WO2022177026A1

WO2022177026A1 - Flexible polyether urethane foam and urethane mask

Info

Publication number: WO2022177026A1
Application number: PCT/JP2022/007340
Authority: WO
Inventors: 拓朗北村; 良幸岩崎
Original assignee: 株式会社イノアックコーポレーション
Priority date: 2021-02-22
Filing date: 2022-02-22
Publication date: 2022-08-25
Also published as: JPWO2022177026A1

Abstract

The purpose of the present invention is to provide flexible polyether urethane foam which is heat-sealable, is less apt to hydrolyze, is less apt to be deteriorated by laundering, etc., has high durability, and is suitable for urethane masks.　The flexible polyether urethane foam is one formed from a composition of starting materials for polyurethane foam production. The flexible polyether urethane foam has an elongation (in accordance with JIS K6400-5) of 100% or higher and a density (in accordance with JIS K7222) of 10-150 kg/m³ and is heat-sealable.

Description

Soft polyether urethane foam and urethane mask

The present invention relates to heat-sealable soft polyether urethane foam and urethane masks.

A urethane mask has been proposed that covers part of the face, including the mouth and nostrils, and is made of soft urethane foam.

Flexible urethane foams include flexible polyether urethane foams and flexible polyester urethane foams.
Flexible polyether urethane foam has poor heat-sealing properties and is difficult to hydrolyze.
Flexible polyester foams have excellent heat-sealing properties and are susceptible to hydrolysis.
Heat-sealing is a type of thermal fusion bonding, and is a method of bonding (adhering) overlapping soft urethane foams together by heat-pressing them with a hot plate or the like.

As a conventional urethane mask, there is one in which the left and right halves of the mask are formed of soft polyester urethane foam, respectively, and the left and right halves of the mask are joined and integrated by heat sealing at the center side (Patent Document 1).
Soft polyester urethane foam used for urethane masks is subjected to film removal (cell film removal) treatment to ensure air permeability.

JP 2015-3275 A

However, since soft polyester urethane foam is easily hydrolyzed, it is easily deteriorated by washing and the like, and has a problem of poor durability.
In addition, there is a problem that the film-removing treatment on the soft polyester urethane foam increases the cost. Furthermore, there is a problem that an odor remains in the soft polyester urethane foam depending on the film removal treatment.

Although conventional flexible polyether urethane foam is difficult to hydrolyze, it is not suitable for applications that require heat sealing because it is inferior in heat sealing properties.

The present invention has been made in view of the above points, and provides a flexible polyether urethane foam that has heat sealability, is resistant to hydrolysis, is less likely to deteriorate due to washing and has high durability, and its flexible polyether urethane foam. To provide a urethane mask formed by

The first means is a soft polyether urethane characterized by having an elongation (JIS K6400-5 compliant) of 100% or more, a density (JIS K7222 compliant) of 10 to 150 kg/m3 ^, and heat sealability. is a form.

The second means is a urethane mask comprising the flexible polyether urethane foam of the first means.

In the first means and the second means, the flexible polyether urethane foam of the present invention may be a laminate in which at least one of a fiber layer, a flexible polyurethane foam and a fabric layer is laminated.
For example, as a first modification, a first substrate that is the flexible polyether urethane foam of the present invention, a fiber layer (intermediate fiber layer) laminated on one side of the first substrate or the second substrate, and the A fiber layer (intermediate fiber layer) and a second substrate that is a flexible polyurethane foam laminated (first substrate/fiber layer/second substrate).
A second variant includes a fabric layer as the second substrate.
As a third modification, a fiber layer is laminated on one side of the flexible polyether urethane foam of the present invention. In relation to the first variant or the second variant, this third variant is the absence of the second substrate.
A fourth variation is the flexible polyether urethane foam of the present invention laminated on one side with a flexible polyurethane foam or fabric layer.
The fibrous layer is preferably composed of nanofibers. As the flexible polyurethane foam, a flexible polyurethane foam having an open-cell structure is preferred.
Heat-sealing of a laminate in which at least one of a fiber layer, a flexible polyurethane foam and a cloth layer is laminated on one side of the flexible polyether urethane foam of the present invention is performed, for example, on a planned joining portion of the flexible polyether urethane foam of the present invention. can be done in a stacked state. Moreover, when the second base material has heat-sealing properties, the second base material side may be overlapped and joined, or the first base material and the second base material may be joined.

Since the flexible polyether urethane foam of the present invention has heat-sealing properties, it can be joined by heat-sealing like polyester urethane foam, and is suitable for applications requiring joining.
Furthermore, the polyether urethane foam of the present invention has an elongation (according to JIS K6400-5) of 100% or more and a density (according to JIS K7222) of 10 to 150 kg/m ³ , and is suitable as a member of a urethane mask. Suitable for urethane masks that require heat sealing.
Furthermore, since the flexible polyether urethane foam of the present invention is less susceptible to hydrolysis than polyester urethane foam, it is less likely to be deteriorated by washing and has high durability, so that it can be used for a urethane mask and repeatedly washed.

It is a perspective view showing a mask of one embodiment of the present invention. FIG. 10 is a perspective view showing a partially cutaway laminate of Modified Mode 1 of the present invention. 1 is a first table showing the composition, physical properties, etc. of Comparative Examples and Examples. Fig. 2 is a second table showing formulations, physical properties, etc. of each example.

An embodiment of the flexible polyether urethane foam of the present invention will be described below.

The flexible polyether urethane foam of the present invention has an elongation (according to JIS K6400-5) of 100% or more, preferably 200% or more, and more preferably 300% or more. There is no particular upper limit. Practically, it is preferable if it is 700% or less. When the elongation is 100% or more, for example, when used as a mask, it can be easily adhered to the face and can reduce the oppressive feeling.

The flexible polyether urethane foam of the present invention has a density (according to JIS K7222) of 10 to 150 kg/m ³ , preferably 20 to 130 kg/m ³ , more preferably 25 to 115 kg/m ³ . It is preferably 30 to 100 kg/m ³ . If the density is low, the strength of the flexible polyether urethane foam may be lowered. On the other hand, when the density is high, elongation of the flexible polyether urethane foam may be deteriorated.

The flexible polyether urethane foam of the present invention has heat sealability. The heat-sealing property of the flexible polyether urethane foam of the present invention is 100 kPa or more, preferably 200 kPa or more, more preferably 500 kPa or more as a result of the heat seal strength test shown below.
In the heat seal strength test, two test pieces each having a length of 100 mm, a width of 30 mm, and a thickness of 10 mm were superimposed, and a range of 20 mm from one end was sandwiched between hot plates of 180 ° C., and the pressure was 1.3 megapascals (MPa) for 30 minutes. After heat-sealing by applying pressure for 2 seconds, the other end sides of the two test pieces are opened 180 degrees and pulled in opposite directions at a tensile speed of 500 mm / min, and the strength at which the two test pieces peel is the heat seal strength. do.

The flexible polyether urethane foam of the present invention has air permeability (in accordance with JIS L1096A method) of preferably 5 cm ³ /cm ² /sec or more, more preferably 10 cm ³ /cm, from the viewpoint of suffocation when wearing a mask. ² /sec or more, more preferably 15 cm ³ /cm ² /sec or more. Since the flexible polyether urethane foam of the present invention has good air permeability, it can reduce the feeling of suffocation when used as a mask.

The flexible polyether urethane foam of the present invention is foamed from a composition of raw materials for producing polyurethane foam containing a polyol, a polyisocyanate, a catalyst and a blowing agent.

Slab foaming is preferable for the foaming of the flexible polyether urethane foam of the present invention. Slab foaming is a method in which a composition of raw materials for producing polyurethane foam is mixed, discharged onto a belt conveyor, and foamed at room temperature under atmospheric pressure. The foam-formed flexible polyether urethane foam is made into a sheet having a predetermined thickness by squeezing. After that, the sheet is punched into a predetermined shape, and the predetermined portions of the predetermined shape are joined by heat sealing (melt adhesion) to form a predetermined article.

One embodiment of forming a mask from the flexible polyether urethane foam of the present invention is shown in FIG.
A punched body 10A shown in (1-A) of FIG. 1 is formed by punching a sheet of flexible polyether urethane foam of the present invention into a mask shape. Reference numeral 13 is an ear hook opening.
The punched body 10A is folded left and right at a central portion 15, which is the center of the left and right of the face, and heat-sealed along the central portion 15 with a predetermined width to form the mask 10, as shown in FIG. 1(1-B). It is formed. A hatched portion indicated by reference numeral 16 is a heat-sealed portion.
The heat-sealed portion 16 of the central portion 15 is heat-sealed so that when the mask 10 is used with the mask 10 spread laterally, the central portion 15 bulges outward to form a three-dimensional shape corresponding to the swelling of the nose. be done. In addition, the mask formed from the flexible polyether urethane foam of the present invention is not limited to the form of the mask shown in FIG.
A heat-sealed portion that is wider than necessary may be cut. A heat-sealed portion with a width of 2-5 mm may be cut along the outwardly bulging curved shape. In addition, two mask halves having an opening as an ear hook on one end side and a curved shape portion bulging outward on the other end side are superimposed, and a 2 to 5 mm gap along the curved shape portion is placed. The mask 10 may be formed by heat sealing with a predetermined width. The curved shape portion becomes a mask positioned at the central portion 15 .

The polyol, polyisocyanate, catalyst and blowing agent contained in the composition used for producing the flexible polyether urethane foam of the present invention are explained.
Polyols include polyether polyols. Polyether polyols include both diols and polyether polyols other than diols.

Examples of diols include polyether polyols having 2 functional groups obtained by addition polymerization of alkylene oxides such as ethylene oxide (EO) and propylene oxide (PO) to dihydric alcohols such as propylene glycol and ethylene glycol.
The molecular weight of the diol is preferably 500-6000, more preferably 800-5000, still more preferably 1500-4500. The hydroxyl value (OHV) of the diol is preferably 18-250 mgKOH/g, more preferably 22-140 mgKOH/g, and even more preferably 24-70 mgKOH/g. When the molecular weight or hydroxyl value (OHV) of the diol is within the above range, the heat sealability of the flexible polyether urethane foam becomes better.
The diol is not limited to one type, and multiple types may be used in combination. The amount of the diol compounded is preferably 5 to 80 parts by weight, preferably 10 to 75 parts by weight, further 30 to 75 parts by weight, and 40 to 75 parts by weight based on 100 parts by weight of the polyol, from the viewpoint of elongation and heat sealability. is preferred.

Examples of polyether polyols other than diols include trihydric or higher polyhydric alcohols such as glycerin, trimethylolpropane and pentaerythritol, amines such as ethylenediamine and aromatic diamines, and ethylene oxide (EO) and propylene oxide (PO). Examples thereof include polyether polyols having 3 or more functional groups obtained by addition polymerization of alkylene oxide.
Polyether polyols other than diols preferably have a hydroxyl value (OHV) of 20 to 200 mgKOH/g, a functional group number of 3 to 5, and a molecular weight of 1,000 to 7,000. The hydroxyl value (OHV) of the polyether polyol other than the diol is more preferably 24-150 mgKOH/g, further preferably 28-100 mgKOH/g. The molecular weight of the polyether polyol other than the diol is more preferably 1400-6000, more preferably 1800-5000. Polyether polyols other than diols are not limited to one type, and multiple types may be used in combination.
In addition, the polyol may contain a polymer polyol together with the polyether polyol. By containing the polymer polyol, the heat sealability of the flexible polyether urethane foam can be further improved. From the viewpoint of improving the heat sealability, the polymer polyol is preferably 5 parts by weight or more, more preferably 10 parts by weight or more, and further preferably 20 parts by weight or more in 100 parts by weight of the polyol. The upper limit of the blending amount when blending the polymer polyol is not particularly limited, but from the viewpoint of elongation and air permeability, it is preferably 70 parts by weight or less, more preferably 60 parts by weight or less per 100 parts by weight of the polyol.

Polymer polyols are polyols in which polymer particles generated by radical polymerization (graft polymerization) of monomers such as acrylonitrile and styrene are dispersed in polyether polyols, and those commonly used in the production of flexible polyurethane foams are used. can. The polymer polyol preferably has a hydroxyl value (OHV) of 20-140 mgKOH/g, a functional group number of 3-5, and a molecular weight of 1000-7000. The hydroxyl value (OHV) of the polymer polyol is more preferably 22-70 mgKOH/g, more preferably 24-50 mgKOH/g. The molecular weight of the polymer polyol is more preferably 1800-7000, more preferably 2600-6000.

As polyisocyanates, aliphatic, alicyclic or aromatic polyisocyanates having two or more isocyanate groups, mixtures thereof, and modified polyisocyanates obtained by modifying them can be used. Examples of aliphatic polyisocyanates include hexamethylene diisocyanate, isophorone diisocyanate, and dicyclohexamethane diisocyanate. Examples of aromatic polyisocyanates include toluene diisocyanate (TDI), diphenylmethane diisocyanate (MDI), naphthalene diisocyanate, xyloxy Examples include diisocyanate, polymeric MDI (crude MDI), and the like. In addition, other prepolymers can also be used.

The isocyanate index (INDEX) is 90 or more, preferably 95-125, more preferably 100-120. The isocyanate index is a value obtained by dividing the number of moles of isocyanate groups in isocyanate by the total number of moles of active hydrogen groups such as hydroxyl groups in polyol and multiplying it by 100. Calculated.

As a catalyst, a known urethanization catalyst can be used in combination. For example, amine catalysts such as triethylamine, triethylenediamine, diethanolamine, dimethylaminomorpholine, N-ethylmorpholine and tetramethylguanidine; tin catalysts such as stannus octoate and dibutyltin dilaurate; phenylmercuric propionate and lead octoate. metal catalysts (also called organometallic catalysts) such as amine catalysts and metal catalysts, or both may be used in combination. The amount of amine catalyst is preferably 0.1 to 2 parts by weight with respect to 100 parts by weight of polyol. The amount of metal catalyst is preferably 0 to 0.5 parts by weight.

As the blowing agent, water, CFC alternatives, or hydrocarbons such as pentane can be used alone or in combination. In the case of water, carbon dioxide gas is generated during the reaction between polyol and polyisocyanate, and the carbon dioxide gas causes foaming. The amount of water as a foaming agent is preferably 0.1 to 6 parts by weight, more preferably 0.8 to 5 parts by weight, even more preferably 1.2 to 4 parts by weight, based on 100 parts by weight of the polyol.

The composition may optionally contain other auxiliary agents and additives. For example, foam stabilizers, colorants, antioxidants, antibacterial agents, ultraviolet absorbers, and the like may be blended.
A known foam stabilizer for flexible polyether urethane foam can be used. Examples thereof include silicone-based foam stabilizers, fluorine-containing compound-based foam stabilizers, and known surfactants.
The coloring agent is appropriately blended according to the color required for the flexible polyether urethane foam.

The modified modes will be specifically described below.
・Modified mode 1
The laminate 100 of Modification Mode 1 shown in FIG. made up of the body.

The first base material 110 is the flexible polyether urethane foam of the present invention, and the second base material 210 is an open-cell flexible polyurethane foam (PUR). A flexible polyurethane foam with an open-cell structure has excellent elongation and strength, provides a high open area ratio, and can improve air permeability. good breathability can be ensured. There are ether-based and polyester-based flexible polyurethane foams having an open-cell structure, and polyester-based foams are preferred from the viewpoint of obtaining good elongation.

In addition, as the open-cell flexible polyurethane foam, a film-removed flexible slab polyurethane foam can be used. The film-removed flexible slab polyurethane foam is obtained by subjecting a flexible slab polyurethane foam to a known film-removing treatment to remove the cell film. The film-removing treatment includes a method of removing the cell membranes of the flexible slab polyurethane foam with a solvent, a method of removing the cell membranes by explosion, and the like. Flexible slab polyurethane foam is formed by slab foaming in which a polyurethane foaming raw material is discharged onto a conveyor belt and continuously foamed.

The number of cells (JIS K6400-1) of the open-cell flexible polyurethane foam is preferably 40 to 110/25 mm. When the number of cells is small, the air permeability is increased, but the strength is decreased. Conversely, when the number of cells is increased, the air permeability is decreased, but the strength is increased. The density of the open-celled flexible polyurethane foam (JIS K7222) is preferably 10 to 150 kg/m ³ , more preferably 20 to 125 kg/m ³ , still more preferably 30 to 100 kg/m ³ . When the density is low, the flexibility and lightness are increased, but the strength is decreased. Conversely, when the density is high, the flexibility and lightness are inferior, but the strength is increased.

Also, the thicknesses of the first base material 110 and the second base material 210 may each be in the range of 0.5 to 2.5 mm. More preferably, the thickness of the first base material 110 is 1.3 to 2.5 mm, and the thickness of the second base material 210 is, for example, 0.5 to 2.5 mm, preferably 0.5 to 2.5 mm. 1.5 mm. Furthermore, it is preferable that the thickness of the laminated first base material 110 and the second base material 210 is 4.0 mm or less. If the thicknesses of the first base material 110 and the second base material 210 are too thin, the strength will be lowered, and conversely, if they are too thick, the flexibility and air permeability will be poor. Further, for example, it is preferable to make the thickness of the first substrate 110 on which the intermediate fiber layer 310 is formed on one side larger than the thickness of the second substrate 210 to facilitate the formation of the intermediate fiber layer 310 . When the first base material 110 and the second base material 210 have different thicknesses, the thicker side, for example the first base material 110, is taken as the suction side (outer side), and the thinner side, for example, the second base material. 210 is preferably on the suction side (face side). It is preferable to inhale and remove particulates and the like from the thicker side, eg, the first substrate 110 , and then aspirate from the thinner side, eg, the second substrate 210 , with the nose of the face. Also, the thickness of the first base material 110 may be thinner than that of the second base material 210 .

The intermediate fiber layer 310 is composed of nanofibers and formed on one side of the first base material 110 (the side facing the second base material 210). Formation of nanofibers can be performed by an electrospinning method. At this time, the polymer solution is sprayed directly onto one side of the first base material 110 from a nozzle to form an intermediate fibrous layer 310 of nanofibers in a web shape in a state of being adhered to one side of the first base material 110 . The electrospinning method uses an apparatus consisting of a DC high voltage power source, an infusion pump, a stainless needle syringe, and a metal collector. A polymer solution is injected from the tip nozzle of the needle syringe. The nozzle and the metal collector are oppositely charged, and when the polymer solution is injected from the syringe, the nanofiber fibers are deposited and form a layer on the first substrate 110 placed on the collector.

The material of nanofibers may be any material that can form nanofibers by electrospinning, such as polystyrene, polycarbonate, poly(meth)acrylate, polyvinyl chloride, polyethylene terephthalate, nylon-6,6, and nylon-4,6. Thermoplastic resins such as polyurethane, polyvinyl alcohol, polylactic acid, polycaprolactone, polyethylene glycol, polyethylene-vinyl acetate copolymer, polyethylene-vinyl alcohol copolymer, polyethylene oxide, biodegradable polymers such as collagen, poly Acrylonitrile, polyamide, polyaniline, paraamide, polyvinyl acetate, acetyl cellulose (acetate) and the like can be mentioned. In particular, polyurethane is a particularly preferable material because it has good adhesion to one side of the first base material 110 and has good elongation when nanofibers are formed by spraying. The intermediate fiber layer 310 made of polyurethane nanofibers has good followability to the elongation of the first base material 110 and the second base material 210, and when the laminate 100 is used as a constituent member of the mask, the mask easily fits on the face. .

The diameter of the nanofiber may be a diameter defined as a nanofiber, specifically, 1 nanometer (nm) to 1 micrometer (μm), preferably 10 nanometers (nm) to 0.8 Micrometers (μm), more preferably 10 nanometers (nm) to 0.5 micrometers (μm), and even more preferably 10 nanometers (nm) to 100 nanometers (nm). If the diameter of the nanofibers is too small, viruses may pass through between the nanofibers of the intermediate fiber layer 310. Conversely, if the diameter of the nanofibers is too large, the air permeability of the intermediate fiber layer 310 is reduced. . A more preferred diameter is between 10 nanometers (nm) and 100 nanometers (nm).

Although the basis weight of the intermediate fiber layer 310 made of nanofibers is not limited, it is preferably 0.10 to 0.80 g/m ² . If the weight per unit area is reduced, the space between the nanofibers becomes large, and viruses may pass between the nanofibers. become.

An example of manufacturing the laminate 100 is shown below. Using a long sheet of soft polyether urethane foam for the first base material, BASF thermoplastic polyurethane pellets are dissolved in a solvent on it, and a urethane nanofiber nonwoven fabric (intermediate fiber layer) is formed by electrospinning. Laminated spinning. The fiber diameter is adjusted to a predetermined wire diameter by adjusting the distance between the spinning nozzle and the long sheet, the discharge amount of the nanofiber raw material discharged from the nozzle, and the voltage. An intermediate fiber layer of spun urethane nanofibers is entwined with the elongated sheet of flexible polyether urethane foam. A long sheet is wound on a roll, and the roll is mounted on a flame welding device. A polyester soft urethane foam is used as the second base material, and a roll of the second base material is attached. The laminate 100 is obtained by laminating and conveying the roll of the urethane nanofiber nonwoven fabric (intermediate fiber layer) of the roll of the first base material while irradiating the second base material with a flame. Instead of the flexible polyether urethane foam of the first substrate, a flexible polyurethane foam (soft polyester foam) or a fabric layer may be used as the substrate to form the intermediate fiber layer (nanofiber nonwoven fabric).

・Modification mode 2
As Modified Mode 2, a laminate (not shown) in which the second substrate 210 of Modified Mode 1 is used as a fabric layer will be described.
Modification 2 is a laminate comprising a first substrate of flexible polyether urethane foam of the present invention, an intermediate fiber layer, and a second substrate of cloth layer. The cloth layer is composed of a sheet of cloth made from fibers or threads. The intermediate fiber layer is made of nanofibers similar to the intermediate fiber layer 310 of the first variant.

The fabric layer can be knitted, woven, non-woven, or made of felt. As the fibers constituting the cloth, those composed of chemical fibers such as polyethylene, polypropylene, nylon, urethane, and rayon, and those composed of natural fibers such as cotton and wool can be used. Polyester fibers are preferable from the standpoint of durability because they are less susceptible to discoloration due to ultraviolet rays. If the cloth has a low hygroscopicity, it is convenient for washing and drying the laminate of Modified Mode 2. Also, since cloth made of cotton or rayon has water absorption properties, it may be used when moisture absorption and moisture retention properties are required for the laminate of modified mode 2. The fabric may be an antimicrobial fabric having antimicrobial properties such as by antimicrobial treatment. The cloth may be one in which surface fibers are raised.

As for the cloth, it is possible to use fabrics that are structurally stretchable depending on how they are woven or knitted, or so-called stretch fabrics that are stretchable by using elastic fibers that have stretchability. When the cloth is a woven fabric, stretchable plain weave, twill weave, and jacquard weave are preferred. When the cloth is knitted, warp knitting, weft knitting, and others can be used. Warp knitting includes tricot, double raschel, etc., and weft knitting includes circular knitting and jersey knitting. be done. Knitted fabrics are preferred because they are more stretchable than woven fabrics and non-woven fabrics.

When the cloth is a nonwoven fabric, the web may be formed by any of a dry method, a spunbond method, a meltblown method, an airlaid method, and the like. From the viewpoint of the efficiency of capturing fine foreign matter such as bacteria, a nonwoven fabric by a meltblown method (meltblown nonwoven fabric) or a nonwoven fabric by a spunbond method (spunbond nonwoven fabric) is preferable. In addition, the nonwoven fabric may be formed by a chemical bond method, a thermal bond method, a needle punch method, a hydroentanglement method (spunlace), or the like. A hydroentanglement method and a needle punch method are preferable.

It is preferable that the elongation rate of the cloth (JIS K6400-5:2004 dumbbell No. 2 type) is 50% to 500%. When the fabric has the aforementioned elongation rate, the stretchability of the soft polyether urethane foam, which is the first base material, is less likely to be hindered by the fabric layer, and the stretchability of the laminate can be improved. When the laminate is used as a mask, it stretches appropriately following the movement of the mouth and the like, and can reduce the burden of wearing. In addition, when the ear hooking portion of the mask is formed from the laminate of Modified Mode 2, the ear hooking portion is less likely to break and the burden on the ear can be reduced. If a cloth having a lower elongation rate than the soft polyether urethane foam that is the first base material is used, excessive elongation of the soft polyether urethane foam that is the first base material is suppressed, resulting in plastic deformation of the soft polyether urethane foam. It is preferable because it is possible to prevent this and make the laminate strong.

The air permeability of the fabric is preferably 10 cm ³ /(cm ² ·sec) or more, more preferably 15 cm ³ /(cm ² ·sec) or more, and 20 cm ³ /(cm ² ·sec) or more. More preferably, it is particularly preferably 25 cm ³ /(cm ² ·sec) or more. The air permeability of the cloth is preferably set to 150 cm ³ /(cm ² ·sec) or less in relation to the efficiency of trapping foreign matter. A fabric having air permeability within the above range can ensure good foreign matter trapping efficiency and appropriate air permeability. And when the layered product of Modified Mode 2 is used for a mask, it is possible to ensure adequate breathability, so that it is possible to reduce the feeling of suffocation and to obtain a good wearing feeling. Further, if the fabric has an air permeability within the above range, when the laminate of Modified Mode 2 is used for a mask, good foreign matter collection efficiency can be obtained. As described above, it is preferable to use a fabric having air permeability within the above range, because it is possible to achieve both ease of breathing and good foreign matter collection efficiency. In the laminate of Modified Mode 2, even if the air permeability of the fabric layer is increased, the intermediate fiber layer can ensure the efficiency of collecting foreign matter. may be set.

The thickness of the fabric layer is preferably 0.1 mm to 0.4 mm. As the cloth layer becomes thicker, the efficiency of trapping foreign matter improves, but the pressure loss of the air passing through the cloth layer increases (the air permeability decreases). The thinner the cloth layer, the lower the efficiency of trapping foreign matter, but the lower the pressure loss of the air passing through itself (the higher the air permeability). When the thickness of the fabric layer is within the above-described range, the laminate of Modified Mode 2 can obtain appropriate breathability. Moreover, when the thickness of the fabric layer is within the above range, the bulkiness of the laminate of Modified Mode 2 can be suppressed.

The intermediate fiber layer is preferably made of nano-sized fibers (nanofibers) from the viewpoint of foreign matter collection efficiency. The fiber diameter of the fibers is preferably 10 nm to 800 nm, more preferably 10 nm to 500 nm, even more preferably 10 nm to 100 nm, from the viewpoint of collecting finer foreign matter. When the fiber diameter of the fiber is within the above range, it is possible to secure the trapping of foreign substances and appropriate air permeability. It is preferable that the fibers constituting the intermediate fiber layer have a smaller fiber diameter than the fibers and threads constituting the fabric layer. By doing so, the cloth layer can be made relatively strong, and the fiber layer can collect microscopic foreign substances such as bacteria that are difficult to collect with the cloth layer.

Materials of fibers of the intermediate fiber layer include, for example, thermoplastic fluororesins such as polyvinylidene fluoride, polystyrene, polycarbonate, poly(meth)acrylate, polyvinyl chloride, polyethylene terephthalate, nylon-6,6, and nylon-4,6. thermoplastic resins such as polyurethane, polyvinyl alcohol, polylactic acid, polycaprolactone, polyethylene glycol, polyethylene-vinyl acetate copolymer, polyethylene-vinyl alcohol copolymer, polyethylene oxide, biodegradable polymers such as collagen, polyacrylonitrile , polyamide, polyaniline, paraamide, polyvinyl acetate, acetylcellulose (acetate) and the like. Polyurethane fibers are preferable because they have good adhesion to the flexible polyether urethane foam of the first base material and have good elongation. When the stretchability of the intermediate fiber layer is good, the soft polyether urethane foam of the first base material and the fabric layer follow the stretchability well. .

The air permeability of the intermediate fiber layer is preferably 10 cm ³ /(cm ² ·sec) or more, more preferably 15 cm ³ /(cm ² ·sec) or more, and more preferably 20 cm ³ /(cm ² ·sec) or more. It is more preferable if there is, and it is particularly preferable if it is 25 cm ³ /(cm ² ·sec) or more. Note that the air permeability of the intermediate fiber layer is preferably set to 150 cm ³ /(cm ² ·sec) or less in relation to the foreign matter collection efficiency. When the fiber diameter of the fibers is within the above range, the foreign matter trapping efficiency and air permeability can be ensured in the laminate of Modified Mode 2. When the layered product of modified mode 2 is used for a mask, it is possible to reduce suffocation due to appropriate ventilation, and a good feeling of wearing can be obtained. In addition, the laminate of Modified Mode 2 provides good foreign matter trapping efficiency.

It is preferable to set the air permeability of the intermediate fiber layer lower than that of the flexible polyether urethane foam of the first base material. By doing so, the intermediate fiber layer supplements the foreign matter collection efficiency that cannot be obtained with the flexible polyether urethane foam of the first base material without impairing the soft polyether urethane foam such as flexibility and elongation. , good foreign matter collection efficiency in the laminate of Modified Mode 2 can be obtained. Moreover, it is preferable to set the air permeability of the intermediate fiber layer to be lower than that of the cloth layer. By doing so, the intermediate fiber layer compensates for the foreign matter collection efficiency that cannot be obtained with the fabric layer without impairing the goodness of the fabric layer such as flexibility and elongation, so that the laminate of the modified mode 2 has good foreign matter. Collection efficiency is obtained.

The fiber basis weight of the intermediate fiber layer is preferably 0.10 g/m ² to 10 g/m ² , more preferably 0.10 g/m ² to 5 g/m ² . By doing so, it is possible to ensure the efficiency of trapping foreign matter and the air permeability of the intermediate fiber layer. It is also possible to set the basis weight of the fibers of the intermediate fiber layer according to the difference in objects to be collected for foreign matter and the fiber diameter of the fiber layer. For example, it can be 0.5 to 10 g/m ² , 0.5 to 5 g/m ² , 1 to 3 g/m ² for intermediate fiber layers having a large fiber diameter. For intermediate fiber layers with a small fiber diameter, it is 0.1 to 1.0 g/m ² , 0.1 to 0.8 g/m ² , 0.1 to 0.6 g/m ² . be able to. In this case, it is effective for collecting small-sized foreign substances such as bacteria and viruses.

The intermediate fiber layer can be formed, for example, by electrospinning.
For example, as described above, using the soft polyether urethane foam as the first base material as a base material, a polymer solution is sprayed on one surface of the base material by an electrospinning method, and fibers are sprayed, and fine fibers are gradually stacked to form an intermediate fiber layer. It is formed. The intermediate fiber layer is laminated by entangling and bonding the fibers to the flexible polyether urethane foam.
Instead of the flexible polyether urethane foam of the first base material, the intermediate fiber layer may be formed using a flexible polyurethane foam (soft polyester foam) or a fabric layer as the base material.

Lamination of flexible polyether urethane foam and other materials includes, for example, frame lamination and adhesion using hot-melt adhesives. Other materials include flexible polyurethane foam (soft polyester foam) and fabric layers. As an adhesion method using a hot-melt adhesive, a roll coater or spray coating is used to sandwich an adhesive layer such as a hot-melt adhesive or apply an adhesive to bond soft polyether urethane foam and other materials. can be pasted together. In this case, a non-woven hot-melt sheet may be used, or a fibrous hot-melt adhesive may be applied.

Using the following components, compositions for producing polyurethane foams having formulations in the comparative examples and examples shown in FIGS. A urethane foam was produced. The urethane foams of Comparative Examples and Examples were not subjected to film removal treatment.

Polyether polyol other than diol; alkylene oxide-added polyether polyol, molecular weight: 3000, number of functional groups: 3, hydroxyl value: 56 mgKOH/g, product name: GP3050N, manufactured by Sanyo Chemical Industries, Ltd. Polymer polyol; molecular weight: 5000, number of functional groups: 3, Hydroxyl value 32 mgKOH/g, product name: EXCENOL 941 (polyether polyol obtained by addition polymerization of propylene oxide to glycerin, 40% by mass of a mixture of styrene:acrylonitrile with a mass ratio of 8:2, graft-polymerized and dispersed. , solid content 40%)
Diol 1; polyether polyol, molecular weight: 1000, functional group number 2, hydroxyl value 108 to 116 mgKOH/g, product name: Actcole D1000, manufactured by Mitsui Chemicals, Inc. Diol 2; polyether polyol, molecular weight: 2000, functional group number 2, Hydroxyl value 54-58 mgKOH/g, Product name: Actcole D2000, Mitsui Chemicals Diol 3; Polyether polyol, Molecular weight: 4000, Number of functional groups 2, Hydroxyl value 26-30 mgKOH/g, Product name: Actcole D4000, Mitsui Chemicals manufactured by Dow Toray Co., Ltd. ・Foam stabilizer: silicone foam stabilizer, product name: SZ1136, Dow Toray Co., Ltd. ・Amine catalyst: N-ethylmorpholine, product name: Kaorizer No. 22, manufactured by Kao Corporation ・Tin catalyst; stannous octoate, product name: MRH110, manufactured by Johoku Chemical Industry ・Blowing agent; water ・Isocyanate; product name: Cosmonate T-80 / T-65, manufactured by Tosoh

The physical properties of the produced polyurethane foam are density (JIS K7222 compliant), tensile strength (JIS K 6400-5K compliant), elongation (JIS K6400-5 compliant), heat seal strength (adhesive strength), air permeability (JIS L1096A compliant ) was measured and the odor was confirmed.

The heat seal strength was measured by stacking two test pieces each having a length of 100 mm, a width of 30 mm, and a thickness of 10 mm. Heat-sealed by pressurizing at 3 MPa (megapascal) for 30 seconds, then using an autograph (manufactured by Shimadzu Corporation), gripping a range of 20 mm from the other end of the two test pieces with a gripper, 180 It was opened twice and pulled in opposite directions at a tensile speed of 500 mm/min, and the strength at which the two test pieces peeled off was measured and taken as the heat seal strength.
A sensory test was performed to confirm the odor. The subjects were asked to smell the odor, and the presence or absence of the odor was sensorily evaluated.

The measurement results of the heat seal strength were judged according to the following criteria.
The heat-sealing strength was judged as "×" when less than 100 kPa, "◯" when less than 100 to 500 kPa, and "⊚" when 500 kPa or more.
The measurement results and determination results are shown in FIG.

The results of Comparative Examples and Examples are shown below.
・Comparative Example A comparative example is an example in which a polyether polyol other than a diol is used alone as a polyol.
The comparative example has a density of 52.5 kg/m ³ , a tensile strength of 64.1 kPa, an elongation of 98.6%, a heat seal strength of no sealability (no adhesion), air permeability of 12.0 cm ³ /cm ² /sec, and odor. None, and the heat seal strength judgment was "x".

Examples 1 to 5 are examples in which the polyol is composed of a polyether polyol other than a diol and diol 2 (molecular weight 2000), and the mixing ratio of diol 2 (molecular weight 2000) in the polyol is varied.

・Example 1
Example 1 is an example in which the blending amount of diol 2 (molecular weight: 2000) was 10.0 parts by weight.
Example 1 has a density of 53.0 kg/m ³ , tensile strength of 73.0 kPa, elongation of 135.0%, heat seal strength of 389.0 kPa, air permeability of 21.0 cm ³ /cm ² /sec, no odor, and heat seal strength. The judgment was "0".

・Example 2
Example 2 is an example in which the blending amount of diol 2 (molecular weight: 2000) is 20.0 parts by weight.
Example 2 has a density of 53.4 kg/m ³ , tensile strength of 78.8 kPa, elongation of 164.9%, heat seal strength of 473.0 kPa, air permeability of 39.0 cm ³ /cm ² /sec, no odor, and heat seal strength. The judgment was "0".

・Example 3
Example 3 is an example in which the blending amount of diol 2 (molecular weight: 2000) was 30.0 parts by weight.
Example 3 has a density of 52.6 kg/m ³ , tensile strength of 77.5 kPa, elongation of 209.5%, heat seal strength of 573.8 kPa, air permeability of 94.0 cm ³ /cm ² /sec, no odor, and heat seal strength. The judgment was "⊚".

・Example 4
Example 4 is an example in which the blending amount of diol 2 (molecular weight: 2000) was 50.0 parts by weight.
Example 4 has a density of 52.4 kg/m ³ , tensile strength of 100.1 kPa, elongation of 305.5%, heat seal strength of 791.6 kPa, air permeability of 122.0 cm ³ /cm ² /sec, no odor, and heat seal strength. The judgment was "⊚".

・Example 5
Example 5 is an example in which the blending amount of diol 2 (molecular weight: 2000) was 70.0 parts by weight.
Example 5 has a density of 52.3 kg/m ³ , tensile strength of 105.5 kPa, elongation of 511.0%, heat seal strength of 854.1 kPa, air permeability of 147.0 cm ³ /cm ² /sec, no odor, and heat seal strength. The judgment was "⊚".

・Example 6
Example 6 is an example in which the polyether polyol other than the diol in Example 4 was reduced from 50.0 parts by weight to 20.0 parts by weight, and 30.0 parts by weight of polymer polyol was blended instead.
Example 6 has a density of 29.8 kg/m ³ , tensile strength of 124.0 kPa, elongation of 261.0%, heat seal strength of 1517.1 kPa, air permeability of 120.0 cm ³ /cm ² /sec, no odor, and heat seal strength. The judgment was "⊚".

Examples 7 to 9 are examples in which the polyol is composed of a polyether polyol other than a diol and diol 3 (molecular weight 4000), and the mixing ratio of diol 3 (molecular weight 4000) in the polyol is varied.

・Example 7
Example 7 is an example in which the blending amount of diol 3 (molecular weight 4000) was 10.0 parts by weight.
Example 7 has a density of 51.7 kg/m ³ , tensile strength of 76.3 kPa, elongation of 152.9%, heat seal strength of 550.7 kPa, air permeability of 33.9 cm ³ /cm ² /sec, no odor, and heat seal strength. The judgment was "⊚".

・Example 8
Example 8 is an example in which the blending amount of Diol 3 (molecular weight 4000) was 30.0 parts by weight.
Example 8 has a density of 52.4 kg/m ³ , tensile strength of 74.1 kPa, elongation of 175.0%, heat seal strength of 667.8 kPa, air permeability of 78.5 cm ³ /cm ² /sec, no odor, and heat seal strength. The judgment was "⊚".

・Example 9
Example 9 is an example in which the amount of diol 3 (molecular weight: 4000) was changed to 70.0 parts by weight.
Example 9 has a density of 62.1 kg/m ³ , tensile strength of 66.8 kPa, elongation of 244.7%, heat seal strength of 627.5 kPa, air permeability of 46.1 cm ³ /cm ² /sec, no odor, and heat seal strength. The judgment was "⊚".

Examples 10 and 11 are examples in which the polyol is composed of a polyether polyol other than a diol and diol 1 (molecular weight 1000), and the mixing ratio of diol 1 (molecular weight 1000) in the polyol is varied.

・Example 10
Example 10 is an example in which 10.0 parts by weight of diol 1 (molecular weight: 1000) was blended.
Example 10 has a density of 49.8 kg/m ³ , tensile strength of 71.6 kPa, elongation of 152.2%, heat seal strength of 540.1 kPa, air permeability of 13.8 cm ³ /cm ² /sec, no odor, and heat seal strength. The judgment was "⊚".
・Example 11
Example 11 is an example in which 30.0 parts by weight of diol 1 (molecular weight: 1000) was added.
Example 11 has a density of 49.6 kg/m ³ , tensile strength of 84.7 kPa, elongation of 215.5%, heat seal strength of 740.1 kPa, air permeability of 9.2 cm ³ /cm ² /sec, no odor, and heat seal strength. The judgment was "⊚".

Examples 12 to 15 are examples in which polymer polyol was blended with polyol and the blending ratio was varied.

・Example 12
In Example 12, 30.0 parts by weight of polyether polyol other than diol, 10.0 parts by weight of polymer polyol, and 60.0 parts by weight of diol 2 (molecular weight: 2000) were added. For example.
Example 12 has a density of 55.2 kg/m ³ , tensile strength of 115.5 kPa, elongation of 241.4%, heat seal strength of 798.0 kPa, air permeability of 24.7 cm ³ /cm ² /sec, no odor, and heat seal strength. The judgment was "⊚".

・Example 13
In Example 13, 20.0 parts by weight of polyether polyol other than diol, 30.0 parts by weight of polymer polyol, and 50.0 parts by weight of diol 2 (molecular weight: 2000) were mixed. For example.
Example 13 has a density of 54.8 kg/m ³ , tensile strength of 150.7 kPa, elongation of 236.6%, heat seal strength of 1066.2 kPa, air permeability of 41.9 cm ³ /cm ² /sec, no odor, and heat seal strength. The judgment was "⊚".

・Example 14
Example 14 is an example in which the blending amount of polyether polyol other than diol is 0 parts by weight, the blending amount of polymer polyol is 50.0 parts by weight, and the blending amount of diol 2 (molecular weight: 2000) is 50.0 parts by weight. be.
Example 14 has a density of 53.9 kg/m ³ , tensile strength of 168.0 kPa, elongation of 205.6%, heat seal strength of 1055.9 kPa, air permeability of 53.6 cm ³ /cm ² /sec, no odor, and heat seal strength. The judgment was "⊚".

・Example 15
Example 15 is an example in which the blending amount of polyether polyol other than diol is 0 parts by weight, the blending amount of polymer polyol is 70.0 parts by weight, and the blending amount of diol 2 (molecular weight: 2000) is 30.0 parts by weight. be.
Example 15 has a density of 55.2 kg/m ³ , tensile strength of 166.4 kPa, elongation of 103.5%, heat seal strength of 1156.8 kPa, air permeability of 6.4 cm ³ /cm ² /sec, no odor, and heat seal strength. The judgment was "⊚".

As described above, in Examples 6 and 12 to 15, the heat seal strength of the flexible polyether urethane foam was increased by blending the polymer polyol. Furthermore, by increasing the proportion of the polymer polyol in the polyol, the heat seal strength can be further increased.

As described above, the flexible polyether urethane foam of the present invention has heat-sealing properties, and is suitable for applications that require bonding (adhesion) by heat-sealing.
In addition, the flexible polyether urethane foam of the present invention has an elongation (JIS K6400-5 compliant) of 100% or more and a density (JIS K7222 compliant) of 10 to 150 kg / m ³ , so it is a member of a urethane mask that requires elongation. It is suitable as
Furthermore, since the flexible polyether urethane foam of the present invention is less susceptible to hydrolysis than polyester urethane foam, it is less likely to be deteriorated by washing and has high durability, so that it can be used for a urethane mask and repeatedly washed.
It should be noted that the present invention is not limited to the embodiments, and can be modified without departing from the gist of the invention.

The flexible polyether urethane foam of the present invention is suitable for urethane masks.

REFERENCE SIGNS LIST 10 mask 13 ear hook opening 15 central portion 16 heat seal portion

Claims

A flexible polyether urethane foam characterized by having an elongation (according to JIS K6400-5) of 100% or more, a density (according to JIS K7222) of 10 to 150 kg/m 3 , and heat sealability.
2. The flexible polyether urethane foam according to claim 1, which has a result of 100 kPa or more in a heat seal strength test shown below.
The heat seal strength test was performed by stacking two test pieces each having a length of 100 mm, a width of 30 mm, and a thickness of 10 mm, sandwiching the range of 20 mm from one end with hot plates of 180°C and applying pressure of 1.3 MPa for 30 seconds. After heat-sealing, the other ends of the two test pieces are opened 180 degrees and pulled in mutually opposite directions at a tensile speed of 500 mm/min.
3. The flexible polyether urethane foam according to claim 1 or 2, wherein the air permeability (in accordance with JIS L1096A method) is 5 cm3 / cm2 /sec or more.
The flexible polyether urethane foam is formed from a composition of raw materials for producing polyurethane foam containing a polyol, a polyisocyanate, a catalyst and a blowing agent,
Said polyols include polyether polyols,
4. The flexible polyether urethane foam according to any one of claims 1 to 3, wherein the polyether polyol includes a diol and a polyether polyol other than the diol.
A urethane mask comprising the flexible polyether urethane foam according to any one of claims 1 to 4.
A urethane mask comprising a laminate in which at least one of a fiber layer, a flexible polyurethane foam, and a cloth layer is laminated on the flexible polyether urethane foam according to any one of claims 1 to 4.