JP2005082926A - Cushioning material and bedding core material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a cushioning material excellent in a cushing property, free from loss of bulkiness and having good air permeability. <P>SOLUTION: The cushioning material 1 is composed of a honey comb structure 2 in which fiber containing a fused material of low-melting fiber is arranged in a vertical direction and a fiber layer 3 attached to one side or both surfaces of the honey comb structure 2. The honey comb structure 2 has high stiffness and is excellent in air permeability. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a cushioning material and a futon core material made of the cushioning material.

  Conventionally, as shown in FIG. 4, a futon core material (21) is provided in which hard cotton (22,22) is stacked in two layers and wound around it with quilting (24). (For example, refer to Patent Documents 1 and 2).

Japanese Patent Laid-Open No. 2000-300396 (Claim 1, FIG. 3) JP-A-5-137857 (Claim 1, FIG. 3)

  In the conventional futon core material (21), the cushioning property is not sufficient, there is a sag, and the air permeability is also insufficient. Furthermore, it takes time and effort to wind the cotton wrap (23), quilting (24), and even if the wrapping (23) or quilting is applied, the shape tends to collapse. There was a problem.

As a means for solving the above-described conventional problems, the present invention provides a honeycomb structure (2) in which fibers containing a melt of low melting point fibers are arranged in the longitudinal direction, and one or both surfaces of the honeycomb structure (2). A cushioning material (1) comprising a fiber layer (3) to be applied is provided.
The honeycomb structure (2) and the fiber layer (3) are bonded by needle punching, or the fiber layer (3) contains low-melting-point fibers, and the honeycomb structure (2) And the fiber layer (3) are bonded to each other by heat-softening the low melting point fiber.
The fiber layer (3) preferably contains silicon-processed fibers, and the fiber layer (3) contains a mixed fiber containing silicon-processed fibers and low-melting fibers at a temperature of 140 ° C to 200 ° C. It is desirable that the heat treatment is performed within the range.
The cushioning material (1) is useful as a futon core material.

[Action]
The honeycomb structure (2) of the present invention contains a melt of low-melting fibers, and therefore high-rigid fibers are arranged in the longitudinal direction, so that it has a high cushioning property and little sag. Furthermore, since the honeycomb structure (2) has a coarse structure, the honeycomb structure (2) is lightweight and the air permeability of the entire cushioning material (1) is improved.
Further, since the fiber layer (3) is applied to one side or both sides of the honeycomb structure (2), even if the honeycomb structure (2) has high rigidity, the surface has a soft feel.
The honeycomb structure (2) and the fiber layer (3) are bonded by needle punching, or the fiber layer (3) contains low melting point fibers, and the honeycomb structure (2) And the fiber layer (3) are bonded to each other by heat-softening the low-melting fiber, so that no quilting is required, and there is no need for the honeycomb structure (2) and the fiber layer (3). The bond strength is high and it is difficult to lose shape.
If the fiber layer (3) contains silicon-processed fibers, the silicon-processed fibers have low friction, so that the fibers slip without being caught by each other, so that the fiber layer (3) has no sag. Further, the fiber layer (3) is obtained by heat-treating a mixed fiber containing silicon-processed fibers and low-melting fibers in a temperature range of 140 ° C. to 200 ° C. by melting the low-melting fibers by heating. Layer (3) is highly rigid and has almost no sag.

〔effect〕
The cushioning material of the present invention has good cushioning properties, almost no sag and light weight, and also has good breathability, so it has excellent heat retention and is not deformed, the surface feel is flexible, and wound cotton and quilting It does not require time-consuming work such as processing, and is particularly useful as a futon core material.

The present invention is described in detail below.
The present invention will be described with reference to an embodiment shown in FIGS. 1 to 3. In the cushioning material (1) shown in FIG. 3, fiber layers (3, 3) are stacked above and below the honeycomb structure (2). Yes.
The fiber layer (3, 3) is composed of a mixed fiber of normal fiber, silicon processed fiber, and low melting point fiber.

[Honeycomb structure]
The honeycomb structure (2) has a coarse structure in which a large number of hexagonal coarse grains are gathered as shown in FIG. 1, and the short diameter d _{1 of the} eye shown in FIG. 2 is usually 5 mm to 15 mm, preferably 7 mm to 13 mm, and the long diameter. Is usually 10 mm to 20 mm, preferably 12 mm to 17 mm.
The honeycomb structure (2) includes low-melting fibers having a melting point of 200 ° C. or lower, desirably 180 ° C. or lower, the fibers are arranged in the longitudinal direction, and the low-melting fibers are made highly rigid by heating and melting. Yes. Examples of the low melting point fiber include polyester fiber, polyamide fiber, and polypropylene fiber having a melting point of 180 ° C. or lower. Polyethylene fiber, polyvinylidene chloride fiber, etc. are used.

[Fiber layer]
The fibers used in the fiber layer (3) are mainly thermoplastic fibers such as polyester fibers, polypropylene fibers and polyethylene fibers, but other polyamide fibers, acrylic fibers, urethane fibers, polyvinyl chloride fibers and polyvinylidene chloride. Synthetic fibers such as fibers, acetate fibers, cotton and wool, or fibers such as natural fibers are also used. The fiber may be a hollow fiber, a core-sheath type composite fiber, a side-by-side type composite fiber, or may be crimped. Desirable fibers include crimped hollow polyester fibers.

Silicon processed fibers may be used in addition to or instead of the fibers.
The silicon-processed fiber is a fiber in which at least a part of the surface of the fiber is coated with a silicon-based resin, and the silicon-processed fiber is modified with, for example, organopolysiloxane, amino-modified organopolysiloxane, epoxy-modified organopolysiloxane, or the like. If the organopolysiloxane is desired, it is carried out by adding a curing agent and adhering it to the fiber surface by a shower method, a dip method or the like and drying or heat-treating it at the spinning step, drawing step or cotton stage. Desirable silicon processed fibers include those using crimped hollow fibers as base fibers.
Furthermore, in addition to the above fibers, low melting point fibers such as those used in the honeycomb structure (2) may be mixed and used.

The fiber layer (3) is preferably a needle felt. When silicon processed fibers are mixed into the fiber layer (3), the silicon processed fibers are generally mixed in the fiber layer (3) by 50 to 60% by mass. Furthermore, when mixing low melting point fiber, this low melting point fiber is mixed 15 to 25 mass%.
The fiber layer (3) has a basis weight of 350 to 450 g and a thickness of 10 to 25 mm.

[Cushioning material]
In the cushioning material (1) of the present invention, the fiber layers (3, 3) are adhered to both sides of the honeycomb structure (2). Bonding between the honeycomb structure (2) and the fiber layer (3, 3) is performed by needle punching. Needle punching may be performed from one side or from both sides.
When the fiber layer (3, 3) contains low melting point fibers, the low melting point fiber and the fiber layer (3) of the honeycomb structure (2) are heated instead of needle punching or heated together with needle punching. These low melting point fibers may be bonded together by softening or melting. In this case, it is desirable to exert a pressing force.

If desired, the fiber layer (3) is heat-treated at a temperature of 140 ° C. to 200 ° C. This heat treatment may be carried out after bonding to the honeycomb structure (2) by the needle punching. When such a heat treatment is performed, the crimped fibers are particularly crimped and stiffened. The heat treatment is preferably performed with hot air that can be easily heated up to the inside.
Furthermore, it is desirable that the fiber layer (3) is subjected to hot water treatment to remove the surfactant adhering to the fibers. The warm water treatment is usually performed by immersing in warm water at 50 to 100 ° C. for about 1 hour.
In the present invention, the fiber layer (3) may be attached only to one side of the honeycomb structure (2).

  The cushioning material of the present invention is useful for futon core materials and the like because it is rich in cushioning properties, has almost no sag, and is excellent in air permeability.

1 to 3 show an embodiment of the present invention.
Honeycomb structure perspective view Top view of honeycomb structure eye Side sectional view of cushioning material Conventional futon core material explanatory diagram

Explanation of symbols

1 Cushioning material (futon core)
2 Honeycomb structure
3 Fiber layer

Claims (6)

  A cushioning material comprising: a honeycomb structure in which fibers containing a melt of low-melting fibers are arranged in the longitudinal direction; and a fiber layer that is deposited on one side or both sides of the honeycomb structure.   The cushioning material according to claim 1, wherein the honeycomb structure and the fiber layer are bonded by needle punching.   The cushioning material according to claim 1 or 2, wherein the fiber layer contains low-melting fibers, and the honeycomb structure and the fiber layer are bonded to each other by heat-softening the low-melting fibers.   The cushioning material according to claims 1 to 3, wherein the fiber layer contains silicon processed fibers.   The cushioning material according to any one of claims 1 to 4, wherein the fiber layer is obtained by heat-treating mixed fibers containing silicon processed fibers and low-melting fibers in a temperature range of 140 ° C to 200 ° C.   A futon core material comprising the cushioning material according to claim 1.

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