JP3351489B2 - Nonwoven laminated net, manufacturing method and product using the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a recyclable nonwoven laminated net having flame retardancy, excellent cushioning properties, heat resistance and vibration absorption, and a method for producing the same. The present invention relates to products and manufacturing methods such as futons, furniture, beds, and cushioning materials for vehicles.

[0002]

2. Description of the Related Art At present, foamed urethane, inelastic crimped fiber-filled cotton,
Resin cotton and hard cotton to which inelastic crimped fibers are bonded are used.

[0003] However, foamed-crosslinked urethane is extremely good in durability as a wadding layer and a cushion material, but is inferior in moisture permeability and heat storage, so that it is easily stuffed.
In addition, when the incinerator is incinerated because it is not thermoplastic and is difficult to recycle, the incinerator is greatly damaged and toxic gas removal is costly. For this reason, landfills have been increased, but there is a problem in that it is difficult to stabilize the ground, so that landfill locations are limited and costs increase. Further, although the processability is excellent, there is a problem of pollution of chemicals used during the production. In addition, in the case of the cotton filled with thermoplastic polyester fiber, since the space between the fibers is not fixed, the shape at the time of use collapses, the fiber moves, and the crimp set causes a decrease in bulkiness and a decrease in elasticity. become.

Japanese Patent Application Laid-Open Publication No. Sho 6 (1994) discloses a resin cotton in which polyester fibers are bonded with an adhesive, for example, a rubber using an adhesive as a rubber.
Nos. 0-11352, JP-A-61-141388 and JP-A-61-141391. Further, JP-A-61-1377 discloses a method using a crosslinkable urethane.
No. 32 publication. These cushioning materials are inferior in durability, are not thermoplastic, cannot be recycled because they are not a single composition, and have problems such as complicated workability and pollution of chemicals used during production. .

[0005] Polyester hard cotton, for example, JP-A-58-3
JP-A No. 1150, JP-A-2-154050, JP-A-3-220354, etc., are disclosed in Japanese Patent Application Laid-Open No. Sho 58-58, because the adhesive component of the heat-bonding fiber used is a brittle amorphous polymer. -136828, JP-A-3-
There is a problem that the adhesive portion is brittle and the durability is poor such that the adhesive portion is easily broken during use and the form and elasticity are reduced. As an improved method, a method of performing confounding treatment has been proposed in Japanese Patent Application Laid-Open No. 4-245965, but there is a problem that the brittleness of the bonded portion is not solved and the elasticity is greatly reduced. In addition, there is also complexity in processing. Further, there is a problem that the bonded portion is hardly deformed and it is difficult to provide soft cushioning. For this reason, the adhesive is soft and the polyester elastomer recovers even if deformed to some extent.
Japanese Patent Application Laid-Open No. 4-240219 discloses a thermal bonding fiber using an inelastic polyester as a core component, and WO-91 / 19032, Japanese Patent Application Laid-Open No. 5-156561 discloses a cushioning material using the fiber. It has been proposed in, for example, JP-A-5-163654. When the adhesive component used in this fiber structure is a soft segment of polyester elastomer, the content of polyalkylene glycol is 30 to 50.
5% by weight of terephthalic acid in the acid component of the hard segment
0-80 mol%, and as another acid component composition
In the same manner as the fiber described in JP-A No. 0-1404, isophthalic acid is contained to increase the amorphousness, and the melting point is also 180.
℃ or lower and low melt viscosity to improve the formation of the heat-bonded part to form an amoeboid bonded part, but plastic deformation is easy, and the core component is inelastic polyester, so plastic deformation especially under heating And there is a problem that heat resistance and compression resistance decrease. As these improved methods, Japanese Patent Application Laid-Open
JP-A-163654 proposes a structure composed of only a polyester elastomer containing isophthalic acid as a sheath component and a heat-adhesive conjugate fiber using an inelastic polyester as a core component. Plastic deformation is remarkable, heat resistance and compression resistance are reduced, and there is a problem in using it for wadding layers and cushion materials. On the other hand, Japanese Patent Application Laid-Open No. Sho 63-163 discloses a method in which a silicone oil agent is applied to a hard cotton base material to reduce the friction coefficient of the fiber, thereby improving durability and improving texture.
It has been proposed in US Pat. However, there is a problem in the adhesiveness of the heat-bonding fiber, and the durability is inferior.

A thermoplastic olefin network used for civil engineering is disclosed in JP-A-47-44839. However, unlike a cushion made of fine fibers, the surface is uneven and the touch is poor, and since the material is olefin, the heat resistance is remarkably inferior and cannot be used as a wading layer or a cushion material. In addition, 3-1766
Japanese Patent Application Laid-Open No. 6-204, there is a method in which discharge filaments having different fineness are fused to each other to form a molding, but this is a net-like structure that is not suitable for a cushion material. In Japanese Patent Publication No. 3-55583,
A method is described in which only the very surface is thinned by a thinning device such as a rotating body before cooling. In this method, the surface cannot be flattened, and a thick and thin linear layer cannot be formed. Therefore, the cushioning material does not provide a comfortable sitting comfort. JP-A-1-207462 discloses a floor mat made of vinyl chloride. However, since it has poor compression recovery at room temperature and extremely poor heat resistance, it is not preferable as a wading material or a cushion material. is there. In addition, the structure mentioned above does not consider the flame retardance at all.

[0007]

SUMMARY OF THE INVENTION In order to solve the above problems,
Non-woven laminated netting suitable for cushioning material with excellent heat resistance and durability, good shape retention and excellent cushioning properties. It is an object to provide products and manufacturing methods such as beds, beds and vehicle cushions.

[0008]

Means for Solving the Problems Means for solving the above-mentioned problems, that is, the present invention provides a soft segment content (A weight%) and a phosphorus content (Bppm) of 60A + 200 ≦ B ≦ 1.
A continuous filament having a fineness of 100,000 deniers or less, made of a thermoplastic elastic resin satisfying the relationship of 00000, is meandered and brought into contact with each other to form a three-dimensional three-dimensional structure in which most of the contact portions are fused. On one or both sides of a net-like body whose both sides are substantially flattened, a short fiber composed of a thermoplastic adhesive resin and a thermoplastic inelastic resin and a short fiber composed of a thermoplastic inelastic resin has a three-dimensional structure. The apparent density at which the formed, fused and integrated layers are laminated and joined is 0.
Nonwoven laminate meshwork of 0.2 g / cm ³ from 01g / cm ^3,
Soft segment amount (A weight%) and phosphorus content (Bppm) are more than 60A + 2 from a multi-row nozzle having a plurality of orifices
A thermoplastic elastic resin satisfying the relationship of 00 ≦ B ≦ 100000 is distributed to each nozzle orifice, and discharged downward from the nozzle at a melting temperature higher than the melting point of the thermoplastic resin by 10 to 80 ° C. Heat-bonding short fibers composed of thermoplastic elastic resin and thermoplastic inelastic resin on one or both surfaces after being sandwiched by a take-off device and cooled in a cooling tank while forming a three-dimensional structure by contacting and fusing with each other. And a short fiber made of a thermoplastic inelastic resin. The three-dimensional web is mixed and opened, and a three-dimensional web is laminated. .

In the present invention, the thermoplastic elastic resin is a polyether-based glycol, polyester-based glycol, polycarbonate-based glycol or long-chain hydrocarbon having a molecular weight of 300 to 5000 as a soft segment. Polyester-based elastomer, polyamide-based elastomer, polyurethane-based elastomer, which is obtained by block-copolymerizing an olefinic compound having a carboxylic acid or a hydroxyl group at a terminal.
And polyolefin-based elastomers. By using a thermoplastic elastic resin, regeneration becomes possible by re-melting, so that recycling becomes easy. For example, as a polyester-based elastomer, a polyester ether block copolymer having a thermoplastic polyester as a hard segment and a polyalkylenediol as a soft segment, or a polyester ester having an aliphatic polyester as a soft segment A block copolymer can be exemplified. More specific examples of polyester ether block copolymers include aromatic dicarboxylic acids such as terephthalic acid, isophthalic acid, naphthalene 2.6 dicarboxylic acid, naphthalene 2.7 dicarboxylic acid, and diphenyl 4.4 4 'dicarboxylic acid. Alicyclic dicarboxylic acids such as 1.4 cyclohexanedicarboxylic acid, aliphatic dicarboxylic acids such as succinic acid, adipic acid, sebacic acid dimer acid, and at least one dicarboxylic acid selected from ester-forming derivatives thereof; Species and aliphatic diols such as 1.4 butanediol, ethylene glycol, trimethylene glycol, tetramethylene glycol, pentamethylene glycol, hexamethylene glycol, 1.1 cyclohexane Alicyclic diols such as dimethanol and 1,4-cyclohexane dimethanol, or these At least one diol component selected from the group consisting of ester-forming derivatives and polyethylene glycol having an average molecular weight of about 300 to 5,000.
A triblock copolymer composed of at least one of polyalkylenediols such as ethylene glycol, polypropylene glycol, polytetramethylene glycol, and ethylene oxide-propylene oxide copolymer. The polyester ester block copolymer is a ternary block copolymer composed of at least one of each of the above dicarboxylic acids, diols, and polyester diols such as polylactone having an average molecular weight of about 300 to 5,000. .
In consideration of thermal adhesion, hydrolysis resistance, stretchability, heat resistance, etc., terephthalic acid or naphthalene 2.6 dicarboxylic acid as a dicarboxylic acid, 1.4 butanediol as a diol component, poly As the alkylenediol, a triblock copolymer of polytetramethylene glycol or a terpolymer of polyester is particularly preferable. In a special case,
Those having a polysiloxane-based soft segment introduced can also be used. The thermoplastic elastomer resin of the present invention also includes those obtained by blending the above-mentioned elastomer with a non-elastomer component, copolymerized product, and polyolefin-based component made into a soft segment. As the polyamide-based elastomer, the hard segments include nylon 6, nylon 66, nylon 610, nylon 612,
Nylon 11, nylon 12, etc. and their copolymerized nylon are used as the skeleton, and the soft segment includes polyethylene glycol, polypropylene glycol, polytetramethylene glycol having an average molecular weight of about 300 to 5000,
A block copolymer composed of at least one kind of polyalkylenediol such as an ethylene oxide-propylene oxide copolymer may be used alone or as a mixture of two or more kinds. Further, those in which a non-elastomer component is blended or copolymerized can be used in the present invention.
As the polyurethane elastomer, (A) a number average molecular weight of 1000 to 60 in the presence or absence of a usual solvent (dimethylformamide, dimethylacetamide, etc.)
The polyether and / or polyester having a hydroxyl group at the terminal of 00 and (B) a polyisocyanate containing an organic diisocyanate as a main component are reacted at both ends with isocyanate.
As a typical example, (C) a polyurethane elastomer obtained by chain extension with a polyamine containing a diamine as a main component can be exemplified. The polyester and polyethers of (A) have an average molecular weight of about 1000
And 6000, preferably 1300 to 5000, such as polybutylene adipate copolymerized polyester, polyethylene glycol, polypropylene glycol, polytetramethylene glycol, and glycols composed of ethylene oxide-propylene oxide copolymer. Polyalkylene dio-
And the polyisocyanate (B) is preferably
A conventionally known polyisocyanate can be used, but an isocyanate mainly composed of diphenylmethane 4.4 'diisocyanate may be used, and a small amount of a conventionally known triisocyanate may be added if necessary. (C)
As the polyamine, mainly known diamines such as ethylenediamine and 1.2 propylenediamine may be used, and trace amounts of triamine and tetraamine may be used in combination as needed. These polyurethane elastomers can be used alone or in combination.
You may mix and use more than one type. In addition, the melting point of the thermoplastic elastic resin of the present invention is preferably 140 ° C. or higher, which can maintain the heat resistance, and the use of 160 ° C. or higher is more preferable because the heat resistance is improved. The reticulated body of the present invention contains a phosphorus-based compound to impart flame retardancy,
Since the thermal stability is slightly inferior to that containing no flame retardant, it is particularly preferable to add an antioxidant or the like as necessary to improve heat resistance and durability. The antioxidant is preferably a hindered antioxidant, which includes a hindered phenol and a hindered amine, and a nitrogen-free hindered antioxidant.
It is particularly preferable to add 1% to 5% of a dofenol-based antioxidant to suppress thermal decomposition because the generation of toxic gas with a small lethal amount during combustion can be suppressed. The soft segment content of the thermoplastic elastic resin constituting the component having the function of absorbing vibration and stress, which is the object of the present invention, is preferably 15% by weight.
The content is more preferably 30% by weight or more, and is preferably 80% by weight or less, more preferably 70% by weight or less from the viewpoint of heat and sag resistance. That is, the soft segment content of the component having the function of absorbing vibration and stress of the elastic network of the present invention is preferably 15% by weight or more and 80% by weight or less, more preferably 30% by weight or more and 70% by weight or less. .

The flame-retardant network of the present invention has a phosphorus content (Bppm) in the thermoplastic elastic resin of 60 A + 200 ≦ B ≦ 10 with respect to the soft segment content (A weight%).
0000 must be satisfied. Unsatisfactory results in poor flame retardancy, which is not preferred. 100000ppm
Exceeding the range is not preferred because the plastic deformation due to the plasticizing effect increases and the heat resistance of the thermoplastic elastic resin deteriorates. The preferred phosphorus content (Bppm) is the soft segment content (A
30A + 1800 ≦ B ≦ 100,000
The more preferable phosphorus content (Bppm) is 16A + 2600 with respect to the soft segment content (A weight%).
≦ B ≦ 50,000. There is a method of imparting high flame retardancy by adding a large amount of halides and inorganic substances, but a large amount of toxic halogen gas with a small lethal amount is generated at the time of combustion, and the problem of poisoning in a fire is reduced. Yes, the incinerator is greatly damaged during incineration, which is not preferable. In the present invention, the content of the halide is at least 1% by weight or less, preferably the content of the halide is 0.5% by weight or less, and more preferably no halide is contained. As the phosphorus-based flame retardant of the present invention, for example, in the case of a polyester-based thermoplastic elastic resin, at the time of resin polymerization, as a flame retardant in a hard segment portion, for example, 10 described in JP-A-51-82392. [2,3-di (2-hydroxyethoxy) -carbonylpropyl] 9,10-dihydro.
A method in which a carboxylic acid such as 9, oxa, 10 phosphaphenylene, or 10 oxylo is copolymerized as a part of an acid component of a hard segment to obtain a polyester-based thermoplastic elastic resin, For example, flame retardancy can be imparted by adding a phosphorus compound such as existing chemical substance number (3) -3735. In addition, examples of the flame retardant capable of imparting flame retardancy include various phosphates, phosphites, phosphonates (the above-mentioned phosphates containing a halogen element as necessary), or polymers derived from these phosphorus compounds. Can be illustrated. In the present invention, various modifiers, additives, coloring agents and the like can be added to the thermoplastic elastic resin as needed. The flame-retardant network of the present invention contains phosphorus for imparting flame retardancy. This is because, as described above, from the viewpoint of safety, cyan gas, halogen gas, etc. generated at the time of fire. The purpose of the present invention is to minimize the amount of toxic gas with low lethality. For this reason, the toxicity index of the combustion gas of the flame-retardant network of the present invention is preferably 6 or less, more preferably 5.5 or less. In addition, since polyester fibers are often used for the side layer and the wadding layer, it is preferable to use a polyester-based thermoplastic elastic resin so that the polyester fiber can be recycled without separation.

The thermoplastic elastic resin constituting the nonwoven fabric laminate network of the present invention preferably has an endothermic peak below the melting point in a melting curve measured by a differential scanning calorimeter. Those having an endothermic peak below the melting point have remarkably improved heat resistance and sag resistance than those having no endothermic peak.
For example, preferred polyester-based thermoplastic resins of the present invention include those containing 90 mol% or more of rigid terephthalic acid or naphthalene 2.6 dicarboxylic acid in the acid component of the hard segment, more preferably terephthalic acid or the like. The content of naphthalene 2.6 dicarboxylic acid is 95 mol% or more, particularly preferably 100 mol%, and after transesterification of the glycol component, polymerization is carried out to a required degree of polymerization, and then as polyalkylenediol, preferably Average molecular weight of 5
00 or more and 5000 or less, particularly preferably 1000 or more and 3 or less
When the amount of polytetramethylene glycol of 000 or less is copolymerized in the range of 15% by weight to 70% by weight, more preferably 30% by weight or more and 60% by weight or less, terephthalic acid having rigidity in the acid component of the hard segment is obtained. Acid and naphthalene 2.
If the content of 6-dicarboxylic acid is large, the crystallinity of the hard segment is improved, the plastic segment is hardly deformed, and the resistance to heat resistance is improved. When the annealing treatment is performed, heat resistance and sag resistance are further improved. After applying compression strain,
Ringing further improves heat resistance and sag resistance. An endothermic peak more clearly appears at a temperature between room temperature and the melting point in the melting curve of the filaments of the network structure treated by a differential scanning calorimeter. When no annealing is performed, an endothermic peak does not appear in the melting curve from room temperature to the melting point. By analogy with this, it is considered that the annealing may cause rearrangement of the hard segments, form pseudo-crystallization-like cross-linking points, and improve heat resistance and sag resistance. (This process is defined as a pseudo-crystallization process.) This pseudo-crystallization effect is also effective for polyamide-based elastic resins and polyurethane-based elastic resins.

In the present invention, the thermoplastic inelastic resin is
Examples thereof include polyester, polyamide, and polyolefin. For example, in the case of polyester, polyethylene terephthalate (PET), polyethylene naphthalate (PE)
N), polycyclohexylene dimethylene terephthalate (PCHDT), polycyclohexylene dimethylene naphthalate (PCHDN), polybutylene terephthalate (PBT), polybutylene naphthalate (PBN), polyaryle And copolymerized polyesters thereof. For polyamides, polycaprolactam (N
Y6), polyhexamethylene adipamide (NY66),
Examples include polyhexamethylene sebacamide (NY6-10). Examples of the polyolefin include polypropylene (PP) and polybutene-1 (PB-1). In the present invention, the glass transition temperature is at least 4
It is preferable to use one at 0 ° C. or higher. As the thermoplastic inelastic resin used in the present invention, polyester is often used for the side material of the cushioning material, so as a cushioning material that can be recycled without being separated when discarded,
Polyesters such as PET, PEN, PBN, and PCHDT which also have good heat resistance are particularly preferred. Furthermore, PET, PE
Flame-retardant polyesters (hereinafter abbreviated as flame-retardant polyesters) which are polycondensed with N, PBN, PCHDT or the like and copolymerized with a phosphorus-containing ester-forming compound or containing a phosphorus-containing flame retardant are preferred. JP-A-51-82392, JP-A-55-7888, and JP-B-55-416.
No. 10 publication and the like. Although vinyl chloride has self-extinguishing properties, it emits a large amount of toxic gas when burnt, and is not preferred for use in the present invention.

According to the present invention, there is provided a three-dimensional three-dimensional structure in which continuous filaments having a fineness of not more than 100,000 denier made of a phosphorus-containing thermoplastic elastic resin are meandered and brought into contact with each other to fuse most of the contact portions. To form a three-dimensional structure of short fibers made of a thermoplastic elastic resin and fibers made of a thermoplastic inelastic resin, on one or both sides of a net-like body whose both sides are substantially flattened. The apparent density at which the fused and integrated layers are laminated and joined is from 0.01 g / cm ³ to 0.1 g / cm ³ .
2 g / cm ³ of a non-woven laminated net. The function of the cushioning material is that the cushioning layer consists of a layer that thickens the basic fineness and makes it a little hard to maintain body shape, and a layer that absorbs vibration a little and increases the density with a component that has good vibration damping properties and absorbs the vibration The surface layer is a soft layer with a finer size and a larger number of constituent fibers, giving a comfortable buttocks touch by moderate sinking, making the pressure distribution in the buttocks evenly distributed and vibrations that could not be absorbed by the cushion layer By integrating the layer that absorbs the vibration and blocks the vibration of the resonance part of the human body, the stress and the vibration can be integrally deformed and absorbed to improve the sitting comfort. In the present invention, the function of the cushion layer is imparted to the mesh formed with the fused three-dimensional three-dimensional structure made of the thermoplastic elastic resin, and the function of the surface layer is made of a short fiber whose thermal adhesive component is made of the thermoplastic elastic resin. It is a nonwoven fabric laminated net that can be provided to a nonwoven fabric (short fiber nonwoven fabric) made of short fibers made of a thermoplastic inelastic resin and joined and integrated to provide a preferable cushioning material function. The short-fiber nonwoven fabric having a surface layer function that constitutes the laminated net of the present invention provides a comfortable buttocks touch by moderate sinking as a soft layer,
The heat bonding component is made of a thermoplastic elastic resin (preferably,
If it exceeds 40% by weight and more than 70% by weight, which can satisfy the vibration absorbing function and the deformation stress absorbing function, the shape retention of short fibers is reduced and the sinking becomes large, so that 70% by weight or less. Staple fiber (thermal bonding fiber)
And a short fiber (base fiber) having a denier of 20 denier or less, which is made of a thermoplastic inelastic resin, is mixed and opened to form a three-dimensional structure, and most of the contact portions are fused by a heat bonding component. The integrated surface is made of a substantially flat nonwoven fabric. If it exceeds 20 denier, the apparent density of the short-fiber nonwoven fabric can be increased to 0.01 g / cm, which can provide a desirable surface layer function.
^{When the} content is ³ or more and 0.05 g / cm ³ or less, the number of components is reduced, and the feature as a dense structure is not obtained, and a comfortable touch is spoiled. In addition, the heat bonding fiber is preferably because the number of constituents decreases as the fineness increases, the number of heat bonding points decreases, the dispersion of deformation stress becomes poor, the stress concentration at the bonding points increases, and the sag resistance decreases, which is preferable. Absent. Furthermore, since the thermal bonding fiber contains a thermoplastic inelastic resin, the larger the fineness, the greater the mechanical deformation of the thermoplastic inelastic resin with respect to compressive deformation, the greater the plastic deformation, and the lower the sag resistance. Is not preferred. On the other hand, if the fineness is too small, the migration with the base fiber is deteriorated, spots are generated at the heat bonding points formed by the heat bonding fibers, the dispersion of deformation stress is deteriorated, and stress concentration occurs at the bonding points, It is not preferable because the compressibility is reduced and easily deformed, and the thermoplastic inelastic resin portion is plastically deformed and recoverability is reduced. Preferred fineness of the heat-bonded fiber is 1 denier or more and 1
It is 5 denier or less, more preferably 2 denier to 6 denier. The matrix fiber is preferably 3 denier to 15 denier, more preferably 5 denier to 13 denier because it is necessary to maintain the elasticity to give a proper sinking. The heat-bonded fiber and the base fiber are mixed and opened to form a three-dimensional structure, and most of the contact portions are substantially fused and integrated by thermal bonding (preferably, all contact points are fused and integrated). By making the non-woven fabric flat, the local pressure of the buttocks can be received by the surface and the pressure distribution can be evenly dispersed, and the three-dimensional three-dimensional structure of the short-fiber non-woven fabric is made of the thermoplastic elastic resin of the heat bonding component. Since the heat bonding fiber and the heat bonding point undergo large deformation, the entire structure deforms and absorbs the deformation stress by energy conversion. When the deformation stress is released, the thermoplastic elastic resin Since the rubber elasticity has the function of easily recovering the original shape, the sag resistance is good.
Further, damage to the cushion layer can be reduced gradually, and the sag resistance of the entire structure is improved. If it is not fused and integrated, the shape cannot be maintained, the local pressure can be received by the surface, the pressure distribution cannot be evenly dispersed, and the entire structure is deformed and energy cannot be converted, so the durability is low. Inferior and not preferred. Since the heat bonding fiber is made of a thermoplastic elastic resin having good vibration absorption, it also functions as a layer that absorbs vibrations that could not be absorbed by the cushion layer and blocks vibrations of the resonance part of the human body. When the heat bonding fiber is made of a thermoplastic inelastic resin, it cannot follow local deformation stress, so that the structure is destroyed due to stress concentration and the recoverability is poor. Further, since the thermoplastic inelastic resin has poor vibration absorption properties, the function as a layer for blocking vibration is inferior and is not preferred. Although the thickness of the short fiber nonwoven fabric layer is not particularly limited, it is preferably 3 mm to 30 mm, and more preferably 5 mm to 20 mm, at which the function of the surface layer can be exhibited. On the other hand, the reticulated body having a cushion layer function forms a three-dimensional three-dimensional structure in which a continuous line of thermoplastic elastic resin is fused to a large part of a contact portion and is fused and integrated, and both surfaces are substantially flat. Most of the vibration is absorbed and attenuated by the vibration absorption function of the thermoplastic elastic resin, and the surface of the mesh body is substantially reduced even when a large deformation stress is applied locally. Flattened, most of the contact area is fused, and the surface is joined to the short fiber non-woven fabric by the surface, so it receives the deformation stress on the surface of the reticulated body, disperses the deformation stress and expresses the body shape holding function Since the filaments made of thermoplastic elastic resin form a three-dimensional structure and are integrated by fusion,
The entire structure is deformed to absorb the deformation stress by energy conversion, and when the deformation stress is released, the rubber elasticity of the thermoplastic elastic resin has the function of easily recovering to the original form, so that the sag resistance is good. It is. In the case of a mesh formed of filaments made of a known inelastic resin alone, if it undergoes a large deformation that cannot be absorbed by the surface layer, it does not have rubber elasticity. When the surface of the reticulated body is not substantially flattened, the local external force transmitted from the short fiber nonwoven fabric is selectively transmitted to the line and the bonding point of the surface, and stress concentration occurs. Such external force may cause fatigue due to stress concentration and reduce sag resistance. When the filaments are made of a thermoplastic elastic resin, stress concentration is relieved because the entire structure is deformed in the three-dimensional structure portion. It does not recover. Furthermore, if the surface is not substantially flat and there are irregularities, the sitting buttocks give a foreign body sensation, which is unfavorable because the sitting comfort becomes poor. In the case where the linear shape is not continuous, in the case of a net having a large fineness, the bonding point becomes a stress transmission point, so that remarkable stress concentration occurs at the bonding point and structural destruction occurs, resulting in poor heat resistance and poor durability. If not fused, the shape cannot be maintained, and the structure does not deform as a single body. Therefore, a fatigue phenomenon due to stress concentration occurs and durability is deteriorated, and at the same time, the shape is deformed and the body shape cannot be maintained, which is not preferable. . A more preferable degree of fusion in the present invention is a state in which most of the portions in contact with the filaments are fused, and most preferably a state in which all the contact portions are fused. In this way, continuous filaments made of thermoplastic elastic resin having good vibration absorption and elastic recovery properties form a three-dimensional three-dimensional structure in which most of the contact portions are fused, are fused and integrated, and the surface is substantially flat. The reticulated body having the function of a cushion layer has a function of receiving deformation stress transmitted from a surface layer composed of a short fiber non-woven fabric made of a thermoplastic elastic resin in a thermal bonding component, improving the dispersion of the stress, and improving individual lines. The stress applied to the shape is reduced, the entire structure is deformed to absorb the deformation stress, and the cushioning property to support the buttocks is also improved. When the stress is released, it recovers, and the vibration transmitted from the frame is also vibration absorbing The cushion layer made of thermoplastic elastic resin having good elastic recovery absorbs and blocks the vibration of the resonance part of the human body, so that the sitting comfort and durability can be improved. For this purpose, the fineness of a filament made of a thermoplastic elastic resin having good vibration absorption and elastic recovery properties that forms the net of the present invention is 100000 denier or less. 0.2 apparent density
In the case of g / cm ³ or less, if the density exceeds 100,000 denier, the number of components decreases, a density unevenness occurs, and a partially inferior durable structure is formed, fatigue due to stress concentration increases, and durability decreases. It is not preferable. The preferred fineness of the filament made of the thermoplastic elastic resin of the present invention is 100 denier or more, since if the fineness is too small, the anti-compression property is too low and the stress absorption due to deformation is reduced. 50,000 denier or less, which does not impair the compactness of the structural surface. More preferably, 500 denier or more,
It is less than 10,000 denier. When the apparent density of the mesh body of the present invention is 0.005 g / cm ³ , the repulsive force is lost, the vibration absorbing ability and the deformation stress absorbing ability are insufficient, and the cushion function may not be easily exhibited.
If it is more than ³ cm3, the resilience may be too high and the sitting comfort may deteriorate, so the function as a cushion body is likely to be developed by utilizing the vibration absorption capacity and the deformation stress absorption function.
g / cm ³ or more 0.20 g / cm ³ or less, and more preferably 0.03 g / cm ³ or more 0.08 g / cm ³ or less. In the present invention, a method of forming a layered structure of different fineness in which the reticulated body has an optimal configuration in combination with the apparent density of linear shapes having different fineness can also be selected as a preferred embodiment. The thickness of the reticulated body of the present invention is not particularly limited. However, if the thickness is less than 5 mm, the stress absorbing function and the stress dispersing function are deteriorated. The thickness is 10 mm or more, more preferably 20 mm or more. The apparent density of the laminated net formed by integrally joining the net of the present invention and the short fiber nonwoven fabric is 0.01 g / cm ³ to 0.2 g / cm ³ . 0.0
If it is less than 1 g / cm ³ , the cushioning functions such as body shape retention and vibration absorption decrease, which is not preferable. If it exceeds 0.2 g / cm ³ , the rebound resilience increases and the sitting comfort deteriorates, which is not preferable. Preferred apparent density is 0.02 g / cm ³
0.1 g / cm ³ , more preferably 0.03 g / cm ³
cm ^{3 to} 0.06 g / cm ³ .

[0014] The cross-sectional shape of the filaments of the mesh body of the present invention is not particularly limited, but it is particularly preferable that a hollow cross-section or a deformed cross-section can impart favorable compression resistance (repulsive force) and touch. The anti-compression property can be adjusted by fineness and the modulus of the material used to make the fineness thinner.For soft materials, the hollowness and irregularity can be increased to adjust the gradient of the initial compressive stress, and the fineness can be made slightly thicker. A material with a high modulus reduces the hollowness and the degree of irregularity, and imparts good compression resistance to comfortable sitting. As another effect of the hollow cross section and the irregular cross section, by increasing the hollow ratio and the degree of irregularity, when the same compression resistance is imparted, the weight can be further reduced, and when used for a seat of an automobile or the like, energy saving can be achieved. In the case of a futon, the handling at the time of raising and lowering is improved. As another preferable method capable of imparting a preferable anti-compression property (repulsive force) and a touch, there is a method of forming a reticular filament of the present invention into a composite structure. Examples of the composite structure include a core-score structure or a side-by-side structure, and a combination structure thereof. However, in order to form a three-dimensional three-dimensional structure in which vibration and deformation stress, which cannot convert energy even if the thermoplastic elastic resin layer undergoes large deformation, can be recovered by converting the energy into energy, 50% or more of the linear surface is soft heat. Examples thereof include a core-score structure or a side-by-side structure occupied by a plastic elastic resin, and a combination thereof. That is,
In the score structure, the sheath component is a thermoplastic elastic resin with a large soft segment content that can easily convert vibration and deformation stress into energy, and the core component is a thermoplastic elastic resin with a small soft segment content to improve anti-compression properties. By giving it, it is possible to give a comfortable touch to the buttocks by moderate sinking. In the side-by-side structure, the melt viscosity of a thermoplastic elastic resin with a large soft segment content that can easily convert vibration and deformation stress into energy is made lower than the melt viscosity of a thermoplastic elastic resin with a small soft segment content that exhibits anti-compression properties. A structure in which the proportion of thermoplastic elastic resin with a large soft segment content occupying a linear surface is increased (figuratively, a structure in which thermoplastic elastic resin is arranged on an eccentric sheet-core structure sheet) The ratio of the thermoplastic elastic resin having a large soft segment content occupying a linear surface
% Is particularly preferred, and most preferably a scoring score when the proportion of the thermoplastic elastic resin having a large soft segment content occupying a linear surface is defined as 100%. When the ratio of the linear surface of the thermoplastic elastic resin having a large soft segment content occupies a large proportion, the fluidity when melting and fusing is high, so that the adhesion becomes strong, and the structure is integrally deformed. In this case, fatigue resistance against stress concentration at the bonding point is improved, and heat resistance and durability are further improved.

[0015] Since the reticulated body made of thermoplastic elastic resin and the short-fiber nonwoven fabric are joined and integrated to form a nonwoven laminated reticulated body having substantially flat surfaces on both sides, other reticulated bodies, nonwoven fabrics, knitted fabrics, hard Uses other heat-adhesive components (heat-bonded nonwoven fabric, heat-bonded fiber, heat-bonded film, heat-bonded resin, etc.), adhesives, etc. to bond with heat-bonded objects such as cotton, film, foam, metal, etc. In order to obtain products such as vehicle seats, marine seats, vehicles, ships, hospitals and other commercial and household beds, furniture chairs, office chairs, futons, etc. Since the contact area with the adhesive surface can be increased,
It is possible to obtain a product having a large bonding area and strong bonding and good bonding durability. In this case, the use of a flame-retardant heat-bonded body can provide a flame-retardant integrated laminated structure, and is a particularly preferred embodiment of the present invention. In addition, by performing the above-described pseudo-crystallization treatment at an arbitrary stage from the network and the laminated network forming step to the product, the component of the thermoplastic elastic resin in the structure was measured by a differential scanning calorimeter. It is more preferable that the melting curve has an endothermic peak at a temperature between room temperature and the melting point, since the heat resistance of the product is remarkably improved. When the filaments of the mesh forming the nonwoven fabric laminated network of the present invention have a composite structure, or by laminating the nonwoven fabric layer of the short fiber having the thermal bonding function, the heat bonding function is provided on the back surface of the nonwoven fabric laminated network. Can be applied, and a reinforcing material or the like can be integrated with heat bonding. For example, when the mesh layer has a sheath-core structure, a thermoplastic elastic resin having a large soft segment content, which is easy to convert the vibration and deformation stress of the sheath component into energy, is used as a heat bonding component, and the resistance of the core component is reduced. A composition in which a thermoplastic elastic resin having a small soft segment content exhibiting compressibility is used as a high melting point component to have a function of holding a net shape, and the melting point of the heat bonding component is lower than the melting point of the high melting point resin by 10 ° C. or more. The function of the heat bonding layer can also be imparted by using. The short-fiber nonwoven fabric of the surface layer of the laminated structure of the present invention is made of a heat-bonding fiber containing a low-melting thermoplastic elastic resin having a high soft segment content and a high melting point, which can easily convert vibration and deformation stress into energy. A preferred thermal bonding function can be imparted also by constituting. The melting point of the heat-adhesive component forming the filaments or fibers in the laminated network body that is preferable for exhibiting the heat-adhesive function is a melting point 15 to 100 ° C. lower than the melting point of the high-melting component, and more preferably 20 to 80 ° C. It has a low melting point. The nonwoven fabric laminated net of the present invention having a heat bonding function has a substantially flat surface, and most of the contact portions are fused, so that the net, nonwoven fabric, knitted fabric, hard cotton, film, Since the area of contact with the surface of the object to be bonded such as foam or metal can be increased, the area of thermal bonding is increased, and a new molded body and a vehicle seat, a boat seat, a vehicle, a boat, etc. Beds for business use such as hospital use and home use, furniture chairs, office chairs and futons can be obtained. In addition, by performing pseudo-crystallization treatment at an arbitrary stage until a new molded product and product are commercialized, the melting line measured by a differential scanning calorimeter was used to measure the filaments of the thermoplastic elastic resin in the structure. It is more preferable that the curve has an endothermic peak at a temperature between room temperature and the melting point, since a product having significantly improved heat resistance and durability can be provided.

Next, the production method of the present invention will be described. According to the production method of the present invention, the soft segment amount (A weight%) and the phosphorus content (Bppm) are 60 A from a multi-row nozzle having a plurality of orifices.
A thermoplastic elastic resin satisfying the relationship of + 200 ≦ B ≦ 100000 is distributed to each nozzle orifice, and at a melting temperature higher than the melting point of the thermoplastic resin by 10 ° C. or more and less than 80 ° C.,
After being discharged downward from the nozzle and brought into contact with each other in a molten state and fused to form a three-dimensional structure, it is sandwiched by a take-off device and cooled in a cooling tank, and then the heat-adhesive component is heated on one or both surfaces. It is a method of manufacturing a flame-retardant laminated network body in which short fibers made of a plastic elastic resin and short fibers made of a thermoplastic inelastic resin are mixed and spread to laminate a three-dimensional web, and then thermoformed while being compressed. Preferably, it is a method of producing a nonwoven fabric laminated net and a product which are annealed at a temperature of at least 10 ° C. below the melting point of the thermoplastic elastic resin in a process from the cooling to the integral molding to the commercialization. In the present invention, as described above, the phosphorus-containing thermoplastic elastic resin can be prepared by adding a phosphorus compound at the time of polymerization and copolymerizing it, or by adding it after polymerization and mixing and kneading it. Mixing and kneading can be carried out using a twin-screw kneading extruder or a single-screw extruder having a kneading function such as dalmage or pin, and can be selected to be performed before melt extrusion or at the time of melt extrusion. If the flame retardant can be supplied at a constant rate, kneading during melt extrusion is the cheapest method. It is easy if the solid flame retardant is dry-mixed with the resin and fed to the extruder to prevent segregation.However, the liquid flame retardant is supplied to the kneading extruder quantitatively while the liquid flame retardant is separately measured. It is most desirable to adopt a method of kneading while supplying. For example, a method of quantitatively supplying a liquid flame retardant from a vent hole of a twin-screw kneading extruder can be exemplified. In this way, the soft segment amount (A weight%) and the phosphorus content (B ppm) are 6
A phosphorus content satisfying the relationship of 0A + 200 ≦ B ≦ 100000 is added to the thermoplastic elastic resin, and then a network is formed. The reticulated body melts the thermoplastic elastic resin by using a general melt extruder, supplies the melted resin to a multi-row nozzle having a plurality of orifices, and discharges the resin below the orifice. The melting temperature at this time is 20 ° C. to 80 ° C. below the melting point of the thermoplastic elastic resin.
℃ higher temperature. 80 ° C from the melting point of thermoplastic elastic resin
If the melting temperature exceeds the above range, thermal decomposition becomes remarkable, and the rubber elasticity of the thermoplastic elastic resin deteriorates. On the other hand, if the temperature is not higher than the melting point of the thermoplastic elastic resin by 10 ° C. or more, melt fracture is generated and normal filament formation cannot be performed. The temperature is lowered, and the filaments may not fuse with each other, resulting in a poorly adhered net-like body, which is not preferable. Preferred melting temperature is 20 ° C to 60 ° C from melting point
Higher temperatures, more preferably 25 to 40 ° C. above the melting point. Although the shape of the orifice is not particularly limited, a hollow cross section (for example, a shape having a triangular hollow, a round hollow, a hollow with a projection, or the like) and a modified cross section (for example, a triangular, Y-shaped, star-shaped, etc. In addition to the above-described effects, the three-dimensional structure formed by the melted discharge filaments is less likely to flow, and conversely, the flow time at the contact point is maintained longer to strengthen the bonding point. It is particularly preferred because it can be In the case of heating for bonding described in Japanese Patent Application Laid-Open No. 1-2075, it is not preferable because the three-dimensional structure is easily relaxed, and it becomes difficult to form a three-dimensional structure. As the effect of improving the properties of the net-like body, the apparent bulk can be increased and the weight can be reduced, and the compression resistance and the resilience can be improved. Hollow ratio of 8 in hollow section
If it exceeds 0%, the cross section is likely to be crushed. Therefore, it is preferably 10% or more and 70% or less, more preferably 20% or more and 60% or less, at which the effect of weight reduction can be exhibited. The pitch between the holes of the orifices must be such that the loop formed by the linear shape can sufficiently contact. The pitch between holes is shortened for a dense structure, and the pitch between holes is increased for a dense structure. The pitch between the holes of the present invention is preferably 3 mm to 20 mm, more preferably 5 mm to 10 mm. In the present invention, different densities and different finenesses can be obtained as desired. A different density layer can be formed by a configuration in which the pitch between rows or the pitch between holes is changed, or a method in which the pitch between both rows and between holes is also changed. Also, if the pressure loss difference at the time of discharge is given by changing the cross-sectional area of the orifice, the principle is that the discharge amount that extrudes the molten thermoplastic elastic resin from the same nozzle at a constant pressure decreases as the orifice with a large pressure loss decreases. Using a nozzle having at least a plurality of rows having different cross-sectional areas of the orifices in a section in the longitudinal direction, it is possible to manufacture a reticulated structure composed of filaments of different fineness. Next, the ink is discharged downward from the nozzle,
While forming a loop, they are brought into contact with each other in a molten state and fused to form a three-dimensional structure, sandwiched by a take-off net, and bent at 45 ° or more in the molten tortuous discharge wire on the surface of the mesh body. After forming the structure by deforming and flattening the surface and bonding the contact points with the unbent discharge filaments, the cooling medium (usually using water at room temperature can increase the cooling rate continuously, This is preferable because the cost is reduced, and the net is formed by quenching to obtain a three-dimensional net-like net of the present invention. It is preferable that the distance between the nozzle surface and the take-up point is at least 40 cm or less to prevent the discharge filament from being cooled and the contact portion from being fused. 10 cm to 40 when the discharge rate of discharge line is as large as 5 g / min or more.
cm is preferable, and when the discharge amount of the discharge filament is as small as less than 5 g / minute, the diameter is preferably 5 cm to 20 cm. The thickness of the net-like body is determined by the width of the opening of the take-off net sandwiching both surfaces of the molten three-dimensional structure (the distance between the take-off nets). In the present invention, the opening width of the take-up net is set to 5 mm or more for the above-described reason. Then, drying with water is performed. However, if a surfactant or the like is added to the cooling medium, draining or drying becomes difficult, and the thermoplastic elastic resin may swell, which is not preferable. still,
A desired loop diameter or wire diameter can be determined by the distance between the nozzle surface and a take-off conveyor placed on a cooling medium for solidifying the resin, the melt viscosity of the resin, the hole diameter of the orifice, and the discharge amount. A pair of take-up conveyors with adjustable intervals installed on the cooling medium sandwich the discharge lines in the molten state and stop and fuse the parts in contact with each other, while continuously drawing into the cooling medium and solidifying. When the body is formed, by adjusting the distance between the conveyors, the thickness can be adjusted while the fused net is in a molten state, and a desired thickness can be obtained. If the conveyor speed is too high, the contact point may be insufficiently formed, or the contact point may be cooled until the fusion point is sufficiently formed, and the fusion of the contact portion may be insufficient.
On the other hand, if the speed is too slow, the melt will stay too much and the density will increase, so it is necessary to set a conveyor speed suitable for the desired apparent density. Next, in the manufacturing method of the present invention, the nonwoven fabric is bonded and integrated with the short fiber nonwoven fabric having the function of the surface layer. The short fibers having a fineness of 20 denier or less in which the heat bonding component is made of a thermoplastic elastic resin are obtained by individually melting a low melting point thermoplastic elastic resin and a high melting point thermoplastic inelastic resin, and by known composite spinning. It is spun and stretched to obtain the finished yarn. However, in this method, since the melting point of the heat-adhesive component is low, it cannot be heat-set at a high temperature during stretching, so that only a high shrinkage ratio of 30% to 80% can be obtained. Dimensional defects occur. In order to solve this problem in the present invention, it is preferable to obtain the finished yarn at a stretch by reducing the shrinkage to 10% or less by high-speed spinning at 3000 m / min or more. Next, crimping is applied,
Cut to a desired cut length to obtain a heat bonded fiber. The composite form of the heat-bonding fiber used in the present invention is not particularly limited. However, since the function as the heat-bonding fiber is necessary, the low-melting-point component is 5% on the surface of the fiber by side-by-side or sea core.
Preferably, it occupies 0% or more, and more preferably, the low melting point component occupies 100% or more of the fiber surface. The matrix fiber is given a latent crimping ability by applying a non-symmetric cooling method or a composite spinning method to an inelastic resin by a known method, and is subjected to heat treatment after drawing to develop a three-dimensional crimp, or cut, or heat-treated after cutting to give a three-dimensional crimp. A matrix fiber is obtained by expressing shrinkage. Since the base fiber is required to have set resistance and heat resistance, the initial tensile resistance is at least 35 g / denier or more, and the initial tensile resistance at 70 ° C. is at least 10 g / denier or more. Is preferred. The degree of crimp of three-dimensional crimps from bulkiness and compression resistance is 1
5% or more, and the number of crimps is preferably 10 to 25 pieces / inch.
The thus obtained heat bonding fiber and base material fiber are mixed and opened. When the amount of the heat bonding fiber is small, the vibration absorbing function is lowered, which is not preferable. If the amount of the heat-bonding fiber is too large, the bulkiness may be reduced, and the preferable ratio of the heat-bonding fiber and the base fiber is 20/80 to 60/40 by weight, and the pre-spreading and mixing are performed with an opener or the like. After opening the fiber with a card or the like to form a three-dimensional structure, the opened web is laminated and compressed on the surface of the mesh body and bonded and integrated by thermoforming, or only the opened web alone is laminated and compressed. Then, a short-fiber nonwoven fabric can be formed by thermoforming to form a short-fiber nonwoven fabric, and then the reticulated body and the short-fiber nonwoven fabric can be joined and integrated. In this case, a heat bonding layer or an adhesive may be separately used between the reticulated body and the short-fiber non-woven fabric to be joined and integrated, or the re-woven body or the short-fiber non-woven fabric may be joined and integrated using a heat bonding function. Good. As a preferred method of the present invention, after the network is once cooled, or in any step leading to commercialization of the laminated structure obtained by integral molding, at a temperature of at least 10 ° C. or less than the melting point of the thermoplastic elastic resin. A more preferable production method is to perform a pseudo-crystallization treatment by annealing to obtain a laminated structure or a product. The pseudo-crystallization temperature is at least 10 ° C. lower than the melting point (Tm),
This is performed at a temperature higher than the α dispersion rising temperature (Tαcr) of Tan δ. This treatment has an endothermic peak below the melting point, and significantly improves heat resistance and sag resistance as compared with those without the pseudo-crystallization treatment (without the endothermic peak). The preferred pseudo crystallization treatment temperature of the present invention is (Tαcr + 10 ° C.) to (Tm−
20 ° C). Pseudo crystallization by simple heat treatment improves heat set resistance. However, it is more preferable to perform annealing by giving a compression deformation of 10% or more, since the heat set resistance is remarkably improved. Further, when the network is once cooled and then subjected to a drying step, a pseudo crystallization treatment can be performed simultaneously by setting the drying temperature to the annealing temperature. In addition, a pseudo crystallization process can be separately performed in a process of commercialization. Next, it is cut into a desired length or shape and used as a cushion material.

In the case of using the nonwoven fabric laminated net of the present invention as a cushion, it is necessary to select a resin, a fineness, a loop diameter and a bulk density to be used depending on the purpose of use and the site of use. For example, in order to provide a soft touch and a moderate sunk and firm bulge, it is preferable to use a low-density, fine fineness and a small loop diameter. To reduce the frequency, moderately change the hardness and the hysteresis at the time of compression linearly to improve body shape retention and maintain durability, medium density and thick fineness,
It is preferable to adopt a structure in which a layer having a relatively large loop diameter and a layer having a low density, a fine fineness and a small loop diameter are laminated and integrated.
Further, it can be formed into a shape suitable for the purpose of use using a molding die or the like to the extent that the three-dimensional structure is not impaired, and can be used as a vehicle seat, a boat seat, a bed, a chair, furniture, or the like by directly covering the side ground. . Of course, it is also possible to use in combination with other materials, for example, a different net-like material, a hard cotton cushion material composed of a short fiber aggregate, a nonwoven fabric, or the like in order to meet the required performance in relation to the application. In addition to the resin manufacturing process, the product is processed into a molded product from the manufacturing process to the extent that the performance is not degraded, and flame retardation, antibacterial and antibacterial, heat resistance, water and oil repellency, coloring, fragrance etc. The function can be imparted by processing such as adding a drug.

[0018]

The present invention will be described in detail with reference to the following examples.

The evaluation in the examples was performed by the following method. 1. Endothermic peak at melting point (Tm) and below the melting point The endothermic peak (melting peak) was obtained from an endothermic curve measured at a heating rate of 20 ° C./min using a Shimadzu TA50 / DSC50 differential thermal analyzer. -H) The temperature was determined. 2. Heat the Tαcr polymer to the melting point + 10 ° C and make the thickness about 300μm.
And a Tan δ (ratio M ″ / tan δ (imaginary elastic modulus M ″ and real part M ′ of elastic modulus) measured at 110 Hz and at a heating rate of 1 ° C./min using a Vibron DDVII model manufactured by Orientec. M ′) is the rise temperature of α-dispersion corresponding to the transition point temperature from the rubber elastic region to the melting region. 3. Apparent density The sample is cut into a size of 15 cm × 15 cm, the height of four places is measured, the volume is determined, and the weight of the sample is indicated by a value obtained by reducing the weight by the volume. (Average value of n = 4) 4. Fineness of filaments Each filamentous portion is cut out from 10 places of the sample, and the cross section is cut out by embedding with an acrylic resin to prepare a section to obtain a photograph of the cross section. The cross-sectional area (Si) of each part is determined from a cross-sectional photograph of each part. Further, the section obtained in the same manner was dissolved in an acrylic resin with acetone, degassed in vacuo, and heated at 40 ° C. using a density gradient tube.
The specific gravity (SGi) measured in is obtained. Next, the linear weight of 9000 m is obtained from the following equation. (Unit cgs) Fineness = [(1 / n) ΣSi × SGi] × 90000000 5. Fusion Check whether the sample is fused by visual judgment. It is judged that what is not separated is fused. 6. Flame Retardancy Those that satisfy the flame retardancy standard (extinguish flame in 60 seconds or less) according to the F-MVSS302 method are judged as pass, and those that do not meet the criteria are judged as fail. 7. Toxicity index of combustion gas It shows the integrated value of the value obtained by dividing each combustion gas amount (mg) measured by the method of JIS-K-7217 by lethal dose (mg / 10 liter) by inhalation for 10 minutes. 8. Heat resistance and durability (70 ° C residual strain) A sample was cut into a size of 15 cm × 15 cm, compressed by 50%, allowed to stand in dry heat at 70 ° C for 22 hours, cooled to remove the compressive strain, and removed after 1 day of thickness ( b) is calculated, and is calculated from the thickness (a) before the processing according to the following equation, that is, (ab) / a × 100. Unit% (average value of n = 3) 9. Repetitive compressive strain A sample was cut into a size of 15 cm × 15 cm, and 50% in a RH chamber at 25 ° C. and 65% with a Shimadzu servo pulsar.
The compression recovery is repeated at a cycle of 1 Hz until the thickness of the sample reaches 20,000 times, the thickness (b) of the sample after standing for 1 day is determined, and the thickness (a) before the treatment is calculated from the following formula, that is, (ab) / a × Calculated from 100. Unit% (average value of n = 3) 10. Sit-to-come The flame-retardant laminated net, cut into the shape of a bucket sheet, is put into a female mold for thermoforming, and is compressed by a male mold and packed 160
Thermoforming for 5 minutes with hot air at ℃-230 ℃
The polyester moquette made of Toyobo Co., Ltd. was covered with a side cushion of a cushion molded in a shape of G, and set on a seating frame. Four seat stoppers were provided at the seat and six back stoppers were placed at the back. A seat was prepared, and a paneler was seated on a seat prepared in a room at 30 ° C. and 75% RH, and the following evaluation was performed. (N
= 5) (1) Feeling of flooring: The degree of feeling of hitting the floor with "doing" while sitting was qualitatively evaluated sensuously. Not felt; ◎, almost felt; ○, slightly felt; △, felt; × (2) Feeling of stuffiness: After sitting for two hours, sensationally felt that the part in contact with the buttocks and the inner part of the crotch was stuffy. It was qualitatively evaluated. Almost no: ◎, slight stuffiness; ○, slight stuffiness; △, noticeable stuffiness; × (3) How long to be patient in 8 hours or less: 1 hour; × within 2 hours; △ within 4 hours;
○: 4 hours or more; ◎ (4) The degree of waist fatigue when seated in a seat for 4 hours was qualitatively evaluated sensoryly. None; ◎, hardly tired; ○, slightly tired; △, very tired; × (5) Overall evaluation: 4 points of ◎ from (1) to (4), ○
Is 3 points, Δ is 2 points, and × is 1 point, 12 points or more do not contain Δ; very good (◎), 12 points or more include Δ; good (○), 10 points or more are × Was evaluated as poor (x), poor x (x), and poor (x).

Example 1 Dimethyl terephthalate (DMT) or dimethyl naphthalate (DM) was used as a polyester elastomer.
N) and 1.4 butanediol (1.4 BD) were charged with a small amount of a catalyst, transesterified by a conventional method, and polytetramethylene glycol (PTMG) was added. -Forming a terester block copolymer elastomer, then adding 2% of an antioxidant,
Table 1 shows the formulation of the thermoplastic elastic resin raw material obtained by mixing, kneading, pelletizing, and vacuum drying at 50 ° C. for 48 hours.

[0021]

[Table 1]

An orifice having a staggered arrangement of a pitch between holes in the width direction of 10 mm and a pitch of holes in the length direction of 5 mm on a nozzle effective surface having a width of 50 cm and a length of 5 cm has an outer diameter of 2 mm and an inner diameter of 1.6.
The resulting thermoplastic elastic resin raw material (A-1 and A-
2) and two extruders having a kneading function separately and quantitatively supplying the same, and as a flame retardant, the existing chemical substance number (3) -37
A-1 and A-2 were added immediately before the orifice, and A-1 was used as a sheath component and A-2 was used as a core component. /
Core: 50/50 weight ratio) at a melting temperature of 245 ° C., and a single hole discharge rate of 2 g / min (A-1: 1 g / min, A-2:
(1 g / min), the cooling water is placed 10 cm below the nozzle surface, cooling water is placed 10 cm below the nozzle surface, and a pair of take-up conveyors with a width of 60 cm are placed in parallel at 5 cm intervals so that a part of the take-up conveyors is placed above the water surface. Then, the discharge line in the molten state is meandered to form a loop, and the contact portion is fused while melting.
A two-dimensional network is formed, and both sides of the molten network are sandwiched between take-up conveyors at a speed of 1 m / min.
After being drawn into a cooling water at 5 ° C. and solidified by fusing and flattening both surfaces, the mesh made of the phosphorus-containing thermoplastic elastic resin obtained by cutting to a predetermined size has a cross-sectional structure of a sheath-core structure. It has a triangular conical hollow section with a hollow ratio of 38% and a fineness of 9000 denier. It has an average apparent density of 0.045 g / cm ³ and a phosphorus content of 10,000p.
pm (60A + 200 = 2780 ppm). Separately, using a known composite spinning machine, a thermoplastic elastic resin A-1 is used as a sheet component, and polybutylene terephthalate (PBT) having a relative viscosity of 1.0 is used as a core component. And dispensed just before the orifice.
/ 50 weight ratio, 1.6 g / hole per hole (0.8 g
/ Min: 0.8 g / min) at a spinning temperature of 265 ° C. and a spinning speed of 3500 m / min and a fineness of 4.1 denier.
A yarn having a shrinkage of 4% at a dry heat of 160 ° C. is converged, mechanically crimped by a crimper in a tow shape, cut into 64 mm and sealed.
Short fibers made of a thermoplastic elastic resin having a score cross section were obtained.
The matrix fiber has an intrinsic viscosity of 0.63 or 0.56 by a conventional method.
Of PET was distributed at a weight ratio of 50/50 to obtain a ratio of 3.
The spinning temperature was 26 g / min (1 g / min: 1 g / min).
Discharge from C-type orifice at 5 ° C, spinning speed 1300
m / min., and then two-stage drawing at 70 ° C and 180 ° C. The drawn yarn was cut into 64 mm, free-heat treated at 170 ° C to develop a three-dimensional crimp, A fineness of 6 denier of a sheath core structure having a hollow ratio of 32%, an initial tensile resistance of 38 g / denier, a degree of crimp of 20%, and a number of crimps of 18
Individual / inch matrix fibers were obtained. The obtained heat-bonded fiber and the base fiber are mixed at a weight ratio of 40/60, preliminarily opened with an opener, and then opened with a card.
2,000 g / m ² , laminated on the mesh, compressed to an apparent density of 0.05 g / cm ³ , heat-treated with hot air at 180 ° C. for 5 minutes, cooled, and laminated on both sides with flat nonwoven fabric A reticulated body was obtained. Then compress 10% of the thickness
Table 2 shows the characteristics of the nonwoven fabric laminated network of the present invention obtained by performing pseudo crystallization treatment with hot air at 00 ° C. for 20 minutes. As is clear from Table 2, Example 1 has excellent heat resistance, excellent durability at room temperature, excellent sitting comfort, excellent flame retardancy, and excellent combustion gas due to the laminated network utilizing the properties of the soft elastic resin. It was a highly safe cushioning material with a low toxicity index. It can be seen that the seat created for evaluation also has excellent performance.

[0023]

[Table 2] Dimethyl isophthalate (DMI) 20 mol% and DMT
Table 1 shows the formulation of a polyester-based thermoplastic elastic resin obtained in the same manner as in Example 1 by charging 80 mol% and 1.4 butanediol (1.4 BD) with a small amount of a catalyst.
Using a nozzle having a circular cross section with a hole diameter of φ1 mm in the orifice hole, using only A-3 as a single component, and having a phosphorus content of 9000
The net obtained in the same manner as in Example 1 except that the flame retardant was added so as to become ppm was a solid round cross section and a fineness of 9000 denier.
And an average apparent density of 0.
046 g / cm ³ , phosphorus content 9000 ppm (60A + 2
00 = 3320 ppm). Next, Table 2 shows the characteristics of the laminated net obtained in the same manner as in Example 1. As is clear from Table 2, Example 2 is a highly safe cushion having heat resistance and durability at room temperature that can be used practically, has excellent sitting comfort, has flame retardancy, and has a low toxicity index of combustion gas. It is a material, and it turns out that the seat made for evaluation is also excellent.

Example 3 Polyurethane-based elastomer, 4,4'-diphenylmethane diisocyanate (MDI), PTMG, and 1.4BD as a chain extender were added and polymerized, and 2% of an antioxidant was added and mixed. After kneading, pelletizing and vacuum drying, the formulation of the polyether urethane polymer is shown in Table 3.

[0025]

[Table 3]

The obtained thermoplastic elastic resin (seed component:
B-1; core component: B-2) with phosphorus content of 12,000 pp
m and the melting temperature was set to 220 ° C., except that the melting temperature was 220 ° C.
The cross-sectional shape of the score structure is a triangular diaper-shaped hollow cross section with a hollow ratio of 40%, a fineness of 9800 denier, an average apparent density of 0.047 g / cm ³ , and a phosphorus content of 12000 ppm.
(60A + 200 = 3260 ppm). On the other hand,
The properties of the heat-bonded fiber obtained in the same manner as in Example 1 except that B-1 was used as the sheath component, PBT having a relative viscosity of 1.0 as the core component, and the spinning temperature was set at 265 ° C. were as follows. 5 denier
The shrinkage at 150 ° C. was 4%. The matrix fiber was the same as that of Example 1 and 1000 g /
m ² , and laminated with the net, at 160 ° C.
And then cooled for 5 minutes with hot air to obtain a laminated structure having flat surfaces on both sides. Then compress 10% of the thickness to 100
Table 2 shows the properties of the laminated network of the present invention obtained by performing pseudo-crystallization treatment with hot air of 20 ° C. for 20 minutes. Example 3 is a highly safe cushioning material which is a laminated mesh body utilizing the properties of soft urethane, and which is excellent in heat resistance, durability at room temperature, and sitting comfort, has flame retardancy, and has a low toxicity index of combustion gas. there were. It turns out that the seat made for evaluation is also excellent.

Comparative Example 1 Polyethylene terephthalate having an intrinsic viscosity of 0.63 (PE
T) The network used in Comparative Example 1 obtained in the same manner as in Example 2 except that only a single component was used and a flame retardant was added so that the phosphorus content was 5000 ppm, and the melting temperature was 280 ° C, Fineness 8800 denier, apparent density 0.047
g / cm ³ , phosphorus content 5000 ppm (60A + 200 =
200 ppm). Next, Table 2 shows the characteristics of the laminated network obtained in the same manner as in Example 2 except that the pseudo-crystallization treatment was not performed. Comparative Example 1 has flame retardancy, but is inferior in heat resistance and durability because of a mesh made of inelastic polyester.
Despite the use of short fiber non-woven fabric for the surface layer, it is a cushion material that is hard and uncomfortable to sit on.

Comparative Example 2 A net obtained in the same manner as in Example 2 except that a flame retardant was added so as to have a phosphorus content of 200 ppm was formed from a filament having a solid round section and a fineness of 9000 denier. With an average apparent density of 0.046 g / cm ³ and a phosphorus content of 200 pp
m (60A + 200 = 3320 ppm). Next, Table 2 shows the characteristics of the laminated network obtained in the same manner as in Example 2 except that the pseudo-crystallization treatment was not performed. Comparative Example 2 is an example of a cushioning material that is made of a thermoplastic elastic resin and therefore has good sitting comfort, but is inferior in heat resistance and durability and rejects flame retardancy.

COMPARATIVE EXAMPLE 3 Example 2 was repeated except that the take-up conveyor net was arranged 60 cm below the nozzle surface and the pseudo-crystallization treatment was not performed after the take-up conveyor net.
Table 2 shows some of the properties of the reticulated body obtained in the same manner as described above.
In addition, the flame retardancy, the apparent density, the residual strain at 70 ° C., the repetitive compressive strain, and the sitting comfort were not evaluated because the adhesion state was poor and the shape retention was poor due to poor adhesion to the nonwoven fabric. Comparative Example 3 is an example that is not suitable for a cushion material because the form is not fixed.

Comparative Example 4 A net obtained in the same manner as in Example 2 except that a flame retardant was added so that the phosphorus content was 121,000 ppm was formed from a filament having a solid round section and a fineness of 9000 denier. With an average apparent density of 0.046 g / cm ³ and a phosphorus content of 121000 ppm (60A + 200 = 3320 pp
m). Next, Table 2 shows the characteristics of the laminated network obtained in the same manner as in Example 2 except that the pseudo-crystallization treatment was not performed. In Comparative Example 4, the phosphorus content was too large, so that the flame retardancy was passed, but the properties of the thermoplastic elastic resin were deteriorated, the sitting comfort was slightly inferior, and the heat resistance and durability were significantly inferior. It is an example of a material.

COMPARATIVE EXAMPLE 5 A single hole was formed by using a nozzle having an orifice diameter of φ1 mm in a staggered arrangement with a pitch between holes in the width direction of 4 mm and a pitch between holes in the length direction of 3 mm on an effective surface of a nozzle having a width of 50 cm and a length of 5 cm. Was discharged at a discharge rate of 0.012 g / min, and a take-up conveyor net was placed 5 cm below the nozzle surface and pulled at 1.5 m / min. Fineness is 4
0 denier, apparent density 0.008 g / cm ³ , phosphorus content 9000 ppm (60A + 200 = 3320 ppm)
The net density of the laminated net is 0.00
Table 2 shows the characteristics of the laminated net formed in the same manner as in Comparative Example 2 except that the pressure was reduced to 9 g / cm ³ . Comparative Example 5 passed the flame retardancy, but the case where the cushion layer was made of a fine mesh with a fine linear fineness was too low in apparent density, the sinking became large, the feeling of flooring became large, and the sitting comfort was increased. It was a slightly inferior cushioning material.

Comparative Example 6 Discharge was performed at a discharge rate of 3 g / min per single hole, the speed of the take-off conveyor net was set to 0.3 m / min, and the same procedure as in Example 2 was performed except that the pseudo-crystallization treatment was not performed. 13 filament fineness
000 denier, the average apparent density of the net is 0.21
g / cm ³ , phosphorus content 9000 ppm (60A + 200 =
Table 2 shows the characteristics of the laminated network produced in the same manner as in Example 2 except that the pseudo-crystallization treatment was not performed using the network of 3320 ppm). Comparative Example 6 had a high apparent density, so that the cushioning material was good in touch but slightly inferior in sitting comfort and insufficient in heat resistance and durability.

COMPARATIVE EXAMPLE 7 A single-hole nozzle having an orifice diameter of 2 mm in a staggered arrangement with a pitch of 10 mm in the width direction and a pitch of 20 mm in the length direction was formed on the effective surface of a nozzle having a width of 50 cm and a length of 5 cm. Discharge at a discharge rate of 25 g / min.
The fineness of the filament obtained in the same manner as in Example 2 except that the take-up conveyor net was arranged below and taken up at 1 m / min was 11
3000 denier, average apparent density 0.154g
/ Cm ³ , phosphorus content 9000 ppm (60A + 200 = 3
Table 2 shows the characteristics of the laminated network produced in the same manner as in Example 2 except that the pseudo-crystallization treatment was performed using the network of 320 ppm). Comparative Example 5 was a cushioning material having a very fine fineness and a density of uneven density, and thus passed the flame retardancy, but had poor heat resistance and durability, and had a slightly worse sitting comfort.

Comparative Example 8 The filaments obtained in the same manner as in Example 2 except that the pseudo-crystallization treatment was not performed, the fineness was 9100 denier, and the average apparent density was 0.1%.
045 g / cm ³ , phosphorus content 9000 ppm (60A + 2
(00 = 3320 ppm) and a thermo-adhesive fiber produced in the same manner as in Example 2 except that pseudo-crystallization treatment was not performed using 4-44-EE7 manufactured by Toyobo Co., Ltd. Table 2 shows the properties of the laminated network formed by laminating a short fiber nonwoven fabric composed of short fibers composed of the following components on the surface layer and joining and integrating the same. Comparative Example 8 was a cushion material having good sitting comfort because the cushion layer was made of a thermoplastic elastic resin, but having poor heat resistance and durability.

Comparative Example 9 The filament fineness was 9000 denier obtained in the same manner as in Example 2 except that the interval (opening width) of the take-off conveyor net was set to 15 cm. 043 g / cm
^3, the phosphorus content 9000ppm (60A + 200 = 332
Table 2 shows the characteristics of the laminated structure produced in the same manner as in Example 2 except that a network (0 ppm) whose surface was not substantially flattened and the pseudo-crystallization treatment was not performed. In Comparative Example 9, since the surface of the mesh body was uneven, the apparent density was low, but the durability was poor, the thermal bonding was insufficient, and the cushioning material was slightly inferior in sitting comfort to feel a little foreign substance. .

Example 4 The nonwoven laminated net obtained in Example 1 was cut into a piece having a length of 120 cm, quilted every 5 cm in thickness, 120 cm in width and 50 cm in length and placed in a side place having a width of 120 cm and a length of 200 cm and mattressed. It was created. Place this mattress on the bed,
The panel feeling was evaluated organoleptically by allowing 4 panelers to use the apparatus in a room at 5 ° C. RH 65% for 7 hours. In addition, a sheet is hung on the bed, and the comforter is 1.8 kg of down / feather: 90/1.
0 was filled with batting, and the pillow was worn by the paneler every day. The evaluation result was a bed with a comfortable sleeping feeling without feeling of flooring, moderate sinking, and no stuffiness. For comparison, a density of 0.04 g / cm ³ and a thickness of 10
Create a similar mattress with a cm urethane foam plate,
The bed was placed on a bed and evaluated for comfort. As a result, it was found that the bed had a little feeling of flooring but had a large sink and was slightly stuffy and had an uncomfortable bed.

Example 5 The nonwoven laminated net obtained in Example 1 was 38 cm wide and 40 cm long.
The product was cut into a 10 cm corner with a 10 cm corner, placed on the office chair frame with the polyester moquette used for the evaluation of sitting comfort on the side, and a commercially available polyurethane cushion was used. Compared with a chair, the sitting comfort is 4
As a result of evaluation by sitting for a time, the feeling of stuffiness, feeling of flooring, and the time of standing while sitting were remarkably excellent in the case of using the nonwoven fabric network of the present invention.

[0038]

According to the present invention, a cushion made of a net-like body having a three-dimensional three-dimensional structure formed by a filament made of a phosphorus-containing thermoplastic elastic resin having good vibration and stress absorption properties and having a substantially flattened fusion-bonded surface. The nonwoven fabric laminated structure of the present invention, in which a short-fiber nonwoven fabric composed of a thermoadhesive fiber having a thermoplastic adhesive resin as a thermal adhesive component and a base fiber made of a thermoplastic inelastic resin is joined and integrated as a surface layer, the vibration isolation It is a highly safe cushioning material that has good heat resistance, heat resistance, bulkiness, good seating comfort, low flammability, low flame index and low combustion gas toxicity index. In addition, products such as vehicle seats, boat seats, vehicles, boats, commercial beds for hospitals and hotels, furniture cushions, bedding products, and the like having the above-mentioned preferable characteristics can be provided. Furthermore,
It is also useful for interior materials and heat insulating materials for vehicles and building materials.

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ identification code FI D01F 6/92 304 D01F 6/92 304H D04H 3/16 D04H 3/16 (58) Investigated field (Int.Cl. ⁷ , DB Name) D04H 1/00-18/00 B32B 1/00-35/00 B68G 1/00-15/00 D01F 1/00-13/04

Claims (6)

(57) [Claims] 1. The amount of soft segment (A weight%) and phosphorus content
Amount (Bppm) is 60A + 200 ≦ B ≦ 100000
The fineness of the thermoplastic elastic resin satisfying the relationship of 10 is 10
Wind continuous filaments of 0000 denier or less
A three-dimensional stand which is brought into contact with one another to fuse most of the contact portion
Form a body structure, both sides of which are substantially flattened
Thermoplastic resin on one or both sides of the reticulated body
Thermoadhesive short fibers made of inelastic resin and thermoplastic inelastic tree
Short fibers made of fat form a three-dimensional structure and are fused and integrated.
The apparent density at which the layers are laminated and joined is 0.01 g / cm
^ThreeTo 0.2g / cm^ThreeNonwoven laminated net. 2. The nonwoven fabric laminate network according to claim 1, wherein the continuous filament has a hollow cross section or a modified cross section. 3. The nonwoven fabric laminate according to claim 1, wherein the thermoplastic elastic resin constituting the continuous filament has an endothermic peak at a temperature from room temperature to a melting point in a melting curve measured by a differential scanning calorimeter. 4. A multi-segment nozzle having a plurality of orifices has a soft segment amount (A weight%) and a phosphorus content (Bpp).
m) distributes a thermoplastic elastic resin satisfying the relationship of 60A + 200 ≦ B ≦ 100000 to each nozzle orifice,
At a melting temperature of 10 to 80 ° C. higher than the melting point of the thermoplastic resin, the resin is discharged downward from the nozzle and brought into contact with each other in a molten state to be fused to form a three-dimensional structure, sandwiched by a take-off device and cooled. After being cooled in a bath, a three-dimensional web is formed by mixing and opening one or both surfaces of a thermoplastic adhesive resin and a thermoplastic adhesive non-elastic resin and a thermo-adhesive short fiber and a thermoplastic non-elastic resin short fiber. A method for producing a laminated nonwoven fabric network by laminating and compressing and thermoforming. 5. The nonwoven laminated net structure according to claim 4, wherein annealing is performed at a temperature of at least 10 ° C. lower than a melting point of the thermoplastic elastic resin in a process from cooling to integral molding and commercialization. Body making. 6. A vehicle seat, a marine seat, a commercial or household bed, a furniture chair, an office chair, etc., using the nonwoven laminated net according to claim 1. And futons.