JP2014064767A - Cushion - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a cushion using a three-dimensional random loop joint structure of a continuous linear body, which is a cushion excellent in cushioning property and quietness.SOLUTION: A cushion includes: a three-dimensional random loop joint structure obtained by forming random loops by winding a continuous linear body comprising a thermoplastic resin, bringing each loop into contact mutually in the molten state, and fusing the most part of contact parts; and a package for packaging the three-dimensional random loop joint structure. The apparent density of the three-dimensional random loop joint structure is 0.005-0.200 g/cm3, and the number of junctions per unit wight of the three-dimensional random loop joint structure is 500-1,200/g.

Description

  The present invention relates to a cushion using a continuous linear three-dimensional random loop joint structure.

  For example, Patent Document 1 proposes to use, as a cushion material, a cushion network structure that is excellent in heat resistance, durability, and cushioning properties, hardly stuffs, and is easy to recycle. In the network structure for cushion described in Patent Document 1, a continuous linear body of 300 denier or more made of a polyester copolymer thermoplastic elastic resin is twisted to form a random loop, and the loops are in contact with each other in a molten state. At least, it is composed of a three-dimensional random loop joint structure in which most of the contact portion is fused.

  However, there is a problem that it is noisy because there is a sound that the random loops are rubbed or the random loops are repelled when the cushion material is compressed and recovered.

  Therefore, for example, in Patent Document 2, as a polyester-based elastic network structure excellent in cushioning and quietness, a continuous linear body having a fineness of 300 dtex or more made of a polyester copolymer is bent and formed into a random loop. The resin containing the silicone resin is 0.4 to 4 weight on the random loop surface of the three-dimensional random loop bonded structure in which the respective loops are brought into contact with each other in a molten state and most of the contact portions are fused. It has been proposed to use a polyester-based elastic network structure with a% adhesion for the cushion body.

  In the cushion body using the polyester-based elastic network structure described in Patent Document 2, although the sound of rubbing between the random loops during compression and recovery of the cushion body has been reduced, the random loops seemed to be able to play. However, there was still room for improvement in terms of quietness.

JP 7-68061 A JP 2010-43376 A

  In view of the above circumstances, an object of the present invention is to provide a cushion using a continuous linear three-dimensional random loop joint structure, which is excellent in cushioning and quietness.

In the present invention, a continuous linear body made of a thermoplastic resin is twisted to form a random loop, and the respective loops are brought into contact with each other in a molten state, and most of the contact portion is fused. A three-dimensional random loop joint structure and a package enclosing the three-dimensional random loop joint structure, and the apparent density of the three-dimensional random loop joint structure is 0.005 to 0.200 g / cm3, This is a cushion in which the number of joint points per unit weight of the three-dimensional random loop joint structure is 500 to 1200 pieces / g.

  Here, in the cushion of the present invention, the number of joint points per unit weight of the three-dimensional random loop joint structure is preferably 550 to 1150 pieces / g, and more preferably 600 to 1100 pieces / g. preferable.

  In the cushion of the present invention, the thermoplastic resin constituting the continuous filament is composed of soft polyolefin, polystyrene-based thermoplastic elastomer, polyester-based thermoplastic elastomer, polyurethane-based thermoplastic elastomer, and polyamide-based thermoplastic elastomer. Preferably, at least one thermoplastic resin selected from the group, more preferably at least one thermoplastic resin selected from the group consisting of a soft polyolefin and a polyester-based thermoplastic elastomer, is a polyester-based thermoplastic elastomer. Even more preferred.

  Moreover, in the cushion of this invention, it is preferable that the fineness of a continuous filament is 200-10000 dtex, it is further more preferable that it is 200-5000 dtex, and it is still more preferable that it is 200-3000 dtex.

  Moreover, in the cushion of this invention, it is preferable that a continuous filament is a hollow cross section.

  Moreover, in the cushion of this invention, it is preferable that a continuous filament is a hollow cross section, and the hollow rate of this hollow cross section is 10 to 50%, and the hollow rate of a hollow cross section is 20 to 40%. Is more preferable.

Moreover, in the cushion of this invention, it is more preferable that a continuous filament is a deformed cross section.

ADVANTAGE OF THE INVENTION According to this invention, it is a cushion using the continuous linear body three-dimensional random loop joining structure, Comprising: The cushion excellent in cushioning property and silence can be provided.

It is a typical perspective view of the cushion of an embodiment which is an example of the cushion of the present invention. It is a typical expanded sectional view in alignment with II-II of FIG. (A) is a typical perspective view of an example of the three-dimensional random loop joining structure used for the cushion of the embodiment, and (b) is a schematic perspective view of the three-dimensional random loop joining structure shown in (a). It is an expansion perspective view. (A), (b) is typical sectional drawing of an example of the continuous linear body shown to Fig.3 (a) and FIG.3 (b). (A)-(c) is typical sectional drawing illustrating an example of the irregular cross section of a continuous linear body. It is a typical block diagram illustrating an example of the manufacturing apparatus of a three-dimensional random loop junction structure. It is a typical block diagram illustrating an example of the manufacturing apparatus of a three-dimensional random loop junction structure. It is a typical perspective view illustrating an example of the usage pattern of the cushion of an embodiment.

  Embodiments of the present invention will be described below. In the drawings of the present invention, the same reference numerals represent the same or corresponding parts.

<Cushion>
FIG. 1 shows a schematic perspective view of a cushion according to an embodiment which is an example of the cushion of the present invention, and FIG. 2 shows a schematic enlarged cross-sectional view along II-II in FIG. As shown in FIG. 1 and FIG. 2, the cushion 1 of the present embodiment includes a three-dimensional random loop joint structure 10 and a package 11 that wraps the three-dimensional random loop joint structure 10.

  As the three-dimensional random loop joint structure 10, a linear loop (continuous linear body 21) is twisted to form a random loop 22, and the respective loops 22 are brought into contact with each other in a molten state, so that most of the contact portion is formed. What is fused is used.

  The package 11 can be used without particular limitation as long as it can wrap the three-dimensional random loop joint structure 10. For example, a cover conventionally used for a cushion can be suitably used.

  In the cushion 1 of the embodiment, the three-dimensional random loop joint structure 10 has the following three requirements (i) to (iii). Therefore, while having favorable cushioning properties, it is possible to provide a cushion that is superior in quietness than before.

  (I) The continuous linear body 21 is made of a thermoplastic resin.

  (Ii) The apparent density of the three-dimensional random loop bonded structure 10 is 0.005 to 0.200 g / cm 3.

  (Iii) The number of bonding points per unit weight of the three-dimensional random loop bonded structure 10 is 500 to 1200 pieces / g.

  The present inventors reduce the sound at the time of compression and recovery, such as a repelling sound and a rubbing sound, by the three-dimensional random loop joint structure 10 satisfying the requirements (i) to (iii) at the same time. However, the present inventors have found that elasticity is ensured and have completed the present invention.

  For example, in conventional network structures such as those described in Patent Document 1 and Patent Document 2, a sound such that a random loop is rubbed or a sound that a random loop can be played is generated during compression or compression recovery. However, since the cushion 1 of the present embodiment includes the three-dimensional random loop joint structure 10 having the above three requirements (i) to (iii), these sounds are greatly reduced. However, it has an excellent effect in that the elasticity at the time of compression is maintained at the same level as that of the conventional network structure.

<Continuous linear structure>
FIG. 3A shows a schematic perspective view of an example of the three-dimensional random loop joint structure 10 used in the cushion 1 of the embodiment, and FIG. 3B shows the tertiary shown in FIG. A schematic enlarged perspective view of the original random loop joint structure 10 is shown.

  As shown in FIG. 3A and FIG. 3B, the three-dimensional random loop joint structure 10 causes the filaments (continuous linear bodies 21) made of a thermoplastic resin to bend, and the continuous linear bodies 21 are formed. Each of them has a three-dimensional network structure joined at least at a part thereof.

  The continuous linear body 21 has a curved random loop 22 that is not a complete ring shape or a complete ring shape due to the winding of the continuous linear body 21. The three-dimensional random loop joint structure 10 has a joint where the random loop 22 of the continuous linear body 21 is joined to the random loop 22 of another continuous linear body 21. Here, the joint portion of the random loop 22 is formed by bringing the random loops 22 of the continuous linear body 21 into contact with each other in a molten state and fusing most of the contact portions. In this way, even if a large deformation is caused by a very large stress, the entire network structure composed of the fused three-dimensional random loop is deformed to absorb the stress, and when the stress is released, the thermoplastic resin Due to the elastic force, the structure can be restored to its original form.

<Continuous filament material>
The thermoplastic resin constituting the continuous linear body 21 is not particularly limited as long as it is capable of twisting the filaments, bringing the continuous filaments into contact with each other, and fusing the contact portion. From the standpoint of compatibility between stability and quietness, soft polyolefin, polystyrene-based thermoplastic elastomer, polyester-based thermoplastic elastomer, polyurethane-based thermoplastic elastomer, and polyamide-based thermoplastic elastomer are preferable, and soft polyolefin and polyester-based thermoplastic elastomer are more preferable. . Furthermore, a polyester-based thermoplastic elastomer is particularly preferable in order to improve heat resistance and durability while achieving both cushioning properties and quietness.

  Preferred examples of the soft polyolefin include low density polyethylene (LDPE), a random copolymer of ethylene and an α olefin having 3 or more carbon atoms, and a block copolymer of ethylene and an α olefin having 3 or more carbon atoms. Examples of the α-olefin having 3 or more carbon atoms include propylene, isoprene, butene-1, pentene-1, hexene-1, 4-methyl-1-pentene, heptene-1, octene-1, nonene-1, decene-1, Undecene-1, dodecene-1, tridecene-1, tetradecene-1, pentadecene-1, hexadecene-1, heptadecene-1, octadecene-1, nonadecene-1 and eicosene-1 can be exemplified as preferred examples, and propylene and isoprene are exemplified. It can illustrate as a more preferable example. Two or more of these α-olefins can be used in combination.

Preferred examples of the polyester-based thermoplastic elastomer include a polyester ether block copolymer having a thermoplastic polyester as a hard segment and a polyalkylene diol as a soft segment, or a polyester ester block copolymer having an aliphatic polyester as a soft segment. It can be illustrated. More specific configurations of the polyester ether block copolymer include terephthalic acid, isophthalic acid, naphthalene-2,6-dicarboxylic acid, naphthalene-2,7-dicarboxylic acid, diphenyl-4,4′-dicarboxylic acid, and the like. Dicarboxylic acids selected from aromatic dicarboxylic acids, alicyclic dicarboxylic acids such as 1,4 cyclohexanedicarboxylic acid, aliphatic dicarboxylic acids such as succinic acid, adipic acid, and sebacic acid dimer acid, or ester-forming derivatives thereof. At least one acid, and aliphatic diols such as 1,4-butanediol, ethylene glycol, trimethylene glycol, tetramethylene glycol, pentamethylene glycol, hexamethylene glycol, 1,1-cyclohexanedimethanol, 1,4- Alicyclics such as cyclohexanedimethanol At least one diol component selected from all or an ester-forming derivative thereof, and polyethylene glycol, polypropylene glycol, polytetramethylene glycol, or ethylene oxide-propylene oxide copolymer having an average molecular weight of about 300 to 5000 A ternary block copolymer comprising at least one polyalkylenediol selected from Examples of the polyester ester block copolymer include a ternary block copolymer composed of at least one of the dicarboxylic acid, a diol, and a polyester diol such as a polylactone having an average molecular weight of about 300 to 5000. In view of thermal adhesiveness, hydrolysis resistance, stretchability, heat resistance, etc., preferably (1) terephthalic acid and / or isophthalic acid as dicarboxylic acid, 1,4-butanediol, polyalkylene as diol component A ternary block copolymer comprising polytetramethylene glycol as a diol, and (2) terephthalic acid or / and naphthalene-2,6-dicarboxylic acid as a dicarboxylic acid, 1,4-butanediol as a diol component, polyester diol As a ternary block copolymer comprising polylactone. Particularly preferred is (1) a ternary block copolymer comprising terephthalic acid and / or isophthalic acid as the dicarboxylic acid, 1,4-butanediol as the diol component, and polytetramethylene glycol as the polyalkylenediol. As a special example, a polysiloxane-based soft segment can be used.

Polystyrene thermoplastic elastomers are random copolymers of styrene and butadiene, block copolymers of styrene and butadiene, random copolymers of styrene and isoprene, block copolymers of styrene and isoprene, or hydrogenated to them. Can be illustrated as a preferred example.

Examples of polyurethane-based thermoplastic elastomers include (A) a polyether and / or polyester having a hydroxyl group at the terminal having a number average molecular weight of 1000 to 6000 in the presence or absence of a normal solvent (dimethylformamide, dimethylacetamide, etc.) ( B) A polyurethane elastomer obtained by extending a chain with a polyamine containing diamine as a main component can be exemplified as a representative example of a prepolymer obtained by reacting a polyisocyanate containing organic diisocyanate as a main component with both ends being isocyanate groups. The polyesters and polyethers of (A) include polybutylene adipate copolymer polyester, polyethylene glycol, polypropylene glycol, polytetramethylene glycol, ethylene oxide-propylene oxide copolymer having an average molecular weight of about 1000 to 6000, preferably 1300 to 5000. Polyalkylene diols such as coalescence are preferred. As the polyisocyanate of (B), a conventionally known polyisocyanate can be used, but an isocyanate mainly composed of diphenylmethane-4,4′-diisocyanate is used. Addition may be used. As the polyamine (C), known diamines such as ethylenediamine and 1,2-propylenediamine are mainly used, and a trace amount of triamine and tetraamine may be used in combination as required. These polyurethane-based thermoplastic elastomers may be used alone or in combination of two or more. In addition, the thermoplastic elastomer of the present invention includes those obtained by blending non-elastomeric components with the above elastomer and those obtained by copolymerization.

As the polyamide-based thermoplastic elastomer, the hard segment has nylon 6, nylon 66, nylon 610, nylon 612, nylon 11, nylon 12, etc. and their copolymer nylon as a skeleton, and the soft segment has an average molecular weight of about 300 to A block copolymer composed of at least one of polyalkylenediols such as 5000 polyethylene glycol, polypropylene glycol, polytetramethylene glycol, ethylene oxide-propylene oxide copolymer, or a mixture of two or more types. Can be illustrated as a preferred example. Further, blended or copolymerized non-elastomeric components can be used in the present invention.

The resin portion of the continuous linear body 21 can be composed of a mixture of two or more different thermoplastic resins depending on the purpose. When composed of a mixture of two or more different thermoplastic resins, at least one selected from the group consisting of soft polyolefin, polystyrene-based thermoplastic elastomer, polyester-based thermoplastic elastomer, polyurethane-based thermoplastic elastomer, and polyamide-based thermoplastic elastomer. It is preferable to include 50% by weight or more of the selected thermoplastic resin, more preferably 60% by weight or more, and even more preferably 70% by weight or more.

  Various additives can be blended in the resin portion of the continuous linear body 21 according to the purpose. Additives include phthalate ester, trimellitic acid ester, fatty acid, epoxy, adipic acid ester, polyester plasticizer, known hindered phenol, sulfur, phosphorus and amine oxidation Light stabilizers such as inhibitors, hindered amines, triazoles, benzophenones, benzoates, nickels, salicyls, antistatic agents, molecular modifiers such as peroxides, epoxy compounds, isocyanate compounds, carbodiimide compounds Compounds having reactive groups such as, metal deactivators, organic and inorganic nucleating agents, neutralizing agents, antacids, antibacterial agents, fluorescent whitening agents, fillers, flame retardants, flame retardant aids, organic In addition, inorganic pigments and the like can be added.

The resin portion of the continuous linear body 21 preferably has an endothermic peak below the melting point in a melting curve measured with a differential scanning calorimeter. Those having an endothermic peak below the melting point have significantly improved heat sag resistance than those having no endothermic peak. For example, as a preferable polyester-based thermoplastic elastomer of the present invention, terephthalic acid or naphthalene-2,6-dicarboxylic acid having a rigid hard segment acid component is 90 mol% or more, more preferably 95 mol% or more, particularly Preferably 100 mol% content and glycol component are transesterified and then polymerized to the required degree of polymerization, and then polyalkylene diol, preferably having an average molecular weight of 500 to 5000, more preferably 1000 to 3000 When the polytetramethylene glycol is copolymerized at 10 wt% or more and 70 wt% or less, more preferably 20 wt% or more and 60 wt% or less, terephthalic acid or naphthalene-2 having a rigid hard segment acid component, Hard segment crystals when the content of 6-dicarboxylic acid is high There was improved, hardly plastically deformed, and to improve the sexual sag resistant anti. In addition, if the annealing treatment is further performed at a temperature lower than the melting point by at least 10 ° C. after the fusion bonding, the heat resistance and sag resistance is further improved. Heat annealing resistance is further improved by annealing after applying compressive strain. The resin portion of the continuous linear body 21 subjected to such a treatment expresses an endothermic peak more clearly at a temperature not lower than the room temperature and not higher than the melting point in the melting curve measured with a differential scanning calorimeter (DSC). When annealing is not performed, the endothermic peak does not appear in the melting curve above the room temperature and below the melting point. By analogy with this, it is considered that the hard segments are rearranged by annealing and pseudo-crystallization-like cross-linking points are formed, and the heat resistance and sag resistance are improved. (Hereinafter, this annealing treatment is sometimes referred to as “pseudo crystallization treatment.”) This pseudo crystallization treatment effect is also effective for soft polyolefins, polystyrene-based thermoplastic elastomers, polyamide-based thermoplastic elastomers, and polyurethane-based thermoplastic elastomers. It is.

<Apparent density of 3D random loop bonded structure>
A preferable range of the average apparent density of the three-dimensional random loop bonded structure 10 is 0.005 g / cm ^{3 to} 0.200 g / cm ³ . Expression of the function as a cushioning material can be expected within the above range. If it is less than 0.005 g / cm ³ , the repulsive force is lost, so it is unsuitable for a cushioning material. If it exceeds 0.200 g / cm ³ , the repulsive force is too high and the seating comfort is deteriorated. A more preferable apparent density of the present invention is 0.010 g / cm ^{3 to} 0.150 g / cm ³ , and a more preferable range is 0.020 g / cm ^{3 to} 0.100 g / cm ³ .

<Number of joints per unit weight of the three-dimensional random loop joint structure>
The number of bonding points per unit weight of the three-dimensional random loop bonded structure 10 is preferably 500 to 1200 pieces / g. The joint point refers to the fusion part between two filaments, and the number of joint points per unit weight (unit: pieces / g) is the 3D random loop joint structure 10 in the longitudinal direction 5 cm × width The number of junction points per unit volume (in units) in a rectangular parallelepiped piece cut in a rectangular parallelepiped shape with a size of 5 cm in direction, including two sample surface layers, and not including the sample ear. : pieces / cm3) apparent density (unit of the pieces: a Xu values in g / cm ^3). The method for measuring the number of joints is a method in which the fusion part is peeled off by pulling two filaments and the number of peelings is measured. In the case where the three-dimensional random loop bonded structure 10 has a band-like density difference of 0.005 g / cm ³ or more in the longitudinal direction or width direction of the sample, the boundary between the dense part and the sparse part The sample is cut so that the line is an intermediate line in the longitudinal direction or the width direction of the individual piece, and the number of junction points per unit weight is measured. As the number of joining points per unit weight increases, the filaments are fixed, the frequency of collision between the filaments decreases, and the silence of the network structure is improved. The number of bonding points per unit weight of the conventional network structure is less than 500 / g, but in the present invention, the desired effect can be obtained by setting it to 500 / g or more. On the other hand, if the number of bonding points per unit weight is larger than 1200 pieces / g, the air permeability deteriorates and the comfort is impaired, which is not preferable. More preferably, it is 550-1150 piece / g, More preferably, it is 600-1100 piece / g, Still more preferably, it is 650-1050 piece / g, Most preferably, it is 700-1000 piece / g.

<Fineness of continuous striatum>
The fineness of the continuous linear body 21 is not particularly limited. However, by reducing the fineness, it is possible to reduce the magnitude of the repelling sound between the filaments, and the effect of the number of joints per unit weight is combined with the effect of the network structure. Silence can be further enhanced. However, if the fineness becomes too small, the hardness of the filaments becomes extremely small and an appropriate cushioning property cannot be maintained. In order to further improve the quietness while maintaining the cushioning property appropriately, the fineness is preferably 200 to 10000 dtex, more preferably 200 to 5000 dtex, and even more preferably 200 to 3000 dtex. . In the present invention, it is possible to use not only continuous filaments composed of filaments having a single fineness but also filaments having different finenesses, and an optimum configuration can be obtained by combining with the apparent density.

<Cross-sectional shape of continuous linear body>
4A and 4B are schematic cross-sectional views of the continuous linear body 21. FIG. The cross-sectional shape of the continuous linear body 21 is not particularly limited. For example, as shown in the schematic cross-sectional view of FIG. 4A, the continuous linear body 21 may have a circular solid cross-section, or the cross-sectional shape of FIG. As shown in the schematic sectional view, it may have a hollow section having a hollow portion 33 inside. Further, as shown in the schematic cross-sectional views of FIGS. 5A to 5C, a triangular shape (FIG. 5A), a Y shape (FIG. 5B), or a star shape (FIG. It may have an irregular cross section different from the circular cross section as in c)). By making the cross-sectional shape of the continuous linear body 21 into a hollow cross section or an irregular cross section, the continuous linear body 21 can be provided with anti-compressibility and bulkiness, and the fineness can be lowered.

<Configuration of three-dimensional random loop joint structure>
As one aspect of the three-dimensional random loop bonded structure 10, preferred characteristics can be imparted by laminating a plurality of layers made of filaments having different fineness and changing the apparent density of each layer. For example, if the surface layer is composed of a fine surface layer and a thick basic layer, the density of the surface layer is slightly increased to increase the number of components, and the stress applied to one of the filaments is decreased to improve the stress distribution. In addition, it is possible to improve the sitting comfort by improving the cushioning property that supports the buttocks. Since the basic layer is thicker and slightly harder, and is a denser layer that is responsible for vibration absorption and body shape retention, the basic layer can have a slightly finer filament and a higher density. As a result, vibration and repulsive stress received from the seat frame surface can be uniformly transmitted to the basic layer so that the entire body can be deformed and energy can be converted, improving the sitting comfort and improving the durability of the cushion. Furthermore, in order to give the seat side thickness and tension, the fineness can be partially reduced to increase the density. Thus, each layer can arbitrarily select a preferable density and fineness according to the purpose. The thickness of each layer of the network structure is not particularly limited, but is preferably 3 mm or more, and more preferably 5 mm or more, in which a function as a cushion body is easily expressed.

The outer surface of the structure of the three-dimensional random loop joint structure 10 has a curved line that is bent at 30 ° or more, preferably 45 ° or more in the middle, and the surface is substantially flattened. It is preferable to have the surface layer part which melt | fused. As a result, the contact points of the filaments on the surface of the network structure are greatly increased to form adhesion points, so that the local external force of the buttocks when sitting is received on the structure surface without giving a sense of foreign matter to the buttocks. The surface structure is deformed as a whole, the entire internal structure is also deformed to absorb the stress, and when the stress is released, the elastic elasticity of the elastic resin appears and the structure is restored to its original form. Can do. If it is not substantially flattened, it gives a feeling of foreign matter to the buttocks, local external force is applied to the surface, and stress concentration may occur selectively up to the surface stripes and adhesion points. There is a case where fatigue due to concentration occurs and the sag resistance decreases. When the outer surface of the structure is flattened, do not use a wading layer or laminate a very thin wading layer and cover the surface with the side ground, for seats or chairs or beds for automobiles, railways, etc., for sofas, It can be used as a cushion mat for futons. If the outer surface of the structure is not flattened, a relatively thick (preferably 10 mm or more) wadding layer needs to be laminated on the surface of the network structure, and the seat and cushion mat must be formed by covering the surface with the side ground. . If necessary, adhesion to the wadding layer or adhesion to the side is easy when the surface is flat, but when the surface is not flattened, the adhesion is incomplete and uneven.

<Hardness of 3D random loop joint structure>
The hardness at 25% compression of the three-dimensional random loop joint structure 10 is not particularly limited, but is preferably 5 kg / Φ200 mm or more. The hardness at 25% compression is the stress at the time of 25% compression of the stress-strain curve obtained by compressing the network structure to 75% with a circular compression plate having a diameter of 200 mm. If the hardness at 25% compression is less than 5 kg / Φ200 mm, sufficient elasticity cannot be obtained, and comfortable cushioning properties are impaired. More preferably, it is 10 kg / Φ200 mm or more, and particularly preferably 15 kg / Φ200 mm or more. The upper limit is not particularly defined, but is preferably 50 kg / Φ200 mm or less, more preferably 45 kg / Φ200 mm or less, and particularly preferably 40 kg / Φ200 mm or less. If it is 50 kg / Φ200 mm or more, it becomes too hard, which is not preferable from the viewpoint of cushioning properties.

<Cushion manufacturing method>
Hereinafter, an example of a method for manufacturing the cushion 1 will be described with reference to the schematic configuration diagrams of FIGS. 6 and 7.

First, as shown in FIG. 6, the thermoplastic resin 42 is put into the extruder 43. The thermoplastic resin is discharged from the extruder 43 to the discharge device 46.

  And the continuous linear body precursor 21a which becomes a thermoplastic resin from each of the some orifice 45 of the discharge apparatus 46 is discharged toward the downward direction.

  Here, it is preferable to discharge the continuous linear body precursor 21a at a temperature 10 to 120 ° C. higher than the melting point of the thermoplastic resin 42 constituting the continuous linear body precursor 21a discharged from the orifice 45.

  Further, the shape of the orifice 45 is not particularly limited, but the orifice 45 has a modified cross-section (for example, a shape in which a cross-sectional moment is increased, such as a triangle, a Y-shape, a star-shape, etc.) And a shape having a projection or the like). In this case, the continuous linear body precursor 21a in the molten state becomes difficult to flow relax, and the continuous linear body precursor 21a is maintained by keeping the flow time at the contact point of the continuous linear body precursor 21a long. The adhesion point of can be strengthened. In this case, the apparent bulk of the three-dimensional random loop joint structure 10 can be increased, the weight can be reduced, the anti-compression property can be improved, and the elasticity can be improved. Therefore, it is possible to make the cushion 1 difficult to sag.

  Further, when the orifice 45 has a hollow cross section, when the hollow ratio exceeds 80%, the hollow portion of the cross section of the continuous linear body precursor 21a is easily crushed. The hollow ratio is preferably 10% or more and 70% or less, more preferably 20% or more and 60% or less, in which the effect of weight reduction can be exhibited.

  Further, the pitch between the orifices 45 is preferably 3 mm or more and 20 mm or less, and more preferably 5 mm or more and 10 mm or less. When the pitch between the orifices 45 is 3 mm or more and 20 mm or less, particularly when the pitch is 5 mm or more and 10 mm or less, the random loops formed by the continuous linear body precursor 21a can be sufficiently brought into contact with each other. In order to make the three-dimensional random loop joint structure 10 a dense structure, a shorter pitch between the orifices 45 is preferable, and in order to make a rough structure, a longer pitch between the orifices 45 is preferable. .

  It should be noted that the three-dimensional random loop bonded structure 10 can be obtained by changing the pitch between the rows of the orifices 45 or the pitch between the holes, or by changing both the pitch between the rows and the pitch between the holes. Different apparent densities can be provided.

  Further, in the case where pressure loss at the time of discharging the continuous linear body precursor 21a is given by changing the cross-sectional area of the orifice 45, when the molten thermoplastic elastomer is discharged from the same nozzle at a constant pressure. The larger the pressure loss, the smaller the discharge amount of the continuous linear body precursor 21a. Utilizing this principle, it is possible to make the continuous linear body 21 formed by the continuous linear body precursor 21a discharged from each orifice 45 different in fineness.

  And as shown in FIG. 7, the continuous linear body precursor 21a is discharged from the some orifice 45 to the atmosphere of temperature higher than the melting | fusing point, and forms a random loop in a molten state by making it twist. The random loops are in contact with each other and fused, and are sandwiched between endless nets 55 of a pair of opposed take-up conveyors 51 and 52 provided in a cooling tank 54 in which a cooling medium 53 such as water is accommodated. The three-dimensional random loop structure 10 is obtained by being cooled in the cooling bath 54 while being pulled.

  Here, in the take-up conveyors 51 and 52, the continuous linear body precursor 21a having a twisted outer surface on both sides of the melted three-dimensional random loop structure 10 is preferably bent at 30 ° or more, more preferably 45 ° or more. The outer surface of the three-dimensional random loop structure 10 is flattened, and at the same time, the three-dimensional random loop structure 10 is formed so as to adhere at the contact point with the unbent continuous linear body precursor 21a. It is preferable.

At this time, the loop diameter, the fineness of the filaments, and the number of joints are determined by the distance between the lower surface of the orifice 45 and the water surface of the cooling medium 53, the melt viscosity of the thermoplastic resin, the hole diameter and the discharge amount of the orifice, and the like.

  Then, it is preferable to perform a pseudo crystallization process by annealing the three-dimensional random loop structure 10. The annealing temperature of the three-dimensional random loop structure 10 for quasi-crystallization treatment should be a temperature that is equal to or higher than Tan dispersion α dispersion rising temperature (Tαcr) and 10 ° C. lower than the melting point (Tm) of the thermoplastic resin. Preferably, it is (Tαcr + 10 ° C.) or more and (Tm−20 ° C.) or less. In this case, the heat resistance and sag resistance of the three-dimensional random loop structure 10 are higher than those having an endothermic peak below the melting point and not subjected to pseudo-crystallization treatment (no endothermic peak). Is significantly improved.

  Although the pseudo crystallization process can be performed simply by the annealing process, the annealing process may be performed after the three-dimensional random loop structure 10 is once cooled and then subjected to compressive deformation of 10% or more. In addition, when the drying process is performed after the three-dimensional random loop structure 10 is once cooled, the pseudo-crystallization process of the three-dimensional random loop structure 10 is performed simultaneously with the drying by setting the drying temperature to the annealing temperature. Can do. Moreover, you may perform an annealing process separately from a drying process.

  And the cushion 1 of this Embodiment is manufactured by cut | disconnecting the three-dimensional random loop structure 10 obtained by making it above into desired length and shape, and wrapping with the package 11 shown in FIG. be able to.

  When the three-dimensional random loop structure 10 is used for the cushion 1, the material of the thermoplastic elastomer, the fineness of the continuous linear body 21, the random loop 21 of the continuous linear body 21, depending on the purpose of use and the use site. The diameter, the apparent density of the three-dimensional random loop structure 10, and the like can be selected as appropriate.

  For example, when the three-dimensional random loop structure 10 is used for the wadding of the surface layer of the cushion 1, it has a low density and a small fineness in order to give a soft touch, moderate subsidence, and a tight bulge. And it is preferable to make the diameter of the small random loop 21. Further, for example, when the three-dimensional random loop structure 10 is used as a middle-layer cushion body of the cushion 1, the resonance frequency is lowered and appropriate hardness is imparted, and the hysteresis during compression is linearly changed. In order to improve body shape retention and durability, it is preferable to have a medium apparent density, a thick fineness, and a slightly larger random loop 21 diameter.

  Further, in order to match the required performance in relation to the use, it is also possible to use the three-dimensional random loop structure 10 in combination with a hard cotton cushion material made of an aggregate of short fibers such as a nonwoven fabric.

  Further, the cushion 1 is commercialized by processing the thermoplastic elastomer from the manufacturing process of the thermoplastic elastomer to the three-dimensional random loop structure 10 as long as the performance of the three-dimensional random loop structure 10 is not deteriorated, except for the manufacturing process of the thermoplastic elastomer. At any stage, the cushion 1 may be provided with functions such as flame retardancy, antibacterial and antibacterial properties, heat resistance, water and oil repellency, coloring, and fragrance by treatment such as addition of chemicals.

  The cushion 1 produced as described above may be an article that functions as a cushion other than at bedtime. Another example of the cushion 1 is illustrated in the schematic perspective view of FIG.

<Synthesis Example 1>
Dimethyl terephthalate (DMT), 1,4-butanediol (1,4-BD) and polytetramethylene glycol (PTMG: average molecular weight 1000) are charged with a small amount of catalyst, and after transesterification by a conventional method, while raising the temperature and reducing the pressure Polycondensation was carried out to produce a polyester ether block copolymer elastomer of DMT / 1,4-BD / PTMG = 100/88/12 mol%, and then 1% antioxidant was added and kneaded and pelletized, followed by 50 ° C. for 48 hours. Vacuum drying was performed to obtain a polyester-based thermoplastic elastomer raw material (A-1). The characteristics are shown in Table 1.

<Synthesis Example 2>
Dimethyl terephthalate (DMT), 1,4-butanediol (1,4-BD) and polytetramethylene glycol (PTMG: average molecular weight 1000) are charged with a small amount of catalyst, and after transesterification by a conventional method, while raising the temperature and reducing the pressure Polycondensation was carried out to produce a polyester ether block copolymer elastomer of DMT / 1,4-BD / PTMG = 100/84/16 mol%, then 1% antioxidant was added and kneaded, pelletized, and 50 ° C. for 48 hours. The polyester-based thermoplastic elastomer raw material (A-2) was obtained by vacuum drying. The characteristics are shown in Table 1.

<Synthesis Example 3>
Dimethyl terephthalate (DMT), 1,4-butanediol (1,4-BD) and polytetramethylene glycol (PTMG: average molecular weight 1000) are charged with a small amount of catalyst, and after transesterification by a conventional method, while raising the temperature and reducing the pressure Polycondensation was carried out to produce a polyester ether block copolymer elastomer of DMT / 1,4-BD / PTMG = 100/72/28 mol%, and then 1% antioxidant was added and kneaded and pelletized, followed by 50 ° C. for 48 hours. The polyester thermoplastic elastomer raw material (A-3) was obtained by vacuum drying. The characteristics are shown in Table 1.

<Method for measuring properties of thermoplastic resin>
・ Melting point (Tm)
Using a Shimadzu TA50, DSC50 differential thermal analyzer, an endothermic peak (melting peak) temperature was determined from an endothermic curve obtained by measuring a 10 g sample from 20 ° C. to 250 ° C. at a rate of temperature increase of 20 ° C./min.
-Flexural modulus Test pieces having a length of 125 mm, a width of 12 mm and a thickness of 6 mm were prepared by an injection molding machine, and measured according to the ASTM D790 standard.

<Example 1>
100 kg of the polyester-based thermoplastic elastomer (A-1) obtained in Synthesis Example 1 and 0.25 kg of a hindered phenol antioxidant (“ADEKA STAB AO330” manufactured by ADEKA), 0.25 kg of a phosphorus-based antioxidant ("ADEKA STAB PEP36" manufactured by ADEKA) was mixed for 5 minutes with a tumbler, melted and kneaded with a twin screw extruder with a screw diameter of 57 mm at a cylinder temperature of 220 ° C and a screw rotation speed of 130 rpm, and extruded into a strand in a water bath. After cooling, pellets of the resin composition were obtained. The obtained resin composition was melted at a temperature of 240 ° C. from a nozzle in which circular hollow orifices having a hole diameter of 3.0 mm were arranged at an interval of 6 mm on a nozzle effective surface having a width of 66 cm and a length of 5 cm, and a single hole was discharged. The continuous linear body precursor which consists of a polyester-type thermoplastic elastomer (A-1) was discharged toward the surface of the cooling water 35 cm below at the amount of 2.4 g / min.

Then, the continuous linear body precursor discharged from the nozzle was taken up by a stainless endless net having a width of 70 cm provided on a pair of take-up conveyors partially exposed above the water surface. Here, the stainless steel endless nets are provided on each of the pair of take-up conveyors, and are arranged so as to face each other and be spaced apart in parallel by 4 cm.

  Random loops are formed in the continuous linear precursors that are taken up by the endless net made of stainless steel, and the random loops of the continuous linear precursors are brought into contact with each other in a molten state. A three-dimensional random loop bonded structure was formed by fusing.

The outer surfaces on both sides of the three-dimensional random loop bonded structure thus formed were sandwiched between stainless endless nets and drawn into 25 ° C. cooling water at a rate of 2.2 m / min for solidification.

Then, the three-dimensional random loop bonded structure drawn out from the cooling water was subjected to pseudo crystallization treatment by drying and heating in a hot air dryer at 100 ° C. for 15 minutes, and then cut into a predetermined size. And about the three-dimensional random loop junction structure obtained in this way, the number of junction points per unit weight of the three-dimensional random loop junction structure is as follows: The fineness of the continuous linear body, the hollowness of the continuous linear body, and the 25% compression hardness of the three-dimensional random loop bonded structure were measured.

<Method for measuring characteristics of three-dimensional random loop bonded structure>
(1) Apparent density sample was cut into a rectangular parallelepiped shape with a sample size of 15 cm × width direction of 15 cm, including two sample surface layers and not including the sample ears, and the heights of the four corners of the rectangular parallelepiped were measured. Thereafter, the volume (cm ³ ) was determined, and the apparent density (g / cm ³ ) was calculated by gradually decreasing the weight (g) of the sample by volume. The apparent density was an average value of n = 4.
(2) Number of junctions per unit weight First, the sample was cut into a rectangular parallelepiped shape with a size of 5 cm in the longitudinal direction and 5 cm in the width direction, including two sample surface layers and no sample ears. A piece was created. Next, after measuring the height of the four corners of this piece, the volume (unit: cm ³ ) is obtained, and the apparent density (unit: g) is determined by gradually decreasing the weight (unit: g) of the sample by volume. / Cm ³ ) was calculated. Next, the number of junction points of this piece is counted, and the number of junction points per unit volume (unit: pieces / cm ³ ) is calculated by dividing this number by the volume of the piece, and the number of junction points per unit volume The number of junctions per unit weight (unit: pieces / g) was calculated by dividing the apparent density by the apparent density. The joining point was a fusion part between two filaments, and the number of junctions was measured by pulling the two filaments and peeling the fusion part. In addition, the number of junction points per unit weight was an average value of n = 2. Further, in the case of a sample having a band-like density difference of 0.005 g / cm ³ or more in apparent density in the longitudinal direction or width direction of the sample, the boundary line between the dense part and the sparse part is the longitudinal direction of the piece or The sample was cut so as to be an intermediate line in the width direction, and the number of junction points per unit weight was measured in the same manner (n = 2).
(3) Fineness of filaments First of all, the sample was cut into a rectangular parallelepiped shape with a size of 30 cm in the longitudinal direction and 30 cm in the width direction, including two sample surface layers, and not including the sample ears. The specific gravity at 40 ° C. of a 1 cm-long striatum collected at 5 places in each mass and 20 places in total was measured using a density gradient tube. Next, the cross-sectional area of the resin portion of the striatum collected at the 20 locations was determined from a photograph enlarged with a microscope, and then the specific gravity obtained was obtained after determining the volume of the striatum length of 10,000 m. And the volume multiplied by the volume was defined as the fineness (gram weight of striatum 10000 m: decitex dtex). (Average value of n = 20).
(4) Hollow ratio First of all, the sample is cut into a rectangular parallelepiped shape so as not to include the sample ear part, including the sample surface layer surface 2 in the size of 30 cm in the longitudinal direction and 30 cm in the width direction, and divided into four equal squares. Then, 1 cm long striatum sampled at 5 places in each mass, 20 places in total, was cleaved after cooling with liquid nitrogen, and the cross section was observed with an electron microscope at a magnification of 50 times. The obtained image was analyzed by a CAD system, the cross-sectional area (A) of the resin part and the cross-sectional area (B) of the hollow part were measured, and the hollow ratio was calculated by the formula {B / (A + B)} × 100. (Average value of n = 20).
(5) A 25% compression hardness sample having a size of 30 cm in the longitudinal direction and 30 cm in the width direction is cut into a rectangular parallelepiped shape so as not to include the sample ear surface, including the sample surface layer surface. The stress at the time of 25% compression of the stress-strain curve obtained by compressing to 75% with a φ200 mm compression plate is shown. (Average value of n = 3)

Further, the three-dimensional random loop bonded structure having an apparent density of 0.04 to 0.05 g / cm ³ produced as described above was cut into a size of 50 cm wide × 50 cm long × 5 cm thick, and a cloth cover Cushioning and quietness were measured as follows for the cushion produced by coating with. The results are shown in Table 2.

(6) Cushioning and quietness 30 panelists in the body weight range of 40-100 kg (20-year-old to 40-year-old male; 5, 20-year-old to 40-year-old female: 5, 40-year-old to 60-year-old male: 5 people, women aged 40-60 years: 5 people, men aged 60-80 years: 5 people, women aged 60-80 years: 5 people) sit on the cushion made as described above The degree of feeling when hitting the floor (cushioning) and the sound generated (silence) was qualitatively evaluated according to the following classification.
A: I don't feel B: I almost don't feel C: I feel a little D: I feel

<Example 2>
Resin composition pellets were obtained in the same manner as in Example 1 except that the thermoplastic resin was the polyester-based thermoplastic elastomer (A-2) obtained in Synthesis Example 2. The nozzle is a nozzle in which round solid-shaped orifices having a hole diameter of 1.0 mm are arranged at intervals of 4 mm on a nozzle effective surface having a width of 64 cm and a length of 3.5 cm, and the melting temperature of the resin composition is 245 ° C. The single hole discharge rate is 2.2 g / min, the water level of the cooling water is 50 cm below the nozzle surface, the interval between the endless nets is 3 cm, and the speed of drawing into the cooling water is 2.6 m / min. A three-dimensional random loop structure and a cushion of Example 2 were produced in the same manner as Example 1 except that there was. About the three-dimensional random loop joint structure and the cushion of Example 2, as in Example 1, the apparent density of the three-dimensional random loop joint structure, the number of joint points per unit weight of the three-dimensional random loop joint structure, The fineness of the continuous linear body, the hollowness of the continuous linear body, the 25% compression hardness of the three-dimensional random loop joint structure, the cushioning properties and the quietness of the cushions were measured. The results are shown in Table 2.

<Example 3>
Resin composition pellets were obtained in the same manner as in Example 1 except that the thermoplastic resin was a polyester-based thermoplastic elastomer (A-2). The melting temperature of the resin composition is 230 ° C., the single hole discharge rate is 2.4 g / min, the water level of the cooling water is 37 cm below the nozzle surface, and the speed of drawing into the cooling water is 1.9 m / min. The three-dimensional random loop structure and cushion of Example 3 were produced in the same manner as in Example 1 except that the speed was. For the three-dimensional random loop joint structure and cushion of Example 3, as in Example 1, the apparent density of the three-dimensional random loop joint structure, the number of joint points per unit weight of the three-dimensional random loop joint structure, The fineness of the continuous linear body, the hollowness of the continuous linear body, the 25% compression hardness of the three-dimensional random loop joint structure, the cushioning properties and the quietness of the cushions were measured. The results are shown in Table 2.

<Example 4>
Resin composition pellets were obtained in the same manner as in Example 1 except that the thermoplastic resin was the polyester-based thermoplastic elastomer (A-2) obtained in Synthesis Example 2. Example The same as Example 1 except that the melting temperature of the resin composition is 230 ° C., the water level of the cooling water is 32 cm below the nozzle surface, and the speed of drawing into the cooling water is 1.8 m / min. Four three-dimensional random loop structures and cushions were prepared. For the three-dimensional random loop joint structure and cushion of Example 4, as in Example 1, the apparent density of the three-dimensional random loop joint structure, the number of joint points per unit weight of the three-dimensional random loop joint structure, The fineness of the continuous linear body, the hollowness of the continuous linear body, the 25% compression hardness of the three-dimensional random loop joint structure, the cushioning properties and the quietness of the cushions were measured. The results are shown in Table 2.

<Example 5>
The thermoplastic resin is the polyester-based thermoplastic elastomer (A-2) obtained in Synthesis Example 2, and the resin composition is the same as in Example 1 except that the cylinder temperature of the twin-screw extruder is 200 ° C. Pellets were obtained. The melting temperature of the resin composition is 220 ° C., the water surface of the cooling water is 37 cm below the nozzle surface, the interval between the endless nets is 4.5 cm, and the speed of drawing into the cooling water is 1.8 m / min. Except for this, the three-dimensional random loop structure and cushion of Example 5 were produced in the same manner as Example 1. For the three-dimensional random loop joint structure and the cushion of Example 5, as in Example 1, the apparent density of the three-dimensional random loop joint structure, the number of joint points per unit weight of the three-dimensional random loop joint structure, The fineness of the continuous linear body, the hollowness of the continuous linear body, the 25% compression hardness of the three-dimensional random loop joint structure, the cushioning properties and the quietness of the cushions were measured. The results are shown in Table 2.

<Example 6>
As a thermoplastic resin, low density polyethylene (“Nipolon Z 1P55A” manufactured by Tosoh Corporation) was used as it was. The melting temperature of the resin composition is 200 ° C., the single-hole discharge rate during discharge is 2.0 g / min, the cooling water level is 37 cm below the nozzle surface, and the endless net spacing is 4.5 cm. The three-dimensional random loop structure and cushion of Example 6 were produced in the same manner as in Example 1 except that the speed of drawing into the cooling water was 1.7 m / min. About the three-dimensional random loop joint structure and the cushion of Example 6, as in Example 1, the apparent density of the three-dimensional random loop joint structure, the number of joint points per unit weight of the three-dimensional random loop joint structure, The fineness of the continuous linear body, the hollowness of the continuous linear body, the 25% compression hardness of the three-dimensional random loop joint structure, the cushioning properties and the quietness of the cushions were measured. The results are shown in Table 2.

<Comparative Example 1>
The nozzle is a nozzle in which round hollow orifices having a hole diameter of 5.0 mm are arranged at an interval of 4 mm on the nozzle effective surface having a width of 64 cm and a length of 4.8 cm, and the melting temperature of the resin composition is 245 ° C. A three-dimensional random loop structure and a cushion of Comparative Example 1 were produced in the same manner as in Example 1 except that the single-hole discharge amount was 3.6 g / min. For the three-dimensional random loop joint structure and the cushion of Comparative Example 1, as in Example 1, the apparent density of the three-dimensional random loop joint structure, the number of joint points per unit weight of the three-dimensional random loop joint structure, The fineness of the continuous linear body, the hollowness of the continuous linear body, the 25% compression hardness of the three-dimensional random loop joint structure, the cushioning properties and the quietness of the cushions were measured. The results are shown in Table 2.

<Comparative example 2>
Resin composition pellets were obtained in the same manner as in Example 1 except that the thermoplastic resin was the polyester-based thermoplastic elastomer (A-2) obtained in Synthesis Example 2. Nozzle is a nozzle with a width of 66 cm and a length of 3.5 cm on a nozzle effective surface arranged with round solid-shaped orifices with a hole diameter of 1.0 mm at intervals of 6 mm, and the melting temperature of the resin composition is 235 ° C. The single hole discharge rate is 1.6 g / min, the water level of the cooling water is 30 cm below the nozzle surface, the interval between the endless nets is 3 cm, and the speed of drawing into the cooling water is 1.0 m / min. A three-dimensional random loop structure and a cushion of Comparative Example 2 were produced in the same manner as Example 1 except that there was. About the three-dimensional random loop joint structure and the cushion of Comparative Example 2, as in Example 1, the apparent density of the three-dimensional random loop joint structure, the number of joint points per unit weight of the three-dimensional random loop joint structure, The fineness of the continuous linear body, the hollowness of the continuous linear body, the 25% compression hardness of the three-dimensional random loop joint structure, the cushioning properties and the quietness of the cushions were measured. The results are shown in Table 2.

<Comparative Example 3>
Resin composition pellets were obtained in the same manner as in Example 1 except that the thermoplastic resin was the polyester-based thermoplastic elastomer (A-2) obtained in Synthesis Example 2. Nozzle is a nozzle with 64cm width and 4.8cm length with a round solid shape orifice with a hole diameter of 5.0mm arranged at an interval of 8mm on the nozzle effective surface, and the single hole discharge rate at the time of discharge is 3.6g / min The water surface of the cooling water is 38 cm below the nozzle surface, and the speed of drawing into the cooling water is 2.0 m / min. A cushion was made. About the three-dimensional random loop joint structure and the cushion of Comparative Example 3, as in Example 1, the apparent density of the three-dimensional random loop joint structure, the number of joint points per unit weight of the three-dimensional random loop joint structure, The fineness of the continuous linear body, the hollowness of the continuous linear body, the 25% compression hardness of the three-dimensional random loop joint structure, the cushioning properties and the quietness of the cushions were measured. The results are shown in Table 2.

<Comparative Example 4>
Resin composition pellets were obtained in the same manner as in Example 1 except that the thermoplastic resin was the polyester-based thermoplastic elastomer (A-2) obtained in Synthesis Example 2. Nozzle is a nozzle with 64cm width and 4.8cm length on a nozzle effective surface with round solid shape orifices with a hole diameter of 3.0mm arranged at intervals of 6mm, and the single-hole discharge rate during discharge is 1.6g / min The water surface of the cooling water is 25 cm below the nozzle surface, and the speed of drawing into the cooling water is 1.4 m / min. A cushion was made. About the three-dimensional random loop joint structure and the cushion of Comparative Example 4, as in Example 1, the apparent density of the three-dimensional random loop joint structure, the number of joint points per unit weight of the three-dimensional random loop joint structure, The fineness of the continuous linear body, the hollowness of the continuous linear body, the 25% compression hardness of the three-dimensional random loop joint structure, the cushioning properties and the quietness of the cushions were measured. The results are shown in Table 2.

<Comparative Example 5>
The resin composition is the same as in Example 1 except that the thermoplastic resin is the polyester-based thermoplastic elastomer (A-3) obtained in Synthesis Example 3, and the cylinder temperature of the twin screw extruder is 200 ° C. Pellets were obtained. The nozzle is a nozzle in which round solid-shaped orifices having a hole diameter of 5.0 mm are arranged at intervals of 8 mm on the nozzle effective surface having a width of 64 cm and a length of 4.8 cm, and the melting temperature of the resin composition is 230 ° C. Example 1 except that the single hole discharge rate is 3.6 g / min, the cooling water level is 38 cm below the nozzle surface, and the speed of drawing into the cooling water is 2.0 m / min. Thus, the three-dimensional random loop structure and the cushion of Comparative Example 5 were produced. About the three-dimensional random loop joint structure and the cushion of Comparative Example 5, as in Example 1, the apparent density of the three-dimensional random loop joint structure, the number of joint points per unit weight of the three-dimensional random loop joint structure, The fineness of the continuous linear body, the hollowness of the continuous linear body, the 25% compression hardness of the three-dimensional random loop joint structure, the cushioning properties and the quietness of the cushions were measured. The results are shown in Table 2.

<Comparative Example 6>
As a thermoplastic resin, low density polyethylene (“Nipolon Z 1P55A” manufactured by Tosoh Corporation) was used as it was. The nozzle is a nozzle in which round solid-shaped orifices having a hole diameter of 5.0 mm are arranged at intervals of 8 mm on a nozzle effective surface having a width of 64 cm and a length of 4.8 cm, and the melting temperature of the resin composition is 200 ° C. The three-dimensional random loop structure and cushion of Comparative Example 6 in the same manner as in Example 1 except that the single-hole discharge rate at that time is 3.0 g / min and the speed of drawing into the cooling water is 1.5 m / min. Was made. For the three-dimensional random loop joint structure and the cushion of Comparative Example 6, as in Example 1, the apparent density of the three-dimensional random loop joint structure, the number of joint points per unit weight of the three-dimensional random loop joint structure, The fineness of the continuous linear body, the hollowness of the continuous linear body, the 25% compression hardness of the three-dimensional random loop joint structure, the cushioning properties and the quietness of the cushions were measured. The results are shown in Table 2.

  As shown in Table 2, a continuous loop made of a thermoplastic resin is twisted to form a random loop, and the respective loops are brought into contact with each other in a molten state, and most of the contact portion is fused. A three-dimensional random loop joint structure and a package that wraps the three-dimensional random loop joint structure, and the apparent density of the three-dimensional random loop joint structure is 0.005 to 0.200 g / cm 3. The cushions of Examples 1 to 6 in which the number of joint points per unit weight of the three-dimensional random loop joint structure is 500 to 1200 pieces / g, compared with the cushions of Comparative Examples 1 to 6, It was confirmed that the cushion and quietness were excellent.

  The present invention can be used for a cushion used in daily life other than at bedtime.

  DESCRIPTION OF SYMBOLS 1 Cushion, 10 3D random loop joining structure, 11 Packaging body, 21 Continuous linear body, 21a Continuous linear body precursor, 22 Random loop, 33 Hollow part, 42 Thermoplastic resin, 43 Extruder, 45 Orifice, 46 Discharge device, 51, 52 Take-up conveyor, 53 Cooling medium, 54 Cooling tank, 55 Endless net.

Claims (13)

A three-dimensional random loop formed by twisting continuous filaments made of a thermoplastic resin to form a random loop, bringing the respective loops into contact with each other in a molten state, and fusing most of the contact portions. A bonded structure;
A package that wraps around the three-dimensional random loop joint structure,
The apparent density of the three-dimensional random loop bonded structure is 0.005 to 0.200 g / cm3,
A cushion, wherein the number of joint points per unit weight of the three-dimensional random loop joint structure is 500 to 1200 pieces / g.   The cushion according to claim 1, wherein the number of joint points per unit weight of the random loop joint structure is 550 to 1150 pieces / g.   The cushion according to claim 2, wherein the number of bonding points per unit weight of the random loop bonded structure is 600 to 1100 pieces / g. The thermoplastic resin is at least one thermoplastic resin selected from the group consisting of soft polyolefin, polystyrene-based thermoplastic elastomer, polyester-based thermoplastic elastomer, polyurethane-based thermoplastic elastomer, and polyamide-based thermoplastic elastomer. The cushion in any one of 1-3. The cushion according to claim 4, wherein the thermoplastic resin is a thermoplastic resin selected from the group consisting of a soft polyolefin and a polyester-based thermoplastic elastomer. The cushion according to claim 5, wherein the thermoplastic resin is a polyester-based thermoplastic elastomer.   The cushion in any one of Claims 1-6 whose fineness of the said continuous filament is 200-10000 decitex.   The cushion according to claim 7, wherein the fineness of the continuous filaments is 200 to 5000 dtex. The cushion of Claim 8 whose fineness of the said continuous filament is 200-3000 decitex.   The cushion according to any one of claims 1 to 9, wherein the continuous filament is a hollow section.   The cushion according to claim 10, wherein the continuous filament has a hollow cross section, and a hollow ratio of the hollow cross section is 10 to 50%. The cushion according to claim 11, wherein the continuous filament has a hollow cross section, and a hollow ratio of the hollow cross section is 20 to 40%. The cushion according to any one of claims 1 to 12, wherein the continuous filament is an irregular cross section.