unit area ratio UAR of the skin portion 6. The flexural rigidity and torsional rigidity of the porous structure 1 are high in the portion where the unit area ratio UAR of the epidermis 6 is high, and the flexural rigidity and torsional rigidity of the porous structure 1 are high in the portion where the unit area ratio UAR of the epidermis 6 is low. Is lowered, and the cushioning property of the porous structure 1 is increased. Therefore, by adjusting the distribution of the unit area ratio UAR of the skin portion 6, the distribution of the flexural rigidity and the torsional rigidity of the porous structure 1 can be adjusted.
By modeling the porous structure 1 having such a structure with a 3D printer, the porous structure 1 having the epidermis portion 6 having a non-uniform unit area ratio (UAR), which could not be realized conventionally, can be easily realized. Moreover, it can be achieved with high accuracy and as expected. In addition, since the degree of freedom in design can be significantly increased, the configuration of the porous structure 1 that meets various required characteristics that could not be met in the past can be freely designed, as simply and as expected. Can be realized. Further, in order to make the unit area ratio UAR of the skin portion 6 non-uniform, it is not necessary to use a plurality of materials having different compositions, and it is sufficient to use only one material having the same composition.
In addition, in the porous structure 1 of each example described in this specification, it is assumed that the unit area ratio UAR of the epidermis portion 6 is non-uniform.

In the examples of FIGS. 2 to 4, the skin portion 6 has a large radius of curvature portion 61 and a small radius of curvature portion 62 having a smaller radius of curvature than the large radius of curvature portion 61. In other words, the large radius of curvature portion 61 is a flatter portion than the small radius of curvature portion 62. In FIGS. 2 to 4, for the sake of clarity, the ranges of the large radius of curvature portion 61 and the small radius of curvature portion 62 are roughly (not strictly) shown by broken lines and alternate long and short dash lines, respectively.
The large radius of curvature portion 61 and the small radius of curvature portion 62 may have a non-uniform radius of curvature or a uniform radius of curvature, respectively. However, the maximum value of the radius of curvature of the small radius of curvature portion 62 (the radius of curvature at the portion of the small radius of curvature portion 62 having the largest radius of curvature) is the minimum value of the radius of curvature of the large radius of curvature portion 61 (the large radius of curvature portion 61). It is smaller than the radius of curvature at the place where the radius of curvature is the smallest. The large radius of curvature portion 61 may be entirely curved in a curved surface, or a part thereof may be flat and the remaining portion may be curved in a curved surface, or the entire portion may be curved. May be flat. The small radius of curvature portion 62 is curved as a whole. The "radius of curvature" of the epidermis 6 is such that the outer surface of the epidermis 6 is smoothly continuous by making each epidermis virtual surface V6 of the epidermis 6 the same thickness as the surrounding pillars 6C. Refers to the radius of curvature of the outer surface of the skin portion 6 at times. At this time, when measuring the radius of curvature of a certain portion of the skin portion 6, if the radius of curvature differs depending on the measurement direction, the smallest radius of curvature shall be the radius of curvature of the portion.
When the skin portion 6 has a large radius of curvature portion 61 and a small radius of curvature portion 62 as in the examples of FIGS. 2 to 4, the pillar portion 6C and the pillar connecting portion 6J in the small radius of curvature portion 62 It is preferable that the small part area ratio SAR, which is the ratio of the total area STA, is higher than the large part area ratio LAR, which is the ratio of the total area LTA of the pillar portion 6C and the pillar connecting portion 6J in the large radius of curvature portion 61. is there.
Here, the small area ratio SAR is calculated when the total area of the small radius of curvature portion 62 is SEA.
SAR [%] = STA [cm ² ] x 100 / (SEA [cm ² ])
Calculated by. The total area SEA of the small radius of curvature portion 62 refers to the area of the region surrounded by the outer edge of the small radius of curvature portion 62, and includes the area of the skin virtual surface V6 in the small radius of curvature portion 62.
Further, the large area ratio LAR is calculated when the total area of the large radius of curvature portion 61 is LEA.
LAR [%] = LTA [cm ² ] x 100 / (LEA [cm ² ])
Calculated by. The total area LEA of the large radius of curvature portion 61 refers to the area of the region surrounded by the outer edge of the large radius of curvature portion 61, and includes the area of the skin virtual surface V6 in the large radius of curvature portion 61.
The small area ratio SAR and the large area ratio LAR are measured in a state where the skin portion 6 is developed on a plane and the skin portion 6 is viewed in a plane. Further, when there are a plurality of small radius of curvature portions 62 separated from each other, the small area ratio SAR is measured for each individual small radius of curvature portion 62. Similarly, when there are a plurality of large radius of curvature portions 61 separated from each other, the majority area ratio LAR is measured for each individual large radius of curvature portion 61.
By lowering the majority area ratio LAR of the relatively flat large radius of curvature portion 61 of the epidermis 6, the porous structure 1 is excellent when a load is applied to the large radius of curvature portion 61. Can exhibit cushioning properties. Further, by increasing the small area ratio SAR of the small radius of curvature portion 62 of the skin portion 6, the flexural rigidity and the torsional rigidity of the porous structure 1 can be effectively improved. Therefore, flexural rigidity and torsional rigidity can be improved while obtaining good cushioning properties.
However, the small area ratio SAR of the small radius of curvature portion 62 may be the same as or lower than the large area ratio LAR of the large radius of curvature portion 61.

In each example described in the present specification, the porous structure 1 is used as a cushioning material, and is continuous from the load receiving surface FS configured to receive the load from the user and the load receiving surface FS. When one or more side surfaces SS (four in the example of FIGS. 2 to 4) are provided, the load receiving surface FS of the porous structure 1 is as shown in the examples of FIGS. 2 to 4. Is composed of the outer surface of the large radius of curvature portion 61 of the skin portion 6, and is one or more between the load receiving surface FS and the side surface SS in the porous structure 1 (in the example of FIGS. 2 to 4). The edge portion E of 4) is composed of the outer surface of the small radius of curvature portion 62 of the skin portion 6, and the small area ratio SAR of the small radius of curvature portion 62 constituting the edge portion E is the load receiving surface FS. It is preferable that the area ratio is higher than the majority area ratio LAR of the large radius of curvature portion 61 constituting the above. In this case, the edge portion E between the load receiving surface FS and the side surface SS in the porous structure 1 is curved in a curved surface (that is, chamfered in a curved surface). In the examples of FIGS. 2 to 4, the edge portion E has an annular shape so as to surround the outer edge of the load receiving surface FS.
By forming the load receiving surface FS of the porous structure 1 with a large radius of curvature portion 61 which is relatively flat and has a low area ratio (most area ratio LAR) in the skin portion 6, the load receiving surface FS is relative to the load receiving surface FS. When a load is applied, the porous structure 1 can exhibit excellent cushioning properties. Further, in general, the flexural rigidity and the torsional rigidity of the porous structure 1 have an extremely high contribution of the edge portion E between the load receiving surface FS and the side surface SS, which corresponds to the outer edge of the load receiving surface FS. Therefore, by forming the edge portion E of the porous structure 1 with the small radius of curvature portion 62 of the epidermis portion 6 which is relatively curved and has a high area ratio (small area ratio SAR), the porous structure 1 The bending rigidity and torsional rigidity of the can be effectively improved. Therefore, flexural rigidity and torsional rigidity can be improved while obtaining good cushioning properties.
However, the small area ratio SAR of the small radius of curvature portion 62 constituting the edge portion E of the porous structure 1 is the large area ratio of the large radius of curvature portion 61 forming the load receiving surface FS of the porous structure 1. It may be the same as or lower than LAR.
The side surface SS of the porous structure 1 is formed by the outer surface of the large radius of curvature portion 61 of the epidermis portion 6 as in the examples of FIGS. 2 to 4, and has a small radius of curvature constituting the edge portion E. It is preferable that the small area ratio SAR of the portion 62 is higher than the large area ratio LAR of the large radius of curvature portion 61 constituting the side surface SS. As a result, flexural rigidity and torsional rigidity can be improved while obtaining good cushioning properties. However, the small area ratio SAR of the small radius of curvature portion 62 forming the edge portion E of the porous structure 1 is the same as the large area ratio LAR of the large radius of curvature portion 61 forming the side surface SS of the porous structure 1. It may be the same or lower.
Further, the back surface BS of the porous structure 1 is composed of the outer surface of the large radius of curvature portion 61 of the epidermis portion 6 as in the examples of FIGS. 2 to 4, and has a small radius of curvature constituting the edge portion E. It is preferable that the small area ratio SAR of the portion 62 is higher than the large area ratio LAR of the large radius of curvature portion 61 constituting the back surface BS. However, the small area ratio SAR of the small radius of curvature portion 62 forming the edge portion E of the porous structure 1 is the same as the large area ratio LAR of the large radius of curvature portion 61 forming the back surface BS of the porous structure 1. It may be the same or lower.

In each example described in the present specification, the porous structure 1 is used as a cushioning material, and is continuous from the load receiving surface FS configured to receive the load from the user and the load receiving surface FS. When one or more side surfaces SS (four in the example of FIGS. 2 to 4) are provided, the load receiving surface FS of the porous structure 1 is as shown in the examples of FIGS. 2 to 4. Is composed of the outer surface of the large radius of curvature portion 61 of the epidermis portion 6, and is one or more between the load receiving surface FS and the side surface SS in the porous structure 1 (in the example of FIGS. 2 to 4). It is preferable that the edge portions E of the four) are curved in a curved surface (that is, chamfered in a curved surface) and are formed by the outer surface of the small radius of curvature portion 62 of the skin portion 6. .. As a result, the edge portion E between the load receiving surface FS and the side surface SS in the porous structure 1 is used as compared with the case where the edge portion E is not curved in a curved surface but is angular (not chamfered). It is possible to reduce the discomfort felt by the user when a person applies a load to the porous structure 1. In this case, it is preferable that the side surface SS of the porous structure 1 is composed of the outer surface of the large radius of curvature portion 61 of the epidermis portion 6, as in the examples of FIGS. 2 to 4. Further, it is preferable that the back surface BS of the porous structure 1 is composed of the outer surface of the large radius of curvature portion 61 of the skin portion 6 as in the examples of FIGS. 2 to 4.

In each of the examples described herein, the epidermis 6 has a non-uniform unit area ratio UAR, as described above. Therefore, the skin portion 6 has a low area ratio portion 63 and a high area ratio portion 64 having a higher unit area ratio UAR than the low area ratio portion 63. In FIGS. 2 to 4, for the sake of clarity, the range of the low area ratio portion 63 and the high area ratio portion 64 is roughly (not strictly) shown by broken lines and two-dot chain lines, respectively. The range of the low area ratio portion 63 and the high area ratio portion 64 and the range of the large radius of curvature portion 61 and the small radius of curvature portion 62 may be different from each other, but in FIGS. , Common dashed line and two-dot chain line indicate these.
The low area ratio portion 63 and the high area ratio portion 64 may have non-uniform unit area ratio UARs, or may have uniform unit area ratio UARs, respectively. However, the minimum value of the unit area ratio UAR of the high area ratio portion 64 (the smallest unit area ratio UAR among the unit area ratio UARs in the high area ratio portion 64) is the unit area ratio UAR of the low area ratio portion 63. Is higher than the maximum value of (the unit area ratio UAR having the largest value among the unit area ratio UARs in the small area ratio portion 63). Here, in specifying the low area ratio portion 63 and the high area ratio portion 64, first, the skin portion 6 is developed on a plane, and then the skin portion 6 is meshed with the skin portion 6 viewed in a plane. It is divided into 1 cm ² square unit area UAs, and the unit area ratio UA is calculated for each unit area UA. Then, among the plurality of unit region UAs in the skin portion 6, the unit region UA having a unit area ratio UA of a predetermined value or more is specified as the high area ratio portion 64, and the unit region UA in the skin portion 6 Among them, the unit area UA whose unit area ratio UA is less than the predetermined value is specified as the low area ratio portion 63.
In each example described in the present specification, from the viewpoint of improving bending rigidity and torsional rigidity while obtaining good cushioning property, most or all of the small radius of curvature portion 62 of the skin portion 6 is the skin portion 6. It is preferable that it is composed of a high area ratio portion 64. In other words, in the plan view of the epidermis portion 6, the total area of the portion of the small radius of curvature portion 62 of the epidermis portion 6 formed by the high area ratio portion 64 of the epidermis portion 6 is the small radius of curvature portion of the epidermis portion 6. Of 62, it is preferable that it is larger than the total area of the portion composed of the low area ratio portion 63 of the epidermis portion 6. Further, in each of the examples described in the present specification, from the same viewpoint, it is preferable that most or all of the large radius of curvature portion 61 of the skin portion 6 is composed of the low area ratio portion 63 of the skin portion 6. Is. In other words, in the plan view of the epidermis portion 6, the total area of the portion of the large radius of curvature portion 61 of the epidermis portion 6 formed by the low area ratio portion 63 of the epidermis portion 6 is the large radius of curvature portion of the epidermis portion 6. Of 61, it is preferable that it is larger than the total area of the portion composed of the high area ratio portion 64 of the skin portion 6.
However, more than half of the small radius of curvature portion 62 of the skin portion 6 may be composed of the low area ratio portion 63 of the skin portion 6. In other words, in the plan view of the epidermis portion 6, the total area of the portion of the small radius of curvature portion 62 of the epidermis portion 6 formed by the low area ratio portion 63 of the epidermis portion 6 is the small radius of curvature portion of the epidermis portion 6. Of 62, the total area of the portion composed of the high area ratio portion 64 of the epidermis portion 6 may be the same as or larger than the total area. Further, from the same viewpoint, more than half of the large radius of curvature portion 61 of the skin portion 6 may be composed of the high area ratio portion 64 of the skin portion 6. In other words, in the plan view of the epidermis portion 6, the total area of the portion of the large radius of curvature portion 61 of the epidermis portion 6 formed by the high area ratio portion 64 of the epidermis portion 6 is the large radius of curvature portion of the epidermis portion 6. Of 61, the total area of the portion composed of the low area ratio portion 63 of the skin portion 6 may be the same as or larger than the total area.

In each of the examples described in the present specification, as in the examples of FIGS. 2 to 4, the average value of the area per epidermis virtual surface V6 in the high area ratio portion 64 of the epidermis portion 6 is the epidermis portion 6. It is preferable that the area is smaller than the average value of the area of the epidermis virtual surface V6 in the low area ratio portion 63 of the above.
As a result, the durability of the porous structure 1 can be improved, and the characteristics of the porous structure 1 as a cushioning material can be improved.
From the same point of view, in each of the examples described in the present specification, as in the examples of FIGS. 2 to 4, the average value of the area per epidermis virtual surface V6 in the small radius of curvature portion 62 of the epidermis portion 6 Is smaller than the average value of the area of the epidermis virtual surface V6 in the large radius of curvature portion 61 of the epidermis portion 6.

In each of the examples described in the present specification, as in the examples of FIGS. 2 to 4, the average value of the lengths of the pillars 6C in the high area ratio portion 64 of the skin portion 6 is the skin portion 6. It is preferable that the length is shorter than the average value of the lengths of the pillars 6C in the low area ratio portion 63 of the above.
As a result, the durability of the porous structure 1 can be improved, and the characteristics of the porous structure as a cushioning material can be improved.
Here, the length of the pillar portion 6C shall be measured along the extending direction of the pillar portion 6C.
From the same point of view, in each of the examples described in the present specification, as in the examples of FIGS. 2 to 4, the average value of the lengths per pillar portion 6C in the small radius of curvature portion 62 of the skin portion 6 Is preferably shorter than the average value of the lengths of the pillars 6C in the large radius of curvature portion 61 of the skin portion 6.

In each of the examples described in the present specification, it is preferable that the widths W6C (FIG. 3) of the plurality of pillars 6C constituting the skin portion 6 are the same as in the examples of FIGS. 2 to 4. is there. As a result, the structure of the epidermis can be simplified, and the production of the porous structure by the 3D printer becomes easy.
However, in each example described in the present specification, the width W6C of each pillar portion 6C constituting the skin portion 6 may be different between the pillar portions 6C.
For example, the average value of the width W6C of the pillar portion 6C in the high area ratio portion 64 of the skin portion 6 may be larger than the average value of the width of the pillar portion in the low area ratio portion. As a result, the durability of the porous structure 1 can be improved, and the characteristics of the porous structure as a cushioning material can be improved.
The width W6C of the pillar portion 6C refers to the maximum width in the cross section measured along a cross section perpendicular to the extending direction of the pillar portion 6C.

In each example described in the present specification, the width W6C (FIG. 3) of each pillar portion 6C constituting the skin portion 6 is along the extending direction of the pillar portion 6C as in the examples of FIGS. It may be uniform, or it may be non-uniform along the extending direction of the column portion 6C.
In each example described in the present specification, the maximum value of the width W6C of each pillar portion 6C constituting the skin portion 6 is preferably 3.0 mm or less from the viewpoint of ensuring the cushioning property of the porous structure 1. It is more preferable that it is 2.5 mm or less, and it is more preferable that it is 2.0 mm or less. From the viewpoint of the durability of the skin portion 6, the minimum value of the width W6C of each pillar portion 6C constituting the skin portion 6 is preferably 0.05 mm or more, and more preferably 0.10 mm or more. , 0.20 mm or more is more preferable. These numerical ranges are more suitable when the porous structure 1 is used for the cushion material, and more suitable when the porous structure 1 is used for the seat pad.

In each of the examples described herein, the thickness T6 of the epidermis 6 (FIG. 6) may be uniform or non-uniform throughout the epidermis 6.
The thickness T6 of the epidermis portion 6 refers to the thickness of the pillar portion 6C or the pillar connecting portion 6J of the epidermis portion 6, and the thickness of the epidermis portion 6 on the epidermis virtual surface V6 is ignored. The thickness T6 of the epidermis portion 6 is measured along a direction perpendicular to the outer surface of the epidermis portion 6.
The maximum value of the thickness T6 of the skin portion 6 is preferably 3.0 mm or less, more preferably 2.5 mm or less, from the viewpoint of ensuring the cushioning property of the porous structure 1, and 2 More preferably, it is 0.0 mm or less. The minimum value of the thickness T6 of the skin portion 6 is preferably 0.05 mm or more, more preferably 0.10 mm or more, and 0.20 mm or more from the viewpoint of durability of the skin portion 6. It is even more preferable to have it. These numerical ranges are more suitable when the porous structure 1 is used for the cushion material, and more suitable when the porous structure 1 is used for the seat pad.

In each of the examples described in the present specification, as in the examples of FIGS. It is preferable, in other words, it is preferable that the cross-sectional area is uniform along the extending direction.
As a result, the structure of the skin portion 6 can be simplified, so that the porous structure 1 can be easily manufactured by the 3D printer.
However, the plurality of pillars 6C of the skin portion 6 may extend while changing the cross-sectional area, that is, the cross-sectional area may be non-uniform along the extending direction.

In each of the examples described in the present specification, as in the examples of FIGS. 2 to 4, the density of the number of pillars 6C per 1 cm ² in the high area ratio portion 64 of the skin portion 6 is the low area of the skin portion 6. It is preferable that the density is higher than the number density of the pillar portion 6C per 1 cm ² in the ratio portion 63. As a result, the characteristics of the porous structure as a cushioning material can be improved while improving the durability.
The number density of the pillar portions 6C per 1 cm ² in the high area ratio portion 64 or the low area ratio portion 63 of the skin portion 6 is within each unit region UA in the high area ratio portion 64 or the low area ratio portion 63, respectively. Refers to the average value of the number of pillars 6C.
Further, in each of the examples described in the present specification, as in the examples of FIGS. 2 to 4, the number density of the column connecting portions 6J per 1 cm ² in the high area ratio portion 64 of the epidermis portion 6 is the epidermis portion 6. It is preferable that the density is higher than the number density of the column connecting portions 6J per 1 cm ² in the low area ratio portion 63 of the above. As a result, the characteristics of the porous structure as a cushioning material can be improved while improving the durability.
The number density of the pillar connecting portions 6J per 1 cm ² in the high area ratio portion 64 or the low area ratio portion 63 of the skin portion 6 is within each unit region UA in the high area ratio portion 64 or the low area ratio portion 63, respectively. Refers to the average value of the number of column joints 6J.

In each of the examples described in the present specification, as in the examples of FIGS. 6 to 7, the portion of the skeleton portion 2 located on the virtual outer contour surface VC of the skeleton portion 2 (specifically, described later). It is preferable that each of the bone portion 2B or the bone joint portion 2J) is connected to the pillar joint portion 6J or the pillar portion 6C of the epidermis portion 6. As a result, the exposure of the skeleton portion 2 to the outside can be effectively suppressed by the epidermis portion 6, so that the durability of the porous structure 1 can be further improved.
Further, in each of the examples described in the present specification, as in the examples of FIGS. 6 to 7, the portion of the skeleton portion 2 located on the virtual outer contour surface VC of the skeleton portion 2 (specifically, It is preferable that each of the bone portion 2B or the bone joint portion 2J) described later is connected to any one of the pillar joint portions 6J in the epidermis portion 6. As a result, as compared with the case where each of the portions of the skeleton portion 2 located on the virtual outer contour surface VC of the skeleton portion 2 is connected to the pillar portion 6C in the epidermis portion 6, the porous structure 1 The durability of the porous structure 1 can be further improved, and the cushioning property of the porous structure 1 can be further improved.

In each of the examples described herein, as in the examples of FIGS. 6 to 7, the porous structure 1 provides a columnar additional connecting portion 7 that connects the skeleton portion 2 and the epidermis portion 6. One or a plurality of them may be provided. In this case, it is preferable that each additional connecting portion 7 is connected to the pillar connecting portion 6J or the pillar portion 6C of the epidermis portion 6, respectively, as in the examples of FIGS. 6 to 7, respectively. It is more preferable that it is connected to the column connecting portion 6J of 6. As a result, the connection between the skeleton portion 2 and the epidermis portion 6 can be reinforced, and the durability of the porous structure 1 can be improved.
However, the porous structure 1 does not have to include the additional connecting portion 7.

In each example described in the present specification, each pillar connecting portion 6J of the skin portion 6 joins end portions 6Ce of two or more arbitrary number of pillar portions 6C extending in different directions from each other. You can. In the example of FIG. 3, each pillar connecting portion 6J of the epidermis portion 6 connects the end portions 6Ce of 5 to 8 pillar portions 6C extending in different directions. From the viewpoint of durability, the number of the pillar portions 6C extending in different directions to which the pillar connecting portions 6J of the skin portion 6 are connected is preferably 3 or more. Further, from the viewpoint of cushioning property, the number of pillar portions 6C extending in different directions to which the pillar connecting portions 6J of the skin portion 6 are connected is preferably 10 or less, and more preferably 6 or less. is there.

In the examples of FIGS. 2 to 4, in the plan view of the epidermis portion 6 (the surface view viewed from the direction perpendicular to the outer surface of the epidermis portion 6), each pillar portion 6C of the epidermis portion 6 is respectively. It extends almost linearly. However, in each example described in the present specification, in the plan view of the skin portion 6, each pillar portion 6C may extend in a curved shape (along the curved shape).

In the examples of FIGS. 2 to 4, in the plan view of the epidermis portion 6 (the surface view viewed from the direction perpendicular to the outer surface of the epidermis portion 6), the epidermis virtual surfaces V6 extend in different directions. It is partitioned by three existing pillars 6C, thereby forming a triangle. However, in each of the examples described herein, in the plan view of the epidermis 6, each epidermis virtual surface V6 is partitioned by four or more pillars 6C extending in different directions, whereby 4 It may be a polygon having one or more vertices (quadrangle, pentagon, etc.). The epidermis virtual surfaces V6 may have the same type of polygons as in the examples of FIGS. 2 to 4, or may have different types of polygons.

In the examples of FIGS. 6 to 7, each pillar portion 6C constituting the skin portion 6 has a circular (perfect circular shape) in cross-sectional shape. As a result, the structure of the skin portion 6 is simplified, the molding of the porous structure 1 by the 3D printer becomes easy, and the porous structure 1 has no sharp portion toward the outside, so that the porous structure 1 is formed. The feel of 1 can be improved. The cross-sectional shape of each pillar portion 6C is a cross-sectional shape perpendicular to each extending direction.
However, in each example described in the present specification, all or part of the pillar portions 6C constituting the skin portion 6 have a polygonal cross-sectional shape (other than an equilateral triangle and an equilateral triangle). It may be a triangle, a quadrangle, etc.), or a circle other than a perfect circle (an ellipse, etc.). Further, each bone portion 2B may have a uniform cross-sectional shape along the extending direction thereof, or may be non-uniform along the extending direction thereof. Further, the cross-sectional shapes of the pillar portions 6C may be different from each other.

In each of the examples described herein, when the epidermis 6 has through holes 66 (FIG. 3), the maximum diameter of each through hole 66 of the epidermis 6 (diameter of the through hole 66 having the largest diameter). ) Is preferably equal to or less than the average value of the diameters of the cell holes C of the skeleton portion 2, and more preferably less than the average value of the diameters of the cell holes C of the skeleton portion 2. As a result, damage to the skeleton portion 2 can be suppressed and the durability of the porous structure 1 can be improved.
When the shape of the through hole 66 when the skin portion 6 is viewed in a plan view is non-circular as in the example of FIG. 3, the “diameter” of the through hole 66 is the through hole when the skin portion 6 is viewed in a plan view. It shall refer to the diameter of the circumscribed circle of 66.

In each example described in the present specification, when the skin portion 6 has the through hole 66 (FIG. 3), the area ratio of the through hole 66 in the skin portion 6 is preferably 50% or more from the viewpoint of improving the air permeability. 70% or more is more preferable. Further, from the viewpoint of improving the durability of the skin portion 6, the area ratio of the through hole 66 in the skin portion 6 is preferably 99% or less, and more preferably 95% or less. The "area ratio of the through holes 66 in the epidermis 6" is the ratio of the total area A4 of all the through holes 66 provided in the epidermis 6 to the total area A3 of the epidermis 6 (A4 × 100 / A3 [A4 × 100 / A3 %]). The “total area A3 of the skin portion 6” refers to the area of the portion surrounded by the outer edge of the skin portion 6, and includes the area occupied by the through hole 66. The "area ratio of the through hole 66 in the epidermis portion 6" is measured in a state where the epidermis portion 6 is developed on a plane and the epidermis portion 6 is viewed in a plane.

<Skeletal part>
Hereinafter, the skeleton portion 2 of the porous structure 1 according to various embodiments of the present invention will be described in more detail with reference to FIGS. 8 to 14.
8 to 11 show an example of the skeleton portion 2. FIG. 8 is a perspective view showing a part of the skeleton portion 2 having the same cell structure as the skeleton portion 2 of FIG. FIG. 9 is a G arrow view showing a state when the skeleton portion 2 of FIG. 8 is viewed from the direction of the G arrow of FIG. FIG. 10 is an H arrow view showing a state when the skeleton portion 2 of FIG. 8 is viewed from the direction of the H arrow of FIG. FIG. 11 is a perspective view showing a cell compartment 21 of the skeleton portion 2 of FIG.
Further, in FIGS. 8 to 13, in order to make it easier to understand the orientation of the porous structure 1, the orientation of the XYZ Cartesian coordinate system fixed to the porous structure 1 of each example is displayed.

As shown in FIGS. 8 to 10, the skeleton portion 2 of the porous structure 1 is composed of a plurality of bone portions 2B and a plurality of bone connecting portions 2J, and the entire skeleton portion 2 is integrally formed. It is configured. In this example, each bone portion 2B is formed in a columnar shape, and in this example, each bone portion 2B extends linearly. Each bone connection portion 2J is a position where a plurality of (for example, four) bone portions 2B extending in different directions are adjacent to each other in the extending direction, and these end portions 2Be are connected to each other. It is combined.
8 to 10 show the skeleton line O of the skeleton portion 2 by a alternate long and short dash line in a part of the porous structure 1. The skeleton line O of the skeleton portion 2 is composed of the skeleton line O of each bone portion 2B and the skeleton line O of each bone connection portion 2J. The skeleton line O of the bone portion 2B is the central axis of the bone portion 2B. The skeleton line O of the bone connection portion 2J is an extension line portion formed by smoothly extending the central axis of each bone portion 2B connected to the bone connection portion 2J into the bone connection portion 2J and connecting them to each other. is there.
The extending direction of the bone portion 2B is the extending direction of the skeleton line O of the bone portion 2B (the portion of the skeleton line O corresponding to the bone portion 2B; the same applies hereinafter).
Since the porous structure 1 includes the skeleton portion 2 almost entirely thereof, it can be compressed / restored and deformed according to the addition / release of an external force while ensuring air permeability, and thus a cushioning material (for example, a sheet). The characteristics as a pad) are improved. In addition, the structure of the porous structure 1 becomes simple, and it becomes easy to model with a 3D printer.
Of each bone portion 2B constituting the skeleton portion 2, a part or all of the bone portions 2B may extend while being curved. In this case, since part or all of the bone portion 2B is curved, it is possible to prevent a sudden shape change of the bone portion 2B and thus the porous structure 1 at the time of inputting a load, and suppress local buckling. be able to.

In this example, each bone portion 2B constituting the skeleton portion 2 has substantially the same shape and length. However, not limited to this example, the shape and / or length of each bone portion 2B constituting the skeleton portion 2 does not have to be the same, for example, the shape and / or length of a part of the bone portion 2B. May be different from other bones 2B. In this case, by making the shape and / or length of the bone portion 2B of the specific portion of the skeleton portion 2 different from that of the other portions, it is possible to intentionally obtain different mechanical properties.

In this example, the width W0 (FIG. 8) and cross-sectional area of each bone portion 2B are constant over the entire length of the bone portion 2B (that is, uniform along the extending direction of the bone portion 2B).
Here, the cross-sectional area of the bone portion 2B refers to the cross-sectional area of the cross section perpendicular to the skeleton line O of the bone portion 2B. Further, the width W0 (FIG. 8) of the bone portion 2B refers to the maximum width in the cross section measured along the cross section perpendicular to the skeleton line O of the bone portion 2B.
However, in each example described in the present specification, a part or all of the bone parts 2B constituting the skeleton part 2 have a width W0 and / or a cross-sectional area of the bone part 2B, respectively. It may be non-uniform along the extending direction of the portion 2B. For example, a part or all of the bone parts 2B constituting the skeleton part 2 have a width W0 of the bone part 2B at a portion including both end portions 2Be in the extending direction of the bone part 2B. However, it may gradually increase or decrease toward both ends in the extending direction of the bone portion 2B. In addition, a part or all of the bone parts 2B constituting the skeleton part 2 are the cross-sectional areas of the bone parts 2B in the portion including the ends 2Be on both sides in the extending direction of the bone part 2B. However, it may gradually increase or decrease toward both ends in the extending direction of the bone portion 2B.

In each of the examples described in the present specification, the width W0 of the bone portion 2B (FIG. 8) is considered from the viewpoint of simplification of the structure of the skeleton portion 2 and the ease of manufacturing the porous structure 1 by the 3D printer. Is preferably 0.05 mm or more, and more preferably 0.10 mm or more. When the width W0 is 0.05 mm or more, modeling is possible with the resolution of a high-performance 3D printer, and when the width W0 is 0.10 mm or more, modeling is possible not only with the resolution of a high-performance 3D printer but also with the resolution of a general-purpose 3D printer.
On the other hand, from the viewpoint of improving the accuracy of the outer edge (outer contour) shape of the skeleton portion 2, reducing the gap (interval) between the cell holes C, and improving the characteristics as a cushioning material, the bone portion The width W0 of 2B is preferably 2.0 mm or less.
It is preferable that each bone portion 2B constituting the skeleton portion 2 satisfies this configuration, but only a part of the bone portions 2B constituting the skeleton portion 2 satisfies this configuration. In that case, the same effect can be obtained, although the degree may vary.

In this example, each bone portion 2B constituting the skeleton portion 2 is columnar and has a circular (perfect circular) cross-sectional shape.
This simplifies the structure of the skeleton portion 2 and facilitates modeling with a 3D printer. In addition, it is easy to reproduce the mechanical properties of a general polyurethane foam produced through a process of foaming by a chemical reaction. Therefore, the characteristics of the porous structure 1 as a cushioning material can be improved. Further, by forming the bone portion 2B in a columnar shape in this way, the durability of the skeleton portion 2 can be improved as compared with the case where the bone portion 2B is replaced with a thin film-like portion.
The cross-sectional shape of each bone portion 2B is a shape in a cross section perpendicular to the central axis (skeleton line O) of the bone portion 2B.
Not limited to this example, only a part of the bones 2B constituting the skeleton 2 may satisfy this configuration, and even in that case, the degree may vary. A similar effect can be obtained.
For example, in each of the examples described in the present specification, all or part of the bones 2B constituting the skeleton 2 have a polygonal cross-sectional shape (other than an equilateral triangle and an equilateral triangle). It may be a triangle, a quadrangle, etc.), or a circle other than a perfect circle (an ellipse, etc.), and even in that case, the same effect as in this example can be obtained. Further, each bone portion 2B may have a uniform cross-sectional shape along the extending direction thereof, or may be non-uniform along the extending direction thereof. Further, the cross-sectional shapes of the bone portions 2B may be different from each other.

In each example described in the present specification, the ratio of the volume VB occupied by the skeleton portion 2 (VB × 100 / VS [%]) to the apparent volume VS of the skeleton portion 2 is 3 to 10%. Suitable. With this configuration, the reaction force generated in the skeleton portion 2 when an external force is applied to the skeleton portion 2, and by extension, the hardness of the skeleton portion 2 (and thus the hardness of the porous structure 1) can be used as a cushioning material, particularly. It can be good as a seat pad, and more particularly as a vehicle seat pad.
Here, the "apparent volume VS of the skeleton portion 2" is the entire internal space surrounded by the virtual outer contour surface VC of the skeleton portion 2 (the volume occupied by the skeleton portion 2 and the cell membrane 3 described later (FIG. 12). ) Is provided, it refers to the volume occupied by the cell film 3 and the volume occupied by the voids).
When the materials constituting the skeleton portion 2 are considered to be the same, the higher the ratio of the volume VB occupied by the skeleton portion 2 to the apparent volume VS of the skeleton portion 2, the more the skeleton portion 2 (and thus the porous structure 1) becomes. It becomes hard. Further, the lower the ratio VB of the volume occupied by the skeleton portion 2 to the apparent volume VS of the skeleton portion 2, the softer the skeleton portion 2 (and thus the porous structure 1).
The reaction force generated in the skeleton portion 2 when an external force is applied to the skeleton portion 2, and the hardness of the skeleton portion 2 (and thus the porous structure 1) are used as a cushioning material, particularly as a seat pad, and more particularly. From the viewpoint of improving the seat pad for a vehicle, it is more preferable that the ratio of the volume VB occupied by the skeleton portion 2 to the apparent volume VS of the skeleton portion 2 is 4 to 8%. ..
Any method may be used for adjusting the ratio of the volume VB occupied by the skeleton portion 2 to the apparent volume VS of the skeleton portion 2, but for example, a part or all of the skeleton portion 2 is formed. A method of adjusting the thickness (cross-sectional area) of the bone portion 2B and / or the size (cross-sectional area) of a part or all of the bone joint portion J constituting the skeleton portion 2 can be mentioned.

In each of the examples described herein, the 25% hardness of the porous structure 1 is preferably 60 to 500 N, more preferably 100 to 450 N. Here, the 25% hardness (N) of the porous structure 1 is such that the porous structure can be compressed by 25% in an environment of 23 ° C. and a relative humidity of 50% using an Instron type compression tester. It is assumed that the measured value is obtained by measuring the required load (N). Thereby, the hardness of the cushion material composed of the porous structure 1 can be made good.

As shown in FIGS. 8 to 10, in this example, the skeleton portion 2 has a plurality of cell partition portions 21 (as many as the number of cell holes C) that internally partition the cell holes C.
FIG. 11 shows one cell compartment 21 alone. The skeleton portion 2 of this example has a structure in which a large number of cell compartments 21 are connected in each of the X, Y, and Z directions.
As shown in FIGS. 8 to 11, each cell partition 21 has a plurality of (14 in this example) annular portions 211, respectively. Each of the annular portions 211 is formed in an annular shape, and the flat cell virtual surface V1 is partitioned by the inner peripheral side edge portions 2111 of the respective annular portions. The plurality of annular portions 211 constituting the cell partition portion 21 are connected to each other so that the cell virtual surfaces V1 partitioned by the inner peripheral side edge portions 2111 do not intersect with each other.
The cell hole C is partitioned by a plurality of annular portions 211 constituting the cell partition portion 21, and a plurality of cell virtual surfaces V1 in which the plurality of annular portions 211 are partitioned. Roughly speaking, the annular portion 211 is a portion that partitions the side of the three-dimensional shape formed by the cell hole C, and the cell virtual surface V1 is a portion that partitions the constituent surface of the three-dimensional shape formed by the cell hole C.
Each annular portion 211 is composed of a plurality of bone portions 2B and a plurality of bone joint portions 2J that connect the end portions 2Be of the plurality of bone portions 2B to each other.
The connecting portion between the pair of annular portions 211 connected to each other is composed of one bone portion 2B shared by the pair of annular portions 211 and a pair of bone connecting portions 2J on both sides thereof. That is, each bone portion 2B and each bone connecting portion 2J are shared by a plurality of annular portions 211 adjacent to each other.

In the example of FIGS. 8 to 10, the annular portion 211 is shared by a pair of cell compartments 21 adjacent to the annular portion 211 (that is, a pair of cell compartments 21 sandwiching the annular portion 211). There is. In other words, the annular portion 211 constitutes each part of a pair of cell compartments 21 adjacent to the annular portion 211.
As a result, the annular portion 211 is not shared by the pair of cell compartments 21 adjacent to the annular portion 211 (that is, the pair of cell compartments 21 sandwiching the annular portion 211), that is, , When the pair of cell compartments 21 are configured independently of each other and the annular portions 211 are formed adjacent to each other or separated from each other, ribs or the like are formed between the annular portions 211. Since the gap (interval) between the cell holes C1 (and by extension, the meat portion of the skeleton portion 2 between the cell holes C1) can be made smaller than when the cell holes C1 are interposed, the porous structure can be made smaller. The characteristics of 1 as a cushion material (particularly a seat pad, and more particularly a vehicle seat pad) can be improved. Therefore, the porous structure 1 having a cushioning property can be easily manufactured by the 3D printer.
It is preferable that each annular portion 211 constituting the skeleton portion 2 satisfies this configuration, but only a part of the annular portions 211 among the annular portions 211 constituting the skeleton portion 2 satisfies this configuration. In that case, the same effect can be obtained, although the degree may vary.
From the same point of view, in each of the examples described herein, the skeleton lines O of the pair of cell compartments 21 adjacent to each other coincide with each other in the annular portion 211 shared by the pair of cell compartments 21. It is preferable to have it.

Each cell virtual surface V1 has a part of one cell hole C partitioned by one surface of the cell virtual surface V1 (the surface of the cell virtual surface V1), and the cell virtual surface V1 A part of another cell hole C is partitioned by the other side surface (the back surface of the cell virtual surface V1). In other words, each cell virtual surface V1 divides a part of separate cell holes C by the surfaces on both the front and back sides thereof. In other words, each cell virtual surface V1 is shared by a pair of cell holes C adjacent to the cell virtual surface V1 (that is, a pair of cell holes C sandwiching the cell virtual surface V1).
As a result, the cell virtual surface V1 is not shared by the pair of cell holes C1 adjacent to the cell virtual surface V1 (that is, the pair of cell holes C1 sandwiching the cell virtual surface V1). That is, the gap (interval) between the cell holes C1 can be reduced as compared with the case where the cell virtual surfaces V1 of the pair of cell holes C1 are separated from each other, so that the porous structure 1 Can improve the characteristics of the cushioning material.
It is preferable that each cell virtual surface V1 constituting the skeleton portion 2 satisfies this configuration, but only a part of the cell virtual surfaces V1 among the cell virtual surfaces V1 constituting the skeleton portion 2 have this configuration. The configuration may be satisfied, and even in that case, the same effect can be obtained, although the degree may vary.

In each example described in the present specification, as in the example of each figure, the skeleton line O of the annular portion 211 shared by the pair of cell compartments 21 adjacent to each other is among the pair of cell compartments 21. It is preferable that it is continuous with each of the skeleton lines O of the portion adjacent to the shared annular portion 211 (see FIG. 8).
As a result, the characteristics of the porous structure 1 as a cushioning material become better.
From the same viewpoint, in each of the examples described in the present specification, as in the example of each figure, the skeleton lines O of the pair of cell compartments 21 adjacent to each other are shared by the pair of cell compartments 21. It is preferable that the annular portions 211 match.
Further, from the same viewpoint, in each of the examples described in the present specification, as in the example of each figure, the bone portion 2B forming the annular portion 211 shared by the pair of cell compartments 21 adjacent to each other is cut off. The cross-sectional area of the bone portion 2B (for example, the cross-sectional area of the bone constant portion 2B1) constitutes the portion of the pair of cell compartments 21 adjacent to the shared annular portion 211 (for example, the bone constant portion 2B1). It is preferable that it is the same as each of the cross-sectional areas of.
It is preferable that all of the annular portions 211 shared by the pair of cell compartments 21 adjacent to each other in the skeleton portion 2 satisfy this configuration, but the pair of cell compartments 21 adjacent to each other in the skeleton portion 2 Of the annular portions 211 shared by the above, only a part of the annular portions 211 may satisfy this configuration, and even in that case, the same effect can be obtained with varying degrees.

In each of the examples described in the present specification, as in the example of each figure, the skeleton line O of the connecting portion between the pair of annular portions 211 connected to each other is attached to the connecting portion of the pair of annular portions 211. It is preferable that it is continuous with each of the skeleton lines O of the adjacent portions (see FIGS. 8 to 11 and 13).
As a result, the characteristics of the porous structure as a cushioning material are improved.
From the same point of view, in each of the examples described in the present specification, as in the example of each figure, the skeleton lines O of the pair of annular portions 211 connected to each other are the connecting portions of the pair of annular portions 211. , It is preferable that they match.
Further, from the same viewpoint, in each of the examples described in the present specification, as in the example of each figure, the cross-sectional area of the bone portion 2B constituting the connecting portion of the pair of annular portions 211 connected to each other adjacent to each other. (For example, the cross-sectional area of the bone constant portion 2B1) is the cross-sectional area of the bone portion 2B (for example, the cross-sectional area of the bone constant portion 2B1) constituting the portion of the pair of annular portions 211 adjacent to the connecting portion. It is preferable that it is the same as.
It is preferable that all of the connecting portions of the pair of annular portions 211 connected to each other in the skeleton portion 2 satisfy this configuration, but the pair of annular portions 211 connected to each other in the skeleton portion 2 are connected to each other. Only a part of the connecting portions of the portions may satisfy this configuration, and even in that case, the same effect can be obtained with varying degrees.

Further, each annular portion 211 is shared by a pair of cell compartments 21 adjacent to the annular portion 211 (that is, a pair of cell compartments 21 sandwiching the annular portion 211 in between). In other words, each annular portion 211 constitutes each part of a pair of cell compartments 21 adjacent to each other.

In this example, each cell virtual surface V1 is not covered by the cell film 3 (FIG. 12) described later and is open, that is, constitutes an opening. Therefore, the cell holes C are communicated with each other through the cell virtual surface V1, and ventilation between the cell holes C is possible. As a result, the air permeability of the skeleton portion 2 can be improved, and the skeleton portion 2 can be easily compressed / restored and deformed in response to the addition / release of an external force.

As shown in FIG. 11, in this example, the skeleton line O of each cell compartment 21 has a polyhedral shape, so that each cell hole C has a substantially polyhedral shape. More specifically, in the examples of FIGS. 8 to 11, the skeleton line O of each cell compartment 21 has the shape of a Kelvin tetradecahedron (truncated octahedron), whereby each cell hole C is formed. It has the shape of a Kelvin tetradecahedron (truncated octahedron). The Kelvin tetradecahedron (truncated octahedron) is a polyhedron composed of six regular quadrilateral constituent surfaces and eight regular hexagonal constituent surfaces. Roughly speaking, the cell holes C constituting the skeleton portion 2 fill the internal space surrounded by the outer edge (outer contour) of the skeleton portion 2 (that is, each cell hole C has no unnecessary gaps). They are arranged in a regular manner so that they can be spread out, in other words, to reduce the gap (interval) between the cell holes C).
As in this example, the shape of the skeleton line O of the cell compartment 21 of a part or all of the skeleton part 2 (all in this example) (and by extension, a part or all of the skeleton part 2 (all in this example)). By making the cell hole C (shape) of the cell hole C a polyhedron, it is possible to make the gap (interval) between the cell holes C constituting the skeleton portion 2 smaller, and to make more cell holes C of the skeleton portion 2 Can be formed inside. Further, as a result, the behavior of compression / restoration deformation of the skeleton portion 2 (and by extension, the porous structure 1) in response to the addition / release of an external force becomes a cushioning material, particularly as a seat pad, and particularly for a vehicle. Better as a seat pad.
The polyhedral shape formed by the skeleton line O of the cell compartment 21 (and thus the polyhedral shape formed by the cell hole C) is not limited to this example, and any shape can be used. For example, even when the shape of the skeleton line O of the cell compartment 21 (and thus the shape formed by the cell hole C) is a substantially tetrahedron, a substantially octahedron, or a substantially dodecahedron, the gap (interval) between the cell holes C is reduced. It is suitable from the viewpoint of Further, the shape of the skeleton line O of a part or all of the cell compartments 21 of the skeleton part 2 (and thus the shape formed by the cell holes C of a part or all of the skeleton part 2) is a three-dimensional shape other than a substantially polyhedron (for example). , Sphere, ellipsoid, cylinder, etc.). Further, the skeleton portion 2 may have only one type of cell partition portion 21 having the same shape of the skeleton line O as the cell partition portion 21, or a plurality of types having different shapes of the skeleton line O. May have a cell compartment 21 of. Similarly, the skeleton portion 2 may have only one type of cell hole C having the same shape as the cell hole C, or may have a plurality of types of cell holes C having different shapes. Good. When the shape of the skeleton line O of the cell compartment 21 (and by extension, the shape of the cell hole C) is substantially Kelvin tetradecahedron (truncated octahedron) as in this example, it is compared with other shapes. It is easiest to reproduce the characteristics of a cushioning material equivalent to general polyurethane foam manufactured through a process of foaming by a chemical reaction.

As shown in FIGS. 8 to 11, in this example, the plurality of (14 in this example) annular portions 211 constituting the cell compartment 21 are one or more (six in this example), respectively. The small annular portion 211S and one or more (eight in this example) large annular portion 211L are included. Each of the small annular portions 211S divides the cell small virtual surface V1S by the inner peripheral side edge portion 2111 of the annular portion. Each macrocyclic portion 211L divides the cell large virtual surface V1L having a larger area than the cell small virtual surface V1S by the inner peripheral side edge portion 2111 of the annular portion.
As can be seen from FIG. 11, in this example, the skeleton line O of the macrocycle portion 211L has a regular hexagonal shape, and the cell large virtual surface V1L also has a substantially regular hexagonal shape. Further, in this example, the skeleton line O of the small annular portion 211S has a regular quadrangle, and accordingly, the cell small virtual surface V1S also has a substantially regular quadrangle. As described above, in this example, the cell small virtual surface V1S and the cell large virtual surface V1L differ not only in area but also in shape.
Each macrocyclic portion 211L has a plurality of (six in this example) bone portions 2B and a plurality of (six in this example) bones connecting the end portions 2Be of the plurality of bone portions 2B. It is composed of a connecting portion 2J and. Each small annular portion 211S has a plurality of (four in this example) bone portions 2B and a plurality of (four in this example) bones connecting the end portions 2Be of the plurality of bone portions 2B. It is composed of a connecting portion 2J and.
By including the small annular portion 211S and the large annular portion 211L having different sizes, the plurality of annular portions 211 constituting the cell partition portion 21 increase the gap (interval) between the cell holes C constituting the skeleton portion 2. It becomes possible to make it smaller. Further, when the shapes of the small annular portion 211S and the large annular portion 211L are different as in this example, the gap (interval) between the cell holes C constituting the skeleton portion 2 can be further reduced.
However, the plurality of annular portions 211 constituting the cell partition portion 21 may have the same size and / or shape, respectively. When the size and shape of each annular portion 211 constituting the cell partition portion 21 are the same, mechanical characteristics equal to each of the X, Y, and Z directions can be obtained.

As in this example, of each annular portion 211 constituting the cell partition portion 21, the skeleton line O of a part or all (all in this example) of the annular portion 211 (by extension, each cell constituting the cell partition portion 21). The cell virtual surface V1) of a part or all (all in this example) of the virtual surface V1 has a substantially polygonal shape, so that the distance between the cell holes C constituting the skeleton portion 2 can be made smaller. It will be possible. Further, the behavior of compression / restoration deformation of the skeleton portion 2 in response to the addition / release of an external force becomes better as a cushion material, particularly as a seat pad, and particularly as a seat pad for a vehicle. Further, since the shape of the annular portion 211 (and by extension, the shape of the cell virtual surface V1) is simplified, the manufacturability and the ease of adjusting the characteristics can be improved. It should be noted that at least one annular portion 211 of each annular portion 211 constituting the skeleton portion 2 (and by extension, at least one cell virtual surface V1 of each cell virtual surface V1 constituting the skeleton portion 2) has this configuration. If the above conditions are satisfied, the same effect can be obtained, although the degree may vary.
It should be noted that the skeleton line O of at least one annular portion 211 of each annular portion 211 constituting the skeleton portion 2 (and by extension, at least one cell virtual surface V1 of each cell virtual surface V1 constituting the skeleton portion 2). However, any substantially polygonal shape other than the substantially regular hexagon and the substantially regular quadrangle as in this example, or a plane shape other than the substantially regular polygon shape (for example, a circle (perfect circle, ellipse, etc.)) may be formed. .. When the shape of the skeleton line O of the annular portion 211 (and thus the shape of the cell virtual surface V1) is a circle (a perfect circle, an ellipse, etc.), the shape of the annular portion 211 (and thus the shape of the cell virtual surface V1) becomes simple. Therefore, the manufacturability and the ease of adjusting the characteristics can be improved, and more uniform mechanical characteristics can be obtained. For example, when the shape of the skeleton line O of the annular portion 211 (and thus the shape of the cell virtual surface V1) is a long ellipse (horizontally long ellipse) in a direction substantially perpendicular to the direction in which the load is applied, the direction in which the load is applied. The annular portion 211 and, by extension, the skeleton portion 2 (and thus the porous structure 1) are more likely to be deformed with respect to the load input, as compared with the case where the ellipse is long in a direction substantially parallel to the above (vertically elongated ellipse). (Becomes soft).

In this example, it is preferable that the skeleton portion 2 has at least one cell hole C having a diameter of 5 mm or more. This facilitates the production of the porous structure 1 using a 3D printer. If the diameter of each cell hole C of the skeleton portion 2 is less than 5 mm, the structure of the skeleton portion 2 becomes too complicated, and as a result, three-dimensional shape data (CAD data, etc.) representing the three-dimensional shape of the porous structure 1 Alternatively, it may be difficult to generate 3D modeling data generated based on the three-dimensional shape data on a computer.
Since the porous structure constituting the conventional seat pad was manufactured through a step of foaming by a chemical reaction, it was not possible to form a cell hole C having a diameter of 5 mm or more.
Further, since the skeleton portion 2 has a cell hole C having a diameter of 5 mm or more, it becomes easy to improve the air permeability and the easiness of deformation of the skeleton portion 2.
From this point of view, it is preferable that the diameters of all the cell holes C constituting the skeleton portion 2 are 5 mm or more, respectively.
The larger the diameter of the cell hole C, the easier it is to manufacture the porous structure 1 using a 3D printer, and it becomes easier to improve the air permeability and the easiness of deformation. From such a viewpoint, the diameter of at least one (preferably all) cell holes C in the skeleton portion 2 is more preferably 8 mm or more, still more preferably 10 mm or more.
On the other hand, if the cell hole C of the skeleton portion 2 is too large, it becomes difficult to form the outer edge (outer contour) shape of the skeleton portion 2 (and thus the porous structure 1) neatly (smoothly), and the cushion material (particularly, The shape accuracy of the seat pad) may deteriorate and the appearance may deteriorate. In addition, the characteristics of the cushion material (particularly the seat pad) may not be sufficiently good. Therefore, from the viewpoint of improving the appearance and the characteristics as a cushioning material, the diameter of each cell hole C of the skeleton portion 2 is preferably less than 30 mm, more preferably 25 mm or less, and further preferably 20 mm or less. ..
The diameter of the cell hole C refers to the diameter of the circumscribed sphere of the cell hole C when the cell hole C has a shape different from the exact spherical shape as in this example.

If the cell hole C of the skeleton portion 2 is too small, the structure of the skeleton portion 2 becomes too complicated, and as a result, three-dimensional shape data (CAD data or the like) representing the three-dimensional shape of the porous structure 1 or its three-dimensional shape. Since it may be difficult to generate 3D modeling data generated based on the shape data on a computer, 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 diameter of the cell hole C having the smallest diameter among the cell holes C constituting the skeleton portion 2 is 0.05 mm or more. It is more preferable that it is 0.10 mm or more. When the diameter of the cell hole C having the minimum diameter is 0.05 mm or more, it can be modeled with the resolution of a high-performance 3D printer, and when it is 0.10 mm or more, not only a high-performance 3D printer but also a general-purpose 3D can be modeled. It can also be modeled at the resolution of the printer.

FIG. 12 is a drawing for explaining a modification of the cell compartment 21 of the porous structure 1, and is a drawing corresponding to FIG. 11. In each of the examples described herein, the porous structure 1 may include one or more cell membranes 3 in addition to the skeleton portion 2, as in the modified example shown in FIG.
The cell film 3 extends over the cell virtual surface V1 partitioned by the annular inner peripheral edge 2111 of the annular portion 211, thereby covering the cell virtual surface V1 partitioned by the annular portion 211. ing. In the porous structure 1 of the example of FIG. 12, at least one of the cell virtual surfaces V1 constituting the skeleton portion 2 is covered with the cell membrane 3. The cell membrane 3 is made of the same material as the skeleton portion 2 and is integrally formed with the skeleton portion 2. In the example of FIG. 12, the cell film 3 is configured to be flat. However, the cell film 3 may be configured to be non-flat (for example, curved (curved)).
It is preferable that the cell membrane 3 has a thickness smaller than the width W0 (FIG. 8) of the bone portion 2B.
Due to the cell membrane 3, the two cell holes C sandwiching the cell virtual surface V1 are not communicated with each other through the cell virtual surface V1 and cannot be ventilated through the cell virtual surface V1. Therefore, a porous structure is formed. The overall air permeability of the body 1 is reduced. By adjusting the number of each cell virtual surface V1 constituting the porous structure 1 covered with the cell membrane 3, the overall air permeability of the porous structure 1 can be adjusted, and if required. Various breathability levels can be achieved. For example, when the porous structure 1 is used for a vehicle seat pad, the effectiveness of the air conditioner in the vehicle can be enhanced, the stuffiness resistance can be enhanced, and the riding comfort can be improved by adjusting the air permeability of the porous structure 1. Can be enhanced. When the porous structure 1 is used for a vehicle seat pad, each cell virtual surface V1 constituting the porous structure 1 is improved from the viewpoint of enhancing the effectiveness and stuffiness resistance of the air conditioner in the vehicle and improving the riding comfort. It is not preferable that all of the cells are covered with the cell membrane 3, in other words, at least one of each cell virtual surface V1 constituting the porous structure 1 is not covered with the cell membrane 3 and is open. Is preferable.
Since the conventional porous structure is manufactured through the step of foaming by a chemical reaction as described above, the film in the communication hole that communicates each cell is formed at the desired position and number. That was difficult. When the porous structure 1 is manufactured by a 3D printer as in this example, by including the information of the cell film 3 in advance in the 3D modeling data read by the 3D printer, it is surely as expected. It is possible to form the cell film 3 by the position and the number.
From the same viewpoint, at least one of the cell small virtual surfaces V1S constituting the skeleton portion 2 may be covered with the cell film 3. And / or at least one of each cell large virtual surface V1L constituting the skeleton portion 2 may be covered with the cell film 3.

In each example described in the present specification, when the porous structure 1 is used for a vehicle seat pad, the porous structure is improved from the viewpoint of enhancing the effectiveness and stuffiness resistance of the air conditioner in the vehicle and enhancing the riding comfort. breathable body 1 is suitably ^{100~700cc / cm 2 / sec, 150~650cc} / cm 2 / sec is more preferred, it is further preferable that 200~600cc / cm ² / sec. Here, the air permeability (cc / cm ² / sec) of the porous structure 1 shall be measured in accordance with 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. ..

13 to 14 are drawings for explaining a second modification of the skeleton portion 2. FIG. 13 is a plan view showing a part of the second modification of the skeleton portion 2, and is a drawing corresponding to FIG. FIG. 14 shows the bone portion 2B of this example alone. FIG. 14A shows a natural state in which no external force is applied to the bone portion 2B, and FIG. 14B shows a state in which an external force is applied to the bone portion 2B. 13 and 14 show the central axis (skeleton line O) of the bone portion 2B.
As shown in FIGS. 13 and 14 (a), each bone portion 2B of the skeleton portion 2 extends while maintaining a constant cross-sectional area, respectively, in the extending direction of the bone constant portion 2B1 and the bone constant portion 2B1. It is composed of a pair of bone changing portions 2B2 extending from the bone constant portion 2B1 to the bone connecting portion 2J while gradually changing the cross-sectional area on both sides of the bone. In this example, each bone change portion 2B2 extends from the bone constant portion 2B1 to the bone joint portion 2J while gradually increasing the cross-sectional area. Not limited to this example, the same effect can be obtained even if only a part of the bone parts 2B constituting the skeleton part 2 satisfies this structure. In addition, some or all of the bone portions 2B constituting the skeleton portion 2 have the bone change portion 2B2 only at one end of the bone constant portion 2B1, and the bone constant portion 2B1 The other end of the bone may be directly connected to the bone joint 2J, and in that case, the same effect can be obtained, although the degree may vary.
Here, the cross-sectional areas of the bone constant portion 2B1 and the bone change portion 2B2 refer to the cross-sectional areas of the cross sections of the bone constant portion 2B1 and the bone change portion 2B2 perpendicular to the skeleton line O, respectively.
In this example, each bone portion 2B constituting the porous structure 1 is composed of a bone constant portion 2B1 and a bone change portion 2B2, and the bone change portion 2B2 is cut off as it goes from the bone constant portion 2B1 to the bone joint portion 2J. Since the area gradually increases, the bone portion 2B has a constricted shape in the vicinity of the boundary between the bone constant portion 2B1 and the bone change portion 2B2 so as to become thinner toward the bone constant portion 2B1. Therefore, when an external force is applied, the bone portion 2B is likely to be buckled and deformed at the constricted portion and the intermediate portion of the bone constant portion 2B1, and the porous structure 1 is likely to be compressively deformed. As a result, the same behavior and characteristics as general polyurethane foam produced through the step of foaming by a chemical reaction can be obtained. Further, as a result, the touch feeling on the surface of the porous structure 1 becomes softer. Therefore, for example, when the porous structure 1 is used for the seat pad, the seated person is given a softer feel when seated, especially at the timing when the seating starts. Such a soft feel is generally preferred by those seated in luxury car seat pads (eg, seated in the backseat when a driver is seated in the backseat). Is what is done.

When the bone portion 2B has the bone constant portion 2B1 in at least a part thereof as in this example, the cross-sectional area A1 of the end 2B21 on either one side (preferably both sides) of the bone portion 2B (FIG. 14 (FIG. 14). The ratio A0 / A1 of the cross-sectional area A0 (FIG. 14 (a)) of the bone constant portion 2B1 to a)) is
0.15 ≤ A0 / A1 ≤ 2.0
It is preferable that the above conditions are satisfied. As a result, the touch feeling on the surface of the porous structure 1 can be made not too soft, not too hard, and moderately hard as a characteristic of the seat pad. Therefore, for example, when the porous structure 1 is used for the seat pad, the seated person is given a feeling of appropriate hardness when sitting, especially at the timing when the seating starts. The smaller the ratio A0 / A1, the softer the touch feeling on the surface of the porous structure 1. If the ratio A0 / A1 is less than 0.15, the touch feeling on the surface of the porous structure 1 may become too soft, which may be unfavorable as a characteristic of the cushion material (particularly the seat pad), and 3D. It is not preferable in terms of manufacturability because it becomes difficult to manufacture with a printer. 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 unfavorable as a characteristic of the cushion material (particularly the seat pad).
The ratio A0 / A1 is more preferably 0.5 or more.
More specifically, in this example, the bone portion 2B has a bone constant portion 2B1 and a pair of bone change portions 2B2 continuous on both sides thereof, and each bone change portion 2B2 gradually increases its cross-sectional area. While increasing, it extends from the bone constant portion 2B1 to the bone joint portion 2J, and the ratio A0 / A1 is less than 1.0. As a result, the touch feeling on the surface of the porous structure 1 can be made relatively soft as a characteristic of the cushion material (particularly the seat pad). Such a soft feel is generally preferred by those seated in luxury car seat pads (eg, seated in the backseat when a driver is seated in the backseat). Is what is done.
It should be noted that each bone portion 2B constituting the skeleton portion 2 may satisfy this configuration, or only a part of the bone portions 2B among the bone portions 2B constituting the skeleton portion 2 satisfies this configuration. In either case, the same effect can be obtained, although the degree may vary.

Instead of this example, the bone change portion 2B2 may extend from the bone constant portion 2B1 to the bone 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 change portion 2B2. As a result, when an external force is applied, the bone constant portion 2B1 is less likely to be deformed, and instead, the portion that is relatively easy to buckle becomes the bone change portion 2B2 (particularly, the portion on the bone joint portion 2J side), which in turn is porous. The structure 1 is less likely to be compressed and deformed. As a result, the touch feeling on the surface of the porous structure 1 becomes harder, and mechanical properties of high hardness can be obtained. Therefore, for example, when the porous structure 1 is used for the seat pad, the seated person is given a harder feel when seated, especially at the timing when the seating starts. Such behavior cannot be obtained with a general polyurethane foam produced through a step of foaming by a chemical reaction. Such a configuration can accommodate users who prefer a stiffer feel. Such a hard feel is preferred by the seated person, for example, in the seat pad of a sports car that performs quick acceleration / deceleration and change of diagonal line.
When the bone change portion 2B2 extends from the bone constant portion 2B1 to the bone joint portion 2J while gradually reducing the cross-sectional area, the ratio A0 / A1 becomes more than 1.0.
It should be noted that each bone portion 2B constituting the skeleton portion 2 may satisfy this configuration, or only a part of the bone portions 2B among the bone portions 2B constituting the skeleton portion 2 satisfies this configuration. In either case, the same effect can be obtained, although the degree may vary.

In each of the above-mentioned examples of FIGS. 8 to 12, the bone portion 2B does not have the bone change portion 2B2 and is composed of only the bone constant portion 2B1. In this case, the cross-sectional area of the bone portion 2B is constant over its entire length. Then, the touch feeling on the surface of the porous structure 1 when an external force is applied becomes moderate hardness. Such a configuration can accommodate users who prefer a medium hardness feel. In addition, it can be suitably applied to seat pads of all types of vehicles such as luxury cars and sports cars.
In this case, the ratio A0 / A1 is 1.0.
It should be noted that each bone portion 2B constituting the skeleton portion 2 may satisfy this configuration, or only a part of the bone portions 2B among the bone portions 2B constituting the skeleton portion 2 satisfies this configuration. In either case, the same effect can be obtained, although the degree may vary.

Returning to the examples of FIGS. 13 to 14, in this example, the bone constant portion 2B1 of each bone portion 2B constituting the skeleton portion 2 has a smaller cross-sectional area than the bone change portion 2B2 and the bone joint portion 2J. More specifically, the cross-sectional area of the bone constant portion 2B1 is the cutoff of each of the bone change portion 2B2 and the bone joint portion 2J (however, except for the boundary portion between the bone constant portion 2B1 and the bone change portion 2B2). Smaller than the area. That is, the fixed bone portion 2B1 is a portion having the smallest (thin) cross-sectional area in the skeleton portion 2. As a result, similarly to the above, when an external force is applied, the bone constant portion 2B1 is easily deformed, and by extension, the porous structure 1 is easily deformed by compression. As a result, the touch feeling on the surface of the porous structure 1 becomes softer.
The cross-sectional area of the bone joint portion 2J refers to the cross-sectional area of the cross section perpendicular to the skeleton line O of the bone joint portion 2J.
Not limited to this example, only a part of the bones 2B constituting the skeleton 2 may satisfy this configuration, and even in that case, the degree may vary. A similar effect can be obtained.

Similarly, in this example, each bone portion 2B constituting the skeleton portion 2 has a bone constant portion 2B1 smaller in width than the bone change portion 2B2 and the bone joint portion 2J. More specifically, the width of the fixed bone portion 2B1 is larger than the width of each of the bone changing portion 2B2 and the bone connecting portion 2J (excluding the boundary portion between the bone constant portion 2B1 and the bone changing portion 2B2). Also small. That is, the fixed bone portion 2B1 is the narrowest (thin) portion in the skeleton portion 2. This also makes it easier for the bone constant portion 2B1 to be deformed when an external force is applied, whereby the touch feeling on the surface of the porous structure 1 becomes softer.
The widths of the fixed bone portion 2B1, the bone changing portion 2B2, and the bone connecting portion 2J are measured along the cross section perpendicular to the skeleton line O of the bone constant portion 2B1, the bone changing portion 2B2, and the bone connecting portion 2J, respectively. Refers to the maximum width in the cross section. The skeleton line O of the bone connection portion 2J is a portion of the skeleton line O corresponding to the bone connection portion 2J. FIG. 14A shows the width W0 of the bone constant portion 2B1 and the width W1 of the bone change portion 2B2 for reference.
Not limited to this example, only a part of the bones 2B constituting the skeleton 2 may satisfy this configuration, and even in that case, the degree may vary. A similar effect can be obtained.

In each of the above examples, the width W0 (FIG. 14) of the bone constant portion 2B1 is 0.05 mm or more from the viewpoint of simplification of the structure of the porous structure 1 and thus the ease of manufacturing a 3D printer. It is preferable to have it, and it is more preferable to have it of 0.10 mm or more. When the width W0 is 0.05 mm or more, modeling is possible with the resolution of a high-performance 3D printer, and when the width W0 is 0.10 mm or more, modeling is possible not only with the resolution of a high-performance 3D printer but also with the resolution of a general-purpose 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, reducing the gap (interval) between the cell holes C, and improving the characteristics as a cushioning material, The width W0 (FIG. 14) of the bone constant portion 2B1 is preferably 0.05 mm or more and 2.0 mm or less.
It is preferable that each bone portion 2B constituting the skeleton portion 2 satisfies this configuration, but only a part of the bone portions 2B constituting the skeleton portion 2 satisfies this configuration. In that case, the same effect can be obtained, although the degree may vary.

As shown in FIG. 14, in this example, each bone portion 2B constituting the skeleton portion 2 has one or a plurality (three in this example) inclined surfaces 2B23 on the side surface of each bone changing portion 2B2. 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 increases from the bone constant portion 2B1 toward the bone connecting portion 2J. It is gradually increasing.
This also makes it easier for the bone portion 2B to buckle and deform at the constricted portion near the boundary between the bone constant portion 2B1 and the bone change portion 2B2 when an external force is applied, and as a result, the porous structure 1 is compressed. It becomes easy to deform. As a result, the touch feeling on 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 refers to the width of the inclined surface 2B23 when measured along the cross section perpendicular to the skeleton line O of the bone changing portion 2B2.
Not limited to this example, only a part of the bones 2B constituting the skeleton 2 may satisfy this configuration, and even in that case, the degree may vary. A similar effect can be obtained.

In this example, each bone portion 2B constituting the skeleton portion 2 has a columnar shape, and the bone constant portion 2B1 and the bone change portion 2B2 have equilateral triangular cross-sectional shapes.
This simplifies the structure of the porous structure 1 and facilitates modeling with a 3D printer. In addition, it is easy to reproduce the mechanical properties of a general polyurethane foam produced through a process of foaming by a chemical reaction. Therefore, the characteristics of the porous structure 1 as a cushioning material can be improved. Further, by forming the bone portion 2B in a columnar shape in this way, the durability of the porous structure 1 can be improved as compared with the case where the bone portion 2B is replaced with a thin film-like portion.
The cross-sectional shapes of the bone constant portion 2B1 and the bone change portion 2B2 are shapes in a cross section perpendicular to the central axis (skeleton line O) of the bone constant portion 2B1 and the bone change portion 2B2, respectively.
Not limited to this example, only a part of the bones 2B constituting the skeleton 2 may satisfy this configuration, and even in that case, the degree may vary. A similar effect can be obtained.
Further, in all or part of the bone portions 2B constituting the skeleton portion 2, the bone constant portion 2B1 and the bone change portion 2B2 have polygonal shapes other than the equilateral triangle (equilateral triangle). It may be a triangle, a quadrangle, etc. other than the above, or it may be a circle (a perfect circle, an ellipse, etc.), and even in that case, the same effect as in this example can be obtained. Further, the bone constant portion 2B1 and the bone change portion 2B2 may have different cross-sectional shapes. Further, each bone portion 2B may have a uniform cross-sectional shape along the extending direction thereof, or may be non-uniform along the extending direction thereof. Further, the cross-sectional shapes of the bone portions 2B may be different from each other.

[Manufacturing method of porous structure and data for 3D modeling]
Next, a method for producing a porous structure according to an embodiment of the present invention will be described with reference to FIGS. 15 and 16.
FIG. 15 shows, as an example, a state in which the porous structure 1 of the example of FIG. 2 is manufactured by a 3D printer. However, the method for producing a porous structure described below can be suitably used for producing the porous structure 1 of any example described above in the present specification.
First, in advance, a computer is used to create three-dimensional shape data (for example, three-dimensional CAD data) representing the three-dimensional shape of the porous structure 1.
Next, the above 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. , Is configured to be modeled. The 3D modeling data 500 includes, for example, slice data representing the two-dimensional shape of each layer of the porous structure 1.
Next, the porous structure 1 is modeled by the 3D printer 400. The 3D printer 400 may perform modeling using any modeling method such as a stereolithography method, a powder sintering lamination method, a hot melt lamination method (FDM method), or an inkjet method. FIG. 15 shows a state in which modeling is performed by the Fused Deposition Modeling method (FDM method).
The 3D printer 400 is for mounting, for example, a control unit 410 configured by a CPU or the like, a modeling unit 420 that performs modeling under the control of the control unit 410, and a modeled object (that is, the porous structure 1) to be modeled. It includes a support base 430, a support base 430, and an accommodating body 440 in which a modeled object is housed. When the Fused Deposition Modeling method (FDM method) is used as in this example, the modeling unit 420 is configured to finally discharge the main material MM constituting 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 the support material SM that supports the main material MM during modeling. As the main material MM, a flexible resin or rubber is preferably used, but it is particularly preferable to use a flexible resin.
In the 3D printer 400 configured in this way, first, the control unit 410 reads the 3D modeling data 500, and based on the three-dimensional shape included in the read 3D modeling data 500, the main material MM is added to the modeling unit 420. , Each layer is sequentially modeled while controlling to discharge the support material SM. At this time, the portion of the porous structure 1 other than the voids (that is, the skeleton portion 2 and the epidermis portion 6) is formed by the main material MM, and the void portion of the porous structure 1 is formed by the support material SM. To do.
After the modeling by the 3D printer 400 is completed, the support material SM is removed from the modeled object. As a result, the porous structure 1 is finally obtained as a modeled object.

Here, with reference to FIG. 16, a case where modeling is performed by a stereolithography method instead of the fused deposition modeling method (FDM method) will be described. FIG. 16 shows a state in which modeling is performed by a stereolithography method.
In this case, the 3D printer 400 has, for example, a control unit 410 configured by a CPU or the like, a modeling unit 420 that performs modeling under the control of the control unit 410, and a modeled object (that is, the porous structure 1) to be modeled. A support base 430 for mounting, a liquid resin LR, a support base 430, and an accommodating body 440 for accommodating a modeled object are provided. The modeling unit 420 has a laser irradiator 423 configured to irradiate an ultraviolet laser beam LL when a stereolithography method is used as in this example. The housing 440 is filled with a liquid resin LR. The liquid resin LR is cured when exposed to the ultraviolet laser light LL emitted from the laser irradiator 423, and becomes a flexible resin.
In the 3D printer 400 configured in this way, first, the control unit 410 reads the 3D modeling data 500, and based on the three-dimensional shape included in the read 3D modeling data 500, the modeling unit 420 receives an ultraviolet laser beam. While controlling to irradiate LL, each layer is sequentially modeled.
After the modeling by the 3D printer 400 is completed, the modeled object is taken out from the housing 440. As a result, the porous structure 1 is finally obtained as a modeled object.

When the porous structure 1 is made of resin, the porous structure 1 as a modeled object may be heated in an oven after the modeling by the 3D printer 400 is completed. In that case, the bond between the layers constituting the porous structure 1 can be strengthened, thereby reducing the anisotropy of the porous structure 1, so that the characteristics of the porous structure 1 as a cushioning material can be further improved. ..
Further, when the porous structure 1 is made of rubber, the porous structure 1 as a modeled object may be vulcanized after the modeling by the 3D printer 400 is completed.

The porous structure of the present invention and the porous structure produced by using the method for producing the porous structure of the present invention or the data for 3D modeling are preferably used as a cushioning material, and are suitable for sitting. It is more preferable to use it as a cushioning material (seat pad or the like), and it is more preferable to use it as a vehicle seat pad.

1: Porous structure,
2: Skeletal part, 2B: Bone part, 2Be: Bone part end, 2B1: Bone constant part, 2B2: Bone change part, 2B21: Bone connection side end of bone change part, 2B22: Bone of bone change part End on the fixed part side, 2B23: Inclined surface of bone change part, 2J: Bone joint part, 21: Cell compartment part, 211: Ring part, 211L: Large ring part, 211S: Small ring part, 2111: Inside the ring part Peripheral edge,
C: Cell hole, O: Skeleton line, V1: Cell virtual surface, V1L: Cell large virtual surface, V1S: Cell small virtual surface, VC: Virtual outer contour surface of skeleton part,
3: Cell membrane,
6: Skin part, 6C: Pillar part, 6Ce: Column part end, 6J: Pillar joint part, 61: Large radius of curvature part, 62: Small radius of curvature part, 63: Low area ratio part, 64: High area ratio Part, 65: Surface film, 66: Through hole,
UA: Unit area, V6: Epidermis virtual surface,
7: Additional connection part,
FS: Load receiving surface, SS: Side surface, E: Edge between load receiving surface and side surface, BS: Back surface,
300: Vehicle seat,
301: Frame,
302: Seat pad (vehicle seat pad), 310: Cushion pad part, 311: Main pad part (seat part), 311t: Lower thigh, 311h: Lower buttock, 312: Side pad part, 320: Back pad part, 321 : Main pad part, 322: Side pad part, 340: Headrest part, 341: Main pad part, 342: Side pad part,
TD: Thickness direction,
400: 3D printer, 410: Control unit, 420: Modeling unit, 421: Main material nozzle, 422: Support material nozzle, 423: Laser irradiator, 430: Support stand, 440: Container, MM: Main material, SM: Support material, LL: Ultraviolet laser light, LR: Liquid resin, 500: Data for 3D modeling

Claims (15)

A porous structure made of flexible resin or rubber.
The porous structure is
The skeleton that separates multiple cell holes,
An epidermis portion that covers at least a part of the virtual outer contour surface of the skeleton portion and is integrally formed with the skeleton portion.
Is equipped with
The epidermis is
A plurality of pillars extending along the virtual outer contour surface of the skeleton, and
A plurality of column joints, each of which connects the ends of the plurality of columns,
A plurality of epidermis virtual surfaces partitioned between the plurality of pillars, and
Have and
The skin portion is a porous structure in which the unit area ratio, which is the ratio of the total area of the pillar portion and the pillar joint portion within 1 cm ² , is non-uniform. The epidermis is
Large radius of curvature part and
A small radius of curvature portion having a smaller radius of curvature than the large radius of curvature portion,
Have and
The small area ratio, which is the ratio of the total area of the column portion and the column joint portion in the small radius of curvature portion, is the ratio of the total area of the column portion and the column joint portion in the large radius of curvature portion. The porous structure according to claim 1, which is higher than the majority area ratio. The porous structure is used as a cushioning material and is used as a cushioning material.
The porous structure is
With a load receiving surface configured to receive the load from the user,
A side surface continuous from the load receiving surface,
Have and
The load receiving surface of the porous structure is composed of the large radius of curvature portion of the skin portion.
The porous structure according to claim 2, wherein the edge portion between the load receiving surface and the side surface of the porous structure is formed by the small radius of curvature portion of the skin portion. The epidermis is
Low area ratio part and
A high area ratio portion having a higher unit area ratio than the low area ratio portion,
Have and
The average value of the area per piece of the epidermis virtual surface in the high area ratio portion is smaller than the average value of the area per piece of the epidermis virtual surface in the low area ratio portion, claims 1 to 3. The porous structure according to any one of the above. The epidermis is
Low area ratio part and
A high area ratio portion having a higher unit area ratio than the low area ratio portion,
Have and
Claims 1 to 4 that the average value of the lengths of the pillars in the high area ratio portion is shorter than the average value of the lengths of the pillars in the low area ratio portion. The porous structure according to any one of the above. The epidermis is
Low area ratio part and
A high area ratio portion having a higher unit area ratio than the low area ratio portion,
Have and
The porosity according to any one of claims 1 to 5, wherein the average value of the width of the pillar portion in the high area ratio portion is larger than the average value of the width of the pillar portion in the low area ratio portion. Structure. The epidermis is
Low area ratio part and
A high area ratio portion having a higher unit area ratio than the low area ratio portion,
Have and
The number density of said post coupling portion of the number density and 1cm ² per the column portion per 1cm ² in the high area ratio portion, respectively, the number density and 1cm of the pillar portion per 1cm ² in the low area ratio portion The porous structure according to any one of claims 1 to 6, which is higher than the number density of the column joints per ^two . The porous structure according to any one of claims 1 to 7, wherein each of the portions of the skeleton portion located on the virtual outer contour surface is connected to any one of the pillar connecting portions. body. The porous structure according to any one of claims 1 to 8, wherein each of the plurality of pillars extends while maintaining a constant cross-sectional area. The porous structure according to any one of claims 1 to 9, wherein the porous structure is used for a seat pad. The skeleton is
With multiple bones
A plurality of bone joints, each of which connects the ends of the plurality of bones,
Consists of
The skeleton portion has a plurality of cell partition portions that internally partition the cell holes.
The porous structure according to any one of claims 1 to 10, wherein each of the cell compartments has a plurality of annular portions formed in an annular shape. The porous structure according to claim 11, wherein the annular portion is shared by the pair of cell compartments adjacent to the annular portion. The porous structure according to any one of claims 1 to 12, wherein the porous structure is formed by a 3D printer. A method for producing a porous structure, which comprises producing the porous structure according to any one of claims 1 to 12 using a 3D printer. This is 3D modeling data that is read into 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 12.