JP2002306284A - Cushion material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a cushion material having low repulsion performance and high air permeability. SOLUTION: This cushion material 1 is formed by putting granular materials of low-repulsive polyurethane foam in an air permeable cover.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a low resilience and high air permeability suitable for a pillow, a bedding, a mattress for preventing pressure ulcer, a cushion material for a sofa, a cushion material for office use, a small cushion material for office use, and the like. The present invention relates to a cushion material having:

[0002]

2. Description of the Related Art A cushioning material using a low resilience polyurethane foam is very comfortable because when the load is applied, the cushioning material follows the same and disperses the pressure so that the pressure does not concentrate locally. Although it has an excellent feature of being able to obtain a proper use state, it has a drawback that heat from body temperature is easily stored due to low air permeability of the material, which causes stuffiness and heat feeling.

[0003] For this reason, in the past, processing such as providing air holes in the low resilience polyurethane foam or wrapping the low resilience polyurethane foam with a highly breathable polyurethane foam has been performed. Effect was not obtained, and depending on the processing method, the original low resilience performance of the low resilience polyurethane foam was sometimes impaired.

[0004]

SUMMARY OF THE INVENTION An object of the present invention is to solve the above-mentioned conventional problems and to provide a cushioning material having low resilience and high air permeability.

[0005]

The cushioning material according to the present invention is characterized in that particles of a low resilience polyurethane foam are contained in a breathable cover.

When the particles of the low resilience polyurethane foam are accommodated in the air permeable cover, voids are formed between the particles of the low resilience polyurethane foam accommodated in the cover, and due to the presence of the voids, Good air permeability can be obtained. In addition, since the granular material is made of a low resilience polyurethane foam, the original resilience of the low resilience polyurethane foam is hardly impaired.

The particle size of the low resilience polyurethane foam of the present invention is preferably 1 to 50 mm.

[0008] The air permeability of the cover accommodating such particulate matter is preferably 0.01 to 200 cc / cm ² / sec.

The low rebound polyurethane foam constituting the granular material preferably has a rebound resilience of 15% or less.

[0010] The cushioning material of the present invention may be one in which only particles of a low resilience polyurethane foam are accommodated in a cover. May be contained in a cover.

It is preferable that these granular materials are accommodated 1.0 to 3.0 times the accommodation volume of the cover.

In the present invention, the density (g / c)
m ³ ), hardness (kgf), air permeability (cc / cm ² / se)
c), rebound resilience (%) and compression set (%) are as follows:
The value measured according to JISK6400 is shown.

[0013]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of the cushioning material of the present invention will be described below in detail.

[0014] The cushioning material of the present invention is obtained by accommodating granules of a low resilience polyurethane foam or a mixture of granules of a low resilience polyurethane foam and granules of a general-purpose polyurethane foam in a breathable cover. .

The granular material of the low resilience polyurethane foam can be obtained by pulverizing an ordinary low resilience polyurethane foam lump or mat or sheet with a rotary blade type pulverizer or the like. Similarly, the general-purpose polyurethane foam can be obtained by pulverizing a lump or mat or sheet of the general-purpose polyurethane foam.

The shape of these granular materials is not particularly limited, and may be spherical, cubic, rectangular, cylindrical (including elliptical columns), triangular, quadrangular (including trapezoidal columns, etc.), polygonal columns, and other irregular shapes. It may be a shaped article or a mixture thereof.

Low resilience polyurethane foam granules,
And, the size of the granular material of the general-purpose polyurethane foam is too small or too large, because voids effective for improving air permeability cannot be formed between the granular materials, the average particle diameter of the granular material Is preferably 1 to 50 mm, particularly preferably 5 to 30 mm. Here, the particle diameter of the granular material means the minimum value of the length of one side of a square mesh through which the granular material can pass.

The low-resilience polyurethane foam constituting the granular material has a density of 20 to 150 g / cm ³ , a hardness of 1.0 to 30.0 kgf, and a gas permeability of 0.5 to 300 cc / cm ³ .
cm ² / sec, rebound resilience 15% or less, especially 0-10.
It is preferable to show a physical property value of about 0% and a compression residual strain of about 0 to 5.0%. Such a low resilience polyurethane foam can be produced by a conventional method, for example, by blending the following raw materials. . [Low resilience polyurethane foam compounding (parts by weight)] Polyol (polyol A and polyol B): 100 Polyisocyanate: 25 to 70 Blowing agent: 0.5 to 5.0 Catalyst: 0.01 to 1.0 Foam stabilizer : 0.3 to 2.0

As the polyol, those usually used for polyurethane can be used, and examples thereof include polyether polyol and polymer polyol obtained by polymerizing a vinyl monomer in the polyol. Examples of the polyether polyol include those obtained by adding an alkylene oxide to an initiator such as water, alcohols, amines, and ammonia. Examples of the alcohols include monohydric alcohols (eg, methanol and ethanol), dihydric alcohols (eg, ethylene glycol and propylene glycol), and trihydric alcohols (eg, glycerin,
Trimethylolpropane, etc.), tetrahydric alcohols (D-
Sorbitol), polyhydric alcohols such as hexahydric alcohols and octahydric alcohols. As the amines, monovalent amines (dimethylamine, diethylamine, etc.), divalent amines (methylamine, ethylamine, etc.), trivalent amines (monoethanolamine, diethanolamine, triethanolamine, etc.), tetravalent amines And other polyvalent amines. Examples of the alkylene oxide include ethylene oxide (EO), propylene oxide (PO), 1,2-, 1,4- and 2,3-butylene oxide, and a combination of two or more thereof. Of these, preferred are propylene oxide and / or ethylene oxide, and when used in combination, the addition form may be either block or random.

Preferred as polyol A are polyether polyols and / or polymer polyols. The average number of functional groups of the polyol A is usually 2 to 5,
It is preferably from 2.5 to 3.5, and the hydroxyl value is usually 20
-60 mg-KOH / g, preferably 30-60 mg-
KOH / g. When the hydroxyl value is less than 20 mg-KOH / g, it is difficult to produce a polyurethane foam, and it is also difficult to obtain a polyether polyol as a commercial product. If the hydroxyl value exceeds 60 mg-KOH / g, the resin formed by the polyurethane foam becomes hard,
Moist feel cannot be obtained. The ethylene oxide content of this polyol A is usually 5 to 30% by weight, preferably 10 to 25% by weight, and the percentage of terminal primary hydroxyl groups is usually 5 to 80%, preferably 60 to 75%.

The average number of functional groups of the polyol B is usually 1.
5 to 4.5, preferably 2 to 3, and the hydroxyl value is usually 200 to 300 mg-KOH / g, preferably 240 to 300 mg-KOH / g.
280 mg-KOH / g. 200mg hydroxyl value
If it is less than -KOH / g, the rebound resilience of the foam increases, and if it exceeds 300 mg-KOH / g, the temperature dependence of the foam increases.

Examples of the polyol A include a polyoxyalkylene polyester block copolymer polyol (average number of functional groups: about 3, hydroxyl value: 56 mg-KOH / g) and polyoxyalkylene polyol (average number of functional groups: about 3, hydroxyl value: 56 mg-KOH / g). g) etc., specifically, GP-300
0 (manufactured by Sanyo Chemical Industries, Ltd.) and the like. As the polyol B, a polyoxyalkylene polyol (average number of functional groups: about 3, hydroxyl value 250 mg-KOH /
g), using polyoxyalkylene polyol (average number of functional groups: about 3, hydroxyl value: 280 mg-KOH / g), specifically, Boranol 2070 (manufactured by Dow) or G-700 (manufactured by Asahi Denka Kogyo KK). Can be.

The mixing ratio of the polyol A and the polyol B is preferably 30 to 80% by weight of the polyol B to 70 to 20% by weight of the polyol A.

As the polyisocyanate, known polyisocyanates conventionally used for producing a low resilience polyurethane foam, for example, tolylene diisocyanate (TDI),
Obtained by reacting aromatic polyisocyanates such as diphenylmethane diisocyanate (MDI), phenylene diisocyanate (PDI), and naphthalene diisocyanate (NDI), modified TDI, crude MDI and modified MDI, and excess polyisocyanate with low molecular polyol. A free isocyanate-containing prepolymer and the like can be mentioned, and these can be used alone or in combination of two or more. As the polyisocyanate, specifically, Takenate T-80 (Takeda Pharmaceutical Co., Ltd.)
Co., Ltd.), Coronate T-65 (Nippon Polyurethanes Inc.)
Manufactured) can be used.

Examples of the blowing agent include water and / or halogen-substituted aliphatic hydrocarbon-based blowing agents such as trichlorofluoromethane, dichlorodifluoromethane, trichloroethane, trichloroethylene, tetrachloroethylene, methylene chloride, trichlorotrifluoroethane, and dibromotetrafluoroethane. , Carbon tetrachloride and the like. Among these blowing agents, water is preferred.

As the catalyst, known catalysts usually used for the production of polyurethane, for example, tertiary amines (triethylamine, triethylenediamine, N-methylmorpholine, etc.), quaternary ammonium (tetraethylhydroxylammonium, etc.), imidazoles ( Imidazole, 2
Amine catalysts such as -ethyl-4-methylimidazole, etc., organic tin compounds (tin acetate, tin octylate, dibutyltin dilaurate, dibutyltin chloride, etc.), organic lead compounds (lead octylate, lead naphthenate),
An organic metal-based catalyst such as an organic nickel compound (nickel naphthenate) may be used. Of these, tertiary amines and imidazoles are preferred.

As the foam stabilizer, for example, a silicone-based surfactant which is generally used for conventional polyurethanes such as a siloxane-oxyalkylene block copolymer is used. As the foam stabilizer, specifically, F-242T (manufactured by Shin-Etsu Chemical Co., Ltd.), SH-192 (manufactured by Dow Corning Toray Silicone Co., Ltd.) or the like can be used.

In addition, in the present invention, for example, known additives such as a crosslinking agent, a flame retardant, a coloring agent, a plasticizer, and an internal mold release agent used in the production of ordinary polyurethane foams may be blended as required. May be.

The low-resilience polyurethane foam according to the present invention is prepared by mixing a mixture of a polyol, a foam stabilizer, a catalyst, a foam stabilizer, and other additives with a polyisocyanate at a predetermined ratio, stirring the mixture, and stirring the mixture. It can be produced by foaming according to the method.

As the air-permeable cover material, one made of cloth, leather, synthetic resin or the like can be used, and the degree of air-permeability is 0.01 to 200 cc / cm ² / sec, particularly 0.1 to 50 cc. / Cm ² / sec. If the air permeability is low, sufficient air permeability as a cushion material cannot be obtained, and if the air permeability is excessively large, the strength or the like becomes insufficient, which is not preferable.

The cushioning material of the present invention can be used as a low-resilience polyurethane foam granule or a low-repulsion polyurethane foam granule in a cover formed by molding such a cover material into a bag according to a conventional method. It can be produced by encapsulating a mixture of polyurethane foam and granules.

In this case, the enclosed amount of the particulate matter is 1.0 to 3.0 times the volume of the cover, and particularly 1.1 to 3.0 times.
It is preferably 1.6 times the volume. If the amount of the enclosed particles is less than this range, sufficient cushioning properties as a cushion material cannot be obtained, and if the amount is large, voids effective for air permeability cannot be formed between the particles.

When the particles of the low resilience polyurethane foam and the particles of the general-purpose polyurethane foam are used in combination, there is no particular limitation on the general-purpose polyurethane foam to be used. Rigid or flexible polyurethane foam can be used.

In this case, when the proportion of the low resilience polyurethane foam particles in the mixture of the low resilience polyurethane foam granules and the general-purpose polyurethane foam is excessively small, the low resilience due to the low resilience polyurethane foam granules is obtained. It is preferable that the proportion of the particulate matter of the low resilience polyurethane foam in the mixture is 60% by volume or more because the property is impaired.

The cushioning material of the present invention has the low resilience of the low resilience polyurethane foam and the good air permeability due to the gap between the granular materials. , Sofa cushioning material,
An extremely comfortable use feeling and a good use state can be obtained as office cushion materials, small office cushion materials and the like.

[0036]

The present invention will be described more specifically below with reference to examples and comparative examples.

In the following, the low resilience polyurethane foam and general-purpose polyurethane foam include a low resilience polyurethane foam T-1 or a low resilience polyurethane obtained by foaming and molding a foam material having the following composition in a mold. Form T-2 and general-purpose polyurethane foam A
-1 was crushed to an average particle diameter of 20 mm by a rotary blade crusher.

[0038]

[Table 1]

In Table 1, the materials used are as follows. Polyol A: Actoda 3 manufactured by Takeda Pharmaceutical Co., Ltd.
P56B "polyoxyalkylene polyester book copolymer polyol average number of functional groups: about 3, hydroxyl value: 56 mg-KOH / g Polyol B:" G-700 "polyoxyalkylene polyol manufactured by Asahi Denka Kogyo Co., Ltd. average number of functional groups: about 3, hydroxyl group Value: 280 mg-KOH / g Polyisocyanate: Takeda T-80 manufactured by Takeda Pharmaceutical Co., Ltd. Catalyst C: DABC033 manufactured by Sankyo Air Products Co., Ltd.
LV "Catalyst D:" Stanoct "manufactured by Yoshitomi Pharmaceutical Co., Ltd. Foam stabilizer:" F-242T "manufactured by Shin-Etsu Chemical Co., Ltd.

Examples 1 to 6 and Comparative Example 1 A polypropylene porous film molded into a bag so as to have a thickness of 600 mm × 600 mm × 80 mm as a cover Microporous film made by Sumitomo 3M (air permeability ² cc / cm ² / sec) The cover was filled with the granular material in the amount shown in Table 2 to produce a cushion material.

The pressure relief performance and air permeability of the obtained cushion material were examined by the following methods, and the results are shown in Table 2.

(Decompression performance) A cushion material was placed on the seat surface of a wooden chair, and a man weighing about 70 kg was seated. MAT) and evaluated according to the following criteria. A: The pressure is sufficiently dispersed, and there is no portion to which pressure is applied locally. ：: The pressure is dispersed, and there is almost no pressure applied locally. Δ: Dispersion of pressure is slightly insufficient, and there is a small portion where pressure is locally applied. ×: The pressure is not dispersed, and there are many parts to which pressure is locally applied.

(Breathability) The feeling of use when a man weighing 70 kg was used for 3 hours in a room at a temperature of 21 ° C. and a humidity of 51% was evaluated according to the following criteria. ：: There is no feeling of stuffiness or heat, and it can be used very comfortably. ：: It can be used comfortably for the first time with little feeling of stuffiness or heat. Δ: Some heat and heat were felt, and it was hard to say that it was comfortable. X: Unpleasant feeling stuffiness and heat.

Comparative Examples 2 to 4 Each of a low rebound polyurethane foam T-1 (Comparative Example 2), a low rebound polyurethane foam T-2 (Comparative Example 3) and a general-purpose polyurethane foam A-1 (Comparative Example 4) was 600 mm. The product processed to a size of × 600 mm × 80 mm in thickness was inserted into the same cover as that used in Example 1, and the pressure relief performance and air permeability were examined in the same manner, and the results are shown in Table 2.

[0045]

[Table 2]

Table 2 shows that the cushioning material of the present invention has low resilience and excellent air permeability.

[0047]

As described in detail above, according to the present invention, it is possible to provide a cushioning material having low resilience, high air permeability, and a comfortable feeling of use.

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 3B096 AD04 AD07 3B102 AB07 AC02 4C040 AA01 CC01

Claims (6)

[Claims] 1. A cushioning material in which granules of a low resilience polyurethane foam are accommodated in a breathable cover. 2. The cushion material according to claim 1, wherein the particle size of the low resilience polyurethane foam is 1 to 50 mm. 3. The cushion material according to claim 1, wherein the air permeability of the cover is 0.01 to 200 cc / cm ² / sec. 4. The low rebound polyurethane foam according to claim 1, wherein the low rebound polyurethane foam has a rebound resilience of 15 or less.
% Or less. 5. The air-permeable cover according to claim 1, wherein a mixture of the low resilience polyurethane foam granules and the general-purpose polyurethane foam granules is housed in a breathable cover. Cushioning material. 6. The cushion material according to claim 1, wherein the granular material is accommodated in an amount of 1.0 to 3.0 times the accommodation volume of the cover.