Daily article including polyurethane foam having superior air permeability and method for producing the same

Abstract

To provide a daily article including polyurethane foam having superior air permeability, producible by a simple method and capable of reducing production costs.SOLUTION: A core material 1 of a pillow includes a polyurethane foam having superior air permeability, the polyurethane foam containing 0.5 to 10.0 wt.%, for example 2 wt.%, of charcoal having a particle diameter of 0.75 μm to 58.0 μm, wherein the air permeability of the polyurethane foam is 10.0 to 30.0 cm3 / (cm2 s), for example 18.4 cm3 / (cm2 s), as measured by the test defined in JIS L 1096 A method.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to daily necessities including bedding such as pillows, mattresses, and cushions made of polyurethane foam with excellent breathability, and a method for manufacturing the same.

Background Art

[0002] The invention described in Patent Document 1 provides a formulation in which the amount of halogenated hydrocarbon as a blowing agent is reduced and the amount of water is increased when manufacturing a soft polyurethane foam with excellent breathability, and an amine catalyst used in the formulation. Its configuration is a method for manufacturing a polyurethane foam from a polyol and a polyisocyanate, by using an imidazole compound having a specific structure as a catalyst, reducing the odor of the catalyst, and reducing the amount of halogenated hydrocarbon as a blowing agent and increasing the amount of water.

[0003] The invention described in Patent Document 2 improves the breathability of a polyurethane foam without using a cyclic siloxane. The solution is a polyurethane foam obtained from a composition in which a polyol and a polyisocyanate are mixed. The composition contains a hydrocarbon having 5 to 50 carbon atoms.

[0004] The invention described in Patent Document 3 ensures sufficient breathability and good processability in a polyurethane foam blended with a polyolefin resin. The solution is a polyurethane foam obtained from a composition in which a polyol, a polyisocyanate, and a polyolefin resin powder are mixed. The composition contains a hydrocarbon having 5 to 50 carbon atoms.

[0005] The invention described in Patent Document 4 provides a catalyst composition for producing a soft or semi-rigid polyurethane foam with excellent air permeability and a method for producing a polyurethane foam using the same. It contains (A) an amine compound represented by the following general formula (1) and (B) an amine compound represented by the following general formula (2) and / or the following general formula (3), and is characterized in that the weight ratio of (A) / (B) is in the range of 95 / 5 to 5 / 95. [In the above general formula (1), A represents an oxygen atom or a nitrogen atom to which one methyl group is bonded, and R1 represents a methyl group or a hydroxyethyl group.][In the above general formula (2) and general formula (3), R1, R2, R3, R4, R5, R6 and R7 each independently represent a hydrogen atom or a saturated or unsaturated hydrocarbon group having 1 to 6 carbon atoms, and R8 represents a hydrogen atom, a methyl group, a methoxy group, a hydroxyl group, an amino group, a monomethylamino group, a monoethylamino group, or a dimethylamino group. a represents an integer of 1 to 4, and m and n each independently represent an integer of 0 to 4. However, when one or more substituents selected from R1, R2 and R5 are not hydrogen atoms, R8 represents an amino group, a monomethylamino group, or a monoethylamino group. Further, any two substituents among R1 to R8 may be optionally bonded via a carbon atom, an oxygen atom or a nitrogen atom to form a heterocycle.

[0006] The invention described in Patent Document 5 aims to provide a polyurethane foam for a mattress (a soft foam, hereinafter sometimes referred to as "soft foam for a mattress") that has low density and hardness, is flexible, has high air permeability, and has a small compression set. The means for solving the problem is a polyurethane foam for a mattress obtained by reacting a foam raw material containing a polyol, a polyisocyanate and a blowing agent.

Prior Art Documents

Patent Documents

[0007]

Patent Document 1

Patent Document 2

Patent Document 3

[0008] The above Patent Documents 1 to 5 have the following disadvantages

[0009] It is necessary to manufacture through a complex chemical process using a catalyst or the like, which is disadvantageous in terms of manufacturing time and manufacturing cost

[0010] Therefore, an object of the present invention is to provide a daily necessity including a polyurethane foam excellent in air permeability that can be easily manufactured and whose cost can be reduced [Means for Solving the Problems

[0011] The present invention includes a polyurethane foam containing carbon with a particle size of 0.75 μm to 58.0 μm and 0.5 to 10.0% by weight, and the air permeability of the polyurethane foam is such that the numerical value of the test defined by JIS L 1096 A method is 10.0 to 30.0 cm 3 / (cm 2 ·s), which is a daily necessity including a polyurethane foam excellent in air permeability

[0012] If the polyurethane foam is outside the range of a particle size of 0.75 μm to 58.0 μm, the air permeability will be low. If it is outside the range of 0.5 to 10.0% by weight, the air permeability will be low. If the air permeability of the polyurethane foam is outside the range of the numerical value of the test defined by JIS L 1096 A method being 10.0 to 30.0 cm 3 / (cm 2 ·s), it will be low

[0013] The polyurethane foam is preferably a flexible polyurethane foam

[0014] It is preferable that the polyurethane foam is a core material for bedding. As bedding, pillows, mattresses, cushions, etc. are preferable.

[0015] The polyurethane foam is formed by slab forming or mold forming.

[0016] Another invention of the present invention includes a step of producing a mixture by mixing a polyurethane raw material and carbon and at least mixing a catalyst and a foam stabilizer, and a step of injecting the mixture into a mold, solidifying it, and demolding the polyurethane foam. The polyurethane foam contains carbon with a particle size of 0.75 μm to 58.0 μm and 0.5 to 10.0% by weight, and the air permeability of the polyurethane foam is such that the numerical value of the test specified by JIS L 1096 A method is 10.0 to 30.0 cm 3 / (cm 2 ·s), and it is a method for producing daily necessities including a polyurethane foam having excellent air permeability.

[0017] Another different invention of the present invention includes a step of producing a mixture by mixing a polyurethane raw material and carbon and at least mixing a catalyst and a foam stabilizer, and a step of pouring the mixture into a heating machine and foaming and curing it. The polyurethane foam contains carbon with a particle size of 0.75 μm to 58.0 μm and 0.5 to 10.0% by weight, and the air permeability of the polyurethane foam is such that the numerical value of the test specified by JIS L 1096 A method is 10.0 to 30.0 cm 3 / (cm 2 ·s), and it is a method for producing daily necessities including a polyurethane foam having excellent air permeability.

Effects of the Invention

[0018] The present invention can provide daily necessities made of a soft polyurethane foam with excellent air permeability that can be easily manufactured and the cost can be reduced.

Brief Description of the Drawings

[0019]

Figure 1

Figure 2

Figure 3

Figure 4

Embodiments for Carrying Out the Invention

[0020] Hereinafter, an embodiment of the pillow core material 1 of the present invention will be described with reference to the drawings.

[0021] The pillow core material 1 includes a polyurethane foam containing carbon with a particle size of 0.75 μm to 58.0 μm and 0.5 to 10.0% by weight, for example, 2%. The air permeability of the polyurethane foam is such that the numerical value of the test defined by the JIS L 1096 A method is 10.0 to 30.0, for example, 18.4 cm 3 / (cm 2 ·s), and includes a polyurethane foam with excellent air permeability. As a comparative example, the air permeability of a polyurethane foam not containing carbon is 0.3 cm 3 / (cm 2 ·s), and a surprising result that the air permeability becomes 61 times was obtained.

[0022] The polyurethane foam is a soft polyurethane foam.

[0023] A method for manufacturing the pillow core material 1 according to another embodiment of the present invention includes a step of mixing a polyurethane raw material and carbon to produce a mixture, and a step of injecting the mixture into a mold, solidifying it, and demolding the polyurethane foam. The polyurethane foam contains 0.5 to 10.0% by weight of carbon, and the air permeability of the polyurethane foam is such that the numerical value of the test defined by the JIS L 1096 A method is 10.0 to 30.0 cm 3 / (cm 2 ·s), and it is a method for manufacturing daily necessities including a polyurethane foam with excellent air permeability.

[0024] When a polyol and a polyisocyanate react, they cure by urethanization. By including a foaming agent in this reaction, a product that cures into a foam shape is a polyurethane foam. Polyurethane foam molding is carried out by slab molding or mold molding.

[0025] The mold molding method of the core material 1 of the pillow of the present invention is a molding method in which a raw material mixture is poured into a predetermined mold, cured in the shape of a finished product by heating the entire mold, and the foamed and cured polyurethane foam is molded by cutting or the like.

[0026] Charcoal is made from oak trees or bamboo. It is carbonized at a high temperature of 1000 °C or higher over a long period of time. Then, it is roughly pulverized (to about 1 mm or more) using a crusher. At the same time, impurities other than charcoal are separated, washed, and dried. After that, fine pulverization is carried out. The particle size of the charcoal is 0.75 μm to 58.0 μm.

[0027] Slab molding is a molding method in which a raw material mixture obtained by mixing a polyol, a polyisocyanate, at least a catalyst, and a foam stabilizer is poured into a heating machine without putting it into a mold, and the foamed and cured polyurethane foam is molded by cutting or the like.

[0028] For the manufacturing method of polyurethane foam, manufacturing methods other than the above can also be applied.

[0029] As described above, the present invention can provide daily necessities made of soft polyurethane foam with excellent air permeability that can be easily manufactured and whose cost can be reduced.

[0030] The embodiments of the present invention are not limited to the above embodiments, and modifications and the like can be made without departing from the technical idea of the present invention. Such modifications, equivalents, etc. are also included in the technical scope of the present invention, and it goes without saying that various forms can be adopted as long as they belong to the said technical scope.

Industrial Applicability

[0031] Since the present invention can be widely applied to daily necessities, its industrial applicability is great.

Explanation of Signs

[0032] 1: Pillow core material

Claims

1. A polyurethane foam containing carbon with a particle size of 0.75 μm to 58.0 μm and 0.5 to 10.0% by weight, The air permeability of the polyurethane foam is such that the numerical value of the test specified by JIS L 1096 A method is 10.0 to 30.0 cm ３ / (cm ２ ·s), and the daily necessities include a polyurethane foam having excellent air permeability.

2. The daily necessities according to Claim 1, wherein the polyurethane foam is a flexible polyurethane foam.

3. The daily necessities according to Claim 1 or 2, wherein the polyurethane foam is a core material of bedding.

4. A step of producing a mixture by mixing a polyurethane raw material and carbon and at least mixing a catalyst and a foam stabilizer; A step of injecting the mixture into a mold, solidifying it, and demolding the polyurethane foam; comprising wherein the polyurethane foam contains carbon with a particle size of 0.75 μm to 58.0 μm and 0.5 to 10.0% by weight, The air permeability of the polyurethane foam is such that the numerical value of the test specified by JIS L 1096 A method is 10.0 to 30.0 cm ３ / (cm ２ ·s), A method for manufacturing daily necessities including a polyurethane foam having excellent air permeability.

5. A step of producing a mixture by mixing a polyurethane raw material and carbon and at least mixing a catalyst and a foam stabilizer; A step of pouring the mixture into a heater and foaming and curing it; comprising wherein the polyurethane foam contains carbon with a particle size of 0.75 μm to 58.0 μm and 0.5 to 10.0% by weight, The air permeability of the polyurethane foam is such that the numerical value of the test specified by JIS L 1096 A method is 10.0 to 30.0 cm ３ / (cm ２ ·s), A method for manufacturing daily necessities including a polyurethane foam having excellent air permeability.

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