JP7036370B2 - 高周波融着用ポリウレタンフォーム、積層体、及びその製造方法 - Google Patents
高周波融着用ポリウレタンフォーム、積層体、及びその製造方法 Download PDFInfo
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- JP7036370B2 JP7036370B2 JP2017238048A JP2017238048A JP7036370B2 JP 7036370 B2 JP7036370 B2 JP 7036370B2 JP 2017238048 A JP2017238048 A JP 2017238048A JP 2017238048 A JP2017238048 A JP 2017238048A JP 7036370 B2 JP7036370 B2 JP 7036370B2
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- polyurethane foam
- frequency fusion
- adhesive
- compressive load
- frequency
- Prior art date
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Description
特許文献1には、高周波融着により短時間で接着でき、優れた接着強度を発揮することができると共に、圧縮残留ひずみ等の機械的物性を維持することができる高周波融着用のポリウレタン発泡体を提供することを目的として、ポリオール類、ポリイソシアネート類、触媒、発泡剤及び補助発泡剤を含有するポリウレタン発泡体の原料を反応及び発泡させてなり、高周波融着可能なポリウレタン発泡体であって、前記発泡剤は水であってその含有量がポリオール類100質量部当たり3.5~5.0質量部であり、補助発泡剤は液化炭酸ガスであってその含有量がポリオール類100質量部当たり2.3~6.0質量部であると共に、ポリウレタン発泡体の原料には、融点が60~170℃である熱可塑性樹脂の粉体がポリオール類100質量部当たり1~30質量部含まれ、かつポリウレタン発泡体の見掛け密度が12~25kg/m3であることを特徴とする高周波融着用のポリウレタン発泡体が記載されている。
本発明の目的は、高周波融着機の圧着強度が低い場合であっても、熱可塑性樹脂基材と積層して高周波融着した場合に、接着強度が向上した高周波融着用ポリウレタンフォームを提供することである。更に、本発明の他の目的は、該高周波融着用ポリウレタンフォームと熱可塑性樹脂とを熱融着してなる積層体、及びその製造方法を提供することである。
<1> 少なくとも一部の接着部が、非接着部の圧縮荷重より小さい圧縮荷重を有することを特徴とする、高周波融着用ポリウレタンフォーム。
<2> 前記接着部は、切り込み及び凹部から選択される少なくとも1つを有する、<1>に記載の高周波融着用ポリウレタンフォーム。
<3> 前記非接着部の圧縮荷重に対する接着部の圧縮荷重の比率が80%以下である、<1>又は<2>に記載の高周波融着用ポリウレタンフォーム。
<4> 前記非接着部の圧縮荷重に対する接着部の圧縮荷重の比率が65%以下である、<1>又は<2>に記載の高周波融着用ポリウレタンフォーム。
<5> 前記非接着部の引張破断強度に対する接着部の引張破断強度の比率が60%以上である、<1>~<4>のいずれかに記載の高周波融着用ポリウレタンフォーム。
<6> 前記接着部が凹部を有する、<1>~<5>のいずれかに記載の高周波融着用ポリウレタンフォーム。
<7> <1>~<6>のいずれかに記載の高周波融着用ポリウレタンフォームと熱可塑性樹脂とを、前記接着部にて熱融着してなる、積層体。
<8> 自動車用内外装材である、<7>に記載の積層体。
また、質量部及び質量%は、それぞれ、重量部及び重量%と同義である。
本発明の高周波融着用ポリウレタンフォーム(以下、単に「ポリウレタンフォーム」ともいう。)は、少なくとも一部の接着部が、非接着部の圧縮荷重より小さい圧縮荷重を有することを特徴とする。すなわち、接着部の少なくとも一部は、接着部の圧縮荷重が非接着部の圧縮荷重よりも小さい。
高周波融着機の圧着強度が低い場合、高周波融着用ポリウレタンフォームと、基材である熱可塑性樹脂との接着強度が十分に得られないという問題があることが分かった。本発明者は鋭意検討した結果、高周波融着用ポリウレタンフォームの接着部(高周波融着部)の圧縮荷重を、非接着部の圧縮荷重よりも小さくすることにより、接着強度が高まることを見出し、本発明を完成するに至った。
上記の効果が得られる詳細な作用機序は不明であるが、一部は以下のように考えられる。すなわち、高周波融着では、融着ホーンをポリウレタンフォーム側から熱可塑性樹脂基材に向けて押し当て、融着ホーンから高周波を発生させることで、主として熱可塑性樹脂基材を溶融させ、アンカー効果によってポリウレタンフォームと熱可塑性樹脂とを接着させている。このとき、融着ホーンを押し当てる圧着強度が低いと、十分に熱可塑性樹脂基材を溶融させることができず、また、ポリウレタンフォームと溶融した熱可塑性樹脂とを密着させることができず、十分な接着強度が得られないと考えられる。ポリウレタンフォームの接着部の圧縮荷重を、非接着部の圧縮荷重よりも小さくすることで、より小さな力で融着ホーンを押し当てた場合であっても、ポリウレタンフォームが熱可塑性基材と密着し、その結果、接着強度が向上したと推定される。
以下、本発明についてより詳細に説明する。
本発明において、高周波融着用ポリウレタンフォームは、少なくとも一部の接着部の圧縮荷重が、非接着部の圧縮荷重より小さい。
なお、接着部とは、高周波融着において融着ホーンを押し当てて、基材である熱可塑性樹脂と接着させる部分であり、非接着部とは、それ以外の部分を意味する。
本発明において、少なくとも一部の接着部の圧縮荷重が、非接着部の圧縮荷重よりも小さければよく、全ての接着部の圧縮荷重が、非接着部の圧縮荷重よりも小さい必要はないが、非接着部の圧縮荷重よりも小さい圧縮荷重を有する接着部が、接着部全体の50%以上であることが好ましく、70%以上であることがより好ましい。
なお、非接着部の圧縮荷重よりも小さい圧縮荷重を有する接着部が、接着部全体の50%以上であるとは、接着部の個数(接着部の箇所数)を100としたとき、そのうちの50以上の圧縮荷重が、非接着部の圧縮荷重よりも小さいことを意味する。
前記圧縮荷重は、インストロンの電気機械式万能材料試験機にて10Φ(直径10mmの円形)の平板にて圧縮し測定される。
なお、非接着部の圧縮荷重に対する接着部の圧縮荷重の比率とは、非接着部の圧縮荷重を100%としたときの接着部の圧縮荷重を%で示したものである。
接着部は、非接着部の圧縮荷重より小さくなるように処理されていれば特に限定されないが、一方で、接着部の引張破断強度が低下すると、結果としてポリウレタンフォーム全体としての強度が低下し、破断しやすくなり、接着強度が低下するという問題がある。
従って、非接着部の引張破断強度に対する接着部の引張破断強度の比率は、好ましくは20%以上、より好ましくは35%以上、更に好ましくは60%以上、より更に好ましくは70%以上、より更に好ましくは90%以上である。上限は特に限定されない。
なお、非接着部の引張破断強度に対する接着部の引張破断強度の比率とは、非接着部の引張破断強度を100%としたときの接着部の引張破断強度を%で示したものである。
接着部の引張破断強度は、接着部を試料の中央部に配置して、引張破断強度を測定したものである(試験速度:200mm/min)。
本発明において、ポリウレタンフォームの接着部は、非接着部の圧縮荷重より小さくなるように、何らかの処理が施されている。また、接着部は、引張破断強度が上述した範囲となることが好ましい。
具体的には、ポリウレタンフォームの接着部は、切り込み及び凹部から選択される少なくとも1つを有することが好ましい。
図1には、凹部(図1(a))、及び切り込み(図1(b)~(d))の作製に使用する打ち抜き型の例を示す。これらの打ち抜き型により、ポリウレタンフォームの融着ホーンが押し当てられる面に、当該打ち抜き型と同じ形状の切り込み又は凹部が形成される。
ポリウレタンフォームに切り込みを入れることにより、圧縮荷重を小さくすることができる。
本発明のポリウレタンフォームにおける接着部を形成するための切り込みに使用する打ち抜き型の形状としては、図1(b)に示すようなコの字を組み合わせた形状、図1(c)に示すような波型、図1(d)に示すようなコの字形状等、適宜選択することができる。これらのうち抜き型を使用することにより、打ち抜き型の形状の切り込み(ポリウレタンフォームを貫通する切り込み)が、ポリウレタンフォームの接着部となる部分(高周波融着機の融着ホーンが押し上げられる部分)に形成される。
なお、切り込みの形状はこれに限定されるものではない。
ポリウレタンフォームに凹部を設けることにより、該凹部が設けられた部分を接着部とし、圧縮荷重を小さくすることができる。凹部の形成は、具体的には図1(a)に示す罫線刃をポリウレタンフォームに押し当てることで行うことができる。
ポリウレタンフォームの発泡構造を部分的に破壊することで、ポリウレタンフォームに凹部を設ける。凹部の発泡構造は部分的に破壊されており、圧縮荷重が非接着部に比べて小さくなっている。
接着部が凹部を有する場合、融着ホーンによる高周波融着は、接着部の視認性の観点、及び接着性の観点から、ポリウレタンフォームの凹部が設けられた面から行われることが好ましい。
なお、凹部を設ける方法はこれに限定されるものではなく、ポリウレタンフォームの厚み方向の一部を除去して、円柱状又は角柱状の凹部を作製する方法や、ポリウレタンフォームを発泡させる段階で、凹部を設けておく方法などが例示される。また、凹部はポリウレタンフォームの一方の面に設けられていてもよいが、接着部においてポリウレタンフォームの両面から凹部が設けられていることを排除するものではない。
また、引張破断強度に優れた接着部を得る観点からは、図1(a)に示す打ち抜き型により形成された凹部及び図1(d)に示す打ち抜き形により形成される切り込みが好ましく、図1(a)に示す打ち抜き型により形成された凹部がより好ましい。
切り込み及び凹部が形成される面積は、融着ホーンのポリウレタンフォームと接する部分(底面)の面積以上であることが好ましく、切り込み及び凹部が形成される面積は、融着ホーンの底面の面積の2倍以上が好ましく、3倍以上がより好ましく、5倍以上が更に好ましく、30倍以下が好ましく、20倍以下がより好ましく、15倍以下が更に好ましい。凹部を形成することにより、その部分はウレタンフォームとしての性能を損なう場合もある為、大きすぎる凹部を形成することは好ましくない。
本発明において、ポリウレタンフォームは、高周波融着性を有する限り特に限定されない。一般的なポリウレタン発泡体は、熱硬化性樹脂であり、高周波融着性を有しない。従って、高周波融着性を付与するために、従来種々のポリウレタンフォームが使用されている。
なお、ポリウレタンフォームは、一般的に、ポリオール類、ポリイソシアネート類、発泡剤を必須の成分とし、これに触媒、発泡助剤等を加えて、反応及び発泡させることによって得られる。
また、特開2008-31310号公報には、特定の種類及び含有量のポリオール類、ポリイソシアネート類、発泡剤及び触媒に加え、特定のポリエチレン樹脂の水分散液を特定量含むポリウレタン発泡体の原料を反応及び発泡させてなるポリウレタン発泡体が記載されている。
更に、特開2008-111045号公報には、特定の種類及び含有量のポリオール類、ポリイソシアネート類、触媒、発泡剤、及び補助発泡剤に加え、融点が60~170℃である熱可塑性樹脂の粉体が特定量含有されてなる原料を反応及び発泡させて得られる高周波融着用のポリウレタン発泡体が記載されている。
本発明において、ポリウレタンフォームとして、上記のような高周波融着性を有するポリウレタンフォームを適宜選択して使用すればよい。
なお、接着部が凹部を有する場合であっても、非接着部等の凹部が形成されていない部分がシート状であれば、該ポリウレタンフォームはシート状である。
本発明のにおいて、積層体の製造方法は、本発明の高周波融着用ポリウレタンフォームと、熱可塑性樹脂とを積層する工程(以下、工程1ともいう。)、及び前記高周波融着用ポリウレタンフォームの接着部を、熱可塑性樹脂と高周波融着する工程(以下、工程2ともいう。)を有することを特徴とする。
また、本発明の積層体は、本発明の高周波融着用ポリウレタンフォームと、熱可塑性樹脂とを、接着部にて熱融着してなる。
上述した本発明の高周波融着用ポリウレタンフォームを用いることにより、ポリウレタンフォームと熱可塑性樹脂とを、高周波融着により接着することができる。本発明の高周波融着用ポリウレタンフォームを用いることにより、従来よりも圧着強度が低い場合であっても、接着性に優れる。
これらの中でも、ポリエチレン、ポリプロピレン、ポリアミドが好ましく、ポリエチレン、ポリプロピレンがより好ましい。
熱可塑性樹脂の融点は、高周波融着による接着性が良好となる観点から、好ましくは被着体である熱可塑性樹脂の融点との差が±20℃以内、好ましくは±10℃以内、更に好ましくは±5℃以内である。
高周波融着の条件としては、高周波電圧の周波数が、好ましくは10~40kHz、より好ましくは15~35kHzである。振幅は、好ましくは20~80μm、より好ましくは40~75μm、更に好ましくは60~70μmである。
また、高周波振動を与える時間は、好ましくは0.05~2.0秒、より好ましくは0.1~1.0秒である。
高周波融着時の圧力は、0.1~1MPaであることが好ましい。
ここで、高周波融着は、超音波融着を含む概念である。
自動車用内外装材としては、例えば自動車のインストルメンタルパネル、コンソールボックス、アームレスト、ヘッドレスト、ドアトリム、リアパネル、ピラートリム、サンバンザー、トランクルームトリム、トランクリッドトリム、エアーバック収納ボックス、シートバックル、グローブボックス、ステアリングホイールカバー、天井材等の内外装材が挙げられる。
家電・OA機器部品においては、例えばテレビ、ビデオ、洗濯機、乾燥機、掃除機、クーラー、エアコン、リモコンケース、電子レンジ、トースター、コーヒーメーカー、ポット、ジャー、食器洗い器、パーソナルコンピューター、タイプライター、映写機、電話、コピー機、ファクシミリ、テレックス等の耐光性及び耐熱性が求められる各種ハウジング材に適する。
建築・住宅部品においては、例えば家具・机・椅子、壁装飾材料・天井装飾材料・カーテンウォール等の材料、台所・洗面所・トイレ等の屋内用床材、ベランダ・テラス・バルコニー・カーポート等の屋内用床材、玄関マット・テーブルクロス・コースター・灰皿敷等の敷物に適する。
その他の工業部品分野においては、例えば電動工具類などのグリップ等に適する。それ以外にも、かばん・ケース類・ファイル・手帳・アルバム・文房具・カメラボディー・人形やその他玩具等の材料、また、額の外枠に適する。
[測定及び評価方法]
実施例及び比較例において使用した測定及び評価方法は以下の通りである。
(1)圧縮荷重
インストロンの電気機械式万能材料試験機にて、厚み15mmのポリウレタンフォームの接着部及び非接着部を10Φの平板にて圧縮し、2mmまで圧縮した際の荷重を測定した。
ポリウレタンフォームの接着部を試料の中央部に配置した、横30mm×縦100mmの試料を用い、引張試験機にて縦方向に引張、破断強度を測定した(試験速度:200mm/min)。また、非接着部を試料の中央部に配置し、同様に測定した。
高周波融着性は、高周波融着後にポリウレタンフォームを接着部と垂直方向に剥がし、以下の評価基準により評価した。
A:接着部以外の部分でウレタンフォームが千切れて剥がれる
B:接着部にウレタンフォームが残っている(ホーン面積と同等面積)
C:接着部にウレタンフォームが残っている(ホーン面積の50%以上)
D:接着部にウレタンフォームが残っている(ホーン面積の50%未満)、ないしは残っていない
ポリウレタンフォームの製造方法としては、特に限定されるものではなく、ワンショット法、プレポリマー法等の公知の方法を利用できる。ただ、ワンショット法がより好適に発泡することができる。
適切なサイズのポリ容器にポリオールを計量し、更に発泡剤、整泡剤、架橋剤触媒及び添加剤を計量添加した。最後にTDIを計量添加した直後に、撹拌機にて混合し、ビニールやクラフト紙などを敷いた箱の中に混合液を投入した。
これにより、発泡が進行し、ポリウレタンフォームを得ることができる。なお、使用した成分及び添加量は以下の表1の通りである。
1)ポリオール:ポリエーテルポリオール(PPG系ポリエーテルポリオール、「サンニックストリオールGP-3000」(三洋化成工業(株)製)、数平均分子量:3,000)
2)TDI:トリレンジイソシアネート(2,4-トリレンジイソシアネート:2,6-トリレンジイソシアネート=80:20)
3)アミン触媒:TEDA L33(トリエチレンジアミン/ジプロピレングリコール=33/67質量%溶液、東ソー(株)製)
4)架橋剤:DM82162、ダウケミカル社製
5)有機錫触媒:ニッカオクチックス錫(オクチル酸スズ、日本化学産業(株)製)
6)整泡剤:デゴスターブ B 8239 F、エボニック・デグサ・ジャパン(株)製
7)補助発泡剤:SolsticeTM 1233zd(トランス-1-クロロ-3,3,3-トリフルオロプロペン、Honeywell社製)
8)ポリエチレン:サンファインLH411、旭化成ケミカルズ(株)製
9)難燃剤:ダイガード0880、大八化学工業(株)製
10)カラー:POLYTON BLACK UE2030-T、ディーアイシー(株)製
図1(a)に示す打ち抜き型(25mm×25mm)を使用し、製造したポリウレタンフォームの接着部となる部分に凹部を形成した。
得られたポリウレタンフォームについて、非接着部の圧縮荷重、接着部の圧縮荷重をそれぞれ測定した。また、非接着部及び接着部の引張破断強度を測定した。
得られた積層体について、高周波融着性を評価した。
結果を以下の表1に示す。
図1(b)~図1(d)に示す打ち抜き型(25mm×25mm)を使用し、製造したポリウレタンフォームの接着部となる部分に切り込みを形成した以外は、実施例1と同様に接着部を有するポリウレタンフォームを製造し、実施例1と同様に評価した。
結果を以下の表1に示す。
接着部を形成する加工をしなかった以外は実施例1と同様にして評価した。
結果を以下の表2に示す。
なお、特に罫線刃を使用して、凹部を設けた実施例1では、高周波融着性に優れるものであった。
Claims (7)
- 少なくとも一部の接着部が、非接着部の圧縮荷重より小さい圧縮荷重を有することを特徴とし、
前記接着部が切り込みを有し、
前記切り込みが、コの字を組み合わせた形状、波型形状及びコの字形状から選択される形状である、高周波融着用ポリウレタンフォーム。 - 前記非接着部の圧縮荷重に対する接着部の圧縮荷重の比率が80%以下である、請求項1に記載の高周波融着用ポリウレタンフォーム。
- 前記非接着部の圧縮荷重に対する接着部の圧縮荷重の比率が65%以下である、請求項1に記載の高周波融着用ポリウレタンフォーム。
- 前記非接着部の引張破断強度に対する接着部の引張破断強度の比率が60%以上である、請求項1~3のいずれかに記載の高周波融着用ポリウレタンフォーム。
- 請求項1~4のいずれかに記載の高周波融着用ポリウレタンフォームと熱可塑性樹脂とを、前記接着部にて熱融着してなる、積層体。
- 前記熱可塑性樹脂が、ポリエチレン及びポリプロピレンから選択される樹脂である、請求項5に記載の積層体。
- 自動車用内外装材である、請求項5又は6に記載の積層体。
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JPS5746838A (en) * | 1980-05-31 | 1982-03-17 | Tokyo Seat Kk | Welding method of facing member into seat or the like |
JPS6066783A (ja) * | 1983-09-23 | 1985-04-16 | アイシン精機株式会社 | 表皮一体化座席の製造方法 |
JPH0329100U (ja) * | 1989-07-31 | 1991-03-22 | ||
JPH0735983Y2 (ja) * | 1992-02-27 | 1995-08-16 | コマニー株式会社 | ビニールシート貼着パネル |
JPH10337797A (ja) * | 1997-06-04 | 1998-12-22 | Toray Ind Inc | 独立発泡体シート、救命胴衣および水陸両用作業衣 |
US6706136B2 (en) * | 2001-10-16 | 2004-03-16 | Toyo Boseki Kabushiki Kaisha | Resin composition for high-frequency bonding |
JP4896617B2 (ja) | 2006-07-28 | 2012-03-14 | 株式会社イノアックコーポレーション | 高周波融着用のポリウレタン発泡体及びその製造方法 |
JP5007097B2 (ja) | 2006-10-30 | 2012-08-22 | 株式会社イノアックコーポレーション | 高周波融着用のポリウレタン発泡体及びそれを用いた吸音部材 |
JP2011241336A (ja) | 2010-05-20 | 2011-12-01 | Dic Corp | 軟質ポリウレタンフォーム形成用樹脂組成物、及びそれを用いてなる軟質ポリウレタンフォーム |
WO2012120944A1 (ja) * | 2011-03-09 | 2012-09-13 | 東レ株式会社 | ポリオレフィン系樹脂架橋発泡体 |
ES2624624T3 (es) * | 2012-12-05 | 2017-07-17 | Woodwelding Ag | Unión de objetos juntos |
JP2016043684A (ja) * | 2014-08-27 | 2016-04-04 | 難波プレス工業株式会社 | ウレタン発泡体を使用した、軽量で、剛性をもつ平板材の製造方法 |
KR101747557B1 (ko) * | 2015-12-16 | 2017-06-15 | 주식회사 트리라인 | 접이식 매트의 제조방법 및 그 제조방법으로 제조된 접이식 매트 |
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EP3725831A4 (en) | 2021-09-01 |
JP2019104827A (ja) | 2019-06-27 |
WO2019116864A1 (ja) | 2019-06-20 |
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