WO2005087484A1 - 発泡樹脂成形体とその成形方法 - Google Patents
発泡樹脂成形体とその成形方法 Download PDFInfo
- Publication number
- WO2005087484A1 WO2005087484A1 PCT/JP2005/004245 JP2005004245W WO2005087484A1 WO 2005087484 A1 WO2005087484 A1 WO 2005087484A1 JP 2005004245 W JP2005004245 W JP 2005004245W WO 2005087484 A1 WO2005087484 A1 WO 2005087484A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- water
- foamed resin
- molded article
- foamed
- resin molded
- Prior art date
Links
Classifications
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47G—HOUSEHOLD OR TABLE EQUIPMENT
- A47G27/00—Floor fabrics; Fastenings therefor
- A47G27/02—Carpets; Stair runners; Bedside rugs; Foot mats
-
- 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
- B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
- B29C67/20—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 for porous or cellular articles, e.g. of foam plastics, coarse-pored
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B68—SADDLERY; UPHOLSTERY
- B68G—METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
- B68G5/00—Resilient upholstery pads
- B68G5/02—Resilient upholstery pads of cellular material, e.g. sponge rubber
Definitions
- the present invention relates to a foamed resin molded article having high air permeability, having both shape stability and excellent water absorption, and suitable for incontinence breads, diapers to incontinence sheets, foot wiping mats, and the like. It relates to the molding method.
- Sponge made of polyurethane as a main raw material has an excellent tactile sensation and is excellent in water absorption by forming a large number of air bubbles, and is therefore preferably used for applications requiring these properties.
- Patent Document 1 discloses that an absorbent resin is dispersed in an active hydrogen-containing organic compound, and then the absorbent resin is polymerized with a water-soluble monomer or precursor and a crosslinking agent and / or a polysaccharide.
- One that has been formed proposes a resin obtained by reacting a dispersion with an organic polyisocyanate compound!
- the absorbent resin dispersion describes good water absorption of water, but does not mention the water absorption of physiological saline as a model of sweat or urine released from the human body. Also, there is no mention of a specific method for producing an absorbent resin dispersion having stable water absorption!
- Patent Literature 2 Patent Literature 3
- Patent Literature 4 Patent Literature 5 propose a water-absorbing sponge. It is not clear how much the absorbent sponges proposed by these methods have a sufficient absorbency and a stable water absorption. Also, as in Patent Document 1, the water absorption of physiological saline as a model of sweat or urine is not mentioned. The reason why such water absorption is important is unclear because the water-absorbing sponges proposed by them are only manufactured by shaping urethane containing absorbent resin. This is because it is considered that such a method of forming a water-absorbing sponge is difficult to incorporate the water-absorbing resin into the urethane while maintaining the initial water absorption.
- Patent Document 1 Japanese Patent Application Laid-Open No. 08-302218 (2 pages-10 pages, not shown)
- Patent Document 2 JP-A-53-138500 (page 2-5, not shown)
- Patent Document 3 JP-A-59-117519 (page 2-18, no figure)
- Patent Document 4 Japanese Patent Application Laid-Open No. 03-203921 (page 3-18, no figure)
- Patent Document 5 Japanese Patent Application Laid-Open No. 06-206966
- the foamed resin molded article has a characteristic of having excellent air permeability and soft elasticity as a sponge, and is widely used for pillows, cushions, sofas and the like.
- a foamed resin molded body is required to have water absorption that does not necessarily have water absorbency, it is often not appropriate to use a foamed resin molded body alone.
- the foamed and molded resin becomes water-absorbent in addition to having excellent air permeability and soft elasticity, its value as a sponge will be greatly expanded.
- foot wipe mats, hair wipes In addition to towels and rugs in saunas, incontinence pants and diaper power can also be used for repeated use of incontinence sheets.
- the product retains a moderate level of water absorption, maintains the form stability of the product, and extremely discharges disposable products as a product suitable for repeated use.
- the task was to reduce it and contribute to environmental conservation. Therefore, a study was conducted on a foamed resin molded article having water absorption and a molding method of the foamed resin molded article having water absorption.
- a core material obtained by mixing a water-absorbing resin powder, foamed resin particles, and a binder is wrapped in a water-permeable sheet, and the core material and the water-permeable sheet are integrated into a predetermined shape.
- This is a foamed resin molded article that is formed into a single-piece product by heating and forming a core layer, which is a core raw material, into a surface layer made of a water-soluble sheet.
- the foamed resin molded article of the present invention achieves water absorption of the foamed resin molded article as a whole by imparting water absorbency to a core material constituting a core layer wrapped in a surface layer.
- the water-absorbing resin powder constituting the core raw material is a relatively low water-absorbing resin having a water absorption ratio of water or physiological saline of 5 to 100, preferably 10 to 60.
- a polyacrylamide gel resin produced by a polymerization reaction of an acrylamide monomer is crushed and washed with water. It is a powder obtained by heating and drying and, if necessary, crushing to a predetermined average particle size, or a gel resin of isobutylene and maleic anhydride copolymer.
- the water-absorbent resin powder has an average particle size of about 90 m as a guide, and has an average particle diameter of 60 to 120 m, preferably 80 to 100 m.
- the above-mentioned water-absorbing resin powder has the ability to use a polyacrylic acid-based resin. If the water-absorbing power exceeds 100, the stability of the product may be lacking.
- Polyacrylamide-based resin which is preferably a resin or isopropylatariamide-based resin, is suitable for the present invention in terms of stability and the like. More specifically, as the water-absorbing resin powder used in the present invention, a polymer in which acrylamide and ⁇ , ⁇ ′-methylenebisacrylamide are also formed, and a polymer in which ⁇ -substituted acrylamide and the like are formed are more suitable.
- the water-absorbing resin powder is a copolymer of acrylamide and ⁇ , ⁇ ′-methylenebisacrylamide
- the acrylamide concentration is usually considered to be in the range of 3% to 15%. The lower the acrylamide concentration, the more vulnerable the condition after gelling.
- a acrylamide concentration of 7.5% it absorbs 17 g of water and 15 g of 1% saline (equivalent to sweat or urine) per gram of water-absorbing resin powder.
- the concentration of acrylamide is 10%, it absorbs 15g of water and 14g of 1% saline solution per lg of water-absorbing resin powder.
- the concentration of acrylamide is 15%, lg of water-absorbing resin powder will absorb llg of water and 10g of 1% saline solution.
- the foamed resin particles constituting the core raw material may be foamed polyolefin granules, foamed polyurethane granules, or the like, but foamed polyurethane granules are preferred from the viewpoint of elasticity, form stability, and soft feel.
- the binder constituting the core material is preferably a foamable urethane binder, particularly preferably a foamed polyurethane binder.
- the surface layer preferably has air permeability.
- the surface layer is made of a foamed resin having a large number of open cells, and the structure is such that the foamed resin particles made of the foamed resin of the core layer communicate with the air bubbles of the surface layer, that is, the foamed polyurethane having the open cells. It is preferable to use a sheet or a polyester-based nonwoven fabric.
- the foamed resin molded article described above is manufactured according to the following molding method. That is, a foamed resin particle forming step of cutting the foamed resin block into a predetermined average diameter to obtain a foamed resin particle, A water-absorbent resin powder preparation step of crushing, washing with water, heating and drying and crushing the polyacrylamide-based gel resin produced by the polymerization reaction of the acrylamide monomer to obtain a water-absorbent resin powder; Foam obtained in the water-absorbent resin powder preparation process Binder is added to the fat particles and the water-absorbent resin powder, and mixed to obtain a core material.
- a method of molding a foam ⁇ molded article comprising the molding step of forming shape.
- a commercially available water-absorbing resin powder should be used as long as the water or physiological saline has a relatively low water absorption ratio of 5 to 100. Can be.
- a gel resin of a cross-linked type with isobutylene and maleic anhydride copolymer, and other acrylamide-based acrylic acid-based low water-absorbing resin powders can be used.
- the water-absorbing resin powder when powdering and granulating the water-absorbing resin, the water-absorbing resin powder is suspended in water or a water-soluble polymer aqueous solution such as an aqueous polyvinyl alcohol solution, and fine clay minerals such as
- a method of adding a water-swellable montmorillonite mineral, followed by drying, crushing, or pulverizing can also obtain a relatively low water-absorbing resin satisfying the above-mentioned water absorption ratio.
- the predetermined average diameter when the foamed resin block is cut into foamed resin particles is preferably 2 to 15 mm, and more preferably 5 to 10 mm.
- the foamed resin particles having a predetermined average diameter of 2 to 15 mm are dispersed according to the formwork, and immediately after the water-absorbing resin powder is sunk into the gaps formed between the foamed resin particles, the water-absorbing resin powder is removed. Is easily dispersed throughout the core layer.
- the core raw material making process is performed by adding and mixing the foamable urethane binder to the foamed grease particles and the water-absorbent grease powder obtained in the foaming grease forming process and the water absorbing grease powder making process. You should get
- the foamed polyurethane sheet having open cells prepared in advance is disposed on the contact surface side of the lower mold, and the polyester nonwoven fabric prepared in advance is disposed on the contact surface side of the lower mold. It is good to arrange.
- the upper layer sheet disposing step is a core material filling step. It is preferable to cover the core material filled with the above with a foamed polyurethane sheet having open cells, or cover the core material filled in the core material filling step with a polyester-based nonwoven fabric.
- the foamed resin molded article that is, a sponge, to which an appropriate water absorption is imparted.
- the foamed resin molded article having the core layer formed by mixing the water-absorbing resin powder and the foamed resin granules, while exhibiting good water absorption is conversely short-time. And has the advantage of drying. This is because the water-absorbing resin powder mixed in the core layer does not adhere to each other and exists independently of each other, so that it is not necessary to prevent water from evaporating from the surface of each water-absorbing resin powder. The effect is as follows.
- the foamed resin molded article based on the present invention that is, a sponge
- a usage form in which water absorption and drying are repeated and unlike conventional sponges, for example, incontinence pants, diapers, incontinence sheets, foot-wiping mats, kitchens, etc. It can be suitably used for mats and other rugs around water.
- the foamed resin molded article of the present invention is a water-absorbent resin powder having a large average particle size obtained by crushing various gelled resins formed by the polymerization reaction, washing with water, drying by heating and pulverizing (85). — 95 ⁇ m) is mixed with foamed resin particles to form a core layer, thereby reducing the difference in water absorption between water and 1% saline.
- the water-absorbent resin powder obtained by directly heating and drying the polymerized gelled resin without washing it with water is used as it is, the water absorption of 1% saline solution with respect to water is reduced to a fraction, On the other hand, in the water-absorbing resin powder used in the present invention, the water absorption of 1% saline with respect to water remains within a 20% reduction. Thereby, the foamed resin molded article of the present invention has an effect that it can be used for the purpose of absorbing sweat or urine released from the human body and reusing it through washing or the like.
- FIG. 1 is a partially cutaway perspective view showing an example of a foot wiping mat 1 made of a foamed resin molded article according to the present invention
- FIG. 2 is a partially enlarged cross-sectional view of the foot wiping mat 1.
- This example is an example of a foot wiping mat 1 which is considered to be preferable as an application mode of the foamed resin molded article of the present invention.
- the foot wiping mat 1 made of the foamed resin molded article of the present invention has a structure in which the upper surface, the lower surface, and the side surfaces of the core layer 11 are wrapped by the surface layer 12.
- the core layer 11 of this example is made of foamed polyurethane foam (foamed resin block) cut to a diameter of 5 to 10 mm, foamed urethane particles 111, foamable urethane binder, and water absorbent resin.
- the core raw material mixed with the powder 112 is heat-molded integrally and in a sheet shape, and the water-absorbent resin powder 112 is scattered in the gaps between the foamed resin particles 111 which are in close contact with each other.
- the surface layer 12 is formed by a foamed polyurethane sheet 121 covering the upper surface side of the core layer 11 and a foamed polyurethane sheet 122 similarly covering the lower surface side of the core layer 11. 122 are fused.
- the surface layer 12 and the core layer 11 each have air bubbles, and the air bubbles are in a state of being connected to each other.
- air permeability see the thin dashed arrow in FIG. 2
- the water absorbent resin powder 112 scattered in the core layer 11 is covered with the surface layer. It exhibits water absorption through 12 (see thick solid line arrow in Fig. 2).
- a certain amount of water-absorbing resin powder shows high water absorption, but it is difficult to dry once water is absorbed.
- the drying is extremely quick (see the thick broken arrow in FIG. 2).
- the water-absorbing resin powder 112 scattered in the core layer 11 is obtained by crushing a gel resin produced by a polymerization reaction, washing with water, heating and drying, and crushing water and sweat or urine.
- the water absorption with the 1% saline solution close to that of the model can be absorbed without any water attached to the human body.
- the entire foot wiping mat 1 is composed of a core layer 11 in which foaming / fatty particles 111 having foaming / fatty urethane foam power are integrated and foamed urethane sheets 121 and 122 wrapping the core layer 11, the same type Similar to a foam urethane foam mat obtained by simply molding a material, the mat has elasticity and a soft touch.
- the present invention can provide the foot wiping mat 1 having excellent air permeability, shape stability, excellent water absorption, and quick drying.
- a sample based on the present invention was produced, and water and 1% saline were used. Next, the water absorption was measured.
- the sample is a substantially rectangular parallelepiped sponge according to the present invention.
- a non-woven fabric is used as the water-permeable sheet constituting the surface layer.
- the foamed resin particles made of the foamed resin constituting the core raw material are formed by cutting an SS foam block (foamed polyurethane foam) with a cutter to have a predetermined average diameter of 5 to 10 mm.
- the binder used is a polyurethane binder (Sanyo Kasei Co., Ltd., SGI2000, resin 60%, solvent 40%), and the foamed resin particles are sprayed with an airless gun while stirring. Then, after adding a water-absorbing resin powder described later, the mixture was sufficiently stirred and mixed to produce a core material. In this test, the mixing ratio of the core material was 100 g of expanded resin particles, 10 g of binder, and 250 g of water-absorbing resin powder.
- the water-absorbing resin powder is a polyacrylamide water-absorbing resin fine powder obtained by the following procedure. In other words, 11.8 L of tap water in which 99.12 g of sodium bicarbonate (NaHCO) was provided.
- Lilamide solution (Dissolved 6.3 kg of acrylamide, 168 g of ⁇ , ⁇ '-methylenebisacrylamide in 14,582 L of tap water) 4 L, 200 mL of 10% ammonium persulfate solution, and ⁇ , ⁇ , ⁇ ', Add 10 mL of ⁇ '-tetramethylethylenediamine, mix well, and leave until gelled. 30 minutes after gelation, crush the water-absorbing gel finely and wash well with tap water to completely remove unreacted substances (especially acrylamide) remaining inside and outside the water-absorbing gel. Then, the water-absorbing gel is heated (around 100 ° C) and dried.
- the dried water-absorbing gel is finely crushed with a crusher to a particle size of about 80 to 100 m to obtain a water-absorbing resin powder.
- the obtained water-absorbing resin powder had a saturated water absorption of 17 g of water and 15 g of 1% saline solution per gram of the powder.
- the water absorption and drying properties of the sponge thus obtained were examined.
- the water absorption of the sponge was measured. Specifically, the sample sponge was immersed in tap water for 10 minutes, and then the sponge was hung and the weight was measured at the time when the water droplets did not drip. The measured weight of the sponge of the sample at the time when the water droplets did not drip was 800 g. From this, if the dry weight (250 g) of the sample was subtracted from the measured weight (800 g), the water absorption of the sample sponge was 550 g. Similarly, when a test was performed on 1% saline, the water absorption was 490 g. It is about 10% less water absorbent than water.
- the sponge as a foamed resin molded article according to the present invention should exhibit a water absorption of about twice its own weight, and be able to exhibit the same water absorption as 1% saline even with water. But it's a component.
- the sponge absorbed with the tap water is left under a certain condition, and the time required for natural spontaneous drying to return to its own weight, that is, the sponge is completely dried.
- the conditions in this test are room temperature and 60% humidity.
- the sponge which was 800 g at the time of water absorption, became 550 g after 1 day (after 24 hours), 400 g after 2 days (after 48 hours), and 300 g after 3 days (after 72 hours). After 4 days (after 96 hours), it weighed 265 g, returned to its own weight within about 100 hours, and became completely dry.
- the sponge which had absorbed tap water, was completely dried within about one hour when it was forcibly dried using a blow dryer of Nippon Press HG252 type at 100 ° C. From this, the sponge as a resin molded article according to the present invention has a water absorption of about twice its own weight, and can be completely dried within 100 hours under natural drying and only 1 hour under forced drying. It can be seen that it has a quick drying property that can be dried.
- the foamed resin molded article according to the present invention directly provides a product excellent in water absorption and quick drying, for example, a sponge or a water-absorbing sheet material.
- a product excellent in water absorption and quick drying for example, a sponge or a water-absorbing sheet material.
- water-absorbing products such as foot wiping mats and the like, as well as excellent water absorption of sweat released from the human body, utilizing the above-mentioned water absorption and quick-drying properties, they can be used for ordinary mattresses and cushions. it can. Furthermore, it can be used for incontinence pants and ommud nods where local water absorption and quick drying are desired. is there.
- the present invention can be widely applied to the field of application of the foamed resin molded article in which water absorption and quick drying are desired.
- FIG. 1 is a partially broken perspective view showing an example of a foot wiping mat using a foamed resin molded article according to the present invention.
- FIG. 2 is a partially enlarged sectional view of a foot wiping mat.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Absorbent Articles And Supports Therefor (AREA)
- Laminated Bodies (AREA)
- Orthopedics, Nursing, And Contraception (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Abstract
Description
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Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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JP2006510984A JP4358227B2 (ja) | 2004-03-11 | 2005-03-10 | 発泡樹脂成形体とその成形方法 |
Applications Claiming Priority (2)
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JP2004-068382 | 2004-03-11 | ||
JP2004068382 | 2004-03-11 |
Publications (1)
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WO2005087484A1 true WO2005087484A1 (ja) | 2005-09-22 |
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PCT/JP2005/004245 WO2005087484A1 (ja) | 2004-03-11 | 2005-03-10 | 発泡樹脂成形体とその成形方法 |
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WO (1) | WO2005087484A1 (ja) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20220354290A1 (en) * | 2019-07-09 | 2022-11-10 | Simple Green Co., Ltd. | Elastic water-absorbing floor mat |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPH1134173A (ja) * | 1997-07-18 | 1999-02-09 | Yoshiyori Yokoi | クッション体の製造方法 |
JP2002307592A (ja) * | 2001-04-09 | 2002-10-23 | Snova Corp | 吸水マットおよびその製法 |
JP2003153785A (ja) * | 2001-11-19 | 2003-05-27 | Sanotec Co Ltd | 防水用床敷きマット |
JP2003158919A (ja) * | 2003-01-30 | 2003-06-03 | Sanyo Chem Ind Ltd | 再利用可能な吸水性樹脂入りマット及びその再利用方法 |
JP2003165865A (ja) * | 2001-12-03 | 2003-06-10 | Toyo Tire & Rubber Co Ltd | 吸水性ポリウレタン発泡体の製造方法とその方法により製造された吸水性ポリウレタン発泡体とクッション材およびシール材 |
-
2005
- 2005-03-10 WO PCT/JP2005/004245 patent/WO2005087484A1/ja active Application Filing
- 2005-03-10 JP JP2006510984A patent/JP4358227B2/ja not_active Expired - Fee Related
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPH1134173A (ja) * | 1997-07-18 | 1999-02-09 | Yoshiyori Yokoi | クッション体の製造方法 |
JP2002307592A (ja) * | 2001-04-09 | 2002-10-23 | Snova Corp | 吸水マットおよびその製法 |
JP2003153785A (ja) * | 2001-11-19 | 2003-05-27 | Sanotec Co Ltd | 防水用床敷きマット |
JP2003165865A (ja) * | 2001-12-03 | 2003-06-10 | Toyo Tire & Rubber Co Ltd | 吸水性ポリウレタン発泡体の製造方法とその方法により製造された吸水性ポリウレタン発泡体とクッション材およびシール材 |
JP2003158919A (ja) * | 2003-01-30 | 2003-06-03 | Sanyo Chem Ind Ltd | 再利用可能な吸水性樹脂入りマット及びその再利用方法 |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20220354290A1 (en) * | 2019-07-09 | 2022-11-10 | Simple Green Co., Ltd. | Elastic water-absorbing floor mat |
Also Published As
Publication number | Publication date |
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JPWO2005087484A1 (ja) | 2008-01-24 |
JP4358227B2 (ja) | 2009-11-04 |
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