JPWO2006082630A1 - Polyurethane foam and method for producing the same - Google Patents

Polyurethane foam and method for producing the same Download PDF

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JPWO2006082630A1
JPWO2006082630A1 JP2007501467A JP2007501467A JPWO2006082630A1 JP WO2006082630 A1 JPWO2006082630 A1 JP WO2006082630A1 JP 2007501467 A JP2007501467 A JP 2007501467A JP 2007501467 A JP2007501467 A JP 2007501467A JP WO2006082630 A1 JPWO2006082630 A1 JP WO2006082630A1
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JP4898656B2 (en
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景太 今井
景太 今井
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Inoac Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/04—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/04—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities
    • B29C44/0461—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities by having different chemical compositions in different places, e.g. having different concentrations of foaming agent, feeding one composition after the other
    • B29C44/0469—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities by having different chemical compositions in different places, e.g. having different concentrations of foaming agent, feeding one composition after the other provided with physical separators between the different materials, e.g. separating layers, mould walls

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  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Chair Legs, Seat Parts, And Backrests (AREA)
  • Polyurethanes Or Polyureas (AREA)

Abstract

２種類のポリウレタンフォームとなる発泡原料を、反応速度および注入量等を緻密に調整する等の煩雑な手順を実施することなく、異なる物性を有するポリウレタンフォームを一体的に発泡成形させて、傾斜材料的な要素を持たせて物性が連続的に変化したポリウレタンフォームと、その製造方法を提供する。所要の成形型に、発泡・硬化反応の完了時に所要の物性における数値が互いに異なる発泡体となる第１の発泡原料および第２の発泡原料を逐次注入して製造されるポリウレタンフォームであって、前記第１の発泡原料および第２の発泡原料から夫々得られる発泡体が一体的に混在され、該所要の物性における数値が成形型の高さ方向に沿って連続的に変化している。Gradient materials can be obtained by integrally foaming polyurethane foams with different physical properties without carrying out complicated procedures such as finely adjusting the reaction rate and injection amount, etc. A polyurethane foam having physical elements and continuously changing physical properties and a method for producing the same are provided. A polyurethane foam produced by sequentially injecting a first foaming raw material and a second foaming raw material into foams having different numerical values in required physical properties upon completion of the foaming / curing reaction into a required mold, Foams respectively obtained from the first foaming raw material and the second foaming raw material are mixed together, and the numerical values of the required physical properties are continuously changed along the height direction of the mold.

Description

この発明はポリウレタンフォームおよびその製造方法に関し、更に詳細には、所要の物性において異なった値を発現する２つの発泡原料を使用し、異なった値の発現される２つの発泡体が一体的に混在し、かつその値の変化がポリウレタンフォームの高さ方向に沿って連続的に変化した構造となっているポリウレタンフォームおよびその製造方法に関するものである。   The present invention relates to a polyurethane foam and a method for producing the same. More specifically, two foam raw materials that express different values in required physical properties are used, and two foams that express different values are mixed together. In addition, the present invention relates to a polyurethane foam having a structure in which the change in value continuously changes along the height direction of the polyurethane foam, and a method for producing the same.

多様化した素材ニーズに対して、夫々異なる特性(物性)を発現する複数の素材を複合する、所謂複合材料の開発が行なわれている。殊に、例えば２つの素材がその配合割合を徐々に変動させた状態となっている、所謂傾斜材料が大きな注目を集めている。一般に傾斜材料とは、一つの材料の中で、組成や機能が連続的または段階的に変化している材料のことであり、例えば急激な温度勾配中等の過酷な熱環境による変形や破損を回避し得るように、熱伝導率、熱膨張率または耐熱性等の各物性が異なる２つの素材を用いた傾斜材料が知られている。   In response to diversified material needs, so-called composite materials have been developed in which a plurality of materials that express different properties (physical properties) are combined. In particular, so-called gradient materials, in which, for example, two materials are in a state where their blending ratios are gradually changed, are attracting much attention. In general, a gradient material is a material whose composition or function changes continuously or stepwise in a single material, and avoids deformation and breakage due to a severe thermal environment such as during a sudden temperature gradient. As is possible, a gradient material using two materials having different physical properties such as thermal conductivity, thermal expansion coefficient, and heat resistance is known.

しかし前述の傾斜材料は、基本的にこの混合度合いが容易に調整可能または体積拡散等の手段により材料粒子が移動し得る無機系材料に限ってのことであり、一般的に有機材料においては傾斜材料は殆ど知られていなかった。一例として代表的な有機材料の１つであるポリウレタンフォームを使用した座席用のシート用パッドとして、下記の［特許文献１］に記載の発明「クッション材の製造方法」の如く、成形型内に物性の異なる２種類のポリウレタンフォームとなる２種類の発泡原料を異なる部位から夫々分けて注入し、これらから形成される異なる物性を有するポリウレタンフォームを一体的に発泡成形させて、傾斜材料的な要素を持たせるべく製造されるポリウレタンフォームが知られている。
特開２００２−５２５５０号公報 However, the gradient material described above is basically limited to inorganic materials in which the degree of mixing can be easily adjusted or the material particles can move by means such as volume diffusion. The material was hardly known. As an example, as a seat pad for a seat using polyurethane foam which is one of typical organic materials, as in the invention “Cushion Material Manufacturing Method” described in [Patent Document 1] below, Two types of foaming raw materials, which are two types of polyurethane foams with different physical properties, are injected separately from different parts, and polyurethane foams with different physical properties formed from these are integrally foam-molded. Polyurethane foams are known that are manufactured to have the same.
JP 2002-52550 A

しかし、２種類の発泡原料が略同時に注入されるため工程に煩雑さはないが、注入後の発泡・硬化反応の進行過程において、一方の発泡体が他方の発泡体を覆うように制御することが必要とされる。そしてこのような制御を達成するためには、双方の発泡原料の反応速度および注入量等を緻密に調整する必要があるが、このような調整はその手順が煩雑で、かつ要因が多いため、好適な実施が困難である点と、連続的に物性が変化する好適な傾斜材料挙動を示すポリウレタンフォームとはならない点とが問題となっていた。
あった。However, since the two types of foaming raw materials are injected almost simultaneously, the process is not complicated, but in the process of foaming / curing reaction after the injection, one foam should be controlled to cover the other foam. Is needed. And in order to achieve such control, it is necessary to precisely adjust the reaction rate and the injection amount of both foaming raw materials, but such adjustment is complicated and has many factors. There are problems in that it is difficult to carry out suitable implementation and that the polyurethane foam does not exhibit a suitable gradient material behavior in which physical properties continuously change.
there were.

前記課題を克服し、所期の目的を達成するため本発明に係るポリウレタンフォームは、所要の成形型に、発泡・硬化反応の完了時に所要の物性における数値が互いに異なる発泡体となる第１の発泡原料および第２の発泡原料を逐次注入して製造されるポリウレタンフォームであって、
前記第１の発泡原料および第２の発泡原料から夫々得られる発泡体が一体的に混在され、該所要の物性における数値が成形型の高さ方向に沿って連続的に変化していることを特徴とする。In order to overcome the above-mentioned problems and achieve the intended object, the polyurethane foam according to the present invention is a first molding in which a required mold has different numerical values in required physical properties upon completion of the foaming / curing reaction. A polyurethane foam produced by sequentially injecting a foaming raw material and a second foaming raw material,
The foams respectively obtained from the first foaming raw material and the second foaming raw material are integrally mixed, and the numerical values in the required physical properties continuously change along the height direction of the mold. Features.

前記課題を克服し、所期の目的を達成するため本願の別の発明に係るポリウレタンフォームの製造方法は、所要の成形型に、発泡・硬化反応の完了時に所要の物性における数値が互いに異なる発泡体となる第１の発泡原料および第２の発泡原料を逐次注入してたポリウレタンフォームを製造する方法であって、
先に注入されて発泡・硬化反応が進行中の第１の発泡原料が存在する前記成形型内に、第２の発泡原料を注入することで、２つの発泡原料の反応進行中に発生する比重差によって、第２の発泡原料を第１の発泡原料の下側に位置させ、
前記成形型の内部で２つの発泡原料の反応を更に進行させることで、夫々の発泡原料から得られる発泡体を一体的に混在させると共に、該所要の物性における数値が成形型の高さ方向に沿って連続的に変化させるようにしたことを特徴とする。In order to overcome the above-mentioned problems and achieve the intended purpose, a method for producing a polyurethane foam according to another invention of the present application is to form a foam with different required physical properties at the time of completion of the foaming / curing reaction. A method for producing a polyurethane foam in which a first foaming raw material and a second foaming raw material to be a body are sequentially injected,
Specific gravity generated during the reaction of the two foaming raw materials by injecting the second foaming raw material into the mold in which the first foaming raw material in which the foaming / curing reaction is in progress is present. Due to the difference, the second foaming raw material is positioned below the first foaming raw material,
By further advancing the reaction of the two foam raw materials inside the mold, the foams obtained from the respective foam raw materials are mixed together, and the numerical values in the required physical properties are in the height direction of the mold. It is characterized by being continuously changed along.

以上説明した如く、本発明に係るポリウレタンフォームおよびその製造方法によれば、第１の発泡原料の発泡・硬化反応が進行する成形型内に、所要の物性において第１の発泡原料から得られる発泡体とは異なる値を発現する発泡体となる第２の発泡原料を注入することで、夫々違う値となる物性の発現された少なくとも２種類の発泡体が一体的に混在し、かつその物性がポリウレタンフォームの高さ方向に沿って連続的に変化して、所謂傾斜材料となっているポリウレタンフォームを製造し得る。またこのような構造を備えるポリウレタンフォームは、双方の発泡原料の反応進行中の比重差を利用することで達成されるため、製造の際に留意する条件は第２の発泡原料の注入タイミングだけであり、煩雑な調整は必要とされない。   As described above, according to the polyurethane foam and the method for producing the same according to the present invention, the foam obtained from the first foam raw material in the required physical properties is formed in the mold in which the foaming / curing reaction of the first foam raw material proceeds. By injecting the second foaming raw material, which is a foam that expresses a value different from that of the body, at least two types of foams that exhibit different physical properties are mixed together, and the physical properties are It is possible to produce a polyurethane foam that changes continuously along the height direction of the polyurethane foam to form a so-called gradient material. In addition, since the polyurethane foam having such a structure is achieved by utilizing the difference in specific gravity during the reaction of both foam raw materials, the condition to be noted in the production is only the injection timing of the second foam raw material. There is no need for complicated adjustments.

次に本発明に係るポリウレタンフォームおよびその製造方法につき、好適な実施例を挙げて、添付図面を参照しながら以下説明する。なお実施例においては、ポリウレタンフォームが好適に利用されるシート用パッドの場合を例に挙げると共に、連続的に変化させる所要の物性として硬度を用いた場合を説明する。実施例に係るポリウレタンフォーム１０好適に使用されるシート用パッド１２は、図１に示す如く、基本的に乗員が着座した直接接触する部位である前部サポート部３４および後部サポート部３６と、この両側に位置し、該乗員のサイドサポートにより姿勢を保持するサイドサポート部３８,３８とから構成されている。そして前部サポート部３４および後部サポート部３６においては、乗員の乗り心地、ホールド性、乗り降り容易性その他各種要望等の点から、硬度が裏側ほど大きく、また表面側ほど小さく、すなわち高い柔軟性を発現するようになっている。具体的には、硬度の異なる２種類の発泡体が一体的に混在した状態となり、かつその硬度が成形型５０の高さ方向、すなわちポリウレタンフォーム１０の高さ方向(シート用パッド１２の厚さ方向)に沿って連続的に変化する、硬度に明確な境目のない、所謂傾斜材料的な特質を備えた状態となっている。またサイドサポート部３８,３８は、殊に本発明とは直接的に関連がないので詳細な記載を省略する。   Next, the polyurethane foam and the method for producing the same according to the present invention will be described below with reference to the accompanying drawings by way of preferred examples. In the examples, a case of a sheet pad in which polyurethane foam is preferably used will be described as an example, and a case where hardness is used as a required physical property that is continuously changed will be described. As shown in FIG. 1, the seat pad 12 suitably used for the polyurethane foam 10 according to the embodiment basically includes a front support part 34 and a rear support part 36 which are parts in direct contact with which an occupant is seated. It is comprised from the side support parts 38 and 38 which are located in both sides and hold | maintain an attitude | position by the passenger | crew's side support. In the front support part 34 and the rear support part 36, the hardness is larger on the back side and smaller on the front side, that is, high flexibility in terms of rider comfort, holdability, ease of getting on and off, and various other requests. It has come to express. Specifically, two types of foams having different hardnesses are integrally mixed, and the hardness is in the height direction of the mold 50, that is, the height direction of the polyurethane foam 10 (the thickness of the sheet pad 12). It has a so-called gradient material characteristic that changes continuously along the direction) and has no clear boundary in hardness. Further, since the side support portions 38 and 38 are not directly related to the present invention, detailed description thereof is omitted.

そしてこのような構造を備えるポリウレタンフォーム１０(シート用パッド１２)の製造工程は、図２に示す如く、発泡原料準備工程Ｓ１、第１の発泡原料注入工程Ｓ２、第２の発泡原料注入工程Ｓ３、反応進行工程Ｓ４および最終工程Ｓ５から構成される。ここで発泡原料準備工程Ｓ１は、製造されるシート用パッド１２の外部輪郭形状に合致する内部輪郭形状を備え、その底面部５２ａがシート用パッド１２を成形する、例えば図３に示すような成形型５０内に順序をもって注入され、発泡・硬化反応完了時(以下、単に反応完了時と云う)に高い硬度を発現する発泡体となる第１の発泡原料Ｍ１と、発泡・硬化反応(以下、単に反応と云う)完了時に低い硬度を発現する発泡体となる第２の発泡原料Ｍ２とを、夫々の硬度および比重を考慮してポリオールおよびイソシアネートと、各副原料とを適宜選択し、反応・硬化しない状態として準備する工程である。   And the manufacturing process of the polyurethane foam 10 (sheet pad 12) provided with such a structure is as shown in FIG. 2, foaming raw material preparation process S1, first foaming raw material injection process S2, second foaming raw material injection process S3. The reaction progress step S4 and the final step S5. Here, the foaming raw material preparation step S1 has an inner contour shape that matches the outer contour shape of the sheet pad 12 to be manufactured, and the bottom surface portion 52a forms the sheet pad 12, for example, as shown in FIG. A first foam raw material M1 which is injected into the mold 50 in order and becomes a foam that exhibits high hardness when the foaming / curing reaction is completed (hereinafter simply referred to as reaction completion), and a foaming / curing reaction (hereinafter, The second foaming raw material M2 to be a foam that exhibits low hardness upon completion) is appropriately selected from the polyol and isocyanate, and each auxiliary raw material in consideration of the respective hardness and specific gravity. It is a step of preparing as a state that does not cure.

ここで第１の発泡原料Ｍ１および第２の発泡原料Ｍ２としては、反応完了時における発泡体の比重が相互に異なるものが準備されている。本実施例においては、一方の第１の発泡原料Ｍ１は、反応完了時に得られる発泡体が高い硬度を発現するだけでなく、他方の第２の発泡原料Ｍ２の反応完了時に得られる発泡体に較べて小さい比重となるように設定されている。なお本実施例では、成形型５０への注入で第１の発泡原料Ｍ１が上側に位置し、第２の発泡原料Ｍ２が下側に位置するように設定されているため、第１の発泡原料Ｍ１と第２の発泡原料Ｍ２とから得られる夫々の発泡体の比重は、前述の関係としているが、第１の発泡原料Ｍ１から得られる発泡体が、第２の発泡原料Ｍ２から得られる発泡体より比重が大きくなるように設定することも可能である。また一般的な発泡体の代表であるポリウレタンフォームの場合、その発泡原料は殆ど比重(密度)が１.０５ｇ／ｃｍ３程度であり、比重の低下は、反応の進行に伴う発泡によってなされている。Here, as the first foaming raw material M1 and the second foaming raw material M2, those having different specific gravities of the foams upon completion of the reaction are prepared. In this example, one of the first foaming raw materials M1 is not only a foam obtained at the completion of the reaction, but also exhibits a high hardness, and the foam obtained at the completion of the reaction of the other second foaming raw material M2. The specific gravity is set to be smaller. In the present embodiment, since the first foaming material M1 is positioned on the upper side and the second foaming material M2 is positioned on the lower side in the injection into the mold 50, the first foaming material is set. The specific gravity of each foam obtained from M1 and the second foaming raw material M2 is as described above, but the foam obtained from the first foaming raw material M1 is the foam obtained from the second foaming raw material M2. It is also possible to set the specific gravity to be larger than that of the body. In the case of polyurethane foam, which is a typical typical foam, the foam material has a specific gravity (density) of about 1.05 g / cm 3 , and the specific gravity is reduced by foaming as the reaction proceeds. .

第１の発泡原料注入工程Ｓ２は、第１の発泡原料Ｍ１を反応可能状態とすると共に、速やかに成形型５０内に注入する工程である。そして第２の発泡原料注入工程Ｓ３は、先に注入して反応が進行して徐々に比重が軽くなりつつある第１の発泡原料Ｍ１に対して、その上から第２の発泡原料Ｍ２を注入する工程であり、反応進行工程Ｓ４は、成形型５０内に注入された第１の発泡原料Ｍ１および第２の発泡原料Ｍ２が、発泡・硬化反応を進行させてその反応進行中に発生する比重差によって、徐々に一体的に混在した状態になっていき、最終的に成形型５０内部が第１の発泡原料Ｍ１および第２の発泡原料Ｍ２から得られる発泡体で充填させる工程である。なお下型５２に対する上型５３の固定、すなわち成形型５０の閉成は、第２の発泡原料注入工程Ｓ３の完了直後になされる。   The first foaming raw material injection step S2 is a step of allowing the first foaming raw material M1 to be in a reactive state and quickly injecting it into the mold 50. In the second foaming raw material injection step S3, the second foaming raw material M2 is injected from above onto the first foaming raw material M1 which is injected first and the reaction proceeds and the specific gravity is gradually decreasing. The reaction progressing step S4 is a specific gravity generated when the first foaming raw material M1 and the second foaming raw material M2 injected into the mold 50 advance the foaming / curing reaction and the reaction proceeds. Due to the difference, it is a process of gradually becoming a unitary mixture, and finally filling the inside of the mold 50 with the foam obtained from the first foaming raw material M1 and the second foaming raw material M2. The upper die 53 is fixed to the lower die 52, that is, the molding die 50 is closed immediately after the completion of the second foaming material injection step S3.

ここでこの２つの発泡原料Ｍ１およびＭ２の成形型５０に対する注入から始まる反応の度合いおよび比重の状態の経時的な変動は、図４の如きグラフで表すことができる。すなわち、基本的に反応の度合いで表される反応性は第１の発泡原料Ｍ１および第２の発泡原料Ｍ２で差はなく、時間の経過と共に双方とも反応が進行し、この反応に伴う発泡によって２つの発泡原料Ｍ１およびＭ２共に比重が小さくなっている。そして第１の発泡原料Ｍ１と、第２の発泡原料Ｍ２とにおいては、注入開始の時点がずれているため、先に注入される第１の発泡原料Ｍ１の方が先に反応を開始して、第２の発泡原料Ｍ２に先んじて反応が進行し、これに伴って比重も小さくなる。また比重については、第１の発泡原料Ｍ１および第２の発泡原料Ｍ２については、その配合に違いがあり、第１の発泡原料Ｍ１からは比重が小さい発泡体が得られ、第２の発泡原料Ｍ２からは比重が大きい発泡体が得られる。すなわち反応の進行に伴って、第１の発泡原料Ｍ１および第２の発泡原料Ｍ２の比重差はａからｂへと大きくなり、最終的には第１の発泡原料Ｍ１から得られる発泡体の比重と、第２の発泡原料Ｍ２から得られる発泡体の比重との差に収束する。この反応途中の比重差によって、第２の発泡原料Ｍ２の第１の発泡原料Ｍ１下側への配置が可能となっている。なお第１の発泡原料Ｍ１から得られる発泡体の比重については３０〜７０ｋｇ／ｍ３、第２の発泡原料Ｍ２から得られる発泡体の比重については４０〜１００ｋｇ／ｍ３程度として、その比重差を少なくとも１０ｋｇ／ｍ３とすることが好ましい。また図４においては、ＳＧ１は第１の発泡原料Ｍ１から得られる発泡体の比重を、ＳＧ２は第２の発泡原料Ｍ２から得られる発泡体の比重を、ＩＪ１は第１の発泡原料Ｍ１注入開始時点を、ＩＪ２は第２の発泡原料Ｍ２注入開始時点を夫々示し、またＳＧＩは発泡原料発泡前の比重を表している。Here, the degree of reaction starting from the injection of the two foaming raw materials M1 and M2 into the mold 50 and the variation over time of the state of specific gravity can be represented by a graph as shown in FIG. That is, the reactivity represented by the degree of reaction is basically the same between the first foaming raw material M1 and the second foaming raw material M2, and both of the reactions proceed with the passage of time. The specific gravity of the two foaming raw materials M1 and M2 is small. In the first foaming raw material M1 and the second foaming raw material M2, the start time of injection is shifted, so the first foaming raw material M1 injected first starts the reaction first. The reaction proceeds prior to the second foaming raw material M2, and the specific gravity is reduced accordingly. Regarding the specific gravity, the first foaming raw material M1 and the second foaming raw material M2 have different blending, and a foam having a small specific gravity is obtained from the first foaming raw material M1, and the second foaming raw material M2. A foam having a large specific gravity can be obtained from M2. That is, as the reaction proceeds, the specific gravity difference between the first foaming raw material M1 and the second foaming raw material M2 increases from a to b, and finally the specific gravity of the foam obtained from the first foaming raw material M1. And the difference between the specific gravity of the foam obtained from the second foaming raw material M2. Due to the difference in specific gravity during the reaction, the second foaming raw material M2 can be arranged below the first foaming raw material M1. The specific gravity of the foam obtained from the first foam raw material M1 is about 30 to 70 kg / m 3 , the specific gravity of the foam obtained from the second foam raw material M2 is about 40 to 100 kg / m 3 , and the specific gravity difference Is preferably at least 10 kg / m 3 . In FIG. 4, SG 1 is the specific gravity of the foam obtained from the first foaming raw material M1, SG 2 is the specific gravity of the foam obtained from the second foaming raw material M2, and IJ 1 is the first foaming raw material. the M1 injection start point, IJ 2 is the second foaming material M2 injection start time respectively indicate, also SG I represents the specific gravity of the pre-foamed material foam.

このような挙動を示す第１の発泡原料Ｍ１および第２の発泡原料Ｍ２を成形型５０内に注入すると、第１の発泡原料Ｍ１の上から注入された第２の発泡原料Ｍ２が、その比重差故に反応途中の第１の発泡原料Ｍ１を通り抜けて下側の成形型５０の底面部５２ａに沈降することになる。そして成形型５０内で、第２の発泡原料Ｍ２は常に第１の発泡原料Ｍ１、の下、すなわち底面部５２ａ側に位置することになる。そしてその後、時間の経過と共に第１の発泡原料Ｍ１および第２の発泡原料Ｍ２の双方の反応が進行し、これに伴ってその体積が増大し続けることになる。このとき、第１の発泡原料Ｍ１の下方に位置する第２の発泡原料Ｍ２は、その体積増大に係る力によって第１の発泡原料Ｍ１内に下方から徐々に入り込む(浸透する)ことになる。   When the first foaming raw material M1 and the second foaming raw material M2 exhibiting such behavior are injected into the mold 50, the second foaming raw material M2 injected from above the first foaming raw material M1 has its specific gravity. Therefore, it passes through the first foaming raw material M1 in the middle of the reaction and settles on the bottom surface portion 52a of the lower mold 50. And in the shaping | molding die 50, the 2nd foaming raw material M2 will always be located under the 1st foaming raw material M1, ie, the bottom face part 52a side. And after that, reaction of both the 1st foaming raw material M1 and the 2nd foaming raw material M2 advances with progress of time, and the volume continues increasing with this. At this time, the second foaming raw material M2 positioned below the first foaming raw material M1 gradually enters (permeates) into the first foaming raw material M1 from below by the force related to the volume increase.

ところでこの時の反応の度合いは、発泡原料の粘度としても捉えることが可能であり、成形型５０内に注入された第１の発泡原料Ｍ１および第２の発泡原料Ｍ２は、時間の経過と共にその粘度が上昇している。そしてこの第１の発泡原料Ｍ１および第２の発泡原料Ｍ２の双方の粘度を勘案した数値は、第１の発泡原料Ｍ１および第２の発泡原料Ｍ２の混合に係る容易性を示す指標として利用し得る。なおこの第１の発泡原料Ｍ１および第２の発泡原料Ｍ２の混合に係る容易性を示す指標は、本実施例においては以後、相対粘度Ｒと呼称する。   By the way, the degree of reaction at this time can also be grasped as the viscosity of the foaming raw material, and the first foaming raw material M1 and the second foaming raw material M2 injected into the mold 50 are changed over time. The viscosity is rising. The numerical value in consideration of the viscosity of both the first foaming raw material M1 and the second foaming raw material M2 is used as an index indicating the ease of mixing the first foaming raw material M1 and the second foaming raw material M2. obtain. Note that an index indicating the ease of mixing the first foaming raw material M1 and the second foaming raw material M2 is hereinafter referred to as a relative viscosity R in this embodiment.

そしてこの相対粘度Ｒは、図５に示す如く、反応の進行に伴ってほぼ直線的に増加する。すなわち第２の発泡原料Ｍ２の第１の発泡原料Ｍ１に対する浸透は、その反応の進行に伴って増加する粘度(粘度相対Ｒ)によって経時的に困難となり、徐々に抑制されることになる。その結果、成形型５０において、その底面部５２ａでは第２の発泡原料Ｍ２が全体を占めているが、上に向かうに従って、第１の発泡原料Ｍ１の存在量が増加する状態、すなわち成形型５０(ポリウレタンフォーム１０)における各高さ位置において、第１の発泡原料Ｍ１と第２の発泡原料Ｍ２との存在割合が夫々異なった状態となっている。なお図５においては、ＩＪ１は第１の発泡原料Ｍ１注入開始時点を、ＩＪ２は第２の発泡原料Ｍ２注入開始時点を夫々示している。The relative viscosity R increases almost linearly as the reaction proceeds as shown in FIG. That is, the penetration of the second foaming raw material M2 into the first foaming raw material M1 becomes difficult over time due to the viscosity (viscosity relative R) that increases with the progress of the reaction, and is gradually suppressed. As a result, in the molding die 50, the second foaming raw material M2 occupies the entire bottom surface 52a, but the amount of the first foaming raw material M1 increases as it goes upward, that is, the molding die 50. At each height position in the (polyurethane foam 10), the existence ratios of the first foaming raw material M1 and the second foaming raw material M2 are different from each other. In FIG. 5, IJ 1 indicates the start time of injection of the first foaming raw material M1, and IJ 2 indicates the start time of injection of the second foaming raw material M2.

そしてこのような状態となって成形型５０内に存在する第１の発泡原料Ｍ１および第２の発泡原料Ｍ２は、その反応完了と共に発泡体となる。すなわち成形型５０の底面部５２ａにおいては第２の発泡原料Ｍ２が反応した硬度の低い発泡体だけが存在し、上方に行くほど第１の発泡原料Ｍ１が反応した硬度の高い発泡体の存在割合が増加して、最終的には発泡原料Ｍ１が反応した硬度の高い発泡体だけとなった構造を備えたシート用パッド１２を形成する。またこのような構成となるポリウレタンフォーム１０(シート用パッド１２)の製造においては、第１の発泡原料Ｍ１および第２の発泡原料Ｍ２の注入のタイミング、比重の差および硬度の差等の諸条件の適正化が必要となるが、本実施例においては、後に注入される第２の発泡原料Ｍ２の注入時点は好適には、第１の発泡原料Ｍ１が注入後、反応を開始して発泡が始まって比重差が発現し易くなる、所謂クリームタイム経過後で、樹脂化反応が進み粘度増加が顕著に進む以前、具体的には５秒前後の経過後から、１０〜２０秒に達するまでの間に設定される。このように第２の発泡原料Ｍ２の注入タイミングだけを調整することで、双方の発泡原料Ｍ１およびＭ２の反応進行中の比重差を利用して、本発明に係る硬度差が厚さ方向に連続的に変化したポリウレタンフォーム１０を容易に製造し得る。また硬度については、ポリウレタンフォーム１０の高さ(シート用パッド１２の厚さ)に対して直線的、すなわち比例的に変化させたり、または曲線的に、すなわち等差または等比級数的変化させたりするように設定することも可能である。なお硬度の連続的な変化の度合い、すなわち単位厚さ当たりの硬度の変化量は、双方の発泡原料Ｍ１およびＭ２の反応性(反応速度)、得られる発泡体の比重の設定および注入量等を変化させることでも制御可能である。   And the 1st foaming raw material M1 and the 2nd foaming raw material M2 which are in such a state and exist in the shaping | molding die 50 become a foam with the completion of the reaction. That is, in the bottom surface portion 52a of the mold 50, only the foam having a low hardness with which the second foaming raw material M2 has reacted exists, and the proportion of the foam having a high hardness with which the first foaming raw material M1 has reacted as it goes upward. As a result, the sheet pad 12 having a structure having only a foam having high hardness to which the foaming raw material M1 has reacted is formed. Further, in the production of the polyurethane foam 10 (sheet pad 12) having such a configuration, various conditions such as the injection timing of the first foaming raw material M1 and the second foaming raw material M2, the difference in specific gravity and the difference in hardness, etc. However, in this embodiment, the second foaming material M2 to be injected later is preferably injected at the time when the first foaming material M1 is injected and then the reaction is started and foaming is performed. After the so-called cream time elapses, the resinization reaction proceeds and the viscosity increase remarkably progresses, specifically after about 5 seconds, until 10 to 20 seconds are reached. Set between. Thus, by adjusting only the injection timing of the second foaming raw material M2, the hardness difference according to the present invention continues in the thickness direction by utilizing the difference in specific gravity during the reaction of both foaming raw materials M1 and M2. Changed polyurethane foam 10 can be easily manufactured. The hardness is changed linearly, that is, in proportion to the height of the polyurethane foam 10 (thickness of the sheet pad 12), or is changed in a curve, that is, an equal difference or a geometric series. It is also possible to set so as to. The degree of continuous change in hardness, that is, the amount of change in hardness per unit thickness depends on the reactivity (reaction rate) of both foaming raw materials M1 and M2, the specific gravity setting and the injection amount of the obtained foam, etc. It can also be controlled by changing it.

この他、発泡原料の発泡倍率等も考慮すべき要素であるが、基本的に注入された発泡原料が成形型５０内における発泡予定部位に充分に拡がる程度の量および倍率であれば問題なく、これらは公知の経験的知見から導出されている。そしてここまでの工程Ｓ１〜Ｓ４を経ることで成形型５０内に成形されたシート用パッド１２は、最終工程Ｓ５で成形型５０から脱型され、その後、公知の後処理および検査等の実施により完成品たるポリウレタンフォーム１０(シート用パッド１２)とされる。   In addition, although the foaming ratio of the foaming raw material is an element to be considered, there is no problem as long as the injected foaming raw material basically has an amount and a magnification enough to expand to the foaming planned site in the mold 50, These are derived from known empirical findings. And the pad 12 for sheets shape | molded in the shaping | molding die 50 through the process S1-S4 so far is demolded from the shaping | molding die 50 by the last process S5, and then by implementation of well-known post-processing and inspection, etc. The finished polyurethane foam 10 (sheet pad 12) is used.

なお本発明におけるポリウレタンフォームは、シート用パッドに限定されるものではなく、自動車内装材、住宅内装材または各種クッション材等の各種用途に利用可能であり、またその高さ方向に沿って連続的に変化する物性も硬度に限定されるものではなく、この他、反発弾性率またはセルの大きさ、すなわちセル径等や、これら各物性を二重、三重に併有するようにしたものも変化させる物性として採用し得る。例えば変化させる所要の物性として反発弾性率を選択した場合、加えられる力の大きさに拘わらず、常に一定の反発力を発現し得るポリウレタンフォームが製造可能となり、セル径を次第に変化させる場合、特定または一定範囲の周波数に対して好適な吸音特性を示すポリウレタンフォームが製造可能となり、ｔａｎδのピーク発現温度が夫々異なるようした場合には、広い温度域でエネルギー吸収特性が好適なスローリカバリー性を発現するポリウレタンフォームが製造可能となる。   The polyurethane foam in the present invention is not limited to a seat pad, and can be used for various applications such as an automobile interior material, a housing interior material, or various cushion materials, and is continuously along the height direction thereof. The physical properties that change to the above are not limited to the hardness, and in addition, the resilience modulus or the cell size, that is, the cell diameter, etc., and those that have these physical properties double or triple are also changed. It can be adopted as a physical property. For example, when the rebound resilience is selected as the required physical property to be changed, it is possible to produce a polyurethane foam that can always express a certain repulsion force regardless of the magnitude of the applied force, and when the cell diameter is gradually changed, specify Alternatively, polyurethane foams with suitable sound absorption characteristics for a certain range of frequencies can be manufactured, and when the peak expression temperature of tan δ is different, the energy absorption characteristics exhibit suitable slow recovery characteristics over a wide temperature range. The polyurethane foam can be manufactured.

第１の発泡原料Ｍ１または第２の発泡原料Ｍ２から夫々得られる各発泡体の物性は、ポリウレタンフォームの原料であるポリオール、イソシアネートおよびその他の各種副原料の配合組成を適宜設定することで、意図した数値に設定される。具体的に、所要の物性を硬度とした場合には(ポリマー)ポリオール、架橋剤またはイソシアネート等の種類または配合量を変化させることで、また反発弾性率とした場合にはポリオールの分子量や、イソシアネートの種類または配合量や、整泡剤によって調整される通気性を変化させることで、そしてセル径とした場合には整泡剤の種類または添加量を変化させることで、夫々の物性における値を異なる数値とし得る。   The physical properties of the respective foams obtained from the first foaming raw material M1 or the second foaming raw material M2 are determined by appropriately setting the blending composition of polyol, isocyanate and other various auxiliary raw materials that are raw materials of the polyurethane foam. It is set to the numerical value. Specifically, if the required physical properties are hardness, (polymer) by changing the type or blending amount of polyol, cross-linking agent or isocyanate, etc., and if it is rebound resilience, the molecular weight of polyol, isocyanate By changing the type or blending amount and the air permeability adjusted by the foam stabilizer, and in the case of the cell diameter, by changing the kind or addition amount of the foam stabilizer, the value in each physical property can be changed. It can be a different number.

この他、反応完了後のポリウレタンフォームが発現する物性については、当該ポリウレタンフォーム自体が発現する物性だけでなく、その原料である第１の発泡原料Ｍ１および第２の発泡原料Ｍ２に対して、指定単位量当たりの混合量を異なる状態とした、すなわちその濃度を変えるようにした各種機能を発現する第三成分を混合するようにしてもよい。このように調整された第１の発泡原料Ｍ１および第２の発泡原料Ｍ２を用いることで第三成分は、ポリウレタンフォーム１０の高さ位置によって夫々異なった数値となる第１の発泡原料Ｍ１と第２の発泡原料Ｍ２との存在割合に比例して、ポリウレタンフォーム１０の高さ方向に沿って連続的に変化(かつ常に一定値に向けて増大または減少)した状態となる。   In addition, the physical properties of the polyurethane foam after completion of the reaction are specified not only for the physical properties of the polyurethane foam itself, but also for the first foaming raw material M1 and the second foaming raw material M2, which are the raw materials. You may make it mix the 3rd component which expresses the various functions which made the mixing amount per unit amount differ, ie, change the density | concentration. By using the first foaming raw material M1 and the second foaming raw material M2 adjusted as described above, the third component has different values depending on the height position of the polyurethane foam 10 and the first foaming raw material M1 and the second foaming raw material M2. In proportion to the ratio of the two foaming raw materials M2, the polyurethane foam 10 continuously changes along the height direction (and always increases or decreases toward a constant value).

双方の発泡原料Ｍ１,Ｍ２に混合される第三成分としては、制電性物質、導電性物質または超電導物質、磁性物質，抗菌物質、抗菌・防臭物質、消臭物質、形態安定・形状記憶物質、透湿・吸水物質、透湿抑制・防水物質、感温・保温・蓄熟・発熱・吸収物質、発光・蛍光物質或いは撥水・吸油物質等が挙げられ、発現させる機能に応じて適宜選択される。また形状としては、発泡原料Ｍ１,Ｍ２に混合できるものであれば何れのものでも採用可能である。例えばこの第三成分として、フェライト、カーボンまたは導電性フィラーその他の導電性物質が使用された場合には、静電気防止除去、通電または電磁遮蔽可能な、所謂電磁波シールド性がその高さ方向に沿って連続的に変化するように発現されるポリウレタンフォームや、所要の導電性がその高さ方向に沿って連続的に変化するように発現されるポリウレタンフォームが得られる。またエチレンオキサイドのように水酸基を含有する界面活性剤等の吸水性を発現する吸水物質が使用された場合には、ポリウレタンフォームが有している保水性を更に向上させ、液晶表面やＣＲＰ(プリント基板)等のデリケートな作業が必要とされる部材の表面研磨作業や、パチンコ機のパチンコ玉やコイン洗浄等に好適に使用され、かつ機能がその高さ方向に沿って連続的に変化している吸水性を発現するポリウレタンフォームが得られる。   The third component to be mixed in both foaming raw materials M1 and M2 is antistatic material, conductive material or superconducting material, magnetic material, antibacterial material, antibacterial / deodorant material, deodorant material, shape stable / shape memory material Moisture-permeable / water-absorbing substances, moisture-permeable / water-proof substances, temperature-sensitive / heat-retaining / ripening / heat-generating / absorbing substances, luminescent / fluorescent substances, water-repellent / oil-absorbing substances, etc. Is done. Any shape can be used as long as it can be mixed with the foaming raw materials M1 and M2. For example, when ferrite, carbon or conductive fillers or other conductive materials are used as the third component, the so-called electromagnetic wave shielding property capable of preventing static electricity removal, energization or electromagnetic shielding is along the height direction. A polyurethane foam expressed so as to continuously change or a polyurethane foam expressed so that required conductivity continuously changes along its height direction can be obtained. In addition, when a water-absorbing substance such as a surfactant containing a hydroxyl group such as ethylene oxide is used, the water retention property of the polyurethane foam is further improved, and the liquid crystal surface and CRP (printing It is suitably used for surface polishing work of parts that require delicate work such as (substrate), and for pachinko balls and coins washing of pachinko machines, and the function changes continuously along its height direction. A polyurethane foam that exhibits high water absorption is obtained.

(別の実施例)
前述の実施例においては、成形型５０に先ず第１の発泡原料Ｍ１を注入した後に、その上から第２の発泡原料Ｍ２を注入する方法を述べたが、本発明はこれに限定されるものではなく、例えば成形型５０の底面部５２ａ近傍(図３(ｂ)参照)に直接的に第２の発泡原料Ｍ２の注入をなし得る注入手段を設け、ここを介して第２の発泡原料Ｍ２を成形型５０内に注入するようにしてもよい。なお、この場合も第１の発泡原料Ｍ１および第２の発泡原料Ｍ２の反応に伴う比重差によって、本発明に係るポリウレタンフォームの構造が発現されるため、第２の発泡原料Ｍ２の注入時期は、第１の発泡原料Ｍ１の比重が小さくなり始めた後、すなわち反応開始後に設定される。(Another example)
In the above-described embodiment, the method in which the first foaming raw material M1 is first injected into the mold 50 and then the second foaming raw material M2 is injected from above is described. However, the present invention is limited to this. Instead, for example, an injection means capable of directly injecting the second foaming raw material M2 is provided in the vicinity of the bottom surface portion 52a of the mold 50 (see FIG. 3B), and the second foaming raw material M2 is provided therethrough. May be injected into the mold 50. In this case as well, since the structure of the polyurethane foam according to the present invention is expressed by the specific gravity difference caused by the reaction between the first foaming raw material M1 and the second foaming raw material M2, the injection timing of the second foaming raw material M2 is The first foaming raw material M1 is set after the specific gravity starts to decrease, that is, after the start of the reaction.

(変更例)
前述の実施例にように、第１の発泡原料Ｍ１から得られる発泡体の比重および第２の発泡原料Ｍ２から得られる発泡体の比重を異なるものとせず、同一または近い数値関係としてポリウレタンフォーム１０を製造することも可能である。この場合、経過時間と、反応の度合い(粘度)および比重との関係は、図６に示す挙動を示すが、この図から明らかな通り、第１の発泡原料Ｍ１と第２の発泡原料Ｍ２とにおいて、何れもその比重が経時的には同様に推移する(経過時間ＢおよびＣにおける比重差ｂおよび比重差ｃ参照)ため、第２の発泡原料Ｍ２が第１の発泡原料Ｍ１の下側に回り込むだけの比重差が発生している。このとき第２の発泡原料Ｍ２の注入時前後(経過時間Ａにおける比重差ａ参照)と、第１の発泡原料Ｍ１の反応完了時前後(経過時間Ｄにおける比重差ｄ参照)については、比重差が小さくなっているが、前者については反応が殆ど進行しておらず２つの発泡原料Ｍ１およびＭ２の流動性が高いため比重差が小さくても問題はなく、後者については殆ど硬化によって樹脂化が完了しているため比重差は関係がない状態となっているため問題はない。この場合、比重に差違を与える配合組成を考慮しなくてもよいため、第１の発泡原料Ｍ１および第２の発泡原料Ｍ２の配合設計がより容易となる利点がある。なお図６おいては、ＳＧは第１の発泡原料Ｍ１および第２の発泡原料Ｍ２から得られる発泡体の比重を、ＩＪ１は第１の発泡原料Ｍ１注入開始時点を、ＩＪ２は第２の発泡原料Ｍ２注入開始時点を夫々示し、またＳＧＩは発泡原料発泡前の比重を表している。(Example of change)
As in the above-described embodiment, the specific gravity of the foam obtained from the first foam raw material M1 and the specific gravity of the foam obtained from the second foam raw material M2 are not different, and the polyurethane foam 10 has the same or close numerical relationship. Can also be manufactured. In this case, the relationship between the elapsed time, the degree of reaction (viscosity), and the specific gravity shows the behavior shown in FIG. 6, and as is apparent from this figure, the first foaming raw material M1 and the second foaming raw material M2 In both cases, the specific gravity changes similarly over time (see specific gravity difference b and specific gravity difference c at elapsed times B and C), so that the second foaming raw material M2 is below the first foaming raw material M1. There is a specific gravity difference that just wraps around. At this time, the specific gravity difference between before and after the injection of the second foaming raw material M2 (refer to the specific gravity difference a at the elapsed time A) and before and after the completion of the reaction of the first foaming raw material M1 (see the specific gravity difference d at the elapsed time D). However, there is no problem even if the specific gravity difference is small because the reaction of the former is almost not progressing and the flowability of the two foaming raw materials M1 and M2 is high. Since it has been completed, there is no problem because the specific gravity difference is irrelevant. In this case, since it is not necessary to consider the blending composition that gives a difference in specific gravity, there is an advantage that the blending design of the first foaming raw material M1 and the second foaming raw material M2 becomes easier. Note 6 Oite is, SG is the specific gravity of the foam obtained from the first foaming material M1 and the second foaming material M2, IJ 1 is a first foaming material M1 injected beginning, IJ 2 second the foam raw material M2 injection start time respectively indicate, also SG I represents the specific gravity of the pre-foamed material foam.

(別の変更例)
更にこれに対して、反応進行中における比重差が問題となる場合には、例えばポリオールの末端基を変更するまたは増減させる、イソシアネートの反応性を変更する或いは触媒として反応性の高いものまたは低いものを採用するといった公知の方法によって、図７に示す如く、第１の発泡原料Ｍ１の反応性を向上と、第２の発泡原料Ｍ２の反応性を低下との何れか一方または双方をなすことで、発泡に伴う経過時間に対する比重の変動量を制御して、発泡時における第１の発泡原料Ｍ１と第２の発泡原料Ｍ２との比重差をより大きく確保する方法も採用し得る。この場合、経過時間ＡおよびＢにおける比重差ａおよび比重差ｂは、第１の発泡原料Ｍ１および第２の発泡原料Ｍ２の反応性が同一の場合に比較して何れも拡大する。このため相対粘度Ｒの連続的な硬化変化の度合いの設定や、第２の発泡原料Ｍ２注入時のより早い時点での設定が可能となる。なお図７おいては、ＳＧは第１の発泡原料Ｍ１および第２の発泡原料Ｍ２から得られる発泡体の比重を、ＩＪ１は第１の発泡原料Ｍ１注入開始時点を、ＩＪ２は第２の発泡原料Ｍ２注入開始時点を、ＲＵは反応性の向上を、ＲＤは反応性の低下を夫々示し、またＳＧＩは発泡原料発泡前の比重を表している。(Another change example)
On the other hand, when the specific gravity difference during the reaction is a problem, for example, the polyol end group is changed or increased, the isocyanate reactivity is changed, or the catalyst has a high or low reactivity. As shown in FIG. 7, the reactivity of the first foaming raw material M1 is improved and the reactivity of the second foaming raw material M2 is reduced or both by a known method such as adopting A method of controlling the amount of fluctuation of the specific gravity with respect to the elapsed time associated with foaming to ensure a larger specific gravity difference between the first foaming raw material M1 and the second foaming raw material M2 at the time of foaming can also be adopted. In this case, the specific gravity difference a and the specific gravity difference b in the elapsed times A and B are both increased as compared with the case where the reactivity of the first foaming raw material M1 and the second foaming raw material M2 is the same. For this reason, the setting of the degree of continuous curing change of the relative viscosity R and the setting at an earlier point in time when the second foaming raw material M2 is injected become possible. In FIG. 7, SG represents the specific gravity of the foam obtained from the first foaming raw material M1 and the second foaming raw material M2, IJ 1 represents the start of injection of the first foaming raw material M1, and IJ 2 represents the second of the foaming material M2 injection start point, RU is an improvement in reactivity, RD is a decrease in reactivity each show, also SG I represents the specific gravity of the pre-foamed material foam.

(実験例)
以下に本発明に係る方法により製造したポリウレタンフォームについて、所要の物性を測定した実験例を示す。なお本発明は、この実験例に限定されるものではない。(Experimental example)
The experimental example which measured the required physical property about the polyurethane foam manufactured by the method which concerns on this invention below is shown. The present invention is not limited to this experimental example.

(実験１：硬度が異なる発泡体となる発泡原料を使用した場合)
表１に記載する配合組成を使用して、硬度が２４５Ｎ／３１４ｃｍ２、密度５０ｋｇ／ｍ３の発泡体となる第１の発泡原料と、硬度が１１８Ｎ／３１４ｃｍ２、密度６０ｋｇ／ｍ３の発泡体となる第２の発泡原料を夫々調整(硬度および密度は、夫々表１中に併記)し、先ず第１の発泡原料を所要形状(縦４００ｍｍ×横４００ｍｍ×高さ８０ｍｍ)の成形型内に注入し、樹脂化反応が進み粘度増加が顕著に進む以前である７秒後に第２の発泡原料を注入して、当該形状を備える直方体形状のポリウレタンフォームを製造した。そして製造されたポリウレタンフォームを成形型より脱型し、厚さ方向を２０ｍｍの間隔で切断し、切り分けられた各シート状物の全体としての硬度を測定した。なお配合に使用した各原料および硬度の測定方法は下に記す。(Experiment 1: When foaming raw materials that are foams with different hardnesses are used)
Using the composition shown in Table 1, a first foam raw material that becomes a foam with a hardness of 245 N / 314 cm 2 and a density of 50 kg / m 3 , and a foam with a hardness of 118 N / 314 cm 2 and a density of 60 kg / m 3 Each of the second foam raw materials to be a body is adjusted (hardness and density are also shown in Table 1), and the first foam raw material is first placed in a mold having a required shape (length 400 mm × width 400 mm × height 80 mm). The second foaming raw material was injected 7 seconds after the resinification reaction progressed and the viscosity increase remarkably advanced to produce a cuboid-shaped polyurethane foam having the shape. Then, the produced polyurethane foam was removed from the mold, and the thickness direction was cut at intervals of 20 mm, and the hardness of each cut sheet was measured. The raw materials used for the blending and the methods for measuring the hardness are described below.

(使用した原料)
・ポリオールＡ：ポリエーテルポリオール(商品名 ＥＬ−８２８；旭硝子製)
・ポリオールＢ：ポリマーポリオール(商品名 ＦＡ−７２８Ｒ；三洋化成工業製)
・イソシアネート：汎用のＴＤＩ：汎用のＭＤＩ＝８０：２０で混合したもの
・架橋剤：商品名 ＩＲ−９４；三井武田ケミカル製
・触媒Ａ：商品名 ＬＶ−３３；中京油脂製
・触媒Ｂ：商品名 ＢＬ−１１；エアプロダクツ製
・整泡剤：商品名 Ｌ−５３０９；東レダウコーニングシリコーン製
・発泡剤：水
(測定方法)
・硬度：ＪＡＳＯ Ｂ ４０８に準じて測定した。

Figure 2006082630
(Raw materials used)
Polyol A: polyether polyol (trade name EL-828; manufactured by Asahi Glass)
Polyol B: Polymer polyol (trade name FA-728R; manufactured by Sanyo Chemical Industries)
・ Isocyanate: general-purpose TDI: general-purpose MDI mixed at 80:20 ・ Crosslinking agent: trade name IR-94; manufactured by Mitsui Takeda Chemical ・ catalyst A: trade name LV-33; manufactured by Chukyo Yushi ・ Catalyst B: product Name BL-11; Air Products / Foam Stabilizer: Product Name L-5309; Toray Dow Corning Silicone / Foaming Agent: Water
(Measuring method)
Hardness: Measured according to JASO B 408.
Figure 2006082630

(実験１の結果)
製造されたポリウレタンフォームのから切断された各シート状物の硬度(単位：Ｎ／３１４ｃｍ２)を測定した。その結果、その数値は、ポリウレタンフォームの上面から下面に向かって、２４５、１９２、１５１、１１８と、その硬度が徐々に小さくなっていることが確認された。(Result of Experiment 1)
The hardness (unit: N / 314 cm 2 ) of each sheet-like material cut from the produced polyurethane foam was measured. As a result, it was confirmed that the numerical values were 245, 192, 151, 118 and the hardness gradually decreased from the upper surface to the lower surface of the polyurethane foam.

(実験２：反発弾性率が異なる発泡体となる発泡原料を使用した場合)
表２に記載する配合組成を使用して、反発弾性率６５％、密度５０ｋｇ／ｍ３の発泡体となる第１の発泡原料と、反発弾性率４５％、密度６０ｋｇ／ｍ３の発泡体となる第２の発泡原料を夫々調整(反発弾性率および密度は、夫々表２中に併記)し、先ず第１の発泡原料を所要形状(縦４００ｍｍ×横４００ｍｍ×高さ８０ｍｍ)の成形型内に注入し、樹脂化反応が進み粘度増加が顕著に進む以前である７秒後に第２の発泡原料を注入して、当該形状を備える直方体形状のポリウレタンフォームを製造した。そして製造されたポリウレタンフォームを成形型より脱型し、厚さ方向を２０ｍｍの間隔で切断し、切り分けられた各シート状物の全体としての反発弾性率を測定した。なお配合に使用した各原料および反発弾性率の測定方法は下に記す。(Experiment 2: When using foaming raw materials that are foams with different rebound resilience)
Using the blend composition shown in Table 2, a first foam raw material that becomes a foam with a rebound resilience of 65% and a density of 50 kg / m 3 , and a foam with a rebound resilience of 45% and a density of 60 kg / m 3 Each of the second foam raw materials is adjusted (rebound resilience and density are also shown in Table 2), and first, the first foam raw material is placed in a required shape (length 400 mm × width 400 mm × height 80 mm). The second foaming raw material was injected 7 seconds after the resinification reaction progressed and the viscosity increase remarkably advanced to produce a cuboid-shaped polyurethane foam having the shape. Then, the produced polyurethane foam was removed from the mold, and the thickness direction was cut at intervals of 20 mm, and the impact resilience as a whole of each cut sheet was measured. In addition, each raw material used for mixing | blending and the measuring method of a resilience elastic modulus are described below.

(使用した原料)
・ポリオールＡおよびＢ：実験１と同じ
・ポリオールＣ：ポリエーテルポリオール(商品名 ＩＴ−３４；三井武田ケミカル製)
・イソシアネート：汎用のＭＤＩ
・架橋剤：ジエタノールアミン
・触媒ＡおよびＢ：実験１と同じ
・整泡剤：商品名 ＳＺ−１３１３；東レダウコーニングシリコーン製
・発泡剤：水
(測定方法)
・反発弾性率：ＪＡＳＯ Ｂ ４０８に準じて測定した。

Figure 2006082630
(Raw materials used)
Polyol A and B: Same as Experiment 1 Polyol C: Polyether polyol (trade name IT-34; manufactured by Mitsui Takeda Chemical)
・ Isocyanate: General-purpose MDI
・ Crosslinking agent: Diethanolamine ・ Catalysts A and B: Same as Experiment 1 ・ Foam stabilizer: Product name SZ-1313; Made by Toray Dow Corning Silicone ・ Foaming agent: Water
(Measuring method)
-Rebound resilience: measured according to JASO B 408.
Figure 2006082630

(実験２の結果)
製造されたポリウレタンフォームから切断された各シート状物の反発弾性率(％)を測定した。その結果、その数値は、ポリウレタンフォームの上面から下面に向かって、６５、５８、５１、４５と、その反発弾性率が徐々に小さくなっていることが確認された。(Result of Experiment 2)
The rebound resilience (%) of each sheet-like material cut from the produced polyurethane foam was measured. As a result, it was confirmed that the numerical value was 65, 58, 51, 45 and the rebound resilience gradually decreased from the upper surface to the lower surface of the polyurethane foam.

材料の物性や、特性が材料内部で予め設計された勾配をもって、連続的に変化し得る傾斜的な性質を発現するポリウレタンフォームおよびその製造方法は、ポリウレタンフォームが使用される各物品全てについて広く適用が可能である。   Polyurethane foam and its manufacturing method that expresses a gradient property in which the physical properties and characteristics of the material can be continuously changed with a pre-designed gradient inside the material, and its manufacturing method are widely applied to all articles in which polyurethane foam is used. Is possible.

本発明の好適な実施例に係るポリウレタンフォーム(シート用パッド)の内部構造を示す縦断正面図である。1 is a longitudinal front view showing an internal structure of a polyurethane foam (sheet pad) according to a preferred embodiment of the present invention. 実施例に係るポリウレタンフォーム(シート用パッド)を好適に製造する工程の一例を示す工程図である。It is process drawing which shows an example of the process of manufacturing suitably the polyurethane foam (sheet pad) which concerns on an Example. 一般的なシート用パッドを成形する成形型の概略図であって、(ａ)は下型を平面状態で示す図であり、(ｂ)は(ａ)のｂ−ｂ線断面図である。It is the schematic of the shaping | molding die which shape | molds the general pad for sheet | seats, Comprising: (a) is a figure which shows a lower mold | type in a planar state, (b) is the bb sectional view taken on the line of (a). 実施例に係るポリウレタンフォーム(シート用パッド)の製造時の反応の度合いおよび比重差の経時的な変化を示すグラフ図である。It is a graph which shows the time-dependent change of the reaction degree at the time of manufacture of the polyurethane foam (sheet pad) which concerns on an Example, and a specific gravity difference. 実施例に係るポリウレタンフォーム(シート用パッド)をなす第１の発泡原料および第２の発泡原料の粘度の変化を概略的に示すグラフ図である。It is a graph which shows roughly the change of the viscosity of the 1st foaming raw material which makes the polyurethane foam (sheet pad) which concerns on an Example, and a 2nd foaming raw material. 変更例に係るポリウレタンフォームの製造時の反応の度合いおよび比重差の経時的な変化を示すグラフ図である。It is a graph which shows the time-dependent change of the reaction degree at the time of manufacture of the polyurethane foam which concerns on the example of a change, and a specific gravity difference. 別の変更例に係るポリウレタンフォームの製造時の反応の度合いおよび比重差の経時的な変化を示すグラフ図である。It is a graph which shows the time-dependent change of the reaction degree at the time of manufacture of the polyurethane foam which concerns on another example of a change, and a specific gravity difference.

符号の説明Explanation of symbols

１０ ポリウレタンフォーム
１２ シート用パッド
１２ａ 表面
３４ 前部サポート部
３６ 後部サポート部
３８ サイドサポート部
５２ａ 底面部
５０ 成形型
Ｍ１ 第１の発泡原料
Ｍ２ 第２の発泡原料
DESCRIPTION OF SYMBOLS 10 Polyurethane foam 12 Seat pad 12a Surface 34 Front support part 36 Rear support part 38 Side support part 52a Bottom part 50 Mold M1 1st foam raw material M2 2nd foam raw material

この発明はポリウレタンフォームおよびその製造方法に関し、更に詳細には、所要の物性において異なった値を発現する２つの発泡原料を使用し、異なった値の発現される２つの発泡体が一体的に混在し、かつその値の変化がポリウレタンフォームの高さ方向に沿って連続的に変化した構造となっているポリウレタンフォームおよびその製造方法に関するものである。   The present invention relates to a polyurethane foam and a method for producing the same. More specifically, two foam raw materials that express different values in required physical properties are used, and two foams that express different values are mixed together. In addition, the present invention relates to a polyurethane foam having a structure in which the change in value continuously changes along the height direction of the polyurethane foam, and a method for producing the same.

多様化した素材ニーズに対して、夫々異なる特性(物性)を発現する複数の素材を複合する、所謂複合材料の開発が行なわれている。殊に、例えば２つの素材がその配合割合を徐々に変動させた状態となっている、所謂傾斜材料が大きな注目を集めている。一般に傾斜材料とは、一つの材料の中で、組成や機能が連続的または段階的に変化している材料のことであり、例えば急激な温度勾配中等の過酷な熱環境による変形や破損を回避し得るように、熱伝導率、熱膨張率または耐熱性等の各物性が異なる２つの素材を用いた傾斜材料が知られている。   In response to diversified material needs, so-called composite materials have been developed in which a plurality of materials that express different properties (physical properties) are combined. In particular, so-called gradient materials, in which, for example, two materials are in a state where their blending ratios are gradually changed, are attracting much attention. In general, a gradient material is a material whose composition or function changes continuously or stepwise in a single material, and avoids deformation and breakage due to a severe thermal environment such as during a sudden temperature gradient. As is possible, a gradient material using two materials having different physical properties such as thermal conductivity, thermal expansion coefficient, and heat resistance is known.

しかし前述の傾斜材料は、基本的にこの混合度合いが容易に調整可能または体積拡散等の手段により材料粒子が移動し得る無機系材料に限ってのことであり、一般的に有機材料においては傾斜材料は殆ど知られていなかった。一例として代表的な有機材料の１つであるポリウレタンフォームを使用した座席用のシート用パッドとして、下記の［特許文献１］に記載の発明「クッション材の製造方法」の如く、成形型内に物性の異なる２種類のポリウレタンフォームとなる２種類の発泡原料を異なる部位から夫々分けて注入し、これらから形成される異なる物性を有するポリウレタンフォームを一体的に発泡成形させて、傾斜材料的な要素を持たせるべく製造されるポリウレタンフォームが知られている。
特開２００２−５２５５０号公報 However, the gradient material described above is basically limited to inorganic materials in which the degree of mixing can be easily adjusted or the material particles can move by means such as volume diffusion. The material was hardly known. As an example, as a seat pad for a seat using polyurethane foam which is one of typical organic materials, as in the invention “Cushion Material Manufacturing Method” described in [Patent Document 1] below, Two types of foaming raw materials, which are two types of polyurethane foams with different physical properties, are injected separately from different parts, and polyurethane foams with different physical properties formed from these are integrally foam-molded. Polyurethane foams are known that are manufactured to have the same.
JP 2002-52550 A

しかし、２種類の発泡原料が略同時に注入されるため工程に煩雑さはないが、注入後の発泡・硬化反応の進行過程において、一方の発泡体が他方の発泡体を覆うように制御することが必要とされる。そしてこのような制御を達成するためには、双方の発泡原料の反応速度および注入量等を緻密に調整する必要があるが、このような調整はその手順が煩雑で、かつ要因が多いため、好適な実施が困難である点と、連続的に物性が変化する好適な傾斜材料挙動を示すポリウレタンフォームとはならない点とが問題となっていた。
あった。 However, since the two types of foaming raw materials are injected almost simultaneously, the process is not complicated, but in the process of foaming / curing reaction after the injection, one foam should be controlled to cover the other foam. Is needed. And in order to achieve such control, it is necessary to precisely adjust the reaction rate and the injection amount of both foaming raw materials, but such adjustment is complicated and has many factors. There are problems in that it is difficult to carry out suitable implementation and that the polyurethane foam does not exhibit a suitable gradient material behavior in which physical properties continuously change.
there were.

前記課題を克服し、所期の目的を達成するため本発明に係るポリウレタンフォームは、所要の成形型に、発泡・硬化反応の完了時に所要の物性における数値が互いに異なる発泡体となる第１の発泡原料および第２の発泡原料を逐次注入して製造されるポリウレタンフォームであって、
所要の第三成分をその濃度が異なるように混合した前記第１の発泡原料および第２の発泡原料から夫々得られる発泡体が一体的に混在されることで、
前記所要の物性における数値が成形型の高さ方向に沿って連続的に変化すると共に、前記第三成分が成形型の高さ方向に沿って連続的に変化した構造となっていることを特徴とする。 In order to overcome the above-mentioned problems and achieve the intended object, the polyurethane foam according to the present invention is a first molding in which a required mold has different numerical values in required physical properties upon completion of the foaming / curing reaction. A polyurethane foam produced by sequentially injecting a foaming raw material and a second foaming raw material,
In Rukoto each resulting foam is mixed integrally from the required said third component whose concentration was mixed differently in the first foaming material and the second foaming material,
Characterized in that numerical values in the desired physical properties with continuously changes along the height direction of the mold, the third component is in the structure changes continuously along the height direction of the mold And

前記課題を克服し、所期の目的を達成するため本願の別の発明に係るポリウレタンフォームの製造方法は、所要の成形型に、発泡・硬化反応の完了時に所要の物性における数値が互いに異なる発泡体となる第１の発泡原料および第２の発泡原料を逐次注入してたポリウレタンフォームを製造する方法であって、
前記第１の発泡原料および第２の発泡原料に、夫々濃度が異なるように設定された第三成分を予め混合し、
先に注入されて発泡・硬化反応が進行中の第１の発泡原料が存在する前記成形型内に、第２の発泡原料を注入することで、２つの発泡原料の反応進行中に発生する比重差によって、第２の発泡原料を第１の発泡原料の下側に位置させ、
前記成形型の内部で２つの発泡原料の反応を更に進行させることで、夫々の発泡原料から得られる発泡体を一体的に混在させると共に、該所要の物性における数値が成形型の高さ方向に沿って連続的に変化させるようにしたことを特徴とする。 In order to overcome the above-mentioned problems and achieve the intended purpose, a method for producing a polyurethane foam according to another invention of the present application is to form a foam with different required physical properties at the time of completion of the foaming / curing reaction. A method for producing a polyurethane foam in which a first foaming raw material and a second foaming raw material to be a body are sequentially injected,
In the first foaming raw material and the second foaming raw material, a third component set to have a different concentration is mixed in advance,
Specific gravity generated during the reaction of the two foaming raw materials by injecting the second foaming raw material into the mold in which the first foaming raw material in which the foaming / curing reaction is in progress is present. Due to the difference, the second foaming raw material is positioned below the first foaming raw material,
By further advancing the reaction of the two foam raw materials inside the mold, the foams obtained from the respective foam raw materials are mixed together, and the numerical values in the required physical properties are in the height direction of the mold. It is characterized by being continuously changed along.

本発明に係るポリウレタンフォームおよびその製造方法によれば、第１の発泡原料の発泡・硬化反応が進行する成形型内に、所要の物性において第１の発泡原料から得られる発泡体とは異なる値を発現する発泡体となる第２の発泡原料を注入することで、夫々違う値となる物性の発現された少なくとも２種類の発泡体が一体的に混在し、かつその物性がポリウレタンフォームの高さ方向に沿って連続的に変化して、所謂傾斜材料となっているポリウレタンフォームを製造し得る。またこのような構造を備えるポリウレタンフォームは、双方の発泡原料の反応進行中の比重差を利用することで達成されるため、製造の際に留意する条件は第２の発泡原料の注入タイミングだけであり、煩雑な調整は必要とされない。 According to the polyurethane foam and the method for producing the same according to the present invention, a value different from the foam obtained from the first foam raw material in the required physical properties in the mold in which the foaming / curing reaction of the first foam raw material proceeds. By injecting the second foaming raw material, which is a foam that expresses the foam, at least two types of foams having different physical properties are mixed together, and the physical properties are the height of the polyurethane foam. It is possible to produce polyurethane foams that change continuously along the direction and become so-called gradient materials. In addition, since the polyurethane foam having such a structure is achieved by utilizing the difference in specific gravity during the reaction of both foam raw materials, the condition to be noted in the production is only the injection timing of the second foam raw material. There is no need for complicated adjustments.

次に本発明に係るポリウレタンフォームおよびその製造方法につき、好適な実施例を挙げて、添付図面を参照しながら以下説明する。なお実施例においては、ポリウレタンフォームが好適に利用されるシート用パッドの場合を例に挙げると共に、連続的に変化させる所要の物性として硬度を用いた場合を説明する。実施例に係るポリウレタンフォーム１０好適に使用されるシート用パッド１２は、図１に示す如く、基本的に乗員が着座した直接接触する部位である前部サポート部３４および後部サポート部３６と、この両側に位置し、該乗員のサイドサポートにより姿勢を保持するサイドサポート部３８,３８とから構成されている。そして前部サポート部３４および後部サポート部３６においては、乗員の乗り心地、ホールド性、乗り降り容易性その他各種要望等の点から、硬度が裏側ほど大きく、また表面側ほど小さく、すなわち高い柔軟性を発現するようになっている。具体的には、硬度の異なる２種類の発泡体が一体的に混在した状態となり、かつその硬度が成形型５０の高さ方向、すなわちポリウレタンフォーム１０の高さ方向(シート用パッド１２の厚さ方向)に沿って連続的に変化する、硬度に明確な境目のない、所謂傾斜材料的な特質を備えた状態となっている。またサイドサポート部３８,３８は、殊に本発明とは直接的に関連がないので詳細な記載を省略する。   Next, the polyurethane foam and the method for producing the same according to the present invention will be described below with reference to the accompanying drawings by way of preferred examples. In the examples, a case of a sheet pad in which polyurethane foam is preferably used will be described as an example, and a case where hardness is used as a required physical property that is continuously changed will be described. As shown in FIG. 1, the seat pad 12 suitably used for the polyurethane foam 10 according to the embodiment basically includes a front support part 34 and a rear support part 36 which are parts in direct contact with which an occupant is seated. It is comprised from the side support parts 38 and 38 which are located in both sides and hold | maintain an attitude | position by the passenger | crew's side support. In the front support part 34 and the rear support part 36, the hardness is larger on the back side and smaller on the front side, that is, high flexibility in terms of rider comfort, holdability, ease of getting on and off, and various other requests. It has come to express. Specifically, two types of foams having different hardnesses are integrally mixed, and the hardness is in the height direction of the mold 50, that is, the height direction of the polyurethane foam 10 (the thickness of the sheet pad 12). It has a so-called gradient material characteristic that changes continuously along the direction) and has no clear boundary in hardness. Further, since the side support portions 38 and 38 are not directly related to the present invention, detailed description thereof is omitted.

そしてこのような構造を備えるポリウレタンフォーム１０(シート用パッド１２)の製造工程は、図２に示す如く、発泡原料準備工程Ｓ１、第１の発泡原料注入工程Ｓ２、第２の発泡原料注入工程Ｓ３、反応進行工程Ｓ４および最終工程Ｓ５から構成される。ここで発泡原料準備工程Ｓ１は、製造されるシート用パッド１２の外部輪郭形状に合致する内部輪郭形状を備え、その底面部５２ａがシート用パッド１２を成形する、例えば図３に示すような成形型５０内に順序をもって注入され、発泡・硬化反応完了時(以下、単に反応完了時と云う)に高い硬度を発現する発泡体となる第１の発泡原料Ｍ１と、発泡・硬化反応(以下、単に反応と云う)完了時に低い硬度を発現する発泡体となる第２の発泡原料Ｍ２とを、夫々の硬度および比重を考慮してポリオールおよびイソシアネートと、各副原料とを適宜選択し、反応・硬化しない状態として準備する工程である。   And the manufacturing process of the polyurethane foam 10 (sheet pad 12) provided with such a structure is as shown in FIG. 2, foaming raw material preparation process S1, first foaming raw material injection process S2, second foaming raw material injection process S3. The reaction progress step S4 and the final step S5. Here, the foaming raw material preparation step S1 has an inner contour shape that matches the outer contour shape of the sheet pad 12 to be manufactured, and the bottom surface portion 52a forms the sheet pad 12, for example, as shown in FIG. A first foaming raw material M1 that is injected into the mold 50 in order and becomes a foam that exhibits high hardness when the foaming / curing reaction is completed (hereinafter simply referred to as reaction completion), and a foaming / curing reaction (hereinafter, referred to as a foam / curing reaction). The second foaming raw material M2 to be a foam that exhibits low hardness upon completion) is appropriately selected from the polyol and isocyanate, and each auxiliary raw material in consideration of the respective hardness and specific gravity. It is a step of preparing as a state that does not cure.

ここで第１の発泡原料Ｍ１および第２の発泡原料Ｍ２としては、反応完了時における発泡体の比重が相互に異なるものが準備されている。本実施例においては、一方の第１の発泡原料Ｍ１は、反応完了時に得られる発泡体が高い硬度を発現するだけでなく、他方の第２の発泡原料Ｍ２の反応完了時に得られる発泡体に較べて小さい比重となるように設定されている。なお本実施例では、成形型５０への注入で第１の発泡原料Ｍ１が上側に位置し、第２の発泡原料Ｍ２が下側に位置するように設定されているため、第１の発泡原料Ｍ１と第２の発泡原料Ｍ２とから得られる夫々の発泡体の比重は、前述の関係としているが、第１の発泡原料Ｍ１から得られる発泡体が、第２の発泡原料Ｍ２から得られる発泡体より比重が大きくなるように設定することも可能である。また一般的な発泡体の代表であるポリウレタンフォームの場合、その発泡原料は殆ど比重(密度)が１.０５ｇ／ｃｍ３程度であり、比重の低下は、反応の進行に伴う発泡によってなされている。 Here, as the first foaming raw material M1 and the second foaming raw material M2, those having different specific gravities of the foams upon completion of the reaction are prepared. In this example, one of the first foaming raw materials M1 is not only a foam obtained at the completion of the reaction, but also exhibits a high hardness, and the foam obtained at the completion of the reaction of the other second foaming raw material M2. The specific gravity is set to be smaller. In the present embodiment, since the first foaming material M1 is positioned on the upper side and the second foaming material M2 is positioned on the lower side in the injection into the mold 50, the first foaming material is set. The specific gravity of each foam obtained from M1 and the second foaming raw material M2 is as described above, but the foam obtained from the first foaming raw material M1 is the foam obtained from the second foaming raw material M2. It is also possible to set the specific gravity to be larger than that of the body. In the case of polyurethane foam, which is a typical typical foam, the foam material has a specific gravity (density) of about 1.05 g / cm 3 , and the specific gravity is reduced by foaming as the reaction proceeds. .

第１の発泡原料注入工程Ｓ２は、第１の発泡原料Ｍ１を反応可能状態とすると共に、速やかに成形型５０内に注入する工程である。そして第２の発泡原料注入工程Ｓ３は、先に注入して反応が進行して徐々に比重が軽くなりつつある第１の発泡原料Ｍ１に対して、その上から第２の発泡原料Ｍ２を注入する工程であり、反応進行工程Ｓ４は、成形型５０内に注入された第１の発泡原料Ｍ１および第２の発泡原料Ｍ２が、発泡・硬化反応を進行させてその反応進行中に発生する比重差によって、徐々に一体的に混在した状態になっていき、最終的に成形型５０内部が第１の発泡原料Ｍ１および第２の発泡原料Ｍ２から得られる発泡体で充填させる工程である。なお下型５２に対する上型５３の固定、すなわち成形型５０の閉成は、第２の発泡原料注入工程Ｓ３の完了直後になされる。   The first foaming raw material injection step S2 is a step of allowing the first foaming raw material M1 to be in a reactive state and quickly injecting it into the mold 50. In the second foaming raw material injection step S3, the second foaming raw material M2 is injected from above onto the first foaming raw material M1 which is injected first and the reaction proceeds and the specific gravity is gradually decreasing. The reaction progressing step S4 is a specific gravity generated when the first foaming raw material M1 and the second foaming raw material M2 injected into the mold 50 advance the foaming / curing reaction and the reaction proceeds. Due to the difference, it is a process of gradually becoming a unitary mixture, and finally filling the inside of the mold 50 with the foam obtained from the first foaming raw material M1 and the second foaming raw material M2. The upper die 53 is fixed to the lower die 52, that is, the molding die 50 is closed immediately after the completion of the second foaming material injection step S3.

ここでこの２つの発泡原料Ｍ１およびＭ２の成形型５０に対する注入から始まる反応の度合いおよび比重の状態の経時的な変動は、図４の如きグラフで表すことができる。すなわち、基本的に反応の度合いで表される反応性は第１の発泡原料Ｍ１および第２の発泡原料Ｍ２で差はなく、時間の経過と共に双方とも反応が進行し、この反応に伴う発泡によって２つの発泡原料Ｍ１およびＭ２共に比重が小さくなっている。そして第１の発泡原料Ｍ１と、第２の発泡原料Ｍ２とにおいては、注入開始の時点がずれているため、先に注入される第１の発泡原料Ｍ１の方が先に反応を開始して、第２の発泡原料Ｍ２に先んじて反応が進行し、これに伴って比重も小さくなる。また比重については、第１の発泡原料Ｍ１および第２の発泡原料Ｍ２については、その配合に違いがあり、第１の発泡原料Ｍ１からは比重が小さい発泡体が得られ、第２の発泡原料Ｍ２からは比重が大きい発泡体が得られる。すなわち反応の進行に伴って、第１の発泡原料Ｍ１および第２の発泡原料Ｍ２の比重差はａからｂへと大きくなり、最終的には第１の発泡原料Ｍ１から得られる発泡体の比重と、第２の発泡原料Ｍ２から得られる発泡体の比重との差に収束する。この反応途中の比重差によって、第２の発泡原料Ｍ２の第１の発泡原料Ｍ１下側への配置が可能となっている。なお第１の発泡原料Ｍ１から得られる発泡体の比重については３０〜７０ｋｇ／ｍ３、第２の発泡原料Ｍ２から得られる発泡体の比重については４０〜１００ｋｇ／ｍ３程度として、その比重差を少なくとも１０ｋｇ／ｍ３とすることが好ましい。また図４においては、ＳＧ１は第１の発泡原料Ｍ１から得られる発泡体の比重を、ＳＧ２は第２の発泡原料Ｍ２から得られる発泡体の比重を、ＩＪ１は第１の発泡原料Ｍ１注入開始時点を、ＩＪ２は第２の発泡原料Ｍ２注入開始時点を夫々示し、またＳＧＩは発泡原料発泡前の比重を表している。 Here, the degree of reaction starting from the injection of the two foaming raw materials M1 and M2 into the mold 50 and the variation over time of the state of specific gravity can be represented by a graph as shown in FIG. That is, the reactivity represented by the degree of reaction is basically the same between the first foaming raw material M1 and the second foaming raw material M2, and both of the reactions proceed with the passage of time. The specific gravity of the two foaming raw materials M1 and M2 is small. In the first foaming raw material M1 and the second foaming raw material M2, the start time of injection is shifted, so the first foaming raw material M1 injected first starts the reaction first. The reaction proceeds prior to the second foaming raw material M2, and the specific gravity is reduced accordingly. Regarding the specific gravity, the first foaming raw material M1 and the second foaming raw material M2 have different blending, and a foam having a small specific gravity is obtained from the first foaming raw material M1, and the second foaming raw material M2. A foam having a large specific gravity can be obtained from M2. That is, as the reaction proceeds, the specific gravity difference between the first foaming raw material M1 and the second foaming raw material M2 increases from a to b, and finally the specific gravity of the foam obtained from the first foaming raw material M1. And the difference between the specific gravity of the foam obtained from the second foaming raw material M2. Due to the difference in specific gravity during the reaction, the second foaming raw material M2 can be arranged below the first foaming raw material M1. The specific gravity of the foam obtained from the first foam raw material M1 is about 30 to 70 kg / m 3 , the specific gravity of the foam obtained from the second foam raw material M2 is about 40 to 100 kg / m 3 , and the specific gravity difference Is preferably at least 10 kg / m 3 . In FIG. 4, SG 1 is the specific gravity of the foam obtained from the first foaming raw material M1, SG 2 is the specific gravity of the foam obtained from the second foaming raw material M2, and IJ 1 is the first foaming raw material. the M1 injection start point, IJ 2 is the second foaming material M2 injection start time respectively indicate, also SG I represents the specific gravity of the pre-foamed material foam.

このような挙動を示す第１の発泡原料Ｍ１および第２の発泡原料Ｍ２を成形型５０内に注入すると、第１の発泡原料Ｍ１の上から注入された第２の発泡原料Ｍ２が、その比重差故に反応途中の第１の発泡原料Ｍ１を通り抜けて下側の成形型５０の底面部５２ａに沈降することになる。そして成形型５０内で、第２の発泡原料Ｍ２は常に第１の発泡原料Ｍ１、の下、すなわち底面部５２ａ側に位置することになる。そしてその後、時間の経過と共に第１の発泡原料Ｍ１および第２の発泡原料Ｍ２の双方の反応が進行し、これに伴ってその体積が増大し続けることになる。このとき、第１の発泡原料Ｍ１の下方に位置する第２の発泡原料Ｍ２は、その体積増大に係る力によって第１の発泡原料Ｍ１内に下方から徐々に入り込む(浸透する)ことになる。   When the first foaming raw material M1 and the second foaming raw material M2 exhibiting such behavior are injected into the mold 50, the second foaming raw material M2 injected from above the first foaming raw material M1 has its specific gravity. Therefore, it passes through the first foaming raw material M1 in the middle of the reaction and settles on the bottom surface portion 52a of the lower mold 50. And in the shaping | molding die 50, the 2nd foaming raw material M2 will always be located under the 1st foaming raw material M1, ie, the bottom face part 52a side. And after that, reaction of both the 1st foaming raw material M1 and the 2nd foaming raw material M2 advances with progress of time, and the volume continues increasing with this. At this time, the second foaming raw material M2 positioned below the first foaming raw material M1 gradually enters (permeates) into the first foaming raw material M1 from below by the force related to the volume increase.

ところでこの時の反応の度合いは、発泡原料の粘度としても捉えることが可能であり、成形型５０内に注入された第１の発泡原料Ｍ１および第２の発泡原料Ｍ２は、時間の経過と共にその粘度が上昇している。そしてこの第１の発泡原料Ｍ１および第２の発泡原料Ｍ２の双方の粘度を勘案した数値は、第１の発泡原料Ｍ１および第２の発泡原料Ｍ２の混合に係る容易性を示す指標として利用し得る。なおこの第１の発泡原料Ｍ１および第２の発泡原料Ｍ２の混合に係る容易性を示す指標は、本実施例においては以後、相対粘度Ｒと呼称する。   By the way, the degree of reaction at this time can also be grasped as the viscosity of the foaming raw material, and the first foaming raw material M1 and the second foaming raw material M2 injected into the mold 50 are changed over time. The viscosity is rising. The numerical value in consideration of the viscosity of both the first foaming raw material M1 and the second foaming raw material M2 is used as an index indicating the ease of mixing the first foaming raw material M1 and the second foaming raw material M2. obtain. Note that an index indicating the ease of mixing the first foaming raw material M1 and the second foaming raw material M2 is hereinafter referred to as a relative viscosity R in this embodiment.

そしてこの相対粘度Ｒは、図５に示す如く、反応の進行に伴ってほぼ直線的に増加する。すなわち第２の発泡原料Ｍ２の第１の発泡原料Ｍ１に対する浸透は、その反応の進行に伴って増加する粘度(粘度相対Ｒ)によって経時的に困難となり、徐々に抑制されることになる。その結果、成形型５０において、その底面部５２ａでは第２の発泡原料Ｍ２が全体を占めているが、上に向かうに従って、第１の発泡原料Ｍ１の存在量が増加する状態、すなわち成形型５０(ポリウレタンフォーム１０)における各高さ位置において、第１の発泡原料Ｍ１と第２の発泡原料Ｍ２との存在割合が夫々異なった状態となっている。なお図５においては、ＩＪ１は第１の発泡原料Ｍ１注入開始時点を、ＩＪ２は第２の発泡原料Ｍ２注入開始時点を夫々示している。 The relative viscosity R increases almost linearly as the reaction proceeds as shown in FIG. That is, the penetration of the second foaming raw material M2 into the first foaming raw material M1 becomes difficult over time due to the viscosity (viscosity relative R) that increases with the progress of the reaction, and is gradually suppressed. As a result, in the molding die 50, the second foaming raw material M2 occupies the entire bottom surface 52a, but the amount of the first foaming raw material M1 increases as it goes upward, that is, the molding die 50. At each height position in the (polyurethane foam 10), the existence ratios of the first foaming raw material M1 and the second foaming raw material M2 are different from each other. In FIG. 5, IJ 1 indicates the start time of injection of the first foaming raw material M1, and IJ 2 indicates the start time of injection of the second foaming raw material M2.

そしてこのような状態となって成形型５０内に存在する第１の発泡原料Ｍ１および第２の発泡原料Ｍ２は、その反応完了と共に発泡体となる。すなわち成形型５０の底面部５２ａにおいては第２の発泡原料Ｍ２が反応した硬度の低い発泡体だけが存在し、上方に行くほど第１の発泡原料Ｍ１が反応した硬度の高い発泡体の存在割合が増加して、最終的には発泡原料Ｍ１が反応した硬度の高い発泡体だけとなった構造を備えたシート用パッド１２を形成する。またこのような構成となるポリウレタンフォーム１０(シート用パッド１２)の製造においては、第１の発泡原料Ｍ１および第２の発泡原料Ｍ２の注入のタイミング、比重の差および硬度の差等の諸条件の適正化が必要となるが、本実施例においては、後に注入される第２の発泡原料Ｍ２の注入時点は好適には、第１の発泡原料Ｍ１が注入後、反応を開始して発泡が始まって比重差が発現し易くなる、所謂クリームタイム経過後で、樹脂化反応が進み粘度増加が顕著に進む以前、具体的には５秒前後の経過後から、１０〜２０秒に達するまでの間に設定される。このように第２の発泡原料Ｍ２の注入タイミングだけを調整することで、双方の発泡原料Ｍ１およびＭ２の反応進行中の比重差を利用して、本発明に係る硬度差が厚さ方向に連続的に変化したポリウレタンフォーム１０を容易に製造し得る。また硬度については、ポリウレタンフォーム１０の高さ(シート用パッド１２の厚さ)に対して直線的、すなわち比例的に変化させたり、または曲線的に、すなわち等差または等比級数的変化させたりするように設定することも可能である。なお硬度の連続的な変化の度合い、すなわち単位厚さ当たりの硬度の変化量は、双方の発泡原料Ｍ１およびＭ２の反応性(反応速度)、得られる発泡体の比重の設定および注入量等を変化させることでも制御可能である。   And the 1st foaming raw material M1 and the 2nd foaming raw material M2 which are in such a state and exist in the shaping | molding die 50 become a foam with the completion of the reaction. That is, in the bottom surface portion 52a of the mold 50, only the foam having a low hardness with which the second foaming raw material M2 has reacted exists, and the proportion of the foam having a high hardness with which the first foaming raw material M1 has reacted as it goes upward. As a result, the sheet pad 12 having a structure having only a foam having high hardness to which the foaming raw material M1 has reacted is formed. Further, in the production of the polyurethane foam 10 (sheet pad 12) having such a configuration, various conditions such as the injection timing of the first foaming raw material M1 and the second foaming raw material M2, the difference in specific gravity and the difference in hardness, etc. However, in this embodiment, the second foaming material M2 to be injected later is preferably injected at the time when the first foaming material M1 is injected and then the reaction is started and foaming is performed. After the so-called cream time elapses, the resinization reaction proceeds and the viscosity increase remarkably progresses, specifically after about 5 seconds, until 10 to 20 seconds are reached. Set between. Thus, by adjusting only the injection timing of the second foaming raw material M2, the hardness difference according to the present invention continues in the thickness direction by utilizing the difference in specific gravity during the reaction of both foaming raw materials M1 and M2. Changed polyurethane foam 10 can be easily manufactured. The hardness is changed linearly, that is, in proportion to the height of the polyurethane foam 10 (thickness of the sheet pad 12), or is changed in a curve, that is, an equal difference or a geometric series. It is also possible to set so as to. The degree of continuous change in hardness, that is, the amount of change in hardness per unit thickness depends on the reactivity (reaction rate) of both foaming raw materials M1 and M2, the specific gravity setting and the injection amount of the obtained foam, etc. It can also be controlled by changing it.

この他、発泡原料の発泡倍率等も考慮すべき要素であるが、基本的に注入された発泡原料が成形型５０内における発泡予定部位に充分に拡がる程度の量および倍率であれば問題なく、これらは公知の経験的知見から導出されている。そしてここまでの工程Ｓ１〜Ｓ４を経ることで成形型５０内に成形されたシート用パッド１２は、最終工程Ｓ５で成形型５０から脱型され、その後、公知の後処理および検査等の実施により完成品たるポリウレタンフォーム１０(シート用パッド１２)とされる。   In addition, although the foaming ratio of the foaming raw material is an element to be considered, there is no problem as long as the injected foaming raw material basically has an amount and a magnification enough to expand to the foaming planned site in the mold 50, These are derived from known empirical findings. And the pad 12 for sheets shape | molded in the shaping | molding die 50 through the process S1-S4 so far is demolded from the shaping | molding die 50 by the last process S5, and then by implementation of well-known post-processing and inspection, etc. The finished polyurethane foam 10 (sheet pad 12) is used.

なお本発明におけるポリウレタンフォームは、シート用パッドに限定されるものではなく、自動車内装材、住宅内装材または各種クッション材等の各種用途に利用可能であり、またその高さ方向に沿って連続的に変化する物性も硬度に限定されるものではなく、この他、反発弾性率またはセルの大きさ、すなわちセル径等や、これら各物性を二重、三重に併有するようにしたものも変化させる物性として採用し得る。例えば変化させる所要の物性として反発弾性率を選択した場合、加えられる力の大きさに拘わらず、常に一定の反発力を発現し得るポリウレタンフォームが製造可能となり、セル径を次第に変化させる場合、特定または一定範囲の周波数に対して好適な吸音特性を示すポリウレタンフォームが製造可能となり、ｔａｎδのピーク発現温度が夫々異なるようした場合には、広い温度域でエネルギー吸収特性が好適なスローリカバリー性を発現するポリウレタンフォームが製造可能となる。   The polyurethane foam in the present invention is not limited to a seat pad, and can be used for various applications such as an automobile interior material, a housing interior material, or various cushion materials, and is continuously along the height direction thereof. The physical properties that change to the above are not limited to the hardness, and in addition, the resilience modulus or the cell size, that is, the cell diameter, etc., and those that have these physical properties double or triple are also changed. It can be adopted as a physical property. For example, when the rebound resilience is selected as the required physical property to be changed, it is possible to produce a polyurethane foam that can always express a certain repulsion force regardless of the magnitude of the applied force, and when the cell diameter is gradually changed, specify Alternatively, polyurethane foams with suitable sound absorption characteristics for a certain range of frequencies can be manufactured, and when the peak expression temperature of tan δ is different, the energy absorption characteristics exhibit suitable slow recovery characteristics over a wide temperature range. The polyurethane foam can be manufactured.

第１の発泡原料Ｍ１または第２の発泡原料Ｍ２から夫々得られる各発泡体の物性は、ポリウレタンフォームの原料であるポリオール、イソシアネートおよびその他の各種副原料の配合組成を適宜設定することで、意図した数値に設定される。具体的に、所要の物性を硬度とした場合には(ポリマー)ポリオール、架橋剤またはイソシアネート等の種類または配合量を変化させることで、また反発弾性率とした場合にはポリオールの分子量や、イソシアネートの種類または配合量や、整泡剤によって調整される通気性を変化させることで、そしてセル径とした場合には整泡剤の種類または添加量を変化させることで、夫々の物性における値を異なる数値とし得る。   The physical properties of the respective foams obtained from the first foaming raw material M1 or the second foaming raw material M2 are determined by appropriately setting the blending composition of polyol, isocyanate and other various auxiliary raw materials that are raw materials of the polyurethane foam. It is set to the numerical value. Specifically, if the required physical properties are hardness, (polymer) by changing the type or blending amount of polyol, cross-linking agent or isocyanate, etc., and if it is rebound resilience, the molecular weight of polyol, isocyanate By changing the type or blending amount and the air permeability adjusted by the foam stabilizer, and in the case of the cell diameter, by changing the kind or addition amount of the foam stabilizer, the value in each physical property can be changed. It can be a different number.

この他、反応完了後のポリウレタンフォームが発現する物性については、当該ポリウレタンフォーム自体が発現する物性だけでなく、その原料である第１の発泡原料Ｍ１および第２の発泡原料Ｍ２に対して、指定単位量当たりの混合量を異なる状態とした、すなわちその濃度を変えるようにした各種機能を発現する第三成分を混合するようにしてもよい。このように調整された第１の発泡原料Ｍ１および第２の発泡原料Ｍ２を用いることで第三成分は、ポリウレタンフォーム１０の高さ位置によって夫々異なった数値となる第１の発泡原料Ｍ１と第２の発泡原料Ｍ２との存在割合に比例して、ポリウレタンフォーム１０の高さ方向に沿って連続的に変化(かつ常に一定値に向けて増大または減少)した状態となる。   In addition, the physical properties of the polyurethane foam after completion of the reaction are specified not only for the physical properties of the polyurethane foam itself, but also for the first foaming raw material M1 and the second foaming raw material M2, which are the raw materials. You may make it mix the 3rd component which expresses the various functions which made the mixing amount per unit amount differ, ie, change the density | concentration. By using the first foaming raw material M1 and the second foaming raw material M2 adjusted as described above, the third component has different values depending on the height position of the polyurethane foam 10 and the first foaming raw material M1 and the second foaming raw material M2. In proportion to the ratio of the two foaming raw materials M2, the polyurethane foam 10 continuously changes along the height direction (and always increases or decreases toward a constant value).

双方の発泡原料Ｍ１,Ｍ２に混合される第三成分としては、制電性物質、導電性物質または超電導物質、磁性物質，抗菌物質、抗菌・防臭物質、消臭物質、形態安定・形状記憶物質、透湿・吸水物質、透湿抑制・防水物質、感温・保温・蓄熟・発熱・吸収物質、発光・蛍光物質或いは撥水・吸油物質等が挙げられ、発現させる機能に応じて適宜選択される。また形状としては、発泡原料Ｍ１,Ｍ２に混合できるものであれば何れのものでも採用可能である。例えばこの第三成分として、フェライト、カーボンまたは導電性フィラーその他の導電性物質が使用された場合には、静電気防止除去、通電または電磁遮蔽可能な、所謂電磁波シールド性がその高さ方向に沿って連続的に変化するように発現されるポリウレタンフォームや、所要の導電性がその高さ方向に沿って連続的に変化するように発現されるポリウレタンフォームが得られる。またエチレンオキサイドのように水酸基を含有する界面活性剤等の吸水性を発現する吸水物質が使用された場合には、ポリウレタンフォームが有している保水性を更に向上させ、液晶表面やＣＲＰ(プリント基板)等のデリケートな作業が必要とされる部材の表面研磨作業や、パチンコ機のパチンコ玉やコイン洗浄等に好適に使用され、かつ機能がその高さ方向に沿って連続的に変化している吸水性を発現するポリウレタンフォームが得られる。   The third component to be mixed in both foaming raw materials M1 and M2 is antistatic material, conductive material or superconducting material, magnetic material, antibacterial material, antibacterial / deodorant material, deodorant material, shape stable / shape memory material Moisture-permeable / water-absorbing substances, moisture-permeable / water-proof substances, temperature-sensitive / heat-retaining / ripening / heat-generating / absorbing substances, luminescent / fluorescent substances, water-repellent / oil-absorbing substances, etc. Is done. Any shape can be used as long as it can be mixed with the foaming raw materials M1 and M2. For example, when ferrite, carbon or conductive fillers or other conductive materials are used as the third component, the so-called electromagnetic wave shielding property capable of preventing static electricity removal, energization or electromagnetic shielding is along the height direction. A polyurethane foam expressed so as to continuously change or a polyurethane foam expressed so that required conductivity continuously changes along its height direction can be obtained. In addition, when a water-absorbing substance such as a surfactant containing a hydroxyl group such as ethylene oxide is used, the water retention property of the polyurethane foam is further improved, and the liquid crystal surface and CRP (printing It is suitably used for surface polishing work of parts that require delicate work such as (substrate), and for pachinko balls and coins washing of pachinko machines, and the function changes continuously along its height direction. A polyurethane foam that exhibits high water absorption is obtained.

(別の実施例)
前述の実施例においては、成形型５０に先ず第１の発泡原料Ｍ１を注入した後に、その上から第２の発泡原料Ｍ２を注入する方法を述べたが、本発明はこれに限定されるものではなく、例えば成形型５０の底面部５２ａ近傍(図３(ｂ)参照)に直接的に第２の発泡原料Ｍ２の注入をなし得る注入手段を設け、ここを介して第２の発泡原料Ｍ２を成形型５０内に注入するようにしてもよい。なお、この場合も第１の発泡原料Ｍ１および第２の発泡原料Ｍ２の反応に伴う比重差によって、本発明に係るポリウレタンフォームの構造が発現されるため、第２の発泡原料Ｍ２の注入時期は、第１の発泡原料Ｍ１の比重が小さくなり始めた後、すなわち反応開始後に設定される。 (Another example)
In the above-described embodiment, the method in which the first foaming raw material M1 is first injected into the mold 50 and then the second foaming raw material M2 is injected from above is described. However, the present invention is limited to this. Instead, for example, an injection means capable of directly injecting the second foaming raw material M2 is provided in the vicinity of the bottom surface portion 52a of the mold 50 (see FIG. 3B), and the second foaming raw material M2 is provided therethrough. May be injected into the mold 50. In this case as well, since the structure of the polyurethane foam according to the present invention is expressed by the specific gravity difference caused by the reaction between the first foaming raw material M1 and the second foaming raw material M2, the injection timing of the second foaming raw material M2 is The first foaming raw material M1 is set after the specific gravity starts to decrease, that is, after the start of the reaction.

(変更例)
前述の実施例にように、第１の発泡原料Ｍ１から得られる発泡体の比重および第２の発泡原料Ｍ２から得られる発泡体の比重を異なるものとせず、同一または近い数値関係としてポリウレタンフォーム１０を製造することも可能である。この場合、経過時間と、反応の度合い(粘度)および比重との関係は、図６に示す挙動を示すが、この図から明らかな通り、第１の発泡原料Ｍ１と第２の発泡原料Ｍ２とにおいて、何れもその比重が経時的には同様に推移する(経過時間ＢおよびＣにおける比重差ｂおよび比重差ｃ参照)ため、第２の発泡原料Ｍ２が第１の発泡原料Ｍ１の下側に回り込むだけの比重差が発生している。このとき第２の発泡原料Ｍ２の注入時前後(経過時間Ａにおける比重差ａ参照)と、第１の発泡原料Ｍ１の反応完了時前後(経過時間Ｄにおける比重差ｄ参照)については、比重差が小さくなっているが、前者については反応が殆ど進行しておらず２つの発泡原料Ｍ１およびＭ２の流動性が高いため比重差が小さくても問題はなく、後者については殆ど硬化によって樹脂化が完了しているため比重差は関係がない状態となっているため問題はない。この場合、比重に差違を与える配合組成を考慮しなくてもよいため、第１の発泡原料Ｍ１および第２の発泡原料Ｍ２の配合設計がより容易となる利点がある。なお図６おいては、ＳＧは第１の発泡原料Ｍ１および第２の発泡原料Ｍ２から得られる発泡体の比重を、ＩＪ１は第１の発泡原料Ｍ１注入開始時点を、ＩＪ２は第２の発泡原料Ｍ２注入開始時点を夫々示し、またＳＧＩは発泡原料発泡前の比重を表している。 (Example of change)
As in the above-described embodiment, the specific gravity of the foam obtained from the first foam raw material M1 and the specific gravity of the foam obtained from the second foam raw material M2 are not different, and the polyurethane foam 10 has the same or close numerical relationship. Can also be manufactured. In this case, the relationship between the elapsed time, the degree of reaction (viscosity), and the specific gravity shows the behavior shown in FIG. 6, and as is apparent from this figure, the first foaming raw material M1 and the second foaming raw material M2 In both cases, the specific gravity changes similarly over time (see specific gravity difference b and specific gravity difference c at elapsed times B and C), so that the second foaming raw material M2 is below the first foaming raw material M1. There is a specific gravity difference that just wraps around. At this time, the specific gravity difference between before and after the injection of the second foaming raw material M2 (refer to the specific gravity difference a at the elapsed time A) and before and after the completion of the reaction of the first foaming raw material M1 (see the specific gravity difference d at the elapsed time D). However, there is no problem even if the specific gravity difference is small because the reaction of the former is almost not progressing and the flowability of the two foaming raw materials M1 and M2 is high. Since it has been completed, there is no problem because the specific gravity difference is irrelevant. In this case, since it is not necessary to consider the blending composition that gives a difference in specific gravity, there is an advantage that the blending design of the first foaming raw material M1 and the second foaming raw material M2 becomes easier. Note 6 Oite is, SG is the specific gravity of the foam obtained from the first foaming material M1 and the second foaming material M2, IJ 1 is a first foaming material M1 injected beginning, IJ 2 second the foam raw material M2 injection start time respectively indicate, also SG I represents the specific gravity of the pre-foamed material foam.

(別の変更例)
更にこれに対して、反応進行中における比重差が問題となる場合には、例えばポリオールの末端基を変更するまたは増減させる、イソシアネートの反応性を変更する或いは触媒として反応性の高いものまたは低いものを採用するといった公知の方法によって、図７に示す如く、第１の発泡原料Ｍ１の反応性を向上と、第２の発泡原料Ｍ２の反応性を低下との何れか一方または双方をなすことで、発泡に伴う経過時間に対する比重の変動量を制御して、発泡時における第１の発泡原料Ｍ１と第２の発泡原料Ｍ２との比重差をより大きく確保する方法も採用し得る。この場合、経過時間ＡおよびＢにおける比重差ａおよび比重差ｂは、第１の発泡原料Ｍ１および第２の発泡原料Ｍ２の反応性が同一の場合に比較して何れも拡大する。このため相対粘度Ｒの連続的な硬化変化の度合いの設定や、第２の発泡原料Ｍ２注入時のより早い時点での設定が可能となる。なお図７おいては、ＳＧは第１の発泡原料Ｍ１および第２の発泡原料Ｍ２から得られる発泡体の比重を、ＩＪ１は第１の発泡原料Ｍ１注入開始時点を、ＩＪ２は第２の発泡原料Ｍ２注入開始時点を、ＲＵは反応性の向上を、ＲＤは反応性の低下を夫々示し、またＳＧＩは発泡原料発泡前の比重を表している。 (Another change example)
On the other hand, when the specific gravity difference during the reaction is a problem, for example, the polyol end group is changed or increased, the isocyanate reactivity is changed, or the catalyst has a high or low reactivity. As shown in FIG. 7, the reactivity of the first foaming raw material M1 is improved and the reactivity of the second foaming raw material M2 is reduced or both by a known method such as adopting A method of controlling the amount of fluctuation of the specific gravity with respect to the elapsed time associated with foaming to ensure a larger specific gravity difference between the first foaming raw material M1 and the second foaming raw material M2 at the time of foaming can also be adopted. In this case, the specific gravity difference a and the specific gravity difference b in the elapsed times A and B are both increased as compared with the case where the reactivity of the first foaming raw material M1 and the second foaming raw material M2 is the same. For this reason, the setting of the degree of continuous curing change of the relative viscosity R and the setting at an earlier point in time when the second foaming raw material M2 is injected become possible. In FIG. 7, SG represents the specific gravity of the foam obtained from the first foaming raw material M1 and the second foaming raw material M2, IJ 1 represents the start of injection of the first foaming raw material M1, and IJ 2 represents the second of the foaming material M2 injection start point, RU is an improvement in reactivity, RD is a decrease in reactivity each show, also SG I represents the specific gravity of the pre-foamed material foam.

(実験例)
以下に本発明に係る方法により製造したポリウレタンフォームについて、所要の物性を測定した実験例を示す。なお本発明は、この実験例に限定されるものではない。 (Experimental example)
The experimental example which measured the required physical property about the polyurethane foam manufactured by the method which concerns on this invention below is shown. The present invention is not limited to this experimental example.

(実験１：硬度が異なる発泡体となる発泡原料を使用した場合)
表１に記載する配合組成を使用して、硬度が２４５Ｎ／３１４ｃｍ２、密度５０ｋｇ／ｍ３の発泡体となる第１の発泡原料と、硬度が１１８Ｎ／３１４ｃｍ２、密度６０ｋｇ／ｍ３の発泡体となる第２の発泡原料を夫々調整(硬度および密度は、夫々表１中に併記)し、先ず第１の発泡原料を所要形状(縦４００ｍｍ×横４００ｍｍ×高さ８０ｍｍ)の成形型内に注入し、樹脂化反応が進み粘度増加が顕著に進む以前である７秒後に第２の発泡原料を注入して、当該形状を備える直方体形状のポリウレタンフォームを製造した。そして製造されたポリウレタンフォームを成形型より脱型し、厚さ方向を２０ｍｍの間隔で切断し、切り分けられた各シート状物の全体としての硬度を測定した。なお配合に使用した各原料および硬度の測定方法は下に記す。 (Experiment 1: When foaming raw materials that are foams with different hardnesses are used)
Using the composition shown in Table 1, a first foam raw material that becomes a foam with a hardness of 245 N / 314 cm 2 and a density of 50 kg / m 3 , and a foam with a hardness of 118 N / 314 cm 2 and a density of 60 kg / m 3 Each of the second foam raw materials to be a body is adjusted (hardness and density are also shown in Table 1), and the first foam raw material is first placed in a mold having a required shape (length 400 mm × width 400 mm × height 80 mm). The second foaming raw material was injected 7 seconds after the resinification reaction progressed and the viscosity increase remarkably advanced to produce a cuboid-shaped polyurethane foam having the shape. Then, the produced polyurethane foam was removed from the mold, and the thickness direction was cut at intervals of 20 mm, and the hardness of each cut sheet was measured. The raw materials used for the blending and the methods for measuring the hardness are described below.

(使用した原料)
・ポリオールＡ：ポリエーテルポリオール(商品名 ＥＬ−８２８；旭硝子製)
・ポリオールＢ：ポリマーポリオール(商品名 ＦＡ−７２８Ｒ；三洋化成工業製)
・イソシアネート：汎用のＴＤＩ：汎用のＭＤＩ＝８０：２０で混合したもの
・架橋剤：商品名 ＩＲ−９４；三井武田ケミカル製
・触媒Ａ：商品名 ＬＶ−３３；中京油脂製
・触媒Ｂ：商品名 ＢＬ−１１；エアプロダクツ製
・整泡剤：商品名 Ｌ−５３０９；東レダウコーニングシリコーン製
・発泡剤：水
(測定方法)
・硬度：ＪＡＳＯ Ｂ ４０８に準じて測定した。

Figure 2006082630
(Raw materials used)
Polyol A: polyether polyol (trade name EL-828; manufactured by Asahi Glass)
Polyol B: Polymer polyol (trade name FA-728R; manufactured by Sanyo Chemical Industries)
・ Isocyanate: general-purpose TDI: general-purpose MDI mixed at 80:20 ・ Crosslinking agent: trade name IR-94; manufactured by Mitsui Takeda Chemical ・ catalyst A: trade name LV-33; manufactured by Chukyo Yushi ・ Catalyst B: product Name BL-11; Air Products / Foam Stabilizer: Product Name L-5309; Toray Dow Corning Silicone / Foaming Agent: Water
(Measuring method)
Hardness: Measured according to JASO B 408.
Figure 2006082630

(実験１の結果)
製造されたポリウレタンフォームのから切断された各シート状物の硬度(単位：Ｎ／３１４ｃｍ２)を測定した。その結果、その数値は、ポリウレタンフォームの上面から下面に向かって、２４５、１９２、１５１、１１８と、その硬度が徐々に小さくなっていることが確認された。 (Result of Experiment 1)
The hardness (unit: N / 314 cm 2 ) of each sheet-like material cut from the produced polyurethane foam was measured. As a result, it was confirmed that the numerical values were 245, 192, 151, 118 and the hardness gradually decreased from the upper surface to the lower surface of the polyurethane foam.

(実験２：反発弾性率が異なる発泡体となる発泡原料を使用した場合)
表２に記載する配合組成を使用して、反発弾性率６５％、密度５０ｋｇ／ｍ３の発泡体となる第１の発泡原料と、反発弾性率４５％、密度６０ｋｇ／ｍ３の発泡体となる第２の発泡原料を夫々調整(反発弾性率および密度は、夫々表２中に併記)し、先ず第１の発泡原料を所要形状(縦４００ｍｍ×横４００ｍｍ×高さ８０ｍｍ)の成形型内に注入し、樹脂化反応が進み粘度増加が顕著に進む以前である７秒後に第２の発泡原料を注入して、当該形状を備える直方体形状のポリウレタンフォームを製造した。そして製造されたポリウレタンフォームを成形型より脱型し、厚さ方向を２０ｍｍの間隔で切断し、切り分けられた各シート状物の全体としての反発弾性率を測定した。なお配合に使用した各原料および反発弾性率の測定方法は下に記す。 (Experiment 2: When using foaming raw materials that are foams with different rebound resilience)
Using the blend composition shown in Table 2, a first foam raw material that becomes a foam with a rebound resilience of 65% and a density of 50 kg / m 3 , and a foam with a rebound resilience of 45% and a density of 60 kg / m 3 Each of the second foam raw materials is adjusted (rebound resilience and density are also shown in Table 2), and first, the first foam raw material is placed in a required shape (length 400 mm × width 400 mm × height 80 mm). The second foaming raw material was injected 7 seconds after the resinification reaction progressed and the viscosity increase remarkably advanced to produce a cuboid-shaped polyurethane foam having the shape. Then, the produced polyurethane foam was removed from the mold, and the thickness direction was cut at intervals of 20 mm, and the impact resilience as a whole of each cut sheet was measured. In addition, each raw material used for mixing | blending and the measuring method of a resilience elastic modulus are described below.

(使用した原料)
・ポリオールＡおよびＢ：実験１と同じ
・ポリオールＣ：ポリエーテルポリオール(商品名 ＩＴ−３４；三井武田ケミカル製)
・イソシアネート：汎用のＭＤＩ
・架橋剤：ジエタノールアミン
・触媒ＡおよびＢ：実験１と同じ
・整泡剤：商品名 ＳＺ−１３１３；東レダウコーニングシリコーン製
・発泡剤：水
(測定方法)
・反発弾性率：ＪＡＳＯ Ｂ ４０８に準じて測定した。

Figure 2006082630
(Raw materials used)
Polyol A and B: Same as Experiment 1 Polyol C: Polyether polyol (trade name IT-34; manufactured by Mitsui Takeda Chemical)
・ Isocyanate: General-purpose MDI
・ Crosslinking agent: Diethanolamine ・ Catalysts A and B: Same as Experiment 1 ・ Foam stabilizer: Product name SZ-1313; Made by Toray Dow Corning Silicone ・ Foaming agent: Water
(Measuring method)
-Rebound resilience: measured according to JASO B 408.
Figure 2006082630

(実験２の結果)
製造されたポリウレタンフォームから切断された各シート状物の反発弾性率(％)を測定した。その結果、その数値は、ポリウレタンフォームの上面から下面に向かって、６５、５８、５１、４５と、その反発弾性率が徐々に小さくなっていることが確認された。 (Result of Experiment 2)
The rebound resilience (%) of each sheet-like material cut from the produced polyurethane foam was measured. As a result, it was confirmed that the numerical value was 65, 58, 51, 45 and the rebound resilience gradually decreased from the upper surface to the lower surface of the polyurethane foam.

材料の物性や、特性が材料内部で予め設計された勾配をもって、連続的に変化し得る傾斜的な性質を発現するポリウレタンフォームおよびその製造方法は、ポリウレタンフォームが使用される各物品全てについて広く適用が可能である。   Polyurethane foam and its manufacturing method that expresses a gradient property in which the physical properties and characteristics of the material can be continuously changed with a pre-designed gradient inside the material, and its manufacturing method are widely applied to all articles in which polyurethane foam is used. Is possible.

本発明の好適な実施例に係るポリウレタンフォーム(シート用パッド)の内部構造を示す縦断正面図である。1 is a longitudinal front view showing an internal structure of a polyurethane foam (sheet pad) according to a preferred embodiment of the present invention. 実施例に係るポリウレタンフォーム(シート用パッド)を好適に製造する工程の一例を示す工程図である。It is process drawing which shows an example of the process of manufacturing suitably the polyurethane foam (sheet pad) which concerns on an Example. 一般的なシート用パッドを成形する成形型の概略図であって、(ａ)は下型を平面状態で示す図であり、(ｂ)は(ａ)のｂ−ｂ線断面図である。It is the schematic of the shaping | molding die which shape | molds the general pad for sheet | seats, Comprising: (a) is a figure which shows a lower mold | type in a planar state, (b) is the bb sectional view taken on the line of (a). 実施例に係るポリウレタンフォーム(シート用パッド)の製造時の反応の度合いおよび比重差の経時的な変化を示すグラフ図である。It is a graph which shows the time-dependent change of the reaction degree at the time of manufacture of the polyurethane foam (sheet pad) which concerns on an Example, and a specific gravity difference. 実施例に係るポリウレタンフォーム(シート用パッド)をなす第１の発泡原料および第２の発泡原料の粘度の変化を概略的に示すグラフ図である。It is a graph which shows roughly the change of the viscosity of the 1st foaming raw material which makes the polyurethane foam (sheet pad) which concerns on an Example, and a 2nd foaming raw material. 変更例に係るポリウレタンフォームの製造時の反応の度合いおよび比重差の経時的な変化を示すグラフ図である。It is a graph which shows the time-dependent change of the reaction degree at the time of manufacture of the polyurethane foam which concerns on the example of a change, and a specific gravity difference. 別の変更例に係るポリウレタンフォームの製造時の反応の度合いおよび比重差の経時的な変化を示すグラフ図である。It is a graph which shows the time-dependent change of the reaction degree at the time of manufacture of the polyurethane foam which concerns on another example of a change, and a specific gravity difference.

符号の説明Explanation of symbols

１０ ポリウレタンフォーム
１２ シート用パッド
１２ａ 表面
３４ 前部サポート部
３６ 後部サポート部
３８ サイドサポート部
５２ａ 底面部
５０ 成形型
Ｍ１ 第１の発泡原料
Ｍ２ 第２の発泡原料 DESCRIPTION OF SYMBOLS 10 Polyurethane foam 12 Seat pad 12a Surface 34 Front support part 36 Rear support part 38 Side support part 52a Bottom part 50 Mold M1 1st foam raw material M2 2nd foam raw material

Claims (9)

所要の成形型(50)に、発泡・硬化反応の完了時に所要の物性における数値が互いに異なる発泡体となる第１の発泡原料(M1)および第２の発泡原料(M2)を逐次注入して製造されるポリウレタンフォームであって、
前記第１の発泡原料(M1)および第２の発泡原料(M2)から夫々得られる発泡体が一体的に混在され、該所要の物性における数値が成形型(50)の高さ方向に沿って連続的に変化している
ことを特徴とするポリウレタンフォーム。The first foam raw material (M1) and the second foam raw material (M2), which are foams having different numerical values in the required physical properties when the foaming / curing reaction is completed, are sequentially injected into the required mold (50). A polyurethane foam to be produced,
The foams obtained from the first foaming raw material (M1) and the second foaming raw material (M2) are mixed together, and the numerical values of the required physical properties are along the height direction of the mold (50). A polyurethane foam characterized by continuously changing. 前記物性値として、硬度、反発弾性率または／およびセル径が選択されている請求項１記載のポリウレタンフォーム。   The polyurethane foam according to claim 1, wherein hardness, impact resilience, and / or cell diameter are selected as the physical property values. 前記第１の発泡原料(M1)および第２の発泡原料(M2)に対して、所要の第三成分をその濃度が異なるように混合することで、該第三成分が成形型(50)の高さ方向に沿って連続的に変化した構造となっている請求項１または２記載のポリウレタンフォーム。   The required amount of the third component is mixed with the first foaming raw material (M1) and the second foaming raw material (M2) so as to have different concentrations so that the third component of the mold (50) is mixed. The polyurethane foam according to claim 1 or 2, wherein the polyurethane foam has a structure continuously changing along the height direction. 乗員が着座して直接接触する前部サポート部(34)および後部サポート部(36)と、この両側に位置し、該乗員のサイドサポートにより姿勢を保持するサイドサポート部(38,38)とから構成されるシート用パッド(12)の外部輪郭形状に合致する内部輪郭形状を備え、その底面部(52a)がシート用パッド(12)の表面(12a)を形成する成形型(50)が使用され、少なくとも該前部サポート部(34)または後部サポート部(36)には、その一部または全体に硬度の異なる２種類の発泡体が一体的に混在し、シート用パッド(12)の表面(12a)側の硬度が低くなるよう、該シート用パッド(12)の厚さ方向に沿って硬度が連続的に変化している請求項１記載のポリウレタンフォーム。   It consists of a front support part (34) and a rear support part (36) in which an occupant sits and comes into direct contact, and side support parts (38, 38) that are located on both sides and maintain posture by the occupant side support. A molding die (50) having an inner contour shape that matches the outer contour shape of the seat pad (12) and having a bottom surface (52a) forming the surface (12a) of the seat pad (12), is used, At least in the front support part (34) or the rear support part (36), two or more types of foams having different hardnesses are mixed together in part or in whole, and the surface (12a) of the seat pad (12) is mixed. 2. The polyurethane foam according to claim 1, wherein the hardness continuously changes along the thickness direction of the pad for sheet (12) so that the hardness on the side) becomes low. 所要の成形型(50)に、発泡・硬化反応の完了時に所要の物性における数値が互いに異なる発泡体となる第１の発泡原料(M1)および第２の発泡原料(M2)を逐次注入してポリウレタンフォームを製造する方法であって、
先に注入されて発泡・硬化反応が進行中の第１の発泡原料(M1)が存在する前記成形型(50)内に、第２の発泡原料(M2)を注入することで、２つの発泡原料(M1,M2)の反応進行中に発生する比重差によって、第２の発泡原料(M2)を第１の発泡原料(M1)の下側に位置させ、
前記成形型(50)の内部で２つの発泡原料(M1,M2)の反応を更に進行させることで、夫々の発泡原料(M1,M2)から得られる発泡体を一体的に混在させると共に、該所要の物性における数値が成形型(50)の高さ方向に沿って連続的に変化させるようにした
ことを特徴とするポリウレタンフォームの製造方法。The first foam raw material (M1) and the second foam raw material (M2), which are foams having different numerical values in the required physical properties when the foaming / curing reaction is completed, are sequentially injected into the required mold (50). A method for producing a polyurethane foam comprising:
By injecting the second foaming raw material (M2) into the mold (50) in which the first foaming raw material (M1) in which the foaming / curing reaction is in progress is present, the two foams are injected. Due to the specific gravity difference that occurs during the reaction of the raw materials (M1, M2), the second foaming raw material (M2) is positioned below the first foaming raw material (M1),
By further advancing the reaction of the two foam raw materials (M1, M2) inside the mold (50), the foams obtained from the respective foam raw materials (M1, M2) are mixed together, A method for producing a polyurethane foam, characterized in that the numerical values of the required physical properties are continuously changed along the height direction of the mold (50). 前記第１の発泡原料(M1)および第２の発泡原料(M2)には、夫々濃度が異なるように設定された第三成分を予め混合されている請求項５記載のポリウレタンフォームの製造方法。   The method for producing a polyurethane foam according to claim 5, wherein the first foaming raw material (M1) and the second foaming raw material (M2) are premixed with a third component set to have different concentrations. 前記第２の発泡原料(M2)は、前記成形型(50)に先に注入されて発泡・硬化反応の進行中の第１の発泡原料(M1)の上から注入される請求項５または６記載のポリウレタンフォームの製造方法。   The second foaming raw material (M2) is first injected into the mold (50) and injected from above the first foaming raw material (M1) during the foaming / curing reaction. The manufacturing method of the polyurethane foam of description. 前記第１の発泡原料(M1)は、第２の発泡原料(M2)よりもその反応性が低く設定されている請求項５〜７の何れかに記載のポリウレタンフォームの製造方法。   The method for producing a polyurethane foam according to any one of claims 5 to 7, wherein the first foaming raw material (M1) is set to have a lower reactivity than the second foaming raw material (M2). 乗員が着座して直接接触する前部サポート部(34)および後部サポート部(36)と、この両側に位置し、該乗員のサイドサポートにより姿勢を保持するサイドサポート部(38,38)とから構成されるシート用パッド(12)の外部輪郭形状に合致する内部輪郭形状を備え、その底面部(52a)がシート用パッド(12)の表面(12a)を形成する成形型(50)が使用され、前記第１の発泡原料(M1)として高い硬度の発現する発泡体となる原料が使用されると共に、第２の発泡原料(M2)として該第１の発泡原料(M1)から得られる発泡体より低い硬度を発現する発泡体となる原料が使用され、その硬度がシート用パッド(12)の厚さ方向に沿って連続的し、かつ該シート用パッド(12)の表面(12a)側の硬度が低くなっいてる請求項５記載のポリウレタンフォームの製造方法。
It consists of a front support part (34) and a rear support part (36) in which an occupant sits and comes into direct contact, and side support parts (38, 38) that are located on both sides and maintain posture by the occupant side support. A molding die (50) having an inner contour shape that matches the outer contour shape of the seat pad (12) and having a bottom surface (52a) forming the surface (12a) of the seat pad (12), is used, From the foam obtained from the first foaming raw material (M1) as the second foaming raw material (M1), the first foaming raw material (M1) is used as a raw material that becomes a foam exhibiting high hardness. A raw material that becomes a foam that expresses low hardness is used, the hardness is continuous along the thickness direction of the sheet pad (12), and the hardness of the surface (12a) side of the sheet pad (12) The method for producing a polyurethane foam according to claim 5, wherein the ratio is low.
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