JP2720764B2 - Fiber cushion material having irregularities on the surface and method for producing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION The present invention relates to a method for heat-sealing synthetic fibers such as polyester fibers as a base, or mixed cotton such as synthetic fibers and natural fibers and rayon as thermoplastics. More specifically, when using as a mattress for bed, etc. The present invention relates to a sanitary fiber cushion material having a finger pressure effect due to surface irregularities and having excellent air permeability.

[0002]

2. Description of the Related Art In recent years, a fiber cushion material such as polyester has been used instead of a urethane foam cushion material which has been conventionally used. This fiber cushion material is formed by mixing a fiber having a relatively high melting point such as polyester fiber and a low melting point fiber having a lower melting point than the high melting point fiber to form a fiber web, and laminating the fiber web to an appropriate thickness. Then, by heating to a temperature between the melting points of the high-melting fiber and the low-melting fiber, the low-melting fiber is melted to thermally fuse the high-melting fiber to form a mat-shaped cushion material. However, since the conventional fiber cushion material as described above is formed by laminating a fiber web formed by carding with a card machine or a random webber along a thickness direction of the cushion material using a cross wrapper or the like. The carding direction of the fibers in the fiber web is orthogonal to the thickness direction of the cushion material. That is, since the fibers are in a state of lying in the cushion material,
The elastic properties of the fibers themselves have not been fully utilized as a cushion material that applies a load in the thickness direction, and therefore the sag is large and the cushion material is not always satisfactory.

In view of the above points, the present inventor has demanded a fiber cushion material in Japanese Patent Application Laid-Open No. Hei 4-221627 filed as above, utilizing the elastic properties of the fiber itself as it is. Excellent in various properties such as hardness, rebound resilience, compression set, etc.
In addition, a fiber cushion material which has little change over time and excellent durability has already been proposed. This fiber cushion material
A fiber web is formed by mixing a high-melting fiber as a base fiber and a low-melting fiber as a binder fiber having a lower melting point than the high-melting fiber, and forming the fiber web in a direction orthogonal to the thickness direction of the cushioning material. It is manufactured by heating this to a temperature between the melting points of both fiber components to melt the low-melting fiber, and stabilizing the high-melting fiber by heat fusion between the layers and between the layers. Since the web is laminated in a manner orthogonal to the thickness direction of the cushion material, the carding direction of the fibers in the fiber web is parallel to the thickness direction of the cushion material, and the fibers Since it is in a standing state, the elastic properties of the fiber itself are utilized as it is in the thickness direction of the cushion material, and the hardness, cushioning properties, excellent properties such as compression residual ratio, etc. required for the cushion material are excellent, Was, less sag, and has a good cushion material to change over time is also less durable.

[0004]

As described above, the fiber cushion material proposed by the present applicant has a structure in which the fiber web is laminated in a direction perpendicular to the thickness direction so that the fiber is cushioned. In the standing state, the elastic properties of the fiber itself are utilized in the thickness direction of the cushion material as it is, and it is excellent in hardness, cushioning property, compression residual ratio, etc., and has little set and little change with time It has excellent durability. In the present invention, taking this fiber cushion material one step further, cushioning properties, compression residual strain properties, etc., and further improving the settling prevention effect, and at the same time, when used as a bed mattress, etc. It is an object of the present invention to provide a novel fiber cushioning material having an acupressure effect and excellent breathability.

[0005]

In order to achieve the above object, the fiber cushion material according to the present invention comprises a fiber web in which a high-melting fiber and a low-melting fiber having a lower melting point are mixed in a thickness direction. Laminated in a direction orthogonal to the direction, the high-melting fibers are fused by the melting of the low-melting fibers, and the respective fiber webs are heat-sealed, and irregularities are formed on the surface thereof. Is applied. Furthermore, in the present invention, the latex applied to the surface of the fiber cushion material contains a granular or powdery far-infrared radiating ceramics, and the nonwoven fabric is adhered to the top surface of the uneven surface. We provide fiber cushioning materials.

In the present invention, a fiber web in which a high-melting fiber and a low-melting fiber having a lower melting point are mixed is laminated in a direction orthogonal to the thickness direction, and the high-melting fiber is melted to melt the high-melting fiber. A plurality of unit cushion materials between which the melting point fibers and the respective fiber webs are thermally fused are laminated such that the lamination directions of the fiber webs in the vertically adjacent unit cushion materials are orthogonal to each other. A fiber cushion, wherein the unit cushion materials are adhered by an adhesive, and irregularities are formed on the surface of the unit cushion material layer located on the outermost layer, and latex is applied to the irregular surface. Provide materials. Furthermore, in the present invention, the latex applied to the surface of the fiber cushion material contains a granular or powdery far-infrared radiating ceramics, and the nonwoven fabric is adhered to the top surface of the uneven surface. A fiber cushion material comprising:

Further, as a method of manufacturing the cushioning material according to the present invention as described above, a high melting point fiber and a low melting point fiber having a lower melting point than the high melting point fiber are mixed and opened to form a fiber web, This fiber web is laminated in a direction orthogonal to the thickness direction of the cushion material, and the fiber web is heated to a temperature between the melting points of the two fibers to melt the low-melting fiber, and the high-melting fiber is melted by the melted low-melting fiber. And the fiber webs are fused together, cooled to obtain a plate-like cushion material, and latex is applied to the surface of the plate-like cushion material, which is heated and pressed by a mold having irregularities. An object of the present invention is to provide a method for manufacturing a cushion material made of fiber, characterized by forming irregularities on the surface of the latex coated with the latex.

[0008]

As described above, in the fiber cushion material according to the present invention, the fiber web is laminated in a manner orthogonal to the thickness direction of the cushion material, and the carding direction of the fibers in the fiber web is changed to the cushion direction. Since the fiber is parallel to the thickness direction of the material and the fiber stands up in the cushion material, the elastic properties of the fiber itself are utilized in the thickness direction of the cushion material as it is, and the hardness, cushioning property, compression residual ratio In addition to being excellent in various characteristics required as a cushioning material such as etc., there is little settling, little change over time and excellent durability,
It has a finger pressure effect due to the unevenness formed on the surface thereof, and the concave portion of the unevenness serves as a ventilation space and is extremely excellent in air permeability. In addition, the latex applied to this uneven surface exerts a certain acupressure effect by reinforcing the uneven portion, and also more reliably prevents the set of the cushion material, and at the same time, orthogonal to the thickness direction. To prevent cracks between the fiber webs laminated on each other.

In the case where the surface latex layer contains far-infrared radiating ceramics, the far-infrared radiating ceramics are heated by the body temperature of a person when the cushion material is used for batting of a bed mattress or the like. By radiating, a therapeutic effect by far infrared rays can be expected.

[0010] When the nonwoven fabric is stuck on the top surface of the uneven surface, the touch to the unevenness of the surface is softened, the fall of the unevenness is prevented, and the cushion material in the uneven portion is provided. It also has the effect of preventing cracks.

Also, a plurality of the fiber webs in the vertically adjacent unit cushion materials are laminated so that the laminating directions are orthogonal to each other, and irregularities are formed on the surface of the outermost unit cushion material layer. In the case of a fiber cushion material coated with latex, the fiber webs of the unit cushion material vertically adjacent to each other are orthogonal to each other, so that the set of the cushion material as a whole is more reliably prevented, and it is hard and has cushioning properties. It is also excellent in the above-mentioned acupressure effect, air permeability, etc. due to the unevenness of the surface.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in more detail with reference to the accompanying drawings.

FIG. 1 is a perspective view showing one embodiment of a fiber cushion material 1 according to the present invention. The fiber cushion material 1 has corrugated irregularities 2 formed on the surface thereof. A latex layer 3 is formed on the surface of the unevenness 2.

In this fiber cushion material 1, a fiber web 11 in which a high-melting fiber and a low-melting fiber having a lower melting point are mixed is perpendicular to the thickness direction v of the cushion material as shown in FIG. As shown in FIG. 3, a latex 3 is applied to the surface of the fiber-shaped cushioning material 10 which is laminated in the direction h and has a high-melting-point fiber melted between the low-melting-point fibers and between the respective fiber webs. Then, as shown in FIG. 4, this is manufactured by heating and pressing with a mold 4 having corrugated irregularities to form irregularities 2 on the surface on which the latex 3 is applied.

The detailed manufacturing method of the plate-like cushion material 10 is described in the above-mentioned prior application, Japanese Patent Laid-Open No. Hei 4-221627.
This is as described in the official gazette. That is, a low-melting fiber is mixed with a high-melting fiber serving as a base, and this is carded with a drum-type card machine or the like, or a fiber web formed using a random webber or the like is formed in a vertical direction at a predetermined interval. The fiber web is continuously supplied and laminated between a pair of belt conveyors, and the fiber web laminate is passed through a hot-air heating unit at a temperature between the melting points of both fibers, for example, about 145 ° C. to melt the low-melting-point fibers and to increase the temperature. After fusing each fiber such as a melting point fiber and a natural fiber, the fiber is cooled by cold air or the like.

The high melting point fiber as the base fiber in the raw material fiber has a relatively high melting point, such as polyester, polypropylene, acrylic and nylon, and has excellent cushioning properties with high compression elasticity and high strength. Synthetic fibers, or those obtained by crimping these fibers and further improving the elastic properties as a degree of crimp of a specific value or more, may be used. The fiber length of the high melting point fiber may be a normal staple length of about 30 to 100 mm, and the fineness may be 1 to 3 mm.
A general one of about 0 denier may be used. If the melting point of the high melting point fiber is low, the heat resistance of the cushion material as a product may become a problem.
Although a fiber having a temperature of about 200C or higher is used, a fiber having a temperature of 200C or higher is more preferable. In addition, as the base fiber, a mixture of the above synthetic fibers, such as raw cotton, wool, silk, or other vegetable or animal natural fibers having humidity control properties, or rayon can also be used.

The low-melting fiber serving as a fusion component in the raw material fiber has a lower melting point than the high-melting fiber, has a specific softening point and melt viscosity, and has a high melting point when mixed with the high-melting fiber. It is a hot-melt adhesive fiber that can be melted by heating at a temperature equal to or lower than the melting point of the melting point fiber to fuse between the high melting point fibers serving as a base. The components of the low melting point fiber include polyolefins such as polyethylene and polypropylene, and thermoplastic polymers such as polyamide, polyester, polyacrylonitrile, polyvinyl alcohol, polyvinyl chloride, and polyvinylidene chloride. Fibers or heat-adhesive conjugate fibers such as side-by-side or core-in-sheath conjugated polyester fibers with a high melting point component having a part of the surface made of these low melting point components may be used. In the case of this low-melting fiber, the fiber length and the fineness are not particularly limited, and the fiber length may be about 30 to 100 mm and the fineness may be about 1 to 30 denier. As the melting point of the low melting point fiber (low melting point component), it is preferable to use a fiber which is lower than the melting point of the high melting point fiber by 50 ° C. or more.

The mixing ratio of the high-melting fiber and the low-melting fiber is usually in the range of 90:10 to 50:50 by weight of the high-melting fiber to the low-melting fiber. Generally, 70-80% by weight of high melting point fiber and 30-20% by weight of low melting point fiber.
% By weight. In this case, as the proportion of the high-melting fiber increases, that is, as the proportion of the low-melting fiber decreases, the fusion point between the fibers decreases, resulting in a soft cushion material, and conversely, the blending proportion of the low-melting fiber increases. , The fusion point increases and the cushion material becomes a hard cushion material. By adjusting the blending ratio according to the purpose of the cushion material, a cushion material having a desired hardness can be obtained.

For example, 60% by weight of a high melting point polyester fiber as the above-mentioned high melting point fiber, 10% by weight of natural cotton fiber, and 30% by weight of a composite low melting point polyester fiber as a low melting point fiber are mixed. This is carded by a drum card machine or the like, or a fiber web having an appropriate thickness is formed using a webber such as a random webber. The thickness of the fiber web is usually about 1 to 5 mm. The fibrous web is continuously supplied between a pair of vertical belt conveyors, and is continuously folded in a mat shape so as to be folded. At this time, the density of the fiber web laminate increases as the feed speed of both belt conveyors increases, and the density of the laminate decreases as the feed speed decreases. The density is appropriately set according to the hardness of the target cushion material, but is usually 0.005 to 0.005.
About 0.15 g / cm ³ , preferably 0.01 to 0.1
It is about 0 g / cm ³ . The distance between the two belt conveyors is appropriately adjusted in consideration of the thickness of the cushion material to be manufactured, the manufacturing efficiency, the thermal efficiency in the heating section in the subsequent process, the cooling efficiency in the cooling section, and the like, but is usually up to about 100 mm. This is preferable in terms of the manufacturing process, thermal efficiency, and the like.

As the heating means used for heat treatment of the laminated fiber web, in addition to the above-described method using hot air, a wet heat type such as hot water steam and high pressure steam, electric heating, high frequency heating, infrared rays, and infrared rays can be used. Various heating means such as a dry heat type such as an ephemeral type can be used. Regardless of which means is used, in the present invention, since the fiber webs are laminated in a direction perpendicular to the thickness direction, this heating is efficiently performed up to the inside of the laminate.

The cushioning material manufactured as described above is formed by flattening its upper and lower surfaces with a slitter or the like, if necessary, slicing the cushioning material to a predetermined thickness, and further forming a side slitter on both sides. Cut it out and align the edges,
As shown in FIG. 2, a plate-shaped cushion material 10 having a desired size with smooth upper and lower surfaces and both right and left end surfaces is obtained. As shown in the figure, the plate-like cushion material 10
The fiber web 11 is laminated in the width or length direction h of the cushioning material 10 perpendicular to the thickness direction v of the cushioning material 10, and the fibers combed in the fiber web 11 are arranged in the thickness direction v in the plate-like cushioning material 10. Because it is in a standing state, the hardness, elastic properties, etc. of the raw material fibers themselves are utilized in the thickness direction hardness, elastic properties of the cushion material as it is,
It exhibits excellent hardness as a cushioning material and excellent elastic properties with respect to load, and has little damp heat aging due to a change over time, such as urethane foam, and has excellent durability.

Next, in the present invention, the latex 3 is applied to the surface of the plate-like cushion material 10 manufactured as described above, as shown in FIG. The latex 3 is formed by applying latex to the surface of the cushion material 10 by spraying or the like. The latex 3 applied to the surface heats and presses the surface of the plate-shaped cushion material 10 as described later. When forming the irregularities by molding, it is possible to prevent the separation between the fiber webs 11 or to prevent the cushioning material from being cracked at the irregularities, and the latex 3 reinforces the irregularities to more reliably set the cushion material. Can be prevented. The application of latex is not particularly limited, and may be adjusted according to the required surface hardness. In addition, instead of this latex, a synthetic resin paint or the like can be applied, but in that case, it is desirable to use a relatively soft material even after curing so that the surface of the cushion material does not become too hard. .

Then, as described above, the latex 3
As shown in FIG. 4, the plate-like cushion material 10 coated with is coated with the latex 3 by heating and pressure molding with a mold 4 having the unevenness to form the unevenness 2 on the surface. In the drawing, the plate-shaped cushioning material 10 is sandwiched between a corrugated mold 4 and a flat mold 5, and pressure is applied from above and below, and these molds 4, 5 are heated by steam heating or the like. By doing so, the unevenness 2 is formed on one surface of the plate-like cushion material 10 as shown in FIG. In the figure, 6... Are steam holes appropriately formed in the dies 4 and 5, from which steam is supplied into the plate-like cushion material 10 sandwiched between the dies 4 and 5 to efficiently heat the plate. This facilitates the formation of the irregularities 2.

The cushion material heated and pressed between the dies 4 and 5 as described above is released from the mold and then heated to 80.degree.
According to the present invention, as shown in FIG. 1, the surface of the present invention having the unevenness 2 shown in FIG. The fiber cushion material 1 is obtained. In the above embodiment, the unevenness 2 was formed on only one side of the cushion material 1.
Are formed, for example, as shown in FIG. 6, irregularities 2... May be formed on both surfaces thereof. Further, it is not always necessary to apply the latex 3 on the surface where the irregularities 2 are not formed.

The fiber cushioning material 1 according to the present invention manufactured as described above can be used as a mattress, a batting such as a cushion, or the like.
It can also be used by laying on the surface of a futon or the like. In the fiber cushion material 1, a finger pressure effect can be obtained by the unevenness 2 formed on the surface, and at the same time, the unevenness 2
As a result, a space is formed in the surface portion of the fiber cushioning material 1, thereby being extremely excellent in air permeability, preventing moisture, suppressing the growth of mold and bacteria, and being hygienic.
It is also effective for preventing floor rubbing in bedridden cases. Further, the fiber cushion material 1 of the present invention is easily bent as compared with the conventional fiber cushion material because the fiber web 11 is laminated in a direction orthogonal to the thickness direction, but is extremely bent. In such a case, the fiber webs may be split between the fiber webs. However, the formation of the latex layer 3 on the surface may cause the fiber cushion material 1 to crack at the uneven portion or to peel off the laminated fiber webs 11. In addition, since the unevenness is covered with the latex layer 3, there is little set and the durability is excellent. Further, when a latex layer 3 containing far-infrared radiating ceramics is formed on the surface, if the fiber cushion material 1 is used as batting such as a futon or a mattress, the latex on the surface of the fiber cushion material 1 may be changed depending on the human body temperature. The far-infrared radiation ceramics in the layer 3 is heated to emit far-infrared rays, and in addition to the acupressure effect by the unevenness 2 as described above, a therapeutic effect by this far-infrared rays can be expected.

Next, FIGS. 7 to 9 show an embodiment of a bed mattress 100 using the above-described fiber cushion material according to the present invention. The bed mattress 100 is formed by laminating a plurality of unit cushion materials. In the illustrated example, three unit cushion materials 110, 120, and 130 are laminated, and each unit cushion material 110, 120 is laminated. , And 130
In both cases, a fiber web in which the high-melting fiber and the low-melting fiber having a lower melting point are mixed as described above is laminated in a direction orthogonal to the thickness direction, and the high-melting fiber is melted by melting the low-melting fiber. 8, and between the fibrous webs are heat-sealed, and, as shown in FIG. 8, a unit intermediate between the upper and lower adjacent unit cushion materials, that is, the direction A of the fibrous web in the unit cushion material 110 on the upper surface. Cushion material 1
A plurality of fiber webs 20 are stacked so that the direction B of the fiber web at 20, the direction B of the fiber web at the intermediate unit cushion material 120 and the direction C of the fiber web at the unit cushion material 130 on the lower surface are orthogonal to each other. Then, the unit cushion material of each layer is adhered by an adhesive. Each unit cushion material 110, 1
The adhesive for bonding between 20, 130 is not particularly limited,
For example, a quick-drying urethane-based adhesive is used. Further, irregularities 2 are formed on the surfaces of the unit cushion materials 110 and 130 on the upper and lower surfaces, and latex 3 is applied on the irregular surfaces as shown in FIG.

As the unit cushion materials 110 and 130 constituting the upper and lower surfaces of the mattress 100, the above-described fiber cushion material 1 according to the present invention can be used as it is. Further, as the intermediate unit cushion material 120, the plate-like cushion material 10 serving as a base when the fiber cushion material 1 is manufactured may be used.

Further, the mattress 100 of the illustrated example has nonwoven fabrics 7, 7 adhered to the uneven surfaces formed on the upper and lower surfaces thereof. The attachment of the nonwoven fabric 7 is performed by the unit cushion materials 110 and 130 constituting the upper and lower surfaces of the mattress 100.
Is bonded via an adhesive to the uneven surface. As described above, in the case where the nonwoven fabric 7 is stuck to the uneven surface, when the mattress 100 is used for a bed, the touch to the uneven portion on the surface is soft, and the space between the adjacent convex portions is reduced. Are connected by the nonwoven fabric 7, so that the unit cushion material 11
It also has the effect of preventing cracks 0 and 130, and furthermore, the non-woven fabric 7 prevents the non-woven fabric 7 from dropping into uneven portions.

In the mattress 100 shown in the figure, three unit cushion materials are laminated, but the number of the unit cushion material layers is not particularly limited and may be four or more. The thickness of the cushion material layer and the thickness of the entire mattress 100 may be appropriately set as needed.

[0030]

As described above, the fiber cushion material according to the present invention has the hardness of the base fiber itself in the raw fiber,
Since various properties such as elasticity are utilized as they are in the thickness direction of the cushioning material, the cushioning material is strong, has little settling, and has a finger pressure effect due to the unevenness formed on the surface. By forming a space on the surface of the material, it is excellent in air permeability, hygienic by preventing moisture and preventing the occurrence of mold and the like, and is also effective from the viewpoint of preventing floor rubbing. In addition, there is also an advantage that it is easy to bend by forming the irregularities on the surface in this way. Moreover, since the latex is coated on the uneven surface, not only can the set of the cushioning material be further prevented, but also the laminated fiber webs can be peeled off when forming the unevenness on the surface, It is also possible to prevent the cushion material from being cracked at the uneven portions when bent.

Further, when the surface latex contains far-infrared radiating ceramics, the far-infrared radiating ceramics are heated by the human body temperature to emit far-infrared rays when this cushion material is used as a bed mattress or the like. By doing so, a therapeutic effect by far infrared rays can be expected.

In the case where the nonwoven fabric is stuck on the top surface of the uneven surface, the touch to the unevenness on the surface is softened, and the cushion material in the uneven portion is more reliably prevented from cracking. Prevents falling into the inside.

In the case where a plurality of unit cushion materials are stacked so that the laminating directions of the fiber webs are orthogonal to each other, the fiber webs of the unit cushion materials vertically adjacent to each other are orthogonal to each other, so that the entire cushion material is Sag is more reliably prevented, and it is hard and has excellent cushioning properties, and is most suitable for use as a bed mattress or the like. Further, in the case where the surface of the unit cushion material layer located at the outermost layer is formed with irregularities on the surface and the latex layer is formed on the surface, a mattress excellent in acupressure effect due to the irregularities on the surface, air permeability and the like is obtained. be able to.

[Brief description of the drawings]

FIG. 1 is a perspective view showing one example of a fiber cushion material according to the present invention.

FIG. 2 is a perspective view of a plate-like cushion material serving as a base of the fiber cushion material.

FIG. 3 is a side sectional view of a plate-like cushion material having a surface coated with latex.

FIG. 4 is a side sectional view showing a state in which irregularities are formed on the surface of the plate-like cushion material.

FIG. 5 is a side cross-sectional view of a fiber cushion material having irregularities formed on a surface.

FIG. 6 is a side cross-sectional view of a fiber cushion material having irregularities formed on both surfaces.

FIG. 7 is a perspective view of a mattress using the fiber cushion material according to the present invention.

FIG. 8 is an exploded perspective view of a part of the mattress.

FIG. 9 is an enlarged perspective view of a part of the mattress.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Fiber cushion material 2 Concavo-convex 3 Latex 4 Die 5 Die 6 Vapor hole 7 Nonwoven fabric 10 Plate cushion material 11 Textile web 100 Mattress 110 Unit cushion material 120 Unit cushion material 130 Unit cushion material

Claims (7)

(57) [Claims] 1. A fiber web in which a high-melting fiber and a low-melting fiber having a lower melting point are mixed are laminated in a direction orthogonal to a thickness direction. And a fiber cushion material, wherein the fiber webs are heat-sealed with each other, irregularities are formed on the surface thereof, and latex is applied to the irregular surface. 2. The fiber cushioning material according to claim 1, wherein the latex applied on the surface contains granular or powdery far-infrared radiating ceramics. 3. The fiber cushion material according to claim 1, wherein a nonwoven fabric is adhered to a top surface of the uneven surface. 4. A fiber web in which a high-melting fiber and a low-melting fiber having a lower melting point are mixed is laminated in a direction orthogonal to a thickness direction, and the low-melting fiber melts between the high-melting fibers, And a plurality of unit cushion materials in which the respective fiber webs are heat-sealed are stacked such that the lamination directions of the fiber webs in the vertically adjacent unit cushion materials are orthogonal to each other, and between the unit cushion materials of each layer. Are bonded by an adhesive, and irregularities are formed on the surface of the unit cushion material layer located on the outermost layer, and latex is applied to the irregularities surface. 5. The fiber cushioning material according to claim 4, wherein the latex applied on the surface contains granular or powdery far-infrared radiating ceramics. 6. The fiber cushion material according to claim 4, wherein a nonwoven fabric is stuck to the top surface of the uneven surface. 7. A fiber web is formed by mixing and opening high-melting fiber and low-melting fiber having a lower melting point than the high-melting fiber, and forming the fiber web in a direction orthogonal to the thickness direction of the cushion material. It is heated to a temperature between the melting points of the two fibers to melt the low-melting fiber, and the high-melting fiber is fused by the melted low-melting fiber, and between the respective fiber webs. After cooling, a plate-like cushion material is obtained, a latex is applied to the surface of the plate-like cushion material, and this is heated and pressed by a mold having irregularities to form irregularities on the surface to which the latex is applied. A method for producing a fiber cushion material, comprising: