JP2000273231A - Method for producing flexible polyurethane foam and plastic foam - Google Patents

Abstract

[PROBLEMS] To uniformly disperse and mix bamboo charcoal powder in a flexible polyurethane foam. SOLUTION: When air is blown to mix and stir a resin material, bamboo charcoal powder is blown into the resin material together with air, and then foamed.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a plastic foam, particularly a flexible polyurethane foam, which can be widely used for bedding such as futons and pillows, and for building materials such as wall materials and floor materials, and a method for producing the same.

[0002]

2. Description of the Related Art Useful charcoal materials include bamboo charcoal (alcohol bamboo), charcoal (such as kunugi), and bincho charcoal (umame oak). Each of these carbon materials has fine pores and contains carbon as a main component.

When the cross section of bamboo charcoal is observed with a scanning electron microscope, when the conduit through which moisture passes is carbonized, it is hollowed out, and this hollow portion is arranged in an orderly manner. There are more than twice as many. In addition, it is known that crystals of a substance composed of potassium and chlorine atoms are found in the cavity. When bamboo charcoal is eluted in water and analyzed by ion chromatography, the elution component of bamboo charcoal is mainly potassium ion for cation, carbonate ion, phosphate ion and chloride ion for anion. Oxygen, nitrogen,
It is characterized by its high potassium, phosphorus, and silicon contents. It is recognized in a research report entitled "Composition analysis of bamboo charcoal and its elution behavior" by Mr. San.

[0004] On the other hand, the carbonaceous material including bamboo charcoal has a large number of micropores, and therefore has a hygroscopicity (humidity control), a deodorizing (absorbing) odor, a thermal effect by far-infrared radiation, and a heat storage. It is known that bamboo charcoal is far superior to ordinary charcoal and bincho charcoal in these properties. Bamboo charcoal also has a bactericidal property.

Therefore, bamboo charcoal is finely crushed and sandwiched or spread on tatami floors, building material floors and wall materials. Also, due to the ion effect, packing bamboo charcoal particles in bedding mats (futons) and pillows makes it feel like you are in a green bamboo forest, and it is said that it promotes comfortable sleep, Applications to indoor environments are being studied.

However, conventionally, carbonaceous materials including bamboo charcoal are crushed and used alone, and it is necessary to prevent them from moving. Therefore, they are sandwiched or spread while being packed in a breathable bag. There was a problem in that it was troublesome and expensive.

[0007] Therefore, the present invention is to make the carbonaceous material, which is best made of bamboo charcoal, into a plastic foam while powdering it. In this case, the present invention is to provide a method for producing a plastic foam capable of reliably and easily uniformly dispersing a carbonaceous material powder in a raw material resin.

[0008]

That is, the present invention relates to a method for producing a plastic foam in which raw resin is mixed while blowing air, and is foamed into a predetermined shape. The carbon material powder is blown in with air.

More specifically, the plastic foam is a flexible polyurethane foam, and the bamboo charcoal powder is used as the carbon material.
２５25% by weight. The average particle size of bamboo charcoal powder is 0.01 ~
It is desired to be 35 mm. More preferably, it is a flexible polyurethane foam having fine open cells, which itself has compression characteristics, bending fatigue characteristics, heat insulation, ease of processing such as cutting and quilting, and sound absorption.

[0010] The plastic foam of the present invention is produced by a conventionally known ordinary foam molding method. For example, in the case of a flexible polyurethane foam, it is produced by a reaction between a polyester or polyether and an isocyanate, is foamed with carbon dioxide gas during the reaction, and is crosslinked with an isocyanate. The foam may be formed by one of the one-shot method and the prepolymer method. It may be formed in a fixed shape (often a square board shape) using a molding die. After a thick wide foam is formed into an endless board, it may be cut into a required length according to the application.

[0011]

[Function] As plastic foam, ABS foam suitable for ceiling material and wall material, acrylic foam suitable for sandwich material of building material, silicone foam suitable for heat insulating material, suitable for tatami floor, etc. Polystyrene foam, ethylene-vinyl acetate copolymer foam suitable for shoe insoles,
Examples include polyethylene foam suitable for footwear floors and floor mats, and urea resin foam suitable for building materials.

Particularly, when a flexible polyurethane foam is used for bedding, flexible compressibility (elasticity, toughness) is used.
As a prerequisite, the bending fatigue property, that is, the repeated fatigue strength is particularly problematic. Although this kind of functional strength can be controlled by the foam heating, when carbonaceous material (bamboo charcoal) powder is mixed, the relationship with the mixed amount must be considered.
According to the trial production using bamboo charcoal powder, 3 to 3
It must be 0% by weight, preferably 15 to 25% by weight. That is, if the content is more than 30% by weight, safely 25% by weight, the molded product becomes brittle, and if the amount is not set to 3% by weight, more surely not more than 15% by weight, in the case of multipurpose application. This is because the original characteristics of bamboo charcoal cannot be effectively exhibited. The bamboo charcoal powder at that time has an average particle size of 0.01 to 35 mm from the empirical value, and even if the bamboo charcoal powder comes out on the surface of the molded product, it does not break off and is uniformly dispersed as described above. The mixing amount is ensured.

[0013]

According to the soft polyurethane foam containing bamboo charcoal powder according to the present invention, since the soft polyurethane foam has the properties of bamboo charcoal powder in addition to the original properties of the soft polyurethane foam, futons, mats, pillows, etc. It is suitable for use in relation to bedding.

According to the method for producing a plastic foam of the present invention, in the mixing and stirring step, when air is blown, the powder of the carbonaceous material such as bamboo charcoal is mixed into the resin raw material together with the air. In the above, the carbonaceous material powder is uniformly dispersed in the foam, and does not form a joint powder (mamako). In addition, since the mixing amount of the carbonaceous material powder is set to 30% by weight or less, there is an advantage that an excellent material can be obtained for various applications, particularly in terms of flexural fatigue characteristics and the like.

[0015]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS (Embodiment 1) A polyether, isocyanate, catalyst, and blowing agent are used as materials, and air is blown into this liquid material together with bamboo charcoal powder having an average particle size of 1.0 mm to thereby form a resin material. After mixing, stirring and foaming, the mixture was taken out into an endless board having a width of 2 m and a thickness of 4 cm, and a flexible polyurethane foam 1 was formed as shown in FIG. In FIG. 1, the foam 1 has bamboo charcoal powder 2
Were uniformly dispersed in a dotted manner. Next, the flexible polyurethane foam was cut into a rectangular shape, and this was wrapped therein to make a bedclothes for bedding.

(Embodiment 2) As shown in FIG.
Was compressed to half the thickness under heat and pressure to produce a flexible polyurethane foam compression body 1a. According to the compressed body 1a, the thin film 3 is formed on both outer surfaces in the thickness direction by heat melting, and the compressibility (elasticity) is obtained.
However, the bamboo charcoal powder 2 is not exposed to the outer surface by the thin film 3, so that the bamboo charcoal powder 2 on the outer surface can be prevented from falling off. A powder was obtained which was not stained black by hand. At the same time, the amount of bamboo charcoal powder mixed per thickness could be increased according to the compression ratio. Next, the soft polyurethane foam compression body 1a was cut into a predetermined shape to form a wall material.

[Brief description of the drawings]

FIG. 1 is a partially broken perspective view of a flexible polyurethane foam obtained in Example 1.

FIG. 2 is a cross-sectional view of a compression-type flexible polyurethane foam obtained in Example 2.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Soft polyurethane foam 1a Soft polyurethane foam compression body 2 Bamboo charcoal powder 3 Thin film

Claims (5)

[Claims] 1. A flexible polyurethane foam formed in a board shape by mixing 3 to 25% by weight of bamboo charcoal powder. 2. A method for producing a plastic foam, characterized in that in a mixing and stirring step of mixing raw resin while blowing air, powder of carbonaceous material is blown into the raw resin together with air. 3. The raw material resin is polyurethane.
A method for producing the plastic foam according to the above. 4. The carbonaceous material is bamboo charcoal, and 3 to 3
The method for producing a plastic foam according to claim 2 or 3, wherein 0% by weight is mixed. 5. The method for producing a plastic foam according to claim 4, wherein the average particle size of the bamboo charcoal powder is 0.01 to 35 mm.