WO2020170998A1 - Earplug and earplug production method - Google Patents
Earplug and earplug production method Download PDFInfo
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- WO2020170998A1 WO2020170998A1 PCT/JP2020/005968 JP2020005968W WO2020170998A1 WO 2020170998 A1 WO2020170998 A1 WO 2020170998A1 JP 2020005968 W JP2020005968 W JP 2020005968W WO 2020170998 A1 WO2020170998 A1 WO 2020170998A1
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- earplug
- raw material
- antibacterial agent
- inorganic antibacterial
- earplugs
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- A—HUMAN NECESSITIES
- A01—AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
- A01N—PRESERVATION OF BODIES OF HUMANS OR ANIMALS OR PLANTS OR PARTS THEREOF; BIOCIDES, e.g. AS DISINFECTANTS, AS PESTICIDES OR AS HERBICIDES; PEST REPELLANTS OR ATTRACTANTS; PLANT GROWTH REGULATORS
- A01N59/00—Biocides, pest repellants or attractants, or plant growth regulators containing elements or inorganic compounds
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- A—HUMAN NECESSITIES
- A01—AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
- A01N—PRESERVATION OF BODIES OF HUMANS OR ANIMALS OR PLANTS OR PARTS THEREOF; BIOCIDES, e.g. AS DISINFECTANTS, AS PESTICIDES OR AS HERBICIDES; PEST REPELLANTS OR ATTRACTANTS; PLANT GROWTH REGULATORS
- A01N59/00—Biocides, pest repellants or attractants, or plant growth regulators containing elements or inorganic compounds
- A01N59/16—Heavy metals; Compounds thereof
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F11/00—Methods or devices for treatment of the ears or hearing sense; Non-electric hearing aids; Methods or devices for enabling ear patients to achieve auditory perception through physiological senses other than hearing sense; Protective devices for the ears, carried on the body or in the hand
- A61F11/06—Protective devices for the ears
- A61F11/08—Protective devices for the ears internal, e.g. earplugs
- A61F11/10—Protective devices for the ears internal, e.g. earplugs inflatable or expandable
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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
- B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
- B29C39/02—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles
Definitions
- the present invention relates to a soundproof earplug having antibacterial performance and a method for manufacturing the earplug.
- earplugs are often used as soundproof protectors.
- a flange type solid earplug and a sponge type earplug.
- sponge type earplugs one made of urethane foam and the other made of PVC (Polyvinyl Chloride).
- Flange type earplugs made of elastomer or silicone and PVC sponge type earplugs have low water absorption and can be washed and reused. Some flange type earplugs and PVC sponge type earplugs have antibacterial properties (see Patent Document 1).
- sponge type earplugs made of elastic foam polymer or urethane cannot be washed and reused because they are difficult to dry when they contain water.
- sponge type earplugs made of urethane cannot be washed because they contain water and cause a hydrolysis reaction to deteriorate in a short time.
- the flange type earplugs and the PVC sponge type earplugs can be washed and reused and thus can be used hygienically.
- the sponge type earplugs made of an elastic foamed polymer or urethane can be used. It is better than earplugs.
- the sponge type earplugs have both flexibility and shape restoring ability, they can block the external auditory meatus without any gap, and can exhibit higher sound insulation than the flange type earplugs. Therefore, it can be said that the sponge type earplug is superior to the flange type earplug in the original function of protecting the ear from noise.
- An object of the present invention is to provide a sponge type earplug made of urethane foam having antibacterial properties and a manufacturing method thereof.
- the earplug according to the present invention is an earplug that is inserted into the external auditory meatus while being compressed by a finger, and is made of a soft urethane foam containing an inorganic antibacterial agent dispersed therein, and is compressed to the limit with a finger. It is characterized in that the time required from the instant when the compression is completely released to the restoration to the original shape is 40 seconds to 120 seconds.
- the earplug manufacturing method is a raw material preparing step of preparing an earplug raw material containing a urethane resin raw material and a foaming agent, and an earplug raw material and an inorganic antibacterial agent obtained by going through the raw material preparing step. Obtained by going through the mixing step of mixing and, a molding/curing step of injecting the mixture obtained through the mixing step into a mold to mold into an earplug shape and curing, and the molding/curing step.
- the step for restoring the shape is the time required for the molded article to be restored to its original shape from the moment when the compression is instantaneously completely released in a state where the molded article is compressed to the limit with a finger. Is characterized in that
- FIG. 1 is a flow chart schematically showing an embodiment of the earplug manufacturing method according to the present invention.
- an earplug satisfying all the following requirements (A) to (D) is exemplified.
- B) The time required to restore the original shape from the instant when the compression is completely released with the finger compressed to the limit is 40 seconds to 120 seconds.
- the “state of being compressed to a substantially limit” means, for example, a state of being a substantially cylindrical shape having a diameter of about 8 mm to 13 mm in a natural state and being compressed to a substantially cylindrical shape having a diameter of about 5 mm to 6 mm.
- An inorganic antibacterial agent is dispersed and contained in an amount of 0.05% by weight to 2% by weight.
- the inorganic antibacterial agent of (C) is a powdery silver type inorganic antibacterial agent specified by the content of Table 1.
- the earplug exemplified as one embodiment exhibits the following advantageous effects (I) and (II).
- I) Due to the above requirements (A) and (B), the wearability to the external auditory meatus and the noise blocking performance are good.
- II) Sufficient antibacterial property is satisfied by the above requirements (C) and (D).
- the earplugs according to one embodiment include those classified into a hanging bell type, a bullet type, a column type, and the like according to their shapes. Further, the earplugs of one embodiment include earplugs of the type that have a grip and are directly inserted into the ear canal, and earplugs of the type called semi-insert that are attached to a headband or the like.
- the earplug manufacturing method of one embodiment includes a raw material preparation step P1, a mixing step P2, a molding/curing step P3, and a demolding step P4.
- the raw material preparation step P1 is a step of preparing an earplug raw material in which a urethane resin raw material, that is, a polyol and a polyisocyanate as main components, and a foaming agent, a foam stabilizer, a catalyst, a colorant, etc., are mixed as auxiliary components.
- a urethane resin raw material that is, a polyol and a polyisocyanate as main components
- a foaming agent, a foam stabilizer, a catalyst, a colorant, etc. are mixed as auxiliary components.
- the amount of the polyol and polyisocyanate as the urethane resin raw material, the content of the subcomponent such as the foaming agent in the earplug raw material, and the like are 40 seconds to 120 minutes for the shape restoration of the earplug which is the finally obtained molded product. Adjusted to be seconds. If the shape restoration time is less than 40 seconds, there is a high possibility that the earplug will be restored to its original shape between the compression of the earplug and the insertion into the ear canal. It becomes difficult to attach to. This problem is remarkable in the case of a person who has not been trained to wear earplugs.
- the time required for shape restoration exceeds 120 seconds, the time required for the earplug to seal the ear canal after insertion of the earplug into the ear canal is long even for a person who has not received education on wearing earplugs. It will be too much. As described above, when the time required for shape restoration deviates from the range of 40 seconds to 120 seconds, it becomes difficult to realize a user-friendly earplug capable of rapidly exhibiting the original sound insulation performance.
- the mixing step P2 is a step of mixing the earplug raw material obtained through the raw material preparation step P1 and the inorganic antibacterial agent.
- the inorganic antibacterial agent is a powdery silver-based inorganic antibacterial agent specified in Table 1. That is, the inorganic antibacterial agent is composed of silicon dioxide (SiO 2 ), boron oxide (B 2 O 3 ), sodium oxide (Na 2 O) and silver oxide (Ag 2 O), and has an average particle size of 10 ⁇ m and a specific gravity. Is a silver-based inorganic antibacterial agent with a pH of 2.5 and a 1% suspension pH of 8.8.
- the amount of the inorganic antibacterial agent based on the total amount of the earplug raw material and the inorganic antibacterial agent is 0.05% to 2% by weight. If the amount of the inorganic antibacterial agent is less than 0.05% by weight, it will be difficult to realize earplugs having sufficient antibacterial properties. When the amount of the inorganic antibacterial agent exceeds 2% by weight, earplugs having desired wearability and sound insulation performance cannot be obtained, and discoloration of the earplugs due to the inclusion of the antibacterial agent easily occurs. This leads to a reduction in the value of earplugs as a product.
- the molding/curing step P3 is a step of injecting the mixture obtained through the mixing step P2 into a mold to mold it into an earplug shape and cure it. This step is carried out in a temperature range and for a time depending on the composition of the earplug raw material and the inorganic antibacterial agent.
- the temperature range and time are selected as values that can be molded into an earplug having a desired earplug shape and sound insulation performance.
- the demolding step P4 is a step of demolding the molded product obtained by passing through the molding/curing step P3.
- earplugs satisfying all the above requirements (A) to (D) are manufactured.
- the free foam density of the manufactured earplugs is a value suitable for earplug wearing and noise blocking characteristics.
- the range of the free foam density is, for example, 0.13 g/cc to 0.14 g/cc.
- Tables 2 and 3 show the antibacterial activity values when an inorganic antibacterial agent is added to the earplug raw material in an amount of 0.05% by weight to 0.3% by weight.
- Table 2 shows the test results for S. aureus.
- Table 3 shows the test results for E. coli.
- the addition rate of the inorganic antibacterial agent is 0.05% by weight or more, the antibacterial activity value becomes 2.2 or more and the antibacterial effect is obtained.
- a higher antibacterial effect was confirmed against Escherichia coli.
- the antibacterial effect increases in proportion to the addition rate of the inorganic antibacterial agent.
Abstract
Provided is a sponge-type earplug produced from polyurethane having antimicrobial properties. The earplug is produced through a raw material preparation step P1 of preparing an earplug raw material containing a urethane resin raw material and a foaming agent; a mixing step P2 of mixing the earplug raw material and an inorganic antimicrobial; a molding and curing step P3 of injecting the mixture into a mold, molding into an earplug shape, and curing the result; and a demolding step P4 of demolding the ear plug, which is the molded article, from the mold. The raw material preparation step P1 is a step for preparing the earplug raw material in such a manner that the required time for shape recovery for the earplug is 40 to 120 seconds. The required time for shape recovery is the time it takes for the earplug to return to its original shape from a state of being compressed substantially to the limit by fingers, after the compression is instantly completely released.
Description
本発明は、抗菌性能を有する防音用の耳栓及びその製造方法に関する。
The present invention relates to a soundproof earplug having antibacterial performance and a method for manufacturing the earplug.
大音量の騒音は人の聴覚機能の低下を招く原因の一つである。また、騒音が原因となって、平衡障害、精神不安定、思考力・記憶力の低下といった症状が生じることもある。そのため、所定の騒音レベルを超える作業場においては、防音保護具を使用することが求められる。防音保護具として、一般に、耳栓が多く使用される。耳栓には、フランジタイプの固形耳栓とスポンジタイプの耳栓とがある。スポンジタイプの耳栓には、ウレタンフォーム製のものとＰＶＣ（Ｐｏｌｙｖｉｎｙｌ Ｃｈｌｏｒｉｄｅ）製のもとがある。
━ Loud noise is one of the causes of deterioration of human hearing function. Moreover, noise may cause symptoms such as imbalance, mental instability, and deterioration of thinking and memory. Therefore, it is required to use soundproof protective equipment in the workplace where the noise level exceeds a predetermined level. In general, earplugs are often used as soundproof protectors. There are two types of earplugs: a flange type solid earplug and a sponge type earplug. There are two types of sponge type earplugs, one made of urethane foam and the other made of PVC (Polyvinyl Chloride).
エラストマーやシリコーンなどからなるフランジタイプの耳栓やＰＶＣ製のスポンジタイプの耳栓は、吸水性が低いため洗って再使用できる。また、フランジタイプの耳栓やＰＶＣ製のスポンジタイプの耳栓には抗菌性を有するものがある（特許文献１参照）。
Flange type earplugs made of elastomer or silicone and PVC sponge type earplugs have low water absorption and can be washed and reused. Some flange type earplugs and PVC sponge type earplugs have antibacterial properties (see Patent Document 1).
これに対し、弾性発泡ポリマ又はウレタンからなるスポンジタイプの耳栓は、水分を含むと乾燥し難いため、洗って再利用することはできないとされている。特に、ウレタンからなるスポンジタイプの耳栓は、水分を含むと加水分解反応を起こして短時間で劣化してしまうため洗浄不可能である。
On the other hand, it is said that sponge type earplugs made of elastic foam polymer or urethane cannot be washed and reused because they are difficult to dry when they contain water. In particular, sponge type earplugs made of urethane cannot be washed because they contain water and cause a hydrolysis reaction to deteriorate in a short time.
このように、フランジタイプの耳栓やＰＶＣ製のスポンジタイプの耳栓は、洗って再利用できるため衛生的な使用が可能であり、この点においては、弾性発泡ポリマ又はウレタンからなるスポンジタイプの耳栓よりも優れているといえる。
As described above, the flange type earplugs and the PVC sponge type earplugs can be washed and reused and thus can be used hygienically. In this respect, the sponge type earplugs made of an elastic foamed polymer or urethane can be used. It is better than earplugs.
一方、スポンジタイプの耳栓は、柔軟性と形状復元性とを併せ持つため、外耳道を隙間なく塞ぐことができ、フランジタイプの耳栓よりも高い遮音性を発揮し得る。このため、騒音から耳を保護するという耳栓本来の機能において、スポンジタイプの耳栓はフランジタイプの耳栓よりも優れているといえる。
On the other hand, since the sponge type earplugs have both flexibility and shape restoring ability, they can block the external auditory meatus without any gap, and can exhibit higher sound insulation than the flange type earplugs. Therefore, it can be said that the sponge type earplug is superior to the flange type earplug in the original function of protecting the ear from noise.
しかし、ウレタンフォーム製のスポンジタイプの耳栓は、指で圧縮してから外耳道に挿入する必要があるため、指を介してばい菌が付着しやすく、しかも、洗うことができないため、ばい菌が残存し大量に繁殖しやすい。それにもかかわらず、抗菌性を有するウレタンフォーム製のスポンジタイプの耳栓は実現されていなかった。
However, since urethane foam sponge type earplugs must be compressed with your fingers and inserted into the ear canal, germs easily adhere through your fingers and cannot be washed, leaving germs remaining. Easy to breed in large quantities. Nevertheless, sponge type earplugs made of urethane foam having antibacterial properties have not been realized.
本発明は、抗菌性を有するウレタンフォーム製のスポンジタイプの耳栓及びその製造方法を提供することを目的とする。
An object of the present invention is to provide a sponge type earplug made of urethane foam having antibacterial properties and a manufacturing method thereof.
本発明に係る耳栓は、指で圧縮しながら外耳道に挿入される耳栓であって、無機系抗菌剤を分散含有した軟質ウレタンフォームからなり、且つ、指で略限界まで圧縮した状態でその圧縮を瞬時に完全に解除した時点から元の形状に復元するまでの所要時間が４０秒～１２０秒であることを特徴とする。
The earplug according to the present invention is an earplug that is inserted into the external auditory meatus while being compressed by a finger, and is made of a soft urethane foam containing an inorganic antibacterial agent dispersed therein, and is compressed to the limit with a finger. It is characterized in that the time required from the instant when the compression is completely released to the restoration to the original shape is 40 seconds to 120 seconds.
本発明に係る耳栓の製造方法は、ウレタン樹脂原料と発泡剤とを含む耳栓原料を調製する原料調製工程と、前記原料調製工程を経ることにより得られた耳栓原料と無機系抗菌剤とを混合する混合工程と、前記混合工程を経ることにより得られた混合物を金型に注入して耳栓形状に成型し硬化させる成型・硬化工程と、前記成型・硬化工程を経ることにより得られた成型物を前記金型から脱型する脱型工程と、を含み、前記原料調製工程は、前記成型物の形状復元所要時間が４０秒～１２０秒になるように前記耳栓原料を調製する工程であり、前記形状復元所要時間は、前記成型物を指で略限界まで圧縮した状態でその圧縮を瞬時に完全に解除した時点から前記成型物が元の形状に復元するまでの所要時間であることを特徴とする。
The earplug manufacturing method according to the present invention is a raw material preparing step of preparing an earplug raw material containing a urethane resin raw material and a foaming agent, and an earplug raw material and an inorganic antibacterial agent obtained by going through the raw material preparing step. Obtained by going through the mixing step of mixing and, a molding/curing step of injecting the mixture obtained through the mixing step into a mold to mold into an earplug shape and curing, and the molding/curing step. A demolding step of demolding the molded product obtained from the mold, wherein the raw material preparing step prepares the earplug raw material so that the time required to restore the shape of the molded product is 40 seconds to 120 seconds. The step for restoring the shape is the time required for the molded article to be restored to its original shape from the moment when the compression is instantaneously completely released in a state where the molded article is compressed to the limit with a finger. Is characterized in that
本発明によれば、抗菌性を有するウレタンフォーム製のスポンジタイプの耳栓及びその製造方法を提供することができる。
According to the present invention, it is possible to provide a sponge type earplug made of urethane foam having antibacterial properties and a method for manufacturing the earplug.
以下、本発明の一実施形態について詳細に説明する。
Hereinafter, an embodiment of the present invention will be described in detail.
［耳栓の構成］
まず、本発明に係る耳栓の一実施形態について説明する。
ここでは、一実施形態として、下記要件（Ａ）～（Ｄ）をすべて満たす耳栓を例示する。
（Ａ） 指で圧縮しながら外耳道に挿入される軟質ウレタンフォームからなる耳栓である。
（Ｂ） 指で略限界まで圧縮した状態でその圧縮を瞬時に完全に解除した時点から元の形状に復元するまでの所要時間（形状復元所要時間）が４０秒～１２０秒である。「略限界まで圧縮した状態」とは、例えば、自然状態で直径８ｍｍ～１３ｍｍ程度の略円柱形であったものを直径５ｍｍ～６ｍｍ程度の略円柱形になるように圧縮した状態をいう。
（Ｃ） 無機系抗菌剤を０．０５重量%～２重量%分散含有している。
（Ｄ） （Ｃ）の無機系抗菌剤は表１の内容で特定される粉末状の銀系無機抗菌剤である。 [Structure of earplugs]
First, an embodiment of the earplug according to the present invention will be described.
Here, as one embodiment, an earplug satisfying all the following requirements (A) to (D) is exemplified.
(A) An earplug made of soft urethane foam that is inserted into the ear canal while being compressed with a finger.
(B) The time required to restore the original shape from the instant when the compression is completely released with the finger compressed to the limit is 40 seconds to 120 seconds. The “state of being compressed to a substantially limit” means, for example, a state of being a substantially cylindrical shape having a diameter of about 8 mm to 13 mm in a natural state and being compressed to a substantially cylindrical shape having a diameter of about 5 mm to 6 mm.
(C) An inorganic antibacterial agent is dispersed and contained in an amount of 0.05% by weight to 2% by weight.
(D) The inorganic antibacterial agent of (C) is a powdery silver type inorganic antibacterial agent specified by the content of Table 1.
まず、本発明に係る耳栓の一実施形態について説明する。
ここでは、一実施形態として、下記要件（Ａ）～（Ｄ）をすべて満たす耳栓を例示する。
（Ａ） 指で圧縮しながら外耳道に挿入される軟質ウレタンフォームからなる耳栓である。
（Ｂ） 指で略限界まで圧縮した状態でその圧縮を瞬時に完全に解除した時点から元の形状に復元するまでの所要時間（形状復元所要時間）が４０秒～１２０秒である。「略限界まで圧縮した状態」とは、例えば、自然状態で直径８ｍｍ～１３ｍｍ程度の略円柱形であったものを直径５ｍｍ～６ｍｍ程度の略円柱形になるように圧縮した状態をいう。
（Ｃ） 無機系抗菌剤を０．０５重量%～２重量%分散含有している。
（Ｄ） （Ｃ）の無機系抗菌剤は表１の内容で特定される粉末状の銀系無機抗菌剤である。 [Structure of earplugs]
First, an embodiment of the earplug according to the present invention will be described.
Here, as one embodiment, an earplug satisfying all the following requirements (A) to (D) is exemplified.
(A) An earplug made of soft urethane foam that is inserted into the ear canal while being compressed with a finger.
(B) The time required to restore the original shape from the instant when the compression is completely released with the finger compressed to the limit is 40 seconds to 120 seconds. The “state of being compressed to a substantially limit” means, for example, a state of being a substantially cylindrical shape having a diameter of about 8 mm to 13 mm in a natural state and being compressed to a substantially cylindrical shape having a diameter of about 5 mm to 6 mm.
(C) An inorganic antibacterial agent is dispersed and contained in an amount of 0.05% by weight to 2% by weight.
(D) The inorganic antibacterial agent of (C) is a powdery silver type inorganic antibacterial agent specified by the content of Table 1.
上記要件（Ａ）～（Ｄ）をすべて満たすことにより、一実施形態として例示された耳栓は、下記の有利な効果（Ｉ）及び（ＩＩ）を奏する。
（Ｉ） 上記要件（Ａ）及び（Ｂ）により、外耳道への装着性及び騷音遮断性が良好である。
（ＩＩ） 上記要件（Ｃ）及び（Ｄ）により、十分な抗菌性を有する。 By satisfying all of the above requirements (A) to (D), the earplug exemplified as one embodiment exhibits the following advantageous effects (I) and (II).
(I) Due to the above requirements (A) and (B), the wearability to the external auditory meatus and the noise blocking performance are good.
(II) Sufficient antibacterial property is satisfied by the above requirements (C) and (D).
（Ｉ） 上記要件（Ａ）及び（Ｂ）により、外耳道への装着性及び騷音遮断性が良好である。
（ＩＩ） 上記要件（Ｃ）及び（Ｄ）により、十分な抗菌性を有する。 By satisfying all of the above requirements (A) to (D), the earplug exemplified as one embodiment exhibits the following advantageous effects (I) and (II).
(I) Due to the above requirements (A) and (B), the wearability to the external auditory meatus and the noise blocking performance are good.
(II) Sufficient antibacterial property is satisfied by the above requirements (C) and (D).
一実施形態の耳栓には、その形状によって吊り鐘型、弾丸型、円柱型、等に分類されるものが含まれる。また、一実施形態の耳栓には、グリップが付いていてそのまま外耳道に挿入されるタイプの耳栓、ヘッドバンド等に取り付けられるセミインサートと呼ばれるタイプの耳栓が含まれる。
The earplugs according to one embodiment include those classified into a hanging bell type, a bullet type, a column type, and the like according to their shapes. Further, the earplugs of one embodiment include earplugs of the type that have a grip and are directly inserted into the ear canal, and earplugs of the type called semi-insert that are attached to a headband or the like.
［耳栓の製造方法］
次に、本発明に係る耳栓の製造方法の一実施形態について説明する。
図１に示すように、一実施形態の耳栓の製造方法は、原料調製工程Ｐ１と、混合工程Ｐ２と、成型・硬化工程Ｐ３と、脱型工程Ｐ４と、を含む。 [Method for manufacturing earplugs]
Next, an embodiment of the earplug manufacturing method according to the present invention will be described.
As shown in FIG. 1, the earplug manufacturing method of one embodiment includes a raw material preparation step P1, a mixing step P2, a molding/curing step P3, and a demolding step P4.
次に、本発明に係る耳栓の製造方法の一実施形態について説明する。
図１に示すように、一実施形態の耳栓の製造方法は、原料調製工程Ｐ１と、混合工程Ｐ２と、成型・硬化工程Ｐ３と、脱型工程Ｐ４と、を含む。 [Method for manufacturing earplugs]
Next, an embodiment of the earplug manufacturing method according to the present invention will be described.
As shown in FIG. 1, the earplug manufacturing method of one embodiment includes a raw material preparation step P1, a mixing step P2, a molding/curing step P3, and a demolding step P4.
原料調製工程Ｐ１は、ウレタン樹脂原料すなわちポリオール及びポリイソシアネートを主成分とし、これに副成分として発泡剤、整泡剤、触媒、着色剤等を混合した耳栓原料を調製する工程である。
The raw material preparation step P1 is a step of preparing an earplug raw material in which a urethane resin raw material, that is, a polyol and a polyisocyanate as main components, and a foaming agent, a foam stabilizer, a catalyst, a colorant, etc., are mixed as auxiliary components.
ウレタン樹脂原料であるポリオール及びポリイソシアネートの分量、並びに耳栓原料における発泡剤など副成分の含有量、等は、最終的に得られる成型物である耳栓の形状復元所要時間が４０秒～１２０秒になるように調整される。形状復元所要時間が４０秒未満であると、耳栓を圧縮してから外耳道に挿入するまでの間にその耳栓が元の形状に復元してしまう可能性が高くなるため、耳栓を外耳道に装着し難くなる。この問題は、耳栓の装着教育を受けていない人の場合に顕著である。形状復元所要時間が１２０秒を超えると、耳栓の装着教育を受けていない人であっても、耳栓を外耳道に挿入し終えてからその耳栓が外耳道を密閉するまでに要する時間が長くなり過ぎることになる。このように、形状復元所要時間が４０秒～１２０秒の範囲を外れると、本来の遮音性能を迅速に発揮し得る使い勝手の良い耳栓の実現が困難になる。
The amount of the polyol and polyisocyanate as the urethane resin raw material, the content of the subcomponent such as the foaming agent in the earplug raw material, and the like are 40 seconds to 120 minutes for the shape restoration of the earplug which is the finally obtained molded product. Adjusted to be seconds. If the shape restoration time is less than 40 seconds, there is a high possibility that the earplug will be restored to its original shape between the compression of the earplug and the insertion into the ear canal. It becomes difficult to attach to. This problem is remarkable in the case of a person who has not been trained to wear earplugs. If the time required for shape restoration exceeds 120 seconds, the time required for the earplug to seal the ear canal after insertion of the earplug into the ear canal is long even for a person who has not received education on wearing earplugs. It will be too much. As described above, when the time required for shape restoration deviates from the range of 40 seconds to 120 seconds, it becomes difficult to realize a user-friendly earplug capable of rapidly exhibiting the original sound insulation performance.
混合工程Ｐ２は、原料調製工程Ｐ１を経ることにより得られた耳栓原料と無機系抗菌剤とを混合する工程である。無機系抗菌剤は、表１の内容で特定される粉末状の銀系無機抗菌剤である。すなわち、無機系抗菌剤は、二酸化ケイ素（ＳｉＯ２）、酸化ホウ素（Ｂ２Ｏ３）、酸化ナトリウム（Ｎａ２Ｏ）及び酸化銀（Ａｇ２Ｏ）により組成され、平均粒径が１０μｍ、比重が２．５、１％懸濁液のｐHが８．８の銀系無機抗菌剤である。
The mixing step P2 is a step of mixing the earplug raw material obtained through the raw material preparation step P1 and the inorganic antibacterial agent. The inorganic antibacterial agent is a powdery silver-based inorganic antibacterial agent specified in Table 1. That is, the inorganic antibacterial agent is composed of silicon dioxide (SiO 2 ), boron oxide (B 2 O 3 ), sodium oxide (Na 2 O) and silver oxide (Ag 2 O), and has an average particle size of 10 μm and a specific gravity. Is a silver-based inorganic antibacterial agent with a pH of 2.5 and a 1% suspension pH of 8.8.
耳栓原料及び無機系抗菌剤の総量に対する無機系抗菌剤の分量は０．０５重量%～２重量%とする。無機系抗菌剤の分量が０．０５重量%未満であると、十分な抗菌性を有する耳栓の実現が困難になる。無機系抗菌剤の分量が２重量%を超えると、所望の装着性及び遮音性能を有する耳栓が得られなくなるとともに、抗菌剤を含有していることによる耳栓の変色が生じやすくなるため、耳栓の商品としての価値の低下を招くことになる。
The amount of the inorganic antibacterial agent based on the total amount of the earplug raw material and the inorganic antibacterial agent is 0.05% to 2% by weight. If the amount of the inorganic antibacterial agent is less than 0.05% by weight, it will be difficult to realize earplugs having sufficient antibacterial properties. When the amount of the inorganic antibacterial agent exceeds 2% by weight, earplugs having desired wearability and sound insulation performance cannot be obtained, and discoloration of the earplugs due to the inclusion of the antibacterial agent easily occurs. This leads to a reduction in the value of earplugs as a product.
成型・硬化工程Ｐ３は、混合工程Ｐ２を経ることにより得られた混合物を金型に注入して耳栓形状に成型し硬化させる工程である。この工程は、耳栓原料及び無機系抗菌剤の組成に応じた温度範囲及び時間で実施される。当該温度範囲及び時間は、所望の耳栓形状及び遮音性能を有する耳栓に成型可能な値に選定される。
The molding/curing step P3 is a step of injecting the mixture obtained through the mixing step P2 into a mold to mold it into an earplug shape and cure it. This step is carried out in a temperature range and for a time depending on the composition of the earplug raw material and the inorganic antibacterial agent. The temperature range and time are selected as values that can be molded into an earplug having a desired earplug shape and sound insulation performance.
脱型工程Ｐ４は、成型・硬化工程Ｐ３を経ることにより得られた成型物を金型から脱型する工程である。
The demolding step P4 is a step of demolding the molded product obtained by passing through the molding/curing step P3.
上記の製造方法により、上記要件（Ａ）～（Ｄ）をすべて満たす耳栓が製造される。製造される耳栓の自由発泡密度は耳栓着用及び騷音遮断特性に適合した値となる。当該自由発泡密度の範囲は、例えば０．１３ｇ／ｃｃ～０．１４ｇ／ｃｃである。
By the above manufacturing method, earplugs satisfying all the above requirements (A) to (D) are manufactured. The free foam density of the manufactured earplugs is a value suitable for earplug wearing and noise blocking characteristics. The range of the free foam density is, for example, 0.13 g/cc to 0.14 g/cc.
［耳栓の抗菌性］
次に、一実施形態として例示された耳栓の抗菌性に関する試験結果について説明する。
無機系抗菌剤には、抗菌化研社製の銀系無機抗菌剤（ＢＩＯＳＵＲＥ ＳＧＩ）を使用した。試験は、ＪＩＳＬ１９０２に準拠する方法で実施した。
[Antibacterial properties of earplugs]
Next, the test results regarding the antibacterial properties of the earplugs exemplified as one embodiment will be described.
As the inorganic antibacterial agent, a silver type inorganic antibacterial agent (BIOSURE SGI) manufactured by Antibacterial Chemistry Co., Ltd. was used. The test was implemented by the method based on JISL1902.
次に、一実施形態として例示された耳栓の抗菌性に関する試験結果について説明する。
無機系抗菌剤には、抗菌化研社製の銀系無機抗菌剤（ＢＩＯＳＵＲＥ ＳＧＩ）を使用した。試験は、ＪＩＳＬ１９０２に準拠する方法で実施した。
Next, the test results regarding the antibacterial properties of the earplugs exemplified as one embodiment will be described.
As the inorganic antibacterial agent, a silver type inorganic antibacterial agent (BIOSURE SGI) manufactured by Antibacterial Chemistry Co., Ltd. was used. The test was implemented by the method based on JISL1902.
表２及び表３は、耳栓原料に無機系抗菌剤が０．０５重量％～０．３重量％添加されたときの抗菌活性値を示すものである。表２は黄色ブドウ球菌に対する試験結果を示している。表３は大腸菌に対する試験結果を示している。
Tables 2 and 3 show the antibacterial activity values when an inorganic antibacterial agent is added to the earplug raw material in an amount of 0.05% by weight to 0.3% by weight. Table 2 shows the test results for S. aureus. Table 3 shows the test results for E. coli.
黄色ブドウ球菌に対しては、無機系抗菌剤の添加率が０．０５重量％以上の場合に、抗菌活性値が２．２以上となり抗菌効果があることが確かめられた。大腸菌に対しては、さらに高い抗菌効果が確かめられた。また、無機系抗菌剤の添加率に略比例して抗菌効果が高くなることが確かめられた。
For Staphylococcus aureus, it was confirmed that when the addition rate of the inorganic antibacterial agent is 0.05% by weight or more, the antibacterial activity value becomes 2.2 or more and the antibacterial effect is obtained. A higher antibacterial effect was confirmed against Escherichia coli. In addition, it was confirmed that the antibacterial effect increases in proportion to the addition rate of the inorganic antibacterial agent.
以上説明したように、本実施形態によれば、抗菌性を有するウレタンフォーム製のスポンジタイプの耳栓及びその製造方法を実現することができる。
As described above, according to this embodiment, it is possible to realize a sponge type earplug made of urethane foam having antibacterial properties and a manufacturing method thereof.
Ｐ１…原料調製工程、Ｐ２…混合工程、Ｐ３…成型・硬化工程、Ｐ４…脱型工程。
P1... raw material preparation process, P2... mixing process, P3... molding/curing process, P4... demolding process.
Claims (6)
- 指で圧縮しながら外耳道に挿入される防音用の耳栓であって、無機系抗菌剤を分散含有した軟質ウレタンフォームからなり、且つ、指で略限界まで圧縮した状態でその圧縮を瞬時に完全に解除した時点から元の形状に復元するまでの所要時間が４０秒～１２０秒であることを特徴とする耳栓。 A soundproofing earplug that is inserted into the ear canal while being compressed by a finger.It is made of soft urethane foam containing an inorganic antibacterial agent dispersed and is completely compressed instantaneously when compressed to the limit with the finger. An earplug characterized in that the time required from the time of release to the time of restoration to the original shape is 40 seconds to 120 seconds.
- 前記無機系抗菌剤は、二酸化ケイ素、酸化ホウ素、酸化ナトリウム及び酸化銀により組成され、粒径が１０μｍ、比重が２．５、１％懸濁液のｐHが８．８の銀系無機抗菌剤である、請求項１記載の耳栓。 The inorganic antibacterial agent is composed of silicon dioxide, boron oxide, sodium oxide and silver oxide, and has a particle size of 10 μm, a specific gravity of 2.5, and a 1% suspension pH of 8.8. The earplug according to claim 1, which is
- 前記無機系抗菌剤を０．０５重量%～２重量%含んでいる、請求項２記載の耳栓。 The earplug according to claim 2, wherein the inorganic antibacterial agent is contained in an amount of 0.05% to 2% by weight.
- ウレタン樹脂原料と発泡剤とを含む耳栓原料を調製する原料調製工程と、
前記原料調製工程を経ることにより得られた耳栓原料と無機系抗菌剤とを混合する混合工程と、
前記混合工程を経ることにより得られた混合物を金型に注入して耳栓形状に成型し硬化させる成型・硬化工程と、
前記成型・硬化工程を経ることにより得られた成型物を前記金型から脱型する脱型工程と、を含み、
前記原料調製工程は、前記成型物の形状復元所要時間が４０秒～１２０秒になるように前記耳栓原料を調製する工程であり、
前記形状復元所要時間は、前記成型物を指で略限界まで圧縮した状態でその圧縮を瞬時に完全に解除した時点から前記成型物が元の形状に復元するまでの所要時間であることを特徴とする耳栓の製造方法。 A raw material preparation step of preparing an earplug raw material containing a urethane resin raw material and a foaming agent,
A mixing step of mixing the earplug raw material and the inorganic antibacterial agent obtained by going through the raw material preparing step,
A molding/curing step of injecting the mixture obtained by going through the mixing step into a mold to mold it into an earplug shape and cure it,
A demolding step of demolding the molded product obtained by going through the molding/curing step,
The raw material preparing step is a step of preparing the earplug raw material so that the time required for restoring the shape of the molded product is 40 seconds to 120 seconds,
The shape restoration required time is a time required from the instant when the compression is completely released in a state where the molded product is compressed to the limit with a finger until the molded product is restored to its original shape. And a method for manufacturing earplugs. - 前記混合工程において、前記無機系抗菌剤は、二酸化ケイ素、酸化ホウ素、酸化ナトリウム及び酸化銀により組成され、粒径が１０μｍ、比重が２．５、１％懸濁液のｐHが８．８の銀系無機抗菌剤である、請求項４記載の耳栓の製造方法。 In the mixing step, the inorganic antibacterial agent is composed of silicon dioxide, boron oxide, sodium oxide and silver oxide, and has a particle size of 10 μm, a specific gravity of 2.5, and a pH of a 1% suspension having a pH of 8.8. The method for producing earplugs according to claim 4, which is a silver-based inorganic antibacterial agent.
- 前記混合工程において、混合物に対する前記無機系抗菌剤の分量が０．０５重量%～２重量%になるように、耳栓原料と前記無機系抗菌剤とを混合する、請求項５に記載の耳栓の製造方法。 6. The ear according to claim 5, wherein in the mixing step, the earplug raw material and the inorganic antibacterial agent are mixed so that the amount of the inorganic antibacterial agent with respect to the mixture is 0.05% to 2% by weight. Method of manufacturing stopper.
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