JP6073727B2 - Method for producing urethane foam molded body, and stirrer for foamed urethane resin material used therefor - Google Patents

Description

  The present invention relates to a method for producing a urethane foam molded article used as, for example, a sound absorbing material or a vibration absorbing material, and a stirrer for a foamed urethane resin material used therefor.

  Urethane foam moldings are used in various fields such as automobiles as sound absorbing materials, vibration absorbing materials and the like. For example, as described in Patent Documents 1 and 2, urethane foam molded articles in which a magnetic filler or the like is blended to improve heat dissipation are known. The urethane foam molded article is produced by foam molding a mixed raw material in which a polyol component, a polyisocyanate component, a magnetic filler, and the like are mixed in a magnetic field.

JP 2009-51148 A JP 2010-126777 A JP-A-9-296021

  Usually, the mixed raw material is prepared by stirring each component with a stirring blade. In this case, it is necessary to wash the stirring blade and the container every time the mixed raw material is prepared. For this reason, the burden of a cleaning operation is large and it is difficult to automate a series of manufacturing processes. Further, since a solvent is used for cleaning, the influence on the environment becomes a problem.

  Moreover, when the quantity of the filler to mix | blend increases, the viscosity raise of a raw material will become large. Therefore, a large torque is required during stirring. For this reason, the amount of filler is regulated by the stirring device. That is, it is difficult to produce a urethane foam molded article containing a large amount of filler. Further, depending on the type of filler, there is a risk of being pulverized by the shearing force of the stirring blade.

  On the other hand, there is a method in which a polyol component and a polyisocyanate component are each jetted and mixed at a high pressure in a mixing head (collision stirring method). When the filler is blended in the collision stirring method, the filler may be added to the polyol component or the polyisocyanate component in advance. However, for example, when a filler is added to the polyol component, the viscosity increases. If the viscosity of the raw material is large, the load on the pump, piping, hose, etc. becomes large, so that pressure feeding is difficult. Further, if the size of the filler is larger than the diameter of the injection hole of the mixing head, the injection hole may be damaged due to the contact of the filler. Therefore, even in the collision stirring method, the amount and size of the filler are limited.

  Moreover, when a premix polyol is prepared by previously blending a polyol component with a catalyst, a filler, or the like, the polyol component penetrates into the filler or the catalyst is adsorbed on the filler. Thereby, a polyol component and a polyisocyanate component cannot fully react, and the physical property of the urethane foam molded object obtained falls.

  The present invention has been made in view of such a situation, and is a method for producing a urethane foam molded article containing a filler, wherein the liquid raw material and the filler are uniformly distributed regardless of the blending amount and size of the filler. It is an object of the present invention to provide a method for producing a urethane foam molded body that can be mixed with the above. It is another object of the present invention to provide a foamed urethane resin raw material stirring device suitable for use in the production method.

  (1) In order to solve the above problems, the method for producing a urethane foam molded article of the present invention produces a urethane foam molded article by foam molding a foamed urethane resin raw material having a polyol component, a polyisocyanate component, and a filler. A method for producing a urethane foam molded article, wherein the foamed urethane resin material is placed in a closed container, and the closed container is reciprocated so that the foamed urethane resin material is applied to the wall surface of the sealed container by inertial force. It has a stirring step of stirring the foamed urethane resin raw material by repeating collision and reversal of the moving direction, and a foam molding step of foaming the stirred foamed urethane resin raw material.

  In the stirring step, the sealed container containing the urethane foam resin material is reciprocated. Then, the foamed urethane resin raw material repeatedly collides with the wall surface of the sealed container and reverses due to the inertial force. Here, the foamed urethane resin raw material includes a filler. As the closed container reciprocates, the filler moves violently in the liquid raw material such as a polyol component. And stirring of a foaming urethane resin raw material is accelerated | stimulated because a filler plays a role like a stirring element. As a result, raw materials such as a polyol component, a polyisocyanate component, and a filler constituting the foamed urethane resin raw material are quickly mixed. According to the method for producing a urethane foam molded article of the present invention, stirring of the foamed urethane resin raw material is completed in a short time of about several seconds to several tens of seconds. Therefore, stirring of the foamed urethane resin raw material can be completed before the foam curing reaction proceeds.

  The sealed container may be reciprocated linearly or reciprocated in a pendulum shape. The direction of reciprocation may be any direction such as left and right, up and down, and diagonally. In order to uniformly mix the raw materials constituting the foamed urethane resin raw material in a shorter time, it is preferable to reduce the reciprocating stroke and increase the frequency (number of reciprocations per unit time).

  In the method for producing a urethane foam molded article of the present invention, no stirring blade is used for mixing raw materials. For this reason, it is not necessary to wash a stirring blade | wing every time it stirs. Therefore, the burden of the cleaning work is reduced, and it is easy to automate a series of manufacturing processes. Moreover, since no stirring blade is used, mixing can be performed even if the viscosity of the raw material is increased by the addition of a filler. Therefore, for example, a urethane foam molded article containing a large amount of filler can be produced. Further, there is no possibility that the filler is crushed by the stirring blade. Further, it is not necessary to add a filler to the polyol component in advance as in the collision stirring method. For this reason, there is little possibility that the polyol component will soak into the filler or the catalyst will be adsorbed on the filler. Accordingly, a urethane foam molded article having good physical properties can be produced by sufficiently reacting the polyol component and the polyisocyanate component.

  Patent Document 3 discloses a method of applying ultrasonic vibration when mixing polyurethane foam raw materials. The method of Patent Document 3 aims to refine the cell by applying ultrasonic vibration and improve the heat insulation of the polyurethane foam. For this reason, only ultrasonic vibration is applied while stirring with a conventional stirring blade. Moreover, the filler is not mix | blended with the raw material.

  (2) Preferably, in the configuration of (1) above, in the foamed urethane resin raw material, the polyol component and the polyisocyanate component are preferably mixed in advance.

  By mixing the polyol component and the polyisocyanate component in advance before blending the filler, the penetration of the polyol component into the filler and the adsorption of the catalyst can be suppressed. Thereby, the reactivity of a polyol component and a polyisocyanate component improves. Therefore, according to this structure, the urethane foam molding which has a favorable physical property can be manufactured.

  (3) Preferably, in the configuration of (1) or (2), the sealed container is fixed to a reciprocating support member, and the support member is attached to at least one of reciprocating ends in the stirring step. It is better to make it reciprocate while colliding with the stopper.

  When the support member collides with the stopper at the reciprocating end, an impact force due to an inertial force is applied to the foamed urethane resin material. Thereby, the foamed urethane resin raw material is accelerated, and the movement in the sealed container is increased. As a result, mixing of raw materials constituting the urethane foam resin raw material is promoted.

  (4) Preferably, in any one of the constitutions (1) to (3), the filling rate of the foamed urethane resin raw material in the sealed container is preferably 60% by volume or less.

  The movement of the foamed urethane resin material in the sealed container changes depending on the filling rate of the foamed urethane resin material. Therefore, it is desirable to adopt a suitable filling rate according to the shape of the sealed container. According to this configuration, the filling rate is relatively small. For this reason, a foaming urethane resin raw material can be moved largely in an airtight container. Thereby, each raw material mixes rapidly.

  (5) Preferably, in the configuration of any one of the above (1) to (4), the closed container is reciprocated in the vertical direction in the stirring step.

  According to this configuration, the foamed urethane resin raw material can be moved greatly using the space in the sealed container. Thereby, each raw material mixes rapidly.

  (6) Preferably, in any one of the configurations (1) to (5), the filler includes magnetic particles, and in the foam molding step, the foam molding may be performed while applying a magnetic field.

  When a foamed urethane resin raw material having magnetic particles is foam-molded in a magnetic field, the magnetic particles can be oriented in a state of being connected to each other in the urethane foam-molded article to be produced. As a result, a heat transfer path is formed in the urethane foam molded body in the orientation direction of the magnetic particles. That is, according to this structure, the urethane foam molding excellent in heat conductivity can be manufactured efficiently. Further, as described above, in the production method of the present invention, unlike the conventional mixing method using a stirring blade or the like, there are few restrictions on the blending amount of the magnetic particles (filler). Therefore, it is possible to increase the thermal conductivity of the urethane foam molding by blending a large amount of magnetic particles.

  (7) Preferably, in any one of the constitutions (1) to (6), the filler includes thermally conductive particles made of a non-magnetic material, and magnetic particles attached to the surface of the thermally conductive particles. In the foam molding step, foam molding is preferably performed while applying a magnetic field.

  The composite particle of this configuration has thermally conductive particles and magnetic particles attached to the surface thereof. The thermally conductive particles forming the core of the composite particles have a large thermal conductivity, but are made of a nonmagnetic material. For this reason, even if a magnetic field is applied, it is not oriented alone. However, magnetic particles are attached to the surface of the thermally conductive particles constituting the composite particles. For this reason, when the foamed urethane resin material having composite particles is foam-molded in a magnetic field, the magnetic particles on the surface try to be oriented along the lines of magnetic force. Thereby, the composite particles are oriented along the magnetic field lines. That is, according to this configuration, the heat conductive particles that are not originally oriented can be oriented using the magnetic field orientation of the magnetic particles attached to the surface.

  When the composite particles are blended as the filler, the thermal conductivity of the urethane foam molded article can be increased as compared with an embodiment containing only the same amount of magnetic particles. Moreover, even if a compounding quantity is comparatively small, the improvement effect of heat conductivity can be acquired. Therefore, the influence on the physical properties of the urethane foam molded article due to the blending of the filler can be reduced. Further, by reducing the blending amount of the filler, it is possible to reduce the weight of the urethane foam molded body and reduce the cost.

  Thus, according to this structure, the urethane foam molded object excellent in heat conductivity can be manufactured efficiently. Moreover, a stirring blade is not used at the time of stirring the foamed urethane resin raw material. For this reason, the composite particles are not easily pulverized. That is, the heat conductive particles and the magnetic particles are difficult to peel off.

  (8) A stirrer for a foamed urethane resin material according to the present invention is a stirrer for a foamed urethane resin material for stirring a foamed urethane resin material having a polyol component, a polyisocyanate component, and a filler. A sealed container that contains the raw material, a support member that supports the sealed container, and a drive member that is connected to the support member and reciprocates the support member, and reciprocates the sealed container by the drive member, The urethane foam resin material is stirred by collision with the wall surface of the sealed container due to inertial force and repeated reversal of the moving direction.

  As described in the method for producing a urethane foam molded article of the present invention of (1) above, when the closed container containing the foamed urethane resin material is reciprocated, the foamed urethane resin material is subjected to inertial force by the wall surface of the sealed container. Repeated collision and reversal. Here, the foamed urethane resin raw material includes a filler. As the closed container reciprocates, the filler moves violently in the liquid raw material such as a polyol component. And stirring of a foaming urethane resin raw material is accelerated | stimulated because a filler plays a role like a stirring element. As a result, raw materials such as a polyol component, a polyisocyanate component, and a filler constituting the foamed urethane resin raw material are quickly mixed.

  According to the stirrer for a foamed urethane resin material of the present invention, the stirrer of the foamed urethane resin material is completed in a short time of about several seconds to several tens of seconds. Therefore, stirring of the foamed urethane resin raw material can be completed before the foam curing reaction proceeds.

  The reciprocating motion of the sealed container may be linear or pendulum. The direction of reciprocation may be any direction such as left and right, up and down, and diagonally. In order to uniformly mix the raw materials constituting the foamed urethane resin raw material in a shorter time, it is preferable to reduce the reciprocating stroke and increase the frequency (number of reciprocations per unit time).

  According to the stirring device of the present invention, the foamed urethane resin raw material can be stirred without using a stirring blade. For this reason, it is not necessary to clean the stirring blades, and accordingly, the burden of the cleaning work can be reduced. Moreover, it is easy to automate a series of processes for producing a urethane foam molded article. Moreover, since no stirring blade is used, mixing can be performed even if the viscosity of the raw material is increased by the addition of a filler. Therefore, for example, a urethane foam molded body in which a large amount of filler is blended can be produced from the foamed urethane resin raw material stirred by the stirring device of the present invention. Further, there is no possibility that the filler is crushed by the stirring blade. Furthermore, in the stirring apparatus of the present invention, it is not necessary to add a filler to the polyol component in advance as in the collision stirring method. For this reason, there is little possibility that the polyol component will soak into the filler or the catalyst will be adsorbed on the filler. Therefore, if the foamed urethane resin raw material stirred with the stirring device of the present invention is used, the polyol component and the polyisocyanate component can be sufficiently reacted to produce a urethane foam molded article having good physical properties.

  (9) Preferably, in the configuration of (8), at least one of the reciprocating ends of the support member may further include a stopper that collides with the support member.

  When the support member collides with the stopper at the reciprocating end, an impact force due to an inertial force is applied to the foamed urethane resin material. Then, the foamed urethane resin raw material is accelerated, and the movement in the sealed container is increased. Thereby, mixing of each raw material which comprises a foaming urethane resin raw material can be accelerated | stimulated.

  (10) Preferably, in the configuration of the above (8) or (9), the drive member is configured to reciprocate the support member in the vertical direction.

  According to this configuration, the foamed urethane resin raw material can be moved greatly using the space in the sealed container. Thereby, each raw material which comprises a foaming urethane resin raw material can be mixed rapidly.

  (11) Preferably, in any one of the configurations (8) to (10), the closed container is disposed at the other end by extruding the foamed urethane resin material from one end of the closed container to the other end. It is better to have an extrusion member that can discharge the foamed urethane resin raw material from the opened opening.

  After the completion of stirring, the foamed urethane resin raw material has a high viscosity. For this reason, when injecting the foamed urethane resin material from the sealed container into the mold, the foamed urethane resin material may remain attached to the sealed container, which may increase loss. In this regard, according to the present configuration, the sealed container includes the extrusion member. The extruding member extrudes the urethane foam raw material from one end of the sealed container toward the opening at the other end. Thereby, the foamed urethane resin raw material is quickly discharged from the opening. As a result, the foamed urethane resin raw material hardly remains in the sealed container, and the loss of the raw material is reduced. Further, it is possible to eliminate the need for cleaning the sealed container. By doing so, the burden of cleaning work is eliminated, and a series of manufacturing processes can be easily automated. In addition, the solvent used for cleaning is less likely to contaminate the environment.

It is a perspective view of the stirring apparatus of embodiment. It is a disassembled perspective view of the same stirring apparatus. It is a front view of the stirring apparatus. It is a front view in rotation position (theta) = 90 degree of the stirring apparatus. It is a front view in rotation position (theta) = 180 degrees of the stirring apparatus. It is a front view in rotation position (theta) = 270 degrees of the stirring apparatus. It is a graph showing the relationship between a rotation position and the stroke of an airtight container. It is a conceptual diagram of an accommodation process, (a) shows the time at the time of raw material addition, (b) shows the time of sealing, respectively. It is a conceptual diagram of a stirring process. It is a conceptual diagram of a casting process. It is a perspective view of a magnetic induction foam molding apparatus. It is sectional drawing of the same apparatus. It is sectional drawing of an example of the airtight container provided with the extrusion member (at the time of completion | finish of stirring of a foaming urethane resin raw material). Sectional drawing of the same airtight container at the time of discharge | emission of foaming urethane resin raw material is shown.

  Hereinafter, the manufacturing method of the urethane foam molding of this invention and embodiment of the stirring apparatus of a foaming urethane resin raw material are described.

<Stirring device for foamed urethane resin material>
[Constitution]
First, the configuration of the stirrer for foamed urethane resin material of the present embodiment (hereinafter simply referred to as “stirrer” in the embodiments) will be described. In FIG. 1, the perspective view of the stirring apparatus of this embodiment is shown. FIG. 2 shows an exploded perspective view of the stirring device. FIG. 3 shows a front view of the stirring device. As shown in FIGS. 1 to 3, the stirring device 1 of this embodiment includes a support member 2, a frame 3, a drive unit 4, and a sealed container 5. 1 to 3 all show a state at a rotational position θ = 0 ° described later.

(1) Frame 3
The frame 3 includes a base 30, two support columns 31, two guide rails 32, two bearings 33, two transverse beams 34, four stoppers 35, and a motor bracket 36. I have.

  The base 30 is made of steel and has a plate shape. The base 30 is laid on the floor of the factory. The two struts 31 are made of steel and extend in the vertical direction. The two struts 31 project upward from the left front corner and the right front corner of the upper surface of the base 30.

  The two guide rails 32 are made of steel, and are arranged on the front surfaces of the two columns 31. The guide rail 32 has a function as a guide member for guiding a support member 2 described later. The two guide rails 32 extend in the vertical direction. The guide rail 32 has a T-shaped cross section. The two transverse beams 34 are made of steel and are installed between the two columns 31. The two horizontal beams 34 are spaced apart in the vertical direction.

  The four stoppers 35 are made of rubber and have a rectangular parallelepiped block shape. The four stoppers 35 are arranged separately at the top and bottom. The two upper stoppers 35 are disposed on the lower surface of the upper transverse beam 34. The two lower stoppers 35 are disposed on the upper surface of the lower transverse beam 34. The stopper 35 has a function as an impact member that applies an impact to the sealed container 5 described later. Further, the upper stopper 35 has a function as a top dead center regulating member that regulates the top dead center of the support member 2. Further, the lower stopper 35 has a function as a bottom dead center regulating member that regulates the bottom dead center of the support member 2.

  The two bearings 33 have a rectangular parallelepiped block shape. The two bearings 33 are arranged side by side in the front-rear direction at the center of the upper surface of the base 30 in the left-right direction. The motor bracket 36 is made of steel and has a C-shape that opens downward. The motor bracket 36 is disposed at the center in the left-right direction on the upper surface of the base 30. The motor bracket 36 is disposed behind the rear bearing 33.

(2) Drive unit 4
The drive unit 4 includes a link mechanism unit 40, a motor 41, and a rotation shaft 42. The link mechanism 40 is included in the concept of the “drive member” of the present invention.

  The motor 41 is fixed to the rear end of the center of the upper surface of the base 30 in the left-right direction by a motor bracket 36. The rotating shaft 42 is made of steel and extends in the front-rear direction. The rotating shaft 42 is rotatably supported by the two bearings 33. The driving force of the motor 41 is transmitted to the rotating shaft 42 via a gear (not shown).

  The link mechanism unit 40 includes a first arm 400 and a second arm 401. The first arm 400 is made of steel and has a thin plate shape. The center in the longitudinal direction of the first arm 400 is fixed to the front end of the rotating shaft 42. The second arm 401 is made of steel and has a thin plate shape. The second arm 401 is longer than the first arm 400. One end in the longitudinal direction of the second arm 401 is rotatably connected to one end of the first arm 400. Note that nothing is connected to the other end of the first arm 400. The other end of the first arm 400 has a function as a balancer for adjusting the rotation balance.

(3) Support member 2, sealed container 5
The support member 2 includes two collision blocks 20, a stroke adjustment unit 21, a main body 22, four sliders 23, and a container holding unit 24.

  The four sliders 23 are made of steel and have a rectangular parallelepiped block shape. The slider 23 has a function as a guided member guided by the guide member. A groove having a T-shaped cross section is formed in the slider 23. The four sliders 23 are arranged separately on the left and right. The two left sliders 23 are engaged with the left guide rail 32 so as to be movable in the vertical direction. The two sliders 23 on the right are engaged with the guide rail 32 on the right so as to be movable in the vertical direction.

  The main body 22 is made of steel and includes an upper plate 220 and a back plate 221. The upper plate 220 and the back plate 221 are connected in an inverted L shape. Both the upper plate 220 and the back plate 221 have a rectangular plate shape. Four sliders 23 are fixed to the four corners of the rear surface of the back plate 221. Therefore, the main body 22 can reciprocate in the vertical direction along the two guide rails 32.

  The container holding part 24 is disposed on the upper surface of the upper plate 220. The container holding unit 24 includes two side pillars 240 and a pressing plate 241. The two side columns 240 are made of steel and have a prismatic shape. The two side pillars 240 project upward from the vicinity of both left and right edges of the upper surface of the upper plate 220. The pressing plate 241 is made of steel and has a rectangular plate shape. The pressing plate 241 is installed between the upper ends of the two side columns 240.

  The sealed container 5 includes a container body 50 and a lid 51. The closed container 5 contains a foamed urethane resin raw material. The sealed container 5 is held by the container holding part 24. The container main body 50 is made of steel and has a cup shape opening upward. The container body 50 is disposed between the two side columns 240. The lid 51 is made of steel and has a disk shape. The lid | cover 51 is arrange | positioned in the opening part of the container main body 50 so that opening and closing is possible. The lid 51 is pressed from above by a pressing plate 241. The lid 51 hermetically seals the opening of the container body 50.

  The stroke adjustment unit 21 includes an upper end support plate 210, a lower end support plate 211, two inter-spring blocks 212, and four springs 213. The stroke adjusting unit 21 has a function of adjusting the stroke of the reciprocating motion of the hermetic container 5 in the vertical direction.

  The upper end support plate 210 is made of steel and has a rectangular plate shape. The upper end support plate 210 is disposed on the lower surface of the upper plate 220. The lower end support plate 211 is made of steel and has a rectangular plate shape. The lower end support plate 211 is disposed below the upper end support plate 210. The other longitudinal end of the second arm 401 of the link mechanism portion 40 is rotatably connected to the center of the lower end support plate 211 in the left-right direction.

  The four springs 213 are so-called coil springs. Of the four springs 213, the upper two springs 213 are fixed to the lower surface of the upper end support plate 210. The two lower springs 213 are fixed to the upper surface of the lower end support plate 211.

  The two inter-spring blocks 212 are made of steel and have a rectangular parallelepiped block shape. Of the two inter-spring blocks 212, the left inter-spring block 212 is interposed between a pair of upper and lower springs 213. The right inter-spring block 212 is interposed between a pair of upper and lower springs 213 on the right side. With the four springs 213, the distance between the upper end support plate 210 and the lower end support plate 211 can be expanded and contracted in the vertical direction.

[Movement]
Next, the movement of the stirring device of this embodiment will be described. In FIG. 4, the front view in rotational position (theta) = 90 degrees of the stirring apparatus of this embodiment is shown. FIG. 5 shows a front view of the stirring device at the rotational position θ = 180 °. FIG. 6 shows a front view of the stirring device at the rotational position θ = 270 °. FIG. 7 shows a graph showing the relationship between the rotation position and the stroke of the sealed container. 3 to 7 correspond to the position of the connecting portion a between the first arm 400 and the second arm 401 with respect to the rotation shaft 42. 3 to 7, for convenience of explanation, the stopper 35 is shown with a right-up hatching, and the collision block 20 is shown with a left-up hatching.

  When the driving force from the motor 41 is transmitted to the rotating shaft 42, the rotating shaft 42 rotates around its own axis. For this reason, the first arm 400 and the second arm 401 also rotate counterclockwise when viewed from the front in the order of the rotational position θ = 0 ° → 90 ° → 270 ° → 360 ° (= 0 °). Here, the lower arm support plate 211 of the stroke adjusting unit 21 is connected to the second arm 401. On the other hand, as shown in FIG. 1, the moving direction of the support member 2 including the stroke adjusting unit 21 is regulated in the vertical direction by the two guide rails 32 and the four sliders 23. For this reason, the support member 2 reciprocates in the vertical direction by the rotation of the second arm 401.

  As shown in FIG. 3, at the rotational position θ = 0 ° (bottom dead center), the lower surfaces of the two collision blocks 20 of the support member 2 collide with the upper surfaces of the two lower stoppers 35. For this reason, as shown in FIG. 7, the actual stroke (solid line) is shorter than the stroke (dotted line) when the collision block 20 does not collide with the stopper 35. The stroke difference (difference between the dotted line and the solid line) is absorbed by the extension of the four springs 213 of the stroke adjustment unit 21.

  As shown in FIG. 4, at the rotational position θ = 90 °, the two collision blocks 20 of the support member 2 are lifted apart from the two stoppers 35 below.

  As shown in FIG. 5, at the rotational position θ = 180 ° (top dead center), the upper surfaces of the two collision blocks 20 of the support member 2 collide with the lower surfaces of the two upper stoppers 35. For this reason, as shown in FIG. 7, the actual stroke (solid line) is shorter than the stroke (dotted line) when the collision block 20 does not collide with the stopper 35. The stroke difference (difference between the dotted line and the solid line) is absorbed by the four springs 213 of the stroke adjusting unit 21 contracting.

  As shown in FIG. 6, at the rotational position θ = 270 °, the two collision blocks 20 of the support member 2 are separated from the two upper stoppers 35 and are lowered. Thereafter, the rotation position θ = 0 ° shown in FIG.

  Thus, with the rotation of the second arm 401, the support member 2, that is, the sealed container 5, repeats reciprocation in the vertical direction. The top dead center of the stroke of the sealed container 5 is regulated by the two upper stoppers 35. The bottom dead center of the stroke of the sealed container 5 is regulated by the two stoppers 35 below. The moving direction of the sealed container 5 is reversed from top to bottom at the top dead center and from bottom to top at the bottom dead center. At this time, an impact force due to an inertial force is applied to the foamed urethane resin raw material in the sealed container 5.

<Method for producing urethane foam molding>
Next, the manufacturing method of the urethane foam molding of this embodiment is demonstrated. In the method for producing a urethane foam molded body of the present embodiment, after the foamed urethane resin raw material is stirred using the stirring device 1, the foamed urethane resin raw material is foam-molded to manufacture a urethane foam molded body. The manufacturing method of the urethane foam molding of this embodiment has an accommodation process, a stirring process, a casting process, and a foam molding process.

[Containment process]
In this step, the urethane foam resin material having a polyol component, a polyisocyanate component, and a filler is housed in a sealed container. FIG. 8 shows a conceptual diagram of this process. (A) shows when the raw material is charged, and (b) shows when the material is sealed. In FIG. 8, the amount of filler is exaggerated for convenience of explanation. As shown in FIG. 8A, first, the weighed filler F is put into the container body 50. Next, the liquid raw material U1 prepared in advance is put into the container main body 50. And as shown in FIG.8 (b), the cover 51 is put on the opening part of the container main body 50, and it seals. In the present embodiment, the urethane foam resin raw material U2 includes a filler F and a liquid raw material U1. The filling rate of the foamed urethane resin raw material U2 in the sealed container 5 is about 30% by volume.

  As the filler F, the same amount of composite particles having stainless steel particles attached to the surface of expanded graphite particles and composite particles having stainless steel particles attached to the surface of natural graphite particles were used. The compounding quantity of the filler F is about 4 volume% when the volume of the urethane foam molding to manufacture is 100 volume%. In addition, the liquid raw material U1 is prepared by mixing a polyether polyol as a polyol component, a premix polyol (POL) containing a crosslinking agent, a foaming agent, and a catalyst, and diphenylmethane diisocyanate (MDI) as a polyisocyanate component. did.

[Stirring step]
In this step, the closed container is reciprocated to stir the foamed urethane resin material. In FIG. 9, the conceptual diagram of this process is shown. First, the sealed container 5 containing the foamed urethane resin raw material U2 is installed in the stirring device 1 shown in FIG. Specifically, the sealed container 5 is arranged on the upper surface of the upper plate 220 of the support member 2 and fixed by the container holding unit 24. Next, the power of the motor 41 is turned on, and the support member 2 is reciprocated in the vertical direction by the rotation of the first arm 400 and the second arm 401. Thereby, the airtight container 5 reciprocates up and down. Then, as shown in FIG. 9, the foamed urethane resin material U <b> 2 in the sealed container 5 mainly collides with the lid 51 and the bottom surface due to inertial force and repeats reversal. Thereby, the filler F and the liquid raw material U1 are mixed. After the reciprocating motion of the sealed container 5 is performed at a frequency of 2.8 Hz for about 7 seconds, the power of the motor 41 is turned off and the stirring is finished.

[Casting process]
In this step, the foamed urethane resin material is discharged from the sealed container and injected into the mold cavity. In FIG. 10, the conceptual diagram of this process is shown. First, the sealed container 5 is removed from the stirring device 1 and the lid 51 is opened. Next, as shown in FIG. 10, the agitated urethane resin material U <b> 2 from the opening of the container body 50 is placed in the cavity 61 of the lower mold 60 </ b> D of the mold 6 (see FIGS. 11 and 12 described later). Inject. Then, the upper mold 60U is united with the lower mold 60D, and the mold 6 is clamped.

[Foam molding process]
In this step, the molding die is installed in a magnetic induction foam molding apparatus, and the foamed urethane resin material is foam molded. First, the configuration of the magnetic induction foam molding apparatus will be described. FIG. 11 shows a perspective view of the magnetic induction foam molding apparatus. FIG. 12 shows a sectional view of the apparatus. In FIG. 12, for convenience of explanation, hatching of the yoke portion and the core portion is omitted. As shown in FIGS. 11 and 12, the magnetic induction foam molding apparatus 7 includes a gantry 70, an electromagnet portion 72, and a molding die 6.

  The electromagnet portion 72 is placed on the upper surface of the gantry 70. The electromagnet portion 72 and the gantry 70 are fixed by screwing the bracket 71 to each. The electromagnet portion 72 includes yoke portions 73U and 73D, coil portions 74L and 74R, and pole pieces 75U and 75D.

  The yoke portion 73U is made of iron and has a flat plate shape. Similarly, the yoke portion 73D is made of iron and has a flat plate shape. The yoke portions 73U and 73D are arranged to face each other in the vertical direction.

  The coil portion 74L is interposed between the yoke portions 73U and 73D. The coil portion 74L is disposed on the left side of the mold 6. Two coil portions 74L are arranged in the vertical direction. Each of the coil portions 74L includes a core portion 740L and a conducting wire 741L. The core portion 740L is made of iron and has a columnar shape extending in the vertical direction. The conducting wire 741L is wound around the outer peripheral surface of the core portion 740L. The conducting wire 741L is connected to a power source (not shown).

  The coil portion 74R is interposed between the yoke portions 73U and 73D. The coil portion 74 </ b> R is disposed on the right side of the mold 6. Two coil portions 74R are arranged in the vertical direction. The coil portions 74R each have the same configuration as the coil portion 74L. That is, the coil portion 74R includes a core portion 740R and a conducting wire 741R. The conducting wire 741R is wound around the outer peripheral surface of the core portion 740R. The conducting wire 741R is connected to a power source (not shown).

  The pole piece 75U is made of iron and has a flat plate shape. The pole piece 75U is disposed at the center of the lower surface of the yoke portion 73U. The pole piece 75U is interposed between the yoke portion 73U and the mold 6. The pole piece 75D is made of iron and has a flat plate shape. The pole piece 75D is disposed at the center of the upper surface of the yoke portion 73D. The pole piece 75D is interposed between the yoke portion 73D and the mold 6.

  The molding die 6 is disposed between the coil portion 74L and the coil portion 74R. The mold 6 includes an upper mold 60U and a lower mold 60D. The upper mold 60U is made of aluminum and has a square plate shape. The lower mold 60D is made of aluminum and has a rectangular parallelepiped shape. A recess is formed on the upper surface of the lower mold 60D. The said recessed part is exhibiting the rectangular parallelepiped shape opened upwards. Then, the upper die 60U and the lower die 60D are united to define a rectangular parallelepiped cavity 61 (length 130 mm × width 130 mm × thickness 20 mm). The cavity 61 is filled with a foamed urethane resin raw material U2.

  Next, a foam molding method using the magnetic induction foam molding apparatus 7 will be described. First, when both the power source connected to the conducting wire 741L and the power source connected to the conducting wire 741R are turned on, the upper end of the core portion 740L of the coil portion 74L is magnetized to the N pole and the lower end is magnetized to the S pole. For this reason, a magnetic force line L (indicated by a dotted line in FIG. 12) is generated in the core portion 740L from the bottom to the top. Similarly, the upper end of the core portion 740R of the coil portion 74R is magnetized to the N pole and the lower end is magnetized to the S pole. For this reason, lines of magnetic force L are generated in the core portion 740R from below to above.

  The lines of magnetic force L radiated from the upper end of the core portion 740L of the coil portion 74L flow into the cavity 61 of the mold 6 through the yoke portion 73U and the pole piece 75U. Then, it flows into the lower end of the core part 740L through the pole piece 75D and the yoke part 73D. Similarly, the lines of magnetic force L radiated from the upper end of the core portion 740R of the coil portion 74R flow into the cavity 61 of the mold 6 through the yoke portion 73U and the pole piece 75U. Then, it flows into the lower end of the core portion 740R through the pole piece 75D and the yoke portion 73D. Thus, since the magnetic lines L constitute a closed loop, the leakage of the magnetic lines L is suppressed. In the cavity 61 of the mold 6, a uniform magnetic field is formed by magnetic lines of force L that are substantially parallel from the top to the bottom. Specifically, the magnetic flux density in the cavity 61 was about 200 mT. Further, the difference in magnetic flux density in the cavity 61 was within ± 3%.

  Foam molding was performed while applying a magnetic field for the first about 2 minutes, and for about 5 minutes without applying a magnetic field. After the foam molding was completed, the mold was removed to obtain a urethane foam molded article.

<Effect>
Next, the method for producing the urethane foam molded article of the present embodiment and the function and effect of the stirring device will be described. According to the stirring device 1 of the present embodiment, the sealed container 5 containing the foamed urethane resin raw material U2 is reciprocated in the vertical direction at a high frequency of 2.8 Hz. Then, the foamed urethane resin raw material U2 mainly collides with the lid 51 and the bottom surface due to inertial force and repeats reversal. At this time, the filler F in the urethane foam raw material U2 moves violently in the liquid raw material U1. Thereby, the filler F and the liquid raw material U1 are rapidly mixed. That is, according to the stirring apparatus 1 of this embodiment, stirring of the foaming urethane resin raw material U2 containing the filler F can be performed in a short time.

  In the method for producing a urethane foam molded body of the present embodiment, the foamed urethane resin raw material U2 is stirred using the stirring device 1. Therefore, stirring of the foamed urethane resin raw material U2 can be completed before the foam curing reaction proceeds. Further, unlike the collision stirring method, it is not necessary to add the filler F to the polyol component in advance. For this reason, there is little possibility that the polyol component will soak into the filler F or the catalyst will be adsorbed on the filler F. In particular, in the manufacturing method of this embodiment, the polyol component and the polyisocyanate component are mixed in advance to prepare the liquid raw material U1. For this reason, the penetration of the polyol component into the filler F and the adsorption of the catalyst can be further suppressed. Therefore, according to the manufacturing method of the present embodiment, a urethane foam molded article having good physical properties can be easily manufactured.

  According to the stirring device 1 of the present embodiment, no stirring blade is used for mixing the urethane foam resin raw material U2. For this reason, it is not necessary to wash a stirring blade | wing every time it stirs. Therefore, the burden of the cleaning work is reduced, and it is easy to automate a series of manufacturing processes. Moreover, since the stirring blade is not used, even if the raw material viscosity is increased by the addition of the filler F, mixing can be performed. Therefore, according to the manufacturing method of this embodiment using the stirrer 1, for example, a urethane foam molded body in which a large amount of the filler F is blended can also be manufactured. In the present embodiment, composite particles are used as the filler F. However, since the stirring blade is not used during stirring, the possibility that the filler F is crushed is small. That is, the heat conductive particles and the magnetic particles are difficult to peel off.

  Moreover, the composite particles have magnetic particles and heat conductive particles. For this reason, compared with the aspect containing only the same amount of magnetic particles, the thermal conductivity of the urethane foam molded article is increased. Moreover, even if a compounding quantity is comparatively small, the improvement effect of heat conductivity can be acquired. Therefore, the influence on the physical properties of the urethane foam molded product by blending the filler F can be reduced. Moreover, when the compounding quantity of the filler F is reduced, the weight reduction of a urethane foaming molded object and cost reduction are attained.

  In the stirring device 1 of the present embodiment, the moving direction of the sealed container 5 can be regulated by the slider 23 and the guide rail 32. Further, the support member 2 is caused to collide with the stopper 35 at the top dead center and the bottom dead center. Then, the impact force resulting from the inertial force is applied to the urethane foam raw material U2. Thereby, the foamed urethane resin raw material U2 is accelerated, and the movement in the sealed container 5 is increased. As a result, mixing of the filler F and the liquid raw material U1 constituting the urethane foam resin raw material U2 is promoted. Here, the support member 2 includes a stroke adjustment unit 21. The support member 2 can collide with the stopper 35 while allowing the second arm 401 to rotate by the expansion and contraction of the four springs 213 of the stroke adjusting unit 21. Moreover, the stroke of the airtight container 5 can be adjusted by adjusting the lengths of the first arm 400 and the second arm 401. Further, the stroke of the closed container 5 can be adjusted by adjusting the position of the stopper 35.

  In the present embodiment, the hermetic container 5 is reciprocated in the vertical direction. And the filling rate of the urethane-urethane resin raw material U2 in the airtight container 5 is about 30 volume%. In other words, about 70% by volume above the closed container 5 is a space. Therefore, the foamed urethane resin raw material U2 can be moved greatly by utilizing the space in the sealed container 5. Thereby, the filler F and the liquid raw material U1 mix rapidly.

<Others>
In the above, the manufacturing method of the urethane foam molding of this invention and embodiment of the stirring apparatus were demonstrated. However, the embodiment is not particularly limited to the above embodiment. Various modifications and improvements that can be made by those skilled in the art are also possible.

  For example, in the above embodiment, the hermetic container is reciprocated linearly in the vertical direction. However, the sealed container may be reciprocated like a pendulum. Further, the reciprocating direction may be the left-right direction or the oblique direction. Further, the stroke and frequency of the reciprocating motion are not limited. In order to mix the constituent raw materials of the foamed urethane resin raw material uniformly in a shorter time, it is preferable to reduce the reciprocating stroke and increase the frequency. For example, the frequency may be 2 Hz or higher. If it is 5 Hz or more, it is more suitable. Further, the time for reciprocating the closed container (stirring time) is not particularly limited. What is necessary is just to determine suitably considering a stirring state and the advancing state of the foam hardening reaction of a foaming urethane resin raw material.

  In the above embodiment, the support member is caused to collide with the stopper at the top dead center and the bottom dead center. However, the stopper is not always necessary. The configuration of the drive unit is not particularly limited. For example, a cam mechanism portion may be arranged instead of the link mechanism portion. Moreover, you may arrange | position a linear motor as a motor. A ball screw and a fluid (oil, air) cylinder may be arranged instead of the motor. Moreover, you may arrange | position a round rod-shaped guide rod instead of a guide rail. In this case, a guided hole through which the guide rod is inserted may be formed in the slider.

  The structure of the container holding part for fixing the sealed container is not particularly limited. For example, a toggle clamp or the like may be used as the container holding unit. Specifically, a toggle clamp may be disposed on the upper surface of the side column 240 and the lid 51 of the sealed container 5 may be pressed.

  Further, the shape, size, etc. of the sealed container are not particularly limited. For example, you may comprise an airtight container provided with the extrusion member which can discharge | emit foaming urethane resin raw material. As the extrusion member, one that can extrude the foamed urethane resin raw material in the direction of the opening along the side wall of the sealed container is desirable. In FIG. 13, sectional drawing of an example of the airtight container provided with the extrusion member is shown. FIG. 13 shows a state immediately after the stirring of the foamed urethane resin raw material is completed. Further, FIG. 14 shows a cross-sectional view of the sealed container at the time of discharging the foamed urethane resin raw material.

  As shown in FIG. 13, the sealed container 5 includes a container body 50 and a lid 51. Inside the airtight container 5, a foamed urethane resin material U <b> 2 is accommodated. The container body 50 includes a cylindrical portion 500 and a bottom plate 501. The cylinder part 500 is made of steel and has a cylindrical shape that opens up and down. The bottom plate 501 is made of steel and has a disk shape. The bottom plate 501 is disposed in the opening below the cylindrical portion 500. The diameter of the bottom plate 501 is the same as the inner diameter of the cylindrical portion 500. The lid 51 is made of steel and has a disk shape. The lid 51 is disposed in an opening above the cylinder portion 500 so as to be opened and closed.

  From the time when the foamed urethane resin raw material U2 is accommodated until the end of stirring, the bottom plate 501 is fixed to the cylindrical portion 500 by a fixing member (not shown). On the other hand, when the foamed urethane resin material U2 is discharged, the lid 51 is removed and the bottom plate 501 is released. Thereby, as shown in FIG. 14, the bottom plate 501 can be moved in the direction of the opening of the cylindrical portion 500 by being pressed by the pressing jig 52. Thus, the bottom plate 501 is movable along the cylindrical portion 500 when the urethane foam resin material U2 is discharged. The bottom plate 501 is included in the concept of the “extrusion member” of the present invention.

  Here, the pressing jig 52 includes a piston 520 and a rod 521 (in FIG. 14, for convenience of explanation, the pressing jig 52 is omitted from the hatching). The piston 520 has a disk shape. The diameter of the piston 520 is substantially the same as the diameter of the bottom plate 501. The rod 521 is disposed at the center of the upper surface of the piston 520. In FIG. 14, when the rod 521 is moved obliquely downward as indicated by the white arrow, the piston 520 moves along with the bottom plate 501 in the cylindrical portion 500 toward the opening. Thereby, the foamed urethane resin material U2 can be quickly discharged from the opening. At this time, the side peripheral surface of the bottom plate 501 is in sliding contact with the inner peripheral surface of the cylindrical portion 500. Therefore, the foamed urethane resin material U <b> 2 is unlikely to remain in the container body 50. That is, there is little loss of raw materials. Moreover, the cleaning of the container body 50 can be eliminated. By doing so, the burden of cleaning work is eliminated, and a series of manufacturing processes can be easily automated. In addition, the solvent used for cleaning is less likely to contaminate the environment.

  In the said embodiment, the liquid raw material which mixed the polyol component and the polyisocyanate component previously was used. However, premixing of the polyol component and the polyisocyanate component is not always necessary. That is, in the housing step, raw materials such as a crosslinking agent, a foaming agent, a catalyst, etc., in addition to the polyol component, the polyisocyanate component, and the filler, may be charged into the sealed container. Moreover, what is necessary is just to determine the filling rate of a foaming urethane resin raw material suitably according to the shape of an airtight container. For example, 60 volume% or less is suitable.

  In the above embodiment, since composite particles containing magnetic particles are used as the filler, foam molding is performed while applying a magnetic field. However, if the magnetic field orientation of the filler is not necessary, of course, foam molding may be performed without applying a magnetic field. In addition, when foam molding is performed while applying a magnetic field, the apparatus to be used, molding conditions and the like are not particularly limited. For example, when a magnetic field is applied while the viscosity of the foamed urethane resin material is relatively small, the magnetic particles are easily oriented.

What is necessary is just to select the material of a filler suitably according to the use etc. of a urethane foam molding. For example, when improving thermal conductivity, materials having high thermal conductivity, for example, carbon materials such as graphite and carbon fiber, aluminum, gold, silver, copper, and alloys based on these are suitable. It is. In addition, a magnetic material is also preferable from the viewpoint of orientation and formation of a heat transfer path. For example, ferromagnetics such as iron, nickel, cobalt, gadolinium, stainless steel, magnetite, maghemite, manganese zinc ferrite, barium ferrite, strontium ferrite, antiferromagnetic materials such as MnO, Cr ₂ O ₃ , FeCl ₂ , MnAs, And alloys using them. In addition, when a magnetic particle is contained as a filler, there exists a possibility that the self-extinguishing property of a urethane foam molding may fall. Therefore, in order to improve flame retardancy, it is desirable to use expanded graphite or the like having a flame retarding effect as a filler.

  Moreover, you may use the composite particle which compounded several kind of particle | grains like the said embodiment. The composite particles can be produced by a wet electrostatic adsorption method, a dry pulverization and mixing method, a stirring granulation method, a mechanochemical method, or the like. For example, when producing composite particles in which magnetic particles are adhered to the surface of thermally conductive particles by the agitation granulation method, a powder for thermally conductive particles, a powder for magnetic particles, and a binder for adhering both are included. The raw material may be granulated with high-speed stirring. According to the stirring granulation method, the heat conductive particles and the magnetic particles can be softly bonded with the binder. For this reason, even when the thermally conductive particles have a shape with a high thermal conductivity (a shape with a large aspect ratio), they can be combined with the magnetic particles without breaking the shape. The type of binder may be appropriately selected in consideration of the types of heat conductive particles and magnetic particles, the influence on foam molding, and the like. During the production of composite particles, frictional heat is generated by high-speed stirring. For this reason, as a binder, a non-volatile thing is desirable. In view of the environment, a water-based binder is preferable. Examples of the aqueous binder include methyl cellulose, carboxymethyl cellulose, hydroxypropyl methyl cellulose, and polyvinyl alcohol.

  For the polyol component and polyisocyanate component constituting the foamed urethane resin material, known materials may be employed. Examples of the polyol component include polyvalent hydroxy compounds, polyether polyols, polyester polyols, polymer polyols, polyether polyamines, polyester polyamines, alkylene polyols, urea-dispersed polyols, melamine-modified polyols, polycarbonate polyols, What is necessary is just to select suitably from acrylic polyols, polybutadiene polyols, phenol modified polyols, etc. Polyisocyanate components include tolylene diisocyanate, phenylene diisocyanate, xylylene diisocyanate, diphenylmethane diisocyanate, triphenylmethane triisocyanate, polymethylene polyphenyl isocyanate, naphthalene diisocyanate, and derivatives thereof (for example, obtained by reaction with polyols). May be appropriately selected from among prepolymers, modified polyisocyanates and the like.

The foamed urethane resin raw material may further have a catalyst, a foaming agent, a foam stabilizer, a plasticizer, a crosslinking agent, a flame retardant, an antistatic agent, a viscosity reducing agent, a stabilizer, a filler, a colorant, and the like. . Depending on the type of catalyst, the reaction rate of foaming and curing can be adjusted. Moreover, the viscosity of a foaming urethane resin raw material can be adjusted by mix | blending a plasticizer, a viscosity reducing agent, etc. Examples of the catalyst include amine-based catalysts such as tetraethylenediamine, triethylenediamine, and dimethylethanolamine, and organometallic catalysts such as tin laurate and tin octoate. Water is preferred as the foaming agent. In addition to water, methylene chloride, chlorofluorocarbons, CO ₂ gas, and the like can be given. As the foam stabilizer, a silicone foam stabilizer is suitable, and as the crosslinking agent, triethanolamine, diethanolamine and the like are suitable.

  Next, the present invention will be described more specifically with reference to examples.

<Production of composite particles>
Composite particles were produced as follows. As thermally conductive particles, expanded graphite powder (“SYZR502FP” purchased from Sanyo Trading Co., Ltd.) and natural graphite powder (“F # 2” manufactured by Nippon Graphite Industries Co., Ltd.), flake shape, average particle diameter of 130 μm, heat Composite particles were manufactured using stainless steel powder (“DAP410L”, SUS410, spherical shape, average particle diameter of 10 μm, manufactured by Daido Steel Co., Ltd.) as magnetic particles using a conductivity of 250 W / m · K. First, 50 parts by mass of expanded graphite powder, 50 parts by mass of natural graphite powder, 175 parts by mass of stainless steel powder, and 2 parts by mass of hydroxypropylmethylcellulose (“TC-5” manufactured by Shin-Etsu Chemical Co., Ltd.) as a binder, Was put into a container of a high speed stirring type mixing granulator (“NMG-1L” manufactured by Nara Machinery Co., Ltd.) and mixed for about 3 minutes. Next, water was added and mixed for another 20 minutes. The obtained powder was dried to obtain a mixed powder of composite particles A having stainless steel particles attached to the surface of expanded graphite particles and composite particles B having stainless steel particles attached to the surface of natural graphite particles.

<Manufacture of urethane foam molding>
[Example 1]
Using the produced mixed powder as a filler, a urethane foam molded article was produced using the stirring device 1 and the magnetic induction foam molding device 7 of the above embodiment (see FIG. 1, FIG. 11, etc.). The mixed powder is composed of substantially the same amount of composite particles A and composite particles B.

  First, polyether polyol (“S-0248” manufactured by Sumika Bayer Urethane Co., Ltd., average molecular weight 6000, functional group number 3, OH value 28 mg KOH / g) 100 parts by mass, and diethylene glycol as a crosslinking agent (Mitsubishi Chemical Co., Ltd.) ) 2 parts by mass, 0.5 parts by mass of foaming agent water, and amine catalyst (“Kao Raiser (registered trademark) No. 31” and “Kaor riser No. 12” manufactured by Kao Corporation) each of 0. 15 parts by mass, 20.66 parts by mass of a plasticizer dialkyl phthalate (“DL-911P” manufactured by Shell Chemicals Japan Co., Ltd.) and a silicone-based foam stabilizer (“SZ-1333” manufactured by Toray Dow Corning Co., Ltd.) ) 0.5 parts by mass was mixed to prepare a premix polyol. In addition, diphenylmethane diisocyanate (MDI) (“BASFINOAC Polyurethane Co., Ltd.“ Formlite (registered trademark) 7500B ”) was prepared as a polyisocyanate component. And the premix polyol and MDI were mixed and the liquid raw material was prepared.

  Next, the produced mixed powder was put into the container body 50. Subsequently, the prepared liquid raw material was put into the container main body 50. And the lid | cover 51 was put on the opening part of the container main body 50, and it sealed. The filling rate of the mixed powder and the liquid raw material (foamed urethane resin raw material) in the sealed container 5 was about 30% by volume.

  Next, the sealed container 5 was installed in the stirring device 1. And the stirring apparatus 1 was operated and the airtight container 5 was reciprocated at a frequency of 2.8 Hz for about 7 seconds. Then, the foamed urethane resin raw material in the sealed container 5 was injected into the cavity 61 of the mold 6. After the mold 6 was clamped, the mold 6 was installed in the magnetic induction foam molding apparatus 7 to perform foam molding. Foam molding was performed while applying a magnetic field for the first about 2 minutes, and for about 5 minutes without applying a magnetic field. After the foam molding was completed, the mold was removed to obtain a urethane foam molded article. The obtained urethane foam molded article was used as the urethane foam molded article of Example 1. In the urethane foam molded article of Example 1, the content of the filler (composite particles A and B) was about 4% by volume when the volume of the urethane foam molded article was 100% by volume.

[Example 2]
A urethane foam molded article was produced in the same manner as in Example 1 except that only stainless steel powder (same as above) was used as the filler. The obtained urethane foam molded article was used as the urethane foam molded article of Example 2.

[Example 3]
A urethane foam molded body was produced in the same manner as in Example 1 except that only natural graphite powder (same as above) was used as the filler and foam molding was performed without using the magnetic induction foam molding apparatus 7. The obtained urethane foam molded article was used as the urethane foam molded article of Example 3.

<Evaluation>
After stirring, when the foamed urethane resin raw material was poured into the mold 6 from the sealed container 5, the foamed urethane resin raw material was visually observed. In any of the examples, the filler and the liquid raw material were sufficiently mixed. It was. Moreover, the external appearance and cross section of the urethane foam moldings of Examples 1 to 3 were visually observed. As a result, in the urethane foam moldings of Examples 1 and 2, the fillers were aligned and aligned without being aggregated. Also, in the urethane foam molded body of Example 3, the filler was dispersed substantially uniformly without agglomeration.

  According to the method for producing a urethane foam molded article and the stirrer for a foamed urethane resin material of the present invention, the filler and the liquid material can be mixed efficiently in a short time. The manufactured urethane foam molded article can be used in a wide range of fields such as automobiles, electronic devices, and architecture. For example, soundproof tires for reducing noise caused by road surface unevenness, engine covers and side covers arranged in the engine room of a vehicle to reduce engine noise, motors for office automation (OA) devices and home appliances It is suitable as a sound absorbing material for a computer, a heat radiating sound absorbing material for an electronic device such as a personal computer, a sound absorbing material for inner and outer walls of a house, and a vibration isolating material used for a reactor for a power conditioner of a solar power generation system.

1: Stirring device 2: Support member 20: Collision block 21: Stroke adjustment unit 22: Main body 23: Slider 24: Container holding unit 210: Upper end support plate 211: Lower end support plate 212: Spring block 213: Spring 220: Upper plate 221: Back plate 240: Side column 241: Press plate 3: Frame 30: Base 31: Support column 32: Guide rail 33: Bearing 34: Cross beam 35: Stopper 36: Motor bracket 4: Drive unit 40: Link mechanism unit (drive member) 41) Motor 42: Rotating shaft 400: First arm 401: Second arm 5: Sealed container 50: Container body 51: Lid 52: Pressing jig 500: Tube portion 501: Bottom plate (extrusion member) 520: Piston 521: Rod 6: Mold 60D: Lower mold 60U: Upper mold 61: Cavity 7: Magnetic induction foam molding apparatus 70: Mounting frame 71 : Bracket 72: Electromagnet part 73D, 73U: Yoke part 74L, 74R: Coil part 75D, 75U: Pole piece 740L, 740R: Core part 741L, 741R: Conductor a: Connecting part F: Filler L: Magnetic field line U1: Liquid raw material U2 : Raw material for urethane foam

Claims (9)

A method for producing a urethane foam molded article for producing a urethane foam molded article by foam molding a foamed urethane resin raw material having a polyol component, a polyisocyanate component and a filler,
An accommodating step of accommodating the foamed urethane resin raw material in an airtight container fixed to a reciprocating support member ;
The airtight container is reciprocated by reciprocating the support member while colliding with at least one of the reciprocating ends , and the foamed urethane resin material collides with the wall surface of the airtight container due to inertial force. A stirring step of stirring the foamed urethane resin raw material by repeating inversion;
A foam molding step of foam-molding the stirred foamed urethane resin material;
A method for producing a urethane foam molded article comprising:   In the said foaming urethane resin raw material, the said polyol component and the said polyisocyanate component are the manufacturing methods of the urethane foam molding of Claim 1 previously mixed. The method for producing a urethane foam molded article according to claim 1 or 2, wherein a filling rate of the foamed urethane resin raw material in the sealed container is 60% by volume or less. The method for producing a urethane foam molded article according to any one of claims 1 to 3 , wherein in the stirring step, the closed container is reciprocated in the vertical direction. The filler includes magnetic particles,
The method for producing a urethane foam molded article according to any one of claims 1 to 4 , wherein foam molding is performed while applying a magnetic field in the foam molding step. The filler includes composite particles having thermally conductive particles made of a non-magnetic material and magnetic particles attached to the surface of the thermally conductive particles,
The method for producing a urethane foam molded article according to any one of claims 1 to 5 , wherein foam molding is performed while applying a magnetic field in the foam molding step. A stirrer for a foamed urethane resin material for stirring a foamed urethane resin material having a polyol component, a polyisocyanate component and a filler,
A sealed container containing the urethane foam resin raw material;
A support member for supporting the sealed container;
A drive member coupled to the support member for reciprocating the support member;
A stopper that collides with the support member at at least one of the reciprocating ends of the support member;
With
The drive member causes the support member to reciprocate while colliding with at least one of the reciprocating ends of the support member to reciprocate the airtight container, and the urethane foam resin material collides with the wall surface of the airtight container by inertial force. A stirrer for a foamed urethane resin material, which stirs the foamed urethane resin material by repeatedly reversing the moving direction. A stirrer for a foamed urethane resin material for stirring a foamed urethane resin material having a polyol component, a polyisocyanate component and a filler,
A sealed container containing the urethane foam resin raw material;
A support member for supporting the sealed container;
A drive member coupled to the support member for reciprocating the support member;
With
The sealed container includes an extrusion member that extrudes the foamed urethane resin raw material from one end to the other end of the sealed container and can discharge the foamed urethane resin raw material from an opening disposed at the other end.
The airtight container is reciprocated by the driving member, and the foamed urethane resin raw material collides with the wall surface of the airtight container due to inertial force and repeatedly reverses the moving direction, thereby stirring the foamed urethane resin raw material. Stirring device for foamed urethane resin material. The said drive member is a stirring apparatus of the foaming urethane resin raw material of Claim 7 or Claim 8 which reciprocates the said supporting member to an up-down direction.

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