JP4540541B2 - Oily gel for mat - Google Patents

Description

  The present invention relates to an oily gel for mats, and in particular, can suppress the transfer of an oil component to an exterior body and can prevent twisting, curling, displacement, and separation of an oily gel material accommodated in the exterior body. The present invention relates to an oily gel for mats.

  Japanese Patent Application Laid-Open Nos. 52-22045 and 58-147429 disclose oil-based gels in which a rubber component is dissolved in an oily solvent and subjected to a crosslinking treatment. Such an oily gel is excellent in elasticity, flexibility and shape retention, can be plasticized at high temperature, and has the above properties at room temperature. It is used for stress dispersion materials, soundproof materials, vibration-proof materials, etc.

  If this type of gel material is used for a long period of time in the above-mentioned application, the gel material may be rounded (rounded) in the film of the gel coating material, or may not return to its original state due to misalignment or the like. It sometimes deformed. Further, there is a problem due to the adhesiveness between the gel itself and the gel coating material, such as the gel material being damaged.

  In order to solve such a problem, JP-A-9-157448 discloses a liquid composition comprising a rubber component comprising a high molecular weight solid rubber and a low molecular weight liquid rubber, an oily component, a polyisocyanate and an organic peroxide. A technique of directly filling a urethane bag and crosslinking is disclosed.

  However, since an oily gel contains an excessive oil component in order to obtain a good elastic body, the oil component oozes out on the surface of the oily gel, and the cotton cloth, polyurethane, knitted bag, polyethylene foam, polyurethane covering the oily gel There was a problem that the oil component migrated to the outer package made of foam or the like. In particular, in the oily gel molded body obtained by the technique of the above-mentioned JP-A-9-157448, the transfer of the oil component to the urethane bag was remarkably recognized. The transfer of the oil component to the exterior body causes the adhesion of the oil component to the human body and the contamination of clothes, sheets and the like, which is not preferable.

In addition, for the purpose of increasing the working efficiency and absorbing the exuded oil, we tried to reduce the oil seepage by laminating a 10 g / m ² basis paper made of pulp around the oily gel. The base paper was easily torn during production or use. As a result, the oil component oozed out from the location where the base paper broke.

  Alternatively, the oily gels were fused at the locations where the base paper was torn, causing twisting, curling, misalignment, separation, and destruction of the oily gel, resulting in poor durability.

  For example, when base paper with improved breaking strength or plastic film such as polyethylene, polypropylene, polyester, etc. is used, it is oily due to the absence of elongation, which is a characteristic of these materials, and too high tensile strength. The appropriate elasticity of the gel was impaired, making it unsuitable as a mat used for pressure ulcer prevention.

JP-A-52-22045 JP 58-147334 A JP 58-147335 A JP 58-147429 A Japanese Patent Laid-Open No. 9-157448

  The present invention has been made to solve the above-mentioned problems, and the present invention removes the oil component that has exuded from the oily gel without impairing the elasticity required for the mat for the prevention of pressure ulcer etc. An object of the present invention is to provide an oil-based gel body for mats in which the transfer of oil components to the body is reduced and twisting, curling, displacement and separation of the oil-based gel material are eliminated.

  The oily gel for mats of the present invention is an oily gel material obtained from a composition containing a rubber component having an unsaturated double bond, an oil component, and a peroxide crosslinking agent, and has a tensile elongation of 10% or more, and Further, it is characterized by being covered with a nonwoven fabric having a tensile strength of 5 N / 50 mm or more and 200 N / 50 mm or less.

  In this invention, a compounding agent can be contained in the said oil-based gel material.

In the present invention, the nonwoven fabric is at least one selected from the group consisting of polyester, polyurethane, olefin, and rayon, and the basis weight can be 10 g / m ² or more.

  In the present invention, the matte oily gel may be further coated with an exterior body, and the exterior body is at least selected from the group consisting of a cloth polyethylene foam, a polyurethane foam, a knitted bag, and a polyurethane bag. One is preferred.

  According to the present invention, for example, the oil component exuded from the oily gel is removed without impairing the elasticity necessary for the pressure ulcer prevention mat, the transfer of the oil component to the exterior body is reduced, and the oily gel material It is possible to provide an oily gel for mats which can eliminate twisting, curling, displacement and separation.

BEST MODE FOR CARRYING OUT THE INVENTION

Hereinafter, the present invention will be described in detail.
The matte oily gel of the present invention is an oily substance obtained from a composition containing a compounding component such as a rubber component having an unsaturated double bond, an oil component, a peroxide crosslinking agent, and an anti-aging agent as necessary. The gel material is covered with a nonwoven fabric. However, the nonwoven fabric covering the entire surface of the oily gel material needs to have a tensile elongation of 10% or more and a tensile strength of 5 N / 50 mm or more and 200 N / 50 mm or less.

  According to the present invention, the surface of the oily gel material can be covered and fixed with the nonwoven fabric. In this case, an adhesive for coating and fixing is not required, and the nonwoven fabric can be coated and fixed with the wetness of the surface of the oily gel material or the viscosity of the oily gel.

Examples of the non-woven fabric used include polyester, polyurethane, polyolefin, rayon and the like. In the present invention, the nonwoven fabric preferably has a basis weight of 10 g / m ² or less.

  Further, as described above, the nonwoven fabric to be used needs to have a tensile elongation of 10% or more. If the tensile elongation is less than 10%, the nonwoven fabric may not be able to follow the deformation of the oily gel material, the nonwoven fabric may be broken, or the elasticity of the oily gel material may be impaired.

  Furthermore, as described above, the nonwoven fabric used must have a tensile strength of 5 N / 50 mm or more and 200 N / 50 mm or less. If the tensile strength is less than 5N, the nonwoven fabric is easily torn and causes problems such as oil component migration, twisting of the oily gel material, and rounding. On the other hand, if the tensile strength exceeds 200 N, the non-woven fabric may feel a crispness, which causes the elasticity of the oily gel material to be impaired.

  Examples of the rubber component having an unsaturated double bond used to form an oily gel material include natural rubber, polyisoprene rubber, polybutadiene rubber, styrene-butadiene copolymer, and acrylonitrile-butadiene copolymer. , Chloroprene rubber, isobutylene-isoprene copolymer, styrene-chloroprene copolymer, styrene-isoprene-styrene terpolymer, styrene-butadiene-styrene terpolymer, ethylene-propylene-diene terpolymer And synthetic rubber having at least one double bond in the molecule, such as acrylic rubber. Of these synthetic rubbers, polybutadiene rubber, polyisoprene rubber, styrene-butadiene copolymer and the like are particularly preferably used from the viewpoint of mold retention, flexibility, and quality stability.

  The oil component used for forming the oily gel material according to the present invention is preferably a high-boiling compound that is liquid at room temperature and has low evaporability in the temperature range during production of the gel and good compatibility with the rubber component. Used. Examples of oil components include vegetable oils such as olive oil and castor oil, mineral oils such as liquid paraffin and process oil, diethyl sebacate, dioctyl phthalate, dioctyl adipate, ethyl cinnamate, ethyl phenylacetate, ethyl oleate, and benzoic acid. Plasticizers such as ester oils such as benzyl acid and animal oils such as squalane and squalene are used.

  Examples of the peroxide crosslinking agent used for forming the oily gel material according to the present invention include methyl ethyl ketone peroxide, cyclohexanone peroxide, cumene hydroperoxide, dicumyl peroxide, acetyl peroxide, lauroyl peroxide, and benzoyl. Various organic peroxides such as peroxides, t-butylperoxy-2-ethylhexanoate, t-butylperoxybenzoate, peracetic acid, low molecular weight copolymer peroxides of vinyl monomers and oxygen, etc. Is mentioned. These various organic peroxides may be used in the form of a paste dissolved or dispersed in dioctyl phthalate, dibutyl phthalate, toluene, silicon oil or the like, if necessary.

  If necessary, a crosslinking accelerator can be added to these organic peroxides. Examples of the crosslinking accelerator include amines such as N, N-dimethylaniline, N, N-dimethylbenzylamine, tri-2,4,6-dimethylaminomethylphenol, tetraethylenepentamine, triethylenediamine, and naphthenic acid. Examples thereof include metal compounds such as cobalt and tin octenoate.

  In the formation of the oily gel material according to the present invention, an anti-aging agent can be further used. A generally known anti-aging agent can be used as the anti-aging agent, and examples thereof include sulfur, a sulfur-containing phenol-based antioxidant, a hindered phenol-based antioxidant, and a phenol-based antioxidant. It is done.

  In the present invention, the amount of the material used for forming the oily gel material is such that the amount of the rubber component used is 5 to 30 parts by weight with respect to 100 parts by weight of the oil component, and the use of the peroxide crosslinking agent. The amount is preferably 0.05 to 0.5 parts by weight with respect to 100 parts by weight of the oil component. Moreover, it is preferable that the usage-amount of anti-aging agent is 0.01-1 weight part with respect to 100 weight part of oily components.

  In forming the oily gel material according to the present invention, various compounding agents can be further added as necessary. For example, ultraviolet light inhibitors to prevent photodegradation, coloring pigments for imparting special functions to gels, fillers such as dyes and fragrances, carbon black, aerosil, titanium white, calcium carbonate, various clays, etc. A reinforcing filler or the like can be used. Among these, carbon black, aerosil, clay, etc. have a tendency to increase the elastic modulus of the gel after cross-linking, but if the amount of use is appropriately determined, the desired flexibility, mechanical strength and durability can be obtained. It does not hinder the production of a highly elastic gel that retains its properties and has excellent thermal stability. The amount of the above various compounding agents is preferably about 40 parts by weight or less based on the total amount of the material that forms the oily gel state.

  The oily gel material according to the present invention can be formed as follows. That is, first, the rubber component and, if necessary, various compounding agents are added to an excess amount of the oil component and dissolved at room temperature or under heating (about 50 to 150 ° C.). At this time, if necessary, dissolution is performed in an atmosphere of an inert gas such as nitrogen. Next, a peroxide cross-linking agent is uniformly mixed with the dissolved material at a temperature not higher than its decomposition temperature, and the mixture is poured into a mold having a predetermined shape. This mixture can be manufactured in various shapes, for example, hemispherical, disc-shaped, rectangular mat shape, donut shape, or other desired shape made of metal, plastic, porcelain, etc. Can be formed. The mixture injected into these molds is then gelled by crosslinking the rubber component in the mixture under an atmosphere in which the partial pressure of oxygen at 25 ° C. is 10 mmHg or less. In addition, in gelatinization, although it changes also with kinds of a peroxide crosslinking agent and a rubber component, it is generally achieved by the heating conditions for 60 to 170 degreeC for 5 to 360 minutes, Preferably it is 100 to 150 degreeC for 30 to 240 minutes. .

  Means for obtaining an atmospheric condition in which the partial pressure of oxygen is 10 mmHg (25 ° C.) or less is to replace the air in the container (or room) containing the mold with an inert gas such as nitrogen or helium, or to air in the container. It is effective to evacuate the gas so that the partial pressure of oxygen is 10 mmHg (25 ° C.) or less (the degree of vacuum is about 710 mmHgVac or more). In the case of a large mold, the mold itself can be sealed, and the space can be replaced with an inert gas or exhausted. As the atmospheric condition, if the partial pressure of oxygen is 10 mmHg or more, viscous filth due to the influence of oxygen is not generated on the surface of the resulting oily gel.

  The oily gel material thus obtained is a beautiful gel with a uniformly internally cross-linked surface and exhibits very good stress dispersion characteristics. For example, when the gel material is finger pressed with a fingertip, the stress is Without concentrating only on the fingertip of the gel material, the stress is dispersed inside the gel material and deformation occurs. When the stress is removed, the deformation gradually recovers and returns to its original shape. When this characteristic is applied, it effectively acts to prevent congestion of the hips and lower back, particularly as a mat for a wheelchair and a pressure ulcer prevention mat for preventing flooring for seriously ill people.

  The oily gel for mats of the present invention may have an exterior body. That is, in other words, an oil-based gel for mats in which an oil-based gel material is covered with a nonwoven fabric can be effectively packaged with an exterior body. As the exterior body, polyethylene foam, polyurethane foam, knitted cloth, polyurethane bag, and the like can be used. For example, polyurethane bags and the like can be sterilized with ethanol, and an oily gel for mats having an exterior body that can be sterilized is suitable for applications that require sterilization. In addition, when an exterior body such as a polyurethane foam, a polyethylene foam, or a knitted cloth is used, it is possible to reduce the feeling of being irritated when it comes into contact with the skin at the initial stage of use. Furthermore, if an exterior body that can be washed and dried is used, when the mat-like oily gel body becomes dirty, the exterior body can be removed and washed to maintain a clean state.

  In the present invention, two or more of these exterior bodies can be used in an overlapping manner. For example, an oily gel material for mats can be formed by covering an oily gel material covered with a nonwoven fabric with a polyurethane foam and covering the outside with a knitted cloth. In this way, since it becomes possible to have the advantages of the respective exterior bodies, for example, in the case of the above combination example, when the surface of the matte oily gel body is soiled, the outermost exterior body You can remove the knitted cloth that is the body, select and dry it, and if you need to disinfect, remove the outer exterior body and disinfect the polyurethane foam that is the inner exterior body with ethanol etc. is there. As the exterior body, those other than those described above can be used as appropriate according to the purpose or the like, and these exterior bodies can be used in an overlapping manner.

Below, the specific example of the oil-based gel body for mat | matte of this invention is illustrated.
FIG. 1 is a view for explaining a state where the mat oil gel body of the present invention is twisted and then left standing, and is a cross-sectional view of the mat oil gel body in this state. In FIG. 1, the entire surface of the oily gel material 1 is covered with a nonwoven fabric 2. Since the nonwoven fabric 2 is in close contact with the oily gel material 1 and has a predetermined tensile elongation and tensile strength, the nonwoven fabric material 2 can respond to the deformation of the oily gel material 1.

  Here, the oily gel material 1 covered with the nonwoven fabric 2 is covered with a stretchable urethane film 3. When covered with the stretchable urethane film 3 as described above, dirt can be prevented and disinfection becomes possible. According to the present invention, the stretchable urethane film 3 can follow the movement of the oily gel material 1 covered with the nonwoven fabric 2.

  The outer surface of the stretchable urethane film 3 is covered with a surface protective material 4. If a material that can be easily washed is selected as the surface protective material 4, for example, if a cloth cover or the like is selected as the surface protective material 4, washing is easy, and the oily gel for mats can always be kept clean. In addition, if the portion directly in contact with the human body or the like is covered with a cloth cover or the like, it is possible to reduce the sensation when the skin comes into contact with the oily gel body for mat. The surface protecting material 4 can be applied in various shapes, and for example, it can be used in a form in which a handle is provided as shown in FIG. In FIG. 1, the stretchable urethane film 3 and the surface protective material 4 are exterior bodies.

  FIG. 2 is a perspective view showing an example of an oily gel for mats of the present invention. In FIG. 2, the surface protective material 4 containing an oily gel material inside has a handle 5. The handle 5 may be made of the same material as the surface protection material, or may be made of a different material. For example, if the handle 5 is formed of a cloth, it does not get in the way when used as a mat, is convenient to carry, and is easy to wash.

  The oily gel for mats of the present invention can exert a great effect particularly when used in a chair, bed, etc. as a pressure ulcer prevention mat for preventing flooring and the like.

The size of the oil-based gel material is preferably determined as appropriate according to the use and the like. For example, when a rectangular oil-based gel body for mats as shown in FIG. It is preferably 30 cm to 50 cm, 30 cm to 50 cm in width, and 1 cm to 10 cm in thickness. When used for a bed, it is preferably 30 cm to 100 cm in length, 30 cm to 100 cm in width, and 1 cm to 10 cm in thickness.

  EXAMPLES The present invention will be described in detail below using examples, but the present invention is not limited to these. In the following examples, “part” means “part by weight”.

In the following examples, etc., the following measurement methods and evaluation methods were used. << Measurement Methods and Evaluation Methods >>
(1) Measurement of tensile elongation Performed according to Japanese Industrial Standard JIS P-8113. The test piece was cut into a width of 15 mm and a length of about 150 mm, and was pulled with a tensile tester at a gripping interval of 50 mm and a tensile speed of 300 mm / min, and the elongation at break was measured.

(2) Measurement of tensile strength Tensile strength at break was measured by the same method as the measurement of (1) tensile elongation.

(3) Measurement of repulsion stress The load when a steel ball of 12 mmφ is allowed to penetrate 5 mm into the oily gel for mats is measured.

(4) Evaluation of practicality test The oily gel for mats was observed after being used for one month, how it was used, whether there was oil oozing, whether there was any twisting, curling or misalignment. Whether or not there was gel separation was evaluated.

<< Manufacture of oily gel material >>
・ Oily gel I
Into a 1 L 4-necked flask equipped with a stirrer, reflux condenser and dropping funnel, 500 g of liquid paraffin is added, and 0.5 g of phenolic antioxidant and polyisoprene rubber (cis 1,4 bond 92% or more) 50 g was blended while being cut finely, and heated and stirred at 90 ° C. to dissolve completely. Then, after cooling to 40 ° C. or less, 1 g of a paste material in which benzoyl peroxide was dispersed in dioctyl phthalate was added and uniformly dispersed to prepare a viscous solution.

  The obtained viscous solution is poured into a 38 cm × 38 cm × 4 cm mold, the surface is oxygen-blocked with a polyester film, heat-treated at 120 ° C. for 2 hours, and then returned to room temperature. Thereafter, the polyester film was peeled off and extracted from the mold to obtain an oily gel material I (about 38 cm × about 38 cm × about 4 cm).

Example 1
The entire surface of the obtained oil-based gel material I was a urethane non-woven fabric (Kanebo) having a thickness of 0.46 mm, a basis weight of 125.0 g / m ² , a tensile strength of 76.5 N / 50 mm, and a tensile elongation of 540%. Covered with Espasione, Inc., and covered with a knitted cloth bag to produce a pressure ulcer prevention mat.

  The obtained pressure ulcer prevention mat was subjected to measurement of repulsive stress and practicality test. The results are shown in Table 1. According to Table 1, the mat for preventing pressure ulcers of Example 1 can exhibit good pressure dispersion without impairing the elasticity of the oily gel material, and also exudes oil, twists the gel, and curls. It was found to be a good one that does not occur.

(Example 2)
The entire surface of the obtained oily gel material I is a low density polyethylene nonwoven fabric having a thickness of 0.34 mm, a basis weight of 50.0 g / m ² , a tensile strength of 47.0 N / 50 mm, and a tensile elongation of 190%. And covered with a urethane bag (film thickness 0.05 mm) to provide a hermetic seal, and then further covered with a knitted cloth bag to prepare a pressure ulcer prevention mat.

  The obtained pressure ulcer prevention mat was subjected to measurement of repulsive stress and practicality test. The results are shown in Table 1. According to Table 1, the pressure ulcer prevention mat of Example 2 can exhibit good pressure dispersion without impairing the elasticity of the oily gel material, and the oil oozes out, the gel twists and curls up. It was found to be a good one that does not occur.

  Further, when the dirt is generated, the knitted bag can be removed and washed. Furthermore, since the surface of the encapsulated oil-based gel material is hermetically packaged with a urethane bag, the surface of the urethane bag can be easily disinfected with ethanol, and has excellent sanitation.

(Example 3)
The entire surface of the obtained oily gel material I is covered with a polyester nonwoven fabric having a thickness of 0.28 mm, a basis weight of 34.0 g / m ² , a tensile strength of 75.5 N / 50 mm, and a tensile elongation of 40%. Then, it was wrapped in a knitted cloth bag, and further covered with a urethane bag (film thickness 0.05 mm) for hermetic sealing, and then further covered with a knitted cloth bag to prepare a mat for preventing pressure ulcer.

  The obtained pressure ulcer prevention mat was subjected to measurement of repulsive stress and practicality test. The results are shown in Table 1. According to Table 1, the mat for preventing pressure ulcers of Example 3 can exhibit good pressure dispersion without impairing the elasticity of the oily gel material, and also exudes oil, twists the gel, and curls. It was found to be a good one that does not occur.

  In addition, the knitted cloth bag can be removed and washed when soiling occurs. Furthermore, since the surface of the encapsulated oil-based gel material is hermetically packaged with a urethane bag, the surface of the urethane bag can be easily disinfected with ethanol, and has excellent sanitation.

(Comparative Example 1)
The surface of the obtained oily gel material I was directly covered with a urethane bag (film thickness 0.05 mm) for hermetic sealing, and then further covered with a knitted fabric bag to prepare a pressure ulcer prevention mat.

  The obtained pressure ulcer prevention mat was subjected to measurement of repulsive stress and practicality test. The results are shown in Table 1. According to Table 1, it was found that the pressure ulcer prevention mat of Comparative Example 1 is one in which oil exudation, gel twist, and rounding are observed.

(Comparative Example 2)
The surface of the obtained oily gel material I is covered with a base paper having a thickness of 0.03 mm, a basis weight of 11.0 g / m ² , a tensile strength of 5.0 N / 50 mm, and a tensile elongation of 1%. Wrapped in a cloth bag, and further covered with a urethane bag (film thickness 0.05 mm) to provide a hermetic seal, and then further covered with a knitted cloth bag to prepare a pressure ulcer prevention mat.

  The obtained pressure ulcer prevention mat was subjected to measurement of repulsive stress and practicality test. The results are shown in Table 1. According to Table 1, it was found that the pressure ulcer prevention mat of Comparative Example 2 was found to have oil oozing, gel twist, and rounding.

(Comparative Example 3)
The surface of the obtained oily gel material I is covered with polyester having a thickness of 0.47 mm, a basis weight of 100.0 g / m ² , a tensile strength of 480.0 N / 50 mm, and a tensile elongation of 70%. Wrapped in a cloth bag, and then covered with a knitted cloth bag, a pressure ulcer prevention mat was prepared.

  The obtained pressure ulcer prevention mat was subjected to measurement of repulsive stress and practicality test. The results are shown in Table 1. According to Table 1, the mat for preventing pressure ulcers of Comparative Example 3 does not show any oil oozing, twisting of the gel, or curling, but impairs the excellent elasticity of the oily gel material. It turned out to be unsuitable.

The anti-decubitus mats of Examples 1 to 3, the nonwoven fabric coated on the surface of the oily gel material absorbs excess oily components, reduces the transfer of oily components to exterior bodies such as urethane bags, and oil stains during use Could be avoided.
In addition, it was found that the texture and flexibility of the non-woven fabric have the elasticity necessary for pressure ulcer prevention mats, and can be made into products such as mats without impairing the effective elastic properties of oily gel materials. .

  The oily gel body for mats of the present invention has the elasticity required for mats, has little transfer of oil components to the exterior body, and does not cause twisting, curling, misalignment or separation, so it can be used for various mats. Can do. In particular, it can be suitably used for wheelchair mats, bed mats, etc., which are forced to have a long-term sitting posture or a supine posture, and can exert an effect of preventing pressure ulcers.

It is a figure for demonstrating the state left after twisting the oil-based gel body for mats of this invention. It is a perspective view which shows an example of embodiment of the oil-based gel body for mat | matte of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Oily gel material 2 Nonwoven fabric 3 Stretchable urethane film 4 Surface protection material 5 Handle A Oily gel body for mat

Claims (7)

  An oily gel material obtained from a composition containing a rubber component having an unsaturated double bond, an oil component, and a peroxide cross-linking agent has a tensile elongation of 10% or more and a tensile strength of 5 N / 50 mm or more and 200 N / An oily gel for mats, which is covered with a nonwoven fabric of 50 mm or less.   The oily gel for mats according to claim 1, wherein the oily gel material contains a compounding agent.   The oily gel for mats according to claim 2, wherein the compounding agent is an anti-aging agent. 4. The nonwoven fabric according to claim 1, wherein the nonwoven fabric is at least one selected from the group consisting of polyester, polyurethane, olefin, and rayon, and has a basis weight of 10 g / m ² or more. The oily gel for mats as described.   Furthermore, it is coat | covered with the exterior body, This exterior body is at least 1 chosen from the group which consists of a cloth polyethylene foam, a polyurethane foam, a knitted bag, a polyurethane bag, The Claim 1 to 4 characterized by the above-mentioned. The oily gel body for mats according to any one of claims.   After mixing a composition containing a rubber component having an unsaturated double bond, an oil component, and a peroxide crosslinking agent, an oily gel material formed into a predetermined shape has a tensile elongation of 10% or more and a tensile strength. A method for producing an oily gel for mats, comprising forming an oily gel for mats by covering with a non-woven fabric having a thickness of 5 N / 50 mm or more and 200 N / 50 mm or less.   The oil-based gel material for mats according to claim 6, wherein the oil-based gel material formed in the predetermined shape is mixed with the composition and then injected into a mold having a predetermined shape to be gelled. Method.

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