JP3431091B2 - Nonwoven laminated net, manufacturing method and product using the same - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION The present invention relates to a thermoplastic elastic resin and a thermoplastic inelastic material which have excellent cushioning properties, heat resistance durability and vibration absorption properties, and which are laminated and joined with a recyclable short fiber hard cotton layer. TECHNICAL FIELD The present invention relates to a non-woven fabric laminated net with a net made of a resin and a manufacturing method, and products such as a futon, furniture, a bed, and a cushioning material for a vehicle using the non-woven fabric net.

[0002]

2. Description of the Related Art At present, as a cushion material for furniture, beds, trains, automobiles, etc., urethane foam, non-elastic crimped fiber wadding,
In addition, resin cotton or hard cotton to which non-elastic crimped fibers are adhered is used.

However, although the foamed-crosslinked urethane has very good durability as a cushioning material, it is inferior in moisture permeability and water permeability and has a heat storage property, so that it easily steams, and since it is not thermoplastic, it is difficult to recycle and incinerated. If
The incinerator is heavily damaged and the cost of removing toxic gas is high. For this reason, landfilling has become more frequent, but it is difficult to stabilize the ground, and there is a problem that landfilling sites are limited and costs increase. Further, although it has excellent processability, it also has a problem of pollution of chemicals used during manufacturing. In addition, since the fibers are not fixed in the thermoplastic polyester fiber wadding, the form may collapse during use, the fibers may move, and the crimp may cause a decrease in bulkiness and elasticity. become.

As a resin cotton in which polyester fibers are adhered with an adhesive, for example, a rubber-based adhesive is used, Japanese Patent Application Laid-Open No.
0-11352, JP-A 61-141388, JP-A 61-141391 and the like. Further, as a method using a cross-linkable urethane, JP-A-61-1377
No. 32 publication and the like. These cushion materials have inferior durability, and also have problems such as not being recyclable because they are neither thermoplastic nor single composition, and there are problems such as complexity of processability and pollution of chemicals used during manufacturing. .

Polyester hard cotton, for example, JP-A-58-3
1150, JP-A-2-154050, JP-A-3-220354, etc., but since an amorphous polymer having a brittle adhesive component of the heat-bonding fiber used is used (for example, JP-A-58). -136828, Japanese Patent Application Laid-Open No. 3-
However, there is a problem in that durability is poor such that the bonded portion is brittle and the bonded portion is easily broken during use and the form and elasticity are reduced. As an improved method, a method of entanglement treatment has been proposed in Japanese Patent Laid-Open No. 4-245965, but there is a problem that the brittleness of the bonded portion is not solved and the elasticity is largely reduced. In addition, there is complexity during processing. Further, there is a problem that the bonded portion is hard to be deformed and soft cushioning is hard to be imparted. For this reason, the polyester elastomer that is soft even at the bonded portion and recovers even if it is deformed to some extent
A heat-bonding fiber using a non-elastic polyester as a core component is disclosed in JP-A-4-240219, and a cushion material using the fiber is disclosed in WO-91 / 19032, JP-A-5-155651. It is proposed in Japanese Patent Laid-Open No. 5-163654. The adhesive component used in this fiber structure has a polyalkylene glycol content of 30 to 50 as a soft segment of polyester elastomer.
Wt%, 5% terephthalic acid as the acid component of the hard segment
It contains 0 to 80 mol% and is used as another acid component composition
As in the fiber described in Japanese Patent Publication No. 0-1404, isophthalic acid is contained to increase the amorphous property, and the melting point is 180.
The temperature is below ℃, and the heat-bonded part is well formed with a low melt viscosity to form an ameber-shaped bonded part, but it is easy to plastically deform, and because the core component is an inelastic polyester, plastic deformation especially under heating Becomes remarkable, and there is a problem that the heat resistance and compression resistance are lowered. As an improved method for these, Japanese Patent Laid-Open No.
No. 163654 proposes a structure consisting only of a polyester elastomer containing isophthalic acid as a sheath component and a heat-bonding composite fiber using an inelastic polyester as a core component. Plastic deformation becomes remarkable, the heat resistance and compression resistance deteriorate, and there is a problem in using it as a cushion material. On the other hand, there is a method in which a silicone oil is added to a base material of hard cotton to lower the friction coefficient of fibers to improve durability and improve the texture.
It has been proposed in the publication. However, there is a problem with the adhesiveness of the heat-adhesive fiber and the durability is poor, so it is not preferable for use as a cushioning material.

A thermoplastic olefin network used for civil engineering work 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 durability is extremely poor and it cannot be used as a wadding layer or cushion material. In addition, Japanese Patent Publication No. 3-1766
No. 6 discloses a method in which ejection filaments having different fineness are fused to each other to form a mold, but the mesh structure is not suitable as a cushion material. Japanese Examined Patent Publication No. 3-55583 discloses that
A method of thinning only a very surface with a thinning device such as a rotating body before cooling is described. With this method, the surface cannot be flattened and a thick thin linear layer cannot be formed. Therefore, it does not provide a comfortable cushioning material. JP-A-1-207462 discloses a floor mat made of vinyl chloride, but it is not preferable as a cushioning material because it has poor compression recovery at room temperature and remarkably poor heat resistance. Note that no consideration is given to vibration damping in the above-mentioned structure.

[0007]

To solve the above problems,
Isolates vibrations and has excellent heat resistance and durability, shape retention and cushioning properties and is resistant to stuffiness. Thermoplastic elastic resin and thermoplastic non-woven resin are made by laminating and joining short cotton fibers made of thermoplastic elastic resin and thermoplastic inelastic resin. An object of the present invention is to provide a non-woven laminate network and a manufacturing method, which are most suitable for a cushioning material composed of a network in which an elastic resin is composited, and a product and a manufacturing method using a non-woven laminate network such as a futon, furniture, bed, and cushion for a vehicle. And

[0008]

[Means for Solving the Problems] Means for solving the above problems, that is, the present invention provides a continuous composite filament having a fineness of 100 to 10,000 denier, which is a composite of a thermoplastic elastic resin and a thermoplastic non-elastic resin. A three-dimensional three-dimensional structure in which most of the contact portions are fused by being bent and brought into contact with each other to form a three-dimensional three-dimensional structure, both surfaces of which are substantially flattened, and a thermoplastic elastic resin is formed on one surface of the three-dimensional structure. Thermoadhesive composite short fibers made of thermoplastic non-elastic resin are three-dimensionally structured, and most of the contact parts are fused and integrated by the thermoplastic elastic resin, and the non-woven fabric whose surface is substantially flat is joined and integrated. And has a density of 0.01 g / cm ³ to 0.2 g / cm ³ , a non-woven laminated network, a thermoplastic elastic resin and a thermoplastic non-elastic resin from a multi-row nozzle having a plurality of orifices. Can be compounded Like above, the liquid is dispensed immediately before the nozzle orifice, and is discharged downward from the nozzle at a melting temperature higher than the melting point of the thermoplastic resin by 10 to 120 ° C., and in a molten state, they are brought into contact with each other and fused to form a three-dimensional structure. After being formed, sandwiched by a take-up device and cooled in a cooling tank, a thermo-adhesive composite short fiber composed of a thermoplastic elastic resin and a thermoplastic non-elastic resin is opened on one side to form a three-dimensional structured web. It is a method for producing a non-woven laminate network in which most of the contact portions are laminated by fusion with a thermoplastic elastic resin by lamination and compression thermoforming, and a product using the non-woven laminate network.

The thermoplastic elastic resin in the present invention means, as the soft segment, an ether type glycol, a polyester type glycol, a polycarbonate type glycol or a long chain hydrocarbon having a molecular weight of 300 to 5,000. Polyester elastomer obtained by block-copolymerizing an olefinic compound having a carboxylic acid or a hydroxyl group at the terminal, a polyamide elastomer, a polyurethane elastomer,
Examples include polyolefin elastomers. By using a thermoplastic elastic resin, it becomes possible to regenerate by remelting, and thus recycling becomes easy. For example, as the polyester 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 illustrated. More specific examples of the polyester ether block copolymer include aromatic dicarboxylic acids such as terephthalic acid, isophthalic acid, naphthalene 2.6 dicarboxylic acid, naphthalene 2.7 dicarboxylic acid, and diphenyl 4.4'dicarboxylic acid. At least one of alicyclic dicarboxylic acids such as 1,4-cyclohexanedicarboxylic acid, aliphatic dicarboxylic acids such as succinic acid, adipic acid, sebacic acid dimer acid, and dicarboxylic acids selected from ester-forming derivatives thereof Seeds and aliphatic diols such as 1.4 butanediol, ethylene glycol, trimethylene glycol, tetremethylene glycol, pentamethylene glycol and hexamethylene glycol, 1.1 cyclohexane Alicyclic diols such as dimethanol and 1,4-cyclohexane dimethanol, or these Of at least one diole component selected from the ester-forming derivatives thereof and polyethylene glycol having an average molecular weight of about 300 to 5,000.
Is a ternary block copolymer composed of at least one kind of polyalkylenediol such as glycol, polypropylene glycol, polytetramethylene glycol, and glycol made of ethylene oxide-propylene oxide copolymer. . As polyester ester block copolymer
R> is a ternary block copolymer composed of at least one of the above dicarboxylic acids, diol, and polyester diol such as polylactone having an average molecular weight of about 300 to 5,000. Considering heat adhesion, hydrolysis resistance, stretchability, heat resistance, etc., terephthalic acid as dicarboxylic acid, or naphthalene 2.6 dicarboxylic acid, 1.4 butanediol as diole component, and poly The alkylene diol is particularly preferably a terpolymer block copolymer of polytetramethylene glycol or the terpolymer block copolymer of polylactone as the polyester diol. In a special case, it is possible to use the one in which a polysiloxane-based soft segment is introduced. Also, the thermoplastic elastomer resin of the present invention includes those obtained by blending the above elastomer with a non-elastomer component, those obtained by copolymerization, those obtained by softening the polyolefin component, and the like. As a polyamide elastomer,
Nylon 6, nylon 66, nylon 6 for the segment
10, Nylon 612, Nylon 11, Nylon 12, etc. and their copolymerized nylon as the skeleton, and the soft segment has an average molecular weight of about 300 to 5,000 polyethylene glycol, polypropylene glycol, polytetramethylene glycol. A block copolymer composed of at least one kind of polyalkylenediol such as glycol made of ethylene oxide-propylene oxide copolymer may be used alone or in combination of two or more kinds. Furthermore, blends of non-elastomer components and copolymers thereof can be used in the present invention. Examples of the polyurethane elastomer include (A) a polyester and / or a polyester having a hydroxyl group at the terminal with a number average molecular weight of 1000 to 6000 in the presence or absence of a usual solvent (dimethylformamide, dimethylacetamide, etc.). ) A typical example is a polyurethane elastomer obtained by reacting a polyisocyanate containing an organic diisocyanate as a main component with a prepolymer having isocyanate groups at both ends and (C) extending the chain with a polyamine containing a diamine as a main component. Can be illustrated as As the polyester (A) and the polyethers, the average molecular weight is about 1000 to 600.
0, preferably 1300 to 5000 polybutylene adipate copolyester or polyethylene glycol,
Polyalkylenediols such as polypropylene glycol, polytetramethylene glycol, and glycols composed of ethylene oxide-propylene oxide copolymer are preferred, and the polyisocyanate of (B) is a conventionally known polyisocyanate. However, it is also possible to use an isocyanate mainly composed of diphenylmethane 4,4′-diisocyanate, and to add a trace amount of conventionally known triisocyanate or the like, if necessary. As the polyamine (C), known diamines such as ethylenediamine and 1.2 propylenediamine are mainly used, and if necessary, trace amounts of triamine and tetraamine may be used in combination. These polyurethane elastomers may be used alone or in combination of two or more. The melting point of the thermoplastic elastic resin of the present invention is preferably 140 ° C. or higher at which heat resistance and durability can be maintained, and it is more preferable to use a resin having a melting point of 160 ° C. or higher because heat resistance and durability are improved. If necessary, an antioxidant, a light-proofing agent or the like may be added to improve durability. 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 or more, more preferably 30% by weight or more, and heat resistance and sag resistance Therefore, it is preferably 80% by weight or less, and more preferably 70% by weight or less. That is, the soft segment content of the component having the function of absorbing vibrations and stress of the nonwoven fabric laminated 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. is there.

The component comprising the thermoplastic elastic resin constituting the nonwoven fabric laminated network of the present invention preferably has an endothermic peak below the melting point in the melting curve measured by a differential scanning calorimeter. Those having an endothermic peak below the melting point have significantly improved heat resistance and sag resistance than those having no endothermic peak. For example, a preferable polyester-based thermoplastic resin of the present invention contains 90 mol% or more of terephthalic acid or naphthalene 2.6 dicarboxylic acid having rigidity in the acid component of the hard segment, more preferably terephthalic acid or 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 a polyalkylene diol, preferably When the average molecular weight of polytetramethylene glycol having an average molecular weight of 500 or more and 5000 or less, particularly preferably 1000 or more and 3000 or less, is copolymerized in an amount of 15% by weight or more and 70% by weight or less, more preferably 30% by weight or more and 60% by weight or less,
If the content of terephthalic acid or naphthalene 2.6 dicarboxylic acid, which has rigidity in the acid component of the hard segment, is high,
The crystallinity of the de-segment is improved, plastic deformation is less likely to occur, and the heat resistance and fatigue resistance are improved, but if heat treatment is performed at a temperature lower than the melting point by at least 10 ° C or more after annealing by heat, the heat resistance and fatigue resistance will be further improved. The property is improved. If annealing is performed after applying compressive strain, heat resistance and sag resistance are further improved. An endothermic peak is more clearly expressed at a temperature of room temperature or higher and melting point or lower in the melting curve of the nonwoven fabric laminated network treated as described above measured by a differential scanning calorimeter. If annealing is not performed, no endothermic peak appears in the melting curve above room temperature and below the melting point. By analogy with this, it is considered that the annealing causes rearrangement of the hard segments and formation of pseudo-crystallization-like cross-linking points to improve the heat resistance and sag resistance. (This treatment is defined as pseudo crystallization treatment.) This pseudo crystallization treatment effect is also effective for polyamide elastic resin and polyurethane elastic resin.

The thermoplastic non-elastic resin in the present invention means
Examples thereof include polyester, polyamide and polyolefin. In the present invention, it is preferable to use one having a glass transition temperature of 40 ° C. or higher. For example, for polyester, polyethylene terephthalate (PE
T), polyethylene naphthalate (PEN), polycyclohexylene dimethylene terephthalate (PCHD
T), polycyclohexylene dimethylene naphthalate (PCHDN), polybutylene terephthalate (PB)
Examples thereof include T), polybutylene naphthalate (PBN), polyarylate, and copolymerized polyesters thereof. For polyamide, polycaprolactam (NY
6), polyhexamethylene adipamide (NY66), polyhexamethylene sebacamide (NY6-10) and the like. As polyolefin, polypropylene (P
P), polybutene-1 (PB-1) and the like can be exemplified. As the thermoplastic non-elastic resin used in the present invention, polyester is often used for the side material of the cushion material, and therefore PET and PEN having good heat resistance can be used as a cushion material that can be recycled without being separated when discarded. , PBN, P
Polyesters such as CHDT are particularly preferred. Furthermore, P
A flame-retardant polyester (hereinafter abbreviated as flame-retardant polyester) obtained by polycondensation with ET, PEN, PBN, PCHDT or the like to copolymerize a phosphorus-containing ester forming compound or containing a phosphorus-containing flame retardant is preferable. JP-A-51-823
92, JP-A-55-7888, JP-B-55
-41610 and the like are exemplified.
Although vinyl chloride has a self-extinguishing property, it produces a large amount of toxic gas when it is burned, so that it is not preferable to use it in the present invention.

According to the present invention, continuous filaments made of a thermoplastic elastic resin and a thermoplastic non-elastic resin having a fineness of 100,000 denier or less are bent and brought into contact with each other, and most of the contact portions are fused. A three-dimensional structure is formed, and short fibers made of thermoplastic elastic resin and thermoplastic non-elastic resin are three-dimensionally structured on one side of a net-like body whose both sides are substantially flattened. Non-woven fabric whose fusion-melted and integrated surface is substantially flattened by plastic elastic resin is joined and integrated to have a density of 0.01 g / cm ³ to 0.2 g / cm
^{3 is} a non-woven laminated network. The function of the cushion material is
The cushion layer is made up of a layer that thickens the basic fineness and makes it a little harder to support the body shape, and a layer that slightly increases the density with a component with good vibration damping properties to absorb the vibration and block the vibration, and the surface layer is the fineness As a soft layer with a narrower number of constituent fibers, it gives a comfortable touch to the buttocks by a proper subduction and evenly distributes the pressure distribution in the buttocks and absorbs vibrations that could not be absorbed by the cushion layer and By integrating the layer that blocks the vibration of the resonance portion, it is possible to integrally deform and absorb stress and vibration, and improve the sitting comfort. In the present invention, the function of the cushion layer is provided to the net-like body formed by the fused three-dimensional structure made of thermoplastic elastic resin, and the function of the surface layer is made of thermoplastic elastic resin and thermoplastic non-elastic resin. A preferred cushioning material in which fibers are three-dimensionally structured, and most of the contact portions are fused and integrated with a thermoplastic elastic resin into a non-woven fabric (short-fiber non-woven fabric) whose surface is substantially flattened to be joined and integrated. It is a non-woven fabric laminated network capable of imparting the function of. The short fiber non-woven fabric having a surface layer function constituting the non-woven fabric laminated network of the present invention provides a comfortable buttocks touch due to an appropriate subsidence as a soft layer, so that the heat-adhesive component is made of a thermoplastic elastic resin (preferably , 40% by weight or more, which is sufficient for absorbing vibration and deformation stress, and 70% by weight or more, the shape retention of short fibers deteriorates and the subsidence increases. A short fiber having a fineness of 20 denier or less, which is made of a thermoplastic non-elastic resin to be held, has a three-dimensional structure, and the surface where most of the contact portion is fused and integrated by the heat-adhesive component is substantially flattened. Composed of non-woven fabric. Fineness of the short fibers is 20 denier - To below 0.01 g / cm ³ or more 0.05 g / cm ³ exceeding Le and the apparent density of the short fiber nonwoven fabric can impart desirable surface layer functions, configuration number is reduced, It is not preferable because it does not show the characteristics as a dense structure and impairs a comfortable touch. Also,
As the fineness increases, the number of constituents decreases, the thermal bonding points decrease, the dispersion of deformation stress deteriorates, the stress concentration at the bonding points increases, and the sag resistance decreases, which is not preferable. On the other hand, if the fineness is too small, the anti-compression property is lowered and large deformation easily occurs, and the thermoplastic non-elastic resin portion is plastically deformed, and durability is remarkably lowered, which is not preferable. The fineness of the short fibers is preferably 1 denier to 10 denier, and more preferably 3 denier to 6 denier. A non-woven fabric in which the short fibers have a three-dimensional structure, and the surface of the contact portion where most of the contact portions are fused and integrated with a thermoplastic elastic resin (preferably all of the contact points are fused and integrated) is substantially flattened. As a result, the local pressure of the buttocks is received on the surface, the pressure distribution is evenly distributed, and the three-dimensional structure of the short fiber nonwoven fabric is fused and integrated with the thermoplastic elastic resin of the heat bonding component. , While the thermal bonding point is largely deformed, 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 easily restores the original form. Good sag resistance due to its function.
Further, the damage to the cushion layer can be gradually reduced, and the sag resistance of the entire structure is improved. If they are not fused and integrated, the shape cannot be maintained, the local pressure is received by the surface, the pressure distribution cannot be evenly distributed, and the entire structure is deformed and energy conversion is not possible. Inferior and not preferable. Since the heat-adhesive fiber is made of a thermoplastic elastic resin having a good vibration absorption property, it also functions as a layer that absorbs the vibration that could not be absorbed by the cushion layer and blocks the vibration of the resonance part of the human body. When the heat-adhesive component is composed of a thermoplastic non-elastic resin, it cannot follow local deformation stress, and the structure is destroyed due to stress concentration and the recoverability is poor, which is not preferable. Further, since the thermoplastic non-elastic resin has a poor vibration absorbing property, it is not preferable because it has a poor function as a layer for blocking vibration. The thickness of the short fiber non-woven fabric layer is not particularly limited, but is preferably 3 mm to 30 mm and particularly preferably 5 mm to 20 mm so that the surface layer function can be exhibited. On the other hand, in the mesh body having a cushion layer function, continuous filaments made of a thermoplastic elastic resin and a thermoplastic non-elastic resin form a three-dimensional three-dimensional structure, and most of the contact portions are fused and integrated, and both sides are It is substantially flattened, and the vibration absorption function of the thermoplastic elastic resin absorbs and attenuates most of the vibrations given from the outside, and the surface of the reticulate body even when a large deformation stress is locally applied. Is substantially flattened and most of the contact part is fused, and the surface is joined with the short fiber non-woven fabric at the surface, so the surface of the mesh receives the deformation stress and disperses the deformation stress, and the thermoplastic Since the linear composite of elastic resin and thermoplastic non-elastic resin forms a three-dimensional structure and is fused and integrated, the thermoplastic non-elastic resin exhibits anti-compressibility and does not exceed the elastic limit. It deforms and the thermoplastic elastic resin heats up. The elastic non-elastic resin undergoes a large deformation before the elastic limit is exceeded, and the entire fused and integrated structure is deformed and absorbs the deformation stress by energy conversion, and when the deformation stress is released, it becomes thermoplastic. The non-elastic resin elastically recovers, and the thermoplastic elastic resin also exhibits rubber elasticity and easily recovers to its original form, so that it has good sag resistance and the deformation strain linearly changes with respect to the stress at the time of compression. When sitting, it supports the buttocks with a low repulsive force and causes a certain amount of subsidence, so it exerts a body shape retention function without giving a feeling of being on the floor. The present invention has solved the problem that the net-like body made of only the thermoplastic elastic resin is too soft and causes a slight depression, and the body shape holding function can be improved. In the net-like body composed of the filaments made only of the known inelastic resin,
When subjected to a large deformation that cannot be absorbed by the surface layer, it does not have rubber elasticity, so plastic deformation occurs due to compressive deformation and recovery does not occur, resulting in poor durability. When the surface of the reticulate body is not substantially flattened, the local external force transmitted from the short fiber non-woven fabric is selectively transmitted to the filaments and bonding points of the surface, resulting in stress concentration. There is a possibility that fatigue due to stress concentration may occur due to such external force and the sag resistance may deteriorate. When the filaments are made of thermoplastic elastic resin or when the thermoplastic elastic resin and the thermoplastic non-elastic resin are combined, the entire structure is deformed in the three-dimensional structure portion, so stress concentration is relieved. However, in the case of only the non-elastic resin, the stress concentrates at the bonding point as it is, causing structural destruction and not recovering. Furthermore, if the surface is not substantially flattened and has irregularities, the buttocks feel a foreign substance when sitting, which is unfavorable for sitting. When the linear shape is not continuous, the adhesive point becomes a stress transmission point in a net having a large fineness, so that remarkable stress concentration occurs at the adhesive point, resulting in structural destruction and poor heat resistance and durability. If they are not fused, the shape cannot be maintained and the structure does not deform integrally, resulting in a fatigue phenomenon due to stress concentration and poor durability, and at the same time deforming the shape and making it impossible to maintain the body shape, which is not preferable. . The more preferable degree of fusion in the present invention is that most of the portions where the filaments are in contact are fused, and most preferably all the contact portions are in fusion. Thus, the contact portion of the continuous filaments, which is a composite of thermoplastic elastic resin having good vibration absorption and elastic recovery, is fused to form a three-dimensional three-dimensional structure which is fused and integrated so that the surface is substantially The reticulated body with the flattened cushion layer function receives the deformation stress transmitted from the surface layer composed of the short fiber non-woven fabric made of thermoplastic elastic resin on the surface, improves the dispersion of the stress, and is applied to each linear shape. The stress is reduced and the entire structure deforms to absorb the deformation stress, and also improves the cushioning property that supports the buttocks, recovers when the stress is released, and the vibration transmitted from the frame is also vibration absorption and elastic recovery. Since the good thermoplastic elastic resin portion absorbs the vibration of the resonance portion of the human body, the sitting comfort and durability can be improved. For this purpose, the fineness of the filaments forming the mesh body of the present invention is 100,000 denier or less. When the apparent density is 0.2 g / cm ³ or less, the number of constituents decreases when the density exceeds 100,000 denier, and uneven density occurs to form a partially inferior structure, and fatigue due to stress concentration increases. It is not preferable because the durability is lowered. The fineness of the filaments constituting the reticulate body of the present invention is 100 denier or more, because if the fineness is too thin, the anti-compression property becomes too low and the stress absorbability due to deformation decreases. It is 50,000 denier or less so as not to impair the denseness of the surface. More preferably 50
It is 0 denier or more and 10,000 denier or less. When the apparent density of the reticulate body of the present invention is 0.005 g / cm ³ , the repulsive force is lost, and the vibration absorbing ability and the deformation stress absorbing ability become insufficient, which may make it difficult to develop the cushion function. If it is cm ³ or more, the repulsive force may be too high and the sitting comfort may be poor, so it is easy to develop the function as a cushion body by utilizing the vibration absorption capacity and the deformation stress absorption function. 0.01 g / cm ³ or more 0.20 g / Cm ³ or less is preferable, more preferably 0.03 g / cm ³ or more and 0.0
It is 8 g / cm ³ or less. As a preferred embodiment, a method in which the reticulate body in the present invention has a different fineness laminated structure in which a linear shape having a different fineness is combined with an apparent density to have an optimum configuration can be selected. The thickness of the reticulate body of the present invention is not particularly limited, but if the thickness is less than 5 mm, the stress absorbing function and the stress dispersing function are deteriorated. 10mm thickness
It is above, more preferably 20 mm or more. The apparent density as a laminated structure in which the mesh body and the short fiber non-woven fabric of the present invention are integrally bonded is 0.01 g / cm ³ to 0.2 g /
It is cm ³ . If it is less than 0.01 g / cm ³ , the cushioning function such as body shape retention and vibration absorption is deteriorated, which is not preferable. If it exceeds 0.2 g / cm ³ , the impact resilience becomes large and the sitting comfort becomes poor, which is not preferable. Preferred apparent density is ^{0.02g / cm 3 ~0.1g / cm 3} , more preferably ^{0.03g / cm 3 ~0.06g / cm 3} .
If the mesh body and the short fiber non-woven fabric are not joined and integrated, they will not be deformed in the entire structure unless they are joined and integrated under shear deformation.
There is a case where the structure is destroyed due to the heat treatment, and even when the structure is not destroyed, the body shape-retaining layer has no support, so that the body shape is not well maintained, which is not preferable.

The cross-sectional shape of the filaments of the reticulate body of the present invention is not particularly limited, but a hollow cross-section or a deformed cross-section is particularly preferable because it can impart preferable anti-compression property (repulsive force) and touch. The anti-compression property can be adjusted by the fineness and the modulus of the material used to make the fineness fine, or in the soft material the hollowness and the irregularity can be increased to adjust the gradient of the initial compression stress, and the fineness can be made slightly thicker or slightly. A material with a high modulus lowers the hollow ratio and the degree of irregularity to provide anti-compression property with a comfortable sitting feeling. As another effect of the hollow cross section and the irregular cross section, by increasing the hollow ratio and the degree of irregularity, if the same anti-compression property is given, the weight can be further reduced, and the energy saving can be achieved when it is used for the seat of an automobile or the like. If it is a futon or the like, it will be easier to handle when raising and lowering. As another preferable method for imparting preferable anti-compression property (repulsive force) and touch, there is a method of forming the filament of the reticulated body of the present invention into a composite structure. Examples of the composite structure include a score core structure, a side-by-side structure, and a combination structure thereof. However, especially when the cushion layer is largely deformed, the energy and
In order to obtain a three-dimensional three-dimensional structure that can be converted and restored, a sheath-core structure or a side-by-side structure in which 50% or more of the linear surface is occupied by a soft thermoplastic elastic resin, and a combination thereof are mentioned. That is, in the sheath core structure, the sheath component is a thermoplastic elastic resin having a large content of soft segments that can easily convert energy into vibration and deformation stress, and the core component is composed of a thermoplastic inelastic resin exhibiting anti-compression properties. It can give a comfortable touch to the buttocks due to moderate depression. With the side-by-side structure, it is possible to easily convert the vibration and deformation stress into energy, and the melt viscosity of the thermoplastic elastic resin with many soft segment contents is made lower than the melt viscosity of the thermoplastic non-elastic resin showing anti-compressive property to form a linear surface. A structure in which the proportion of the thermoplastic elastic resin that occupies a large amount of the soft segment is increased (metaphorically, a structure in which the thermoplastic elastic resin is arranged in the eccentric sheath-core structure)
It is particularly preferable that the proportion of the thermoplastic elastic resin occupying the linear surface in the large amount of the soft segment is 80% or more, and most preferably the thermoplastic elastic resin occupying the linear surface in the large amount of the soft segment content. Ratio 10
It is the score of 0%. When the proportion of the thermoplastic elastic resin with a large soft segment content that occupies the linear surface is large, the flowability when melting and fusing is high, so there is the effect of strengthening the adhesion, and the structure deforms as a unit. In this case, the fatigue resistance against stress concentration at the bonding points is improved, and the heat resistance and durability are further improved.

Since a linear net-like body in which a thermoplastic elastic resin and a thermoplastic non-elastic resin are composited and a short fiber non-woven fabric are joined and integrated, a non-woven fabric laminated net body in which both surfaces are substantially flattened is provided. Other heat-adhesive components (heat-bonded non-woven fabric, heat-bonded fiber, heat-bonded non-woven fabric, knitted fabric, hard cotton, film, foam, metal, etc.
Heat-adhesive film, heat-adhesive resin, etc.) and adhesives are used to make a monolithic laminated structure, and seats for vehicles, seats for ships, vehicles, ships, hospital beds, etc. When obtaining products such as office chairs and duvets, the contact area with the surface to be adhered can be widened, so that the adhesive area can be widened and a product with strong adhesion and good adhesion durability can be obtained. In addition, by performing the above-mentioned pseudo crystallization treatment at any stage of commercialization from the mesh and the laminated mesh formation step, the component composed of the thermoplastic elastic resin in the nonwoven laminated mesh is analyzed by a differential scanning calorimeter. It is more preferable that the measured melting curve has an endothermic peak at a temperature of room temperature or higher and melting point or lower because the heat resistance and durability of the product is remarkably improved. When the filaments of the reticulated body forming the non-woven fabric laminated network of the present invention have a composite structure, the back surface of the non-woven fabric reticulated body can also be provided with a heat-bonding function, and the reinforcing material and the like can be integrated into the heat-bonding structure. For example, in the sheath core structure, a thermoplastic elastic resin containing a large amount of soft segments, which facilitates energy conversion of vibration and deformation stress of the sheath component, is used as a heat-adhesive component, and a thermoplastic non-compressive material having a compressive property of the core component is used. The function of the heat-bonding layer can also be imparted by using a structure in which the elastic resin has a high melting point component for providing the function of holding the net shape, and the melting point of the heat-bonding component is lower than the melting point of the high-melting resin by 10 ° C. or more. . Also,
The short fiber non-woven fabric of the surface layer of the non-woven fabric laminated network of the present invention is heat-bonded with a thermoplastic elastic resin, and can be used as the heat-bonding layer thereof, but preferably the heat-bonding component has a high soft segment content and a low melting point. By using the thermoplastic elastic resin of (1), it is possible to improve the energy conversion of vibration and deformation stress, and also to impart a good thermal adhesive function. The melting point of the heat-bonding component forming the filaments or fibers in the non-woven laminate network preferable for exhibiting the heat-bonding function is 15 ° C. to 80 ° C. lower than the melting point of the high-melting component, and more preferably 20.
The melting point is lower by 60 ° C to 60 ° C. The non-woven laminate network of the present invention having a heat-bonding function has a substantially flat surface, and most of the contact portions are fused to form a network, a non-woven fabric, a knitted fabric, a hard cotton, a film, Since it is possible to increase the contact area with the surface of the foam, metal, etc. to be heat-bonded, the heat-bonding area becomes wider, and a new heat-bonded new molded body and vehicle seat, ship seat, vehicle, ship, You can get products such as beds for business and home use such as hospitals, furniture chairs, office chairs, and futons. In addition, by performing pseudo crystallization at any stage until new molded products and products are commercialized, the filaments made of the thermoplastic elastic resin in the structure are melted by a differential scanning calorimeter. It is more preferable to make the curve have an endothermic peak at a temperature of room temperature or higher and melting point or lower because a product with significantly improved heat resistance and durability can be provided. When the adherend is adhered in a stretched state at the time of heat-bonding, the adhered body does not relax the stretched state due to the rubber elasticity of the adhesive layer, so that the adherend can be a molded body having tension and less likely to wrinkle.

Next, the manufacturing method of the present invention will be described. The thermoplastic elastic resin and the thermoplastic inelastic resin are distributed in front of each orifice so that the thermoplastic elastic resin and the thermoplastic inelastic resin can be compounded from a multi-row nozzle having a plurality of orifices, and the melting point of the thermoplastic resin is higher than the melting point of the thermoplastic resin by 120 ° C or more.
It is discharged downward from the nozzle at a melting temperature higher than less than, and in a molten state, they are brought into contact with each other and fused to form a three-dimensional structure, sandwiched by a take-up device and cooled in a cooling tank, and then heated on one side. Laminating webs that are three-dimensionally structured by opening short fibers made of plastic elastic resin and inelastic resin,
This is a method for producing a non-woven fabric laminated network in which most of the contact portion is fused and integrated with a thermal adhesive component by compression thermoforming. The reticulated body is prepared by separately melting the thermoplastic elastic resin and the thermoplastic non-elastic resin by using a general melt extruder, and mixing and mixing so as to form a composite just before the orifice as in a general composite spinning method. Discharge downward from the orifice. In the sheath core, the core component is supplied from the center, and the sheath component is merged and discharged from around the core component. On the side-by-side, the components are merged and discharged from the left and right or the front and back. The melting temperature at this time is 10 ° C. to 120 ° C. higher than the melting point of the thermoplastic resin. When the melting temperature is higher than the melting point of the low-melting point component and exceeds 120 ° C., thermal decomposition is remarkable and the characteristics of the thermoplastic resin are deteriorated, which is not preferable. On the other hand, unless the temperature is higher than the melting point of the high-melting point component by 10 ° C. or more, melt fracture occurs and normal filament formation becomes impossible, and the temperature of the filament when contacting and fusing while forming loop after discharge. May decrease, and the filaments may not be fused to each other, resulting in a network having insufficient adhesion. In the case of side-by-side, the linear adhesion may be poor, which is not preferable. The preferred melting temperature is 20 to 100 ° C. higher than the melting point of the low melting point component,
More preferably, the temperature is 30 ° C. to 80 ° C. higher than the melting point, and the temperature is 15 ° C. to 40 ° C. higher than the melting point of the high melting point component,
More preferably, they are combined and discharged at the same melting temperature that is 20 ° C. to 30 ° C. higher than the melting point. Unless the melting temperature difference immediately before joining is 10 ° C. or less, abnormal flow may occur and the formation of the composite morphology may be impaired. The shape of the orifice is not particularly limited, but may be a hollow cross section (for example, a triangular hollow shape, a round hollow shape, a shape with a protrusion, etc.) and / or an irregular cross section (for example, a triangular, Y-shaped, star-shaped cross-section secondary mode). In addition to the above effects, it is difficult for the three-dimensional structure formed by the discharge filaments in the molten state to relax the flow, and on the contrary, the flow time at the contact point is maintained for a long time to strengthen the adhesion point. It is particularly preferable because it can be When heating for adhesion as described in Japanese Patent Application Laid-Open No. 1-2075, the three-dimensional structure is easily relaxed, a planar structure is formed, and a three-dimensional three-dimensional structure becomes difficult, which is not preferable. As an effect of improving the properties of the reticulate body, the apparent bulk can be increased, the weight can be reduced, the anti-compression property can be improved, and the elasticity can be improved, which is difficult to obtain. In the case of a hollow cross section, if the hollow ratio exceeds 80%, the cross section tends to be crushed.
It is 0% or less, and more preferably 20% or more and 60% or less. The pitch between the holes of the orifice needs to be a pitch with which the loop formed by the line can sufficiently contact. The pitch between holes is shortened for a dense structure, and the pitch between holes is lengthened for a coarse 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 fineness can be obtained as desired. The different density layer can be formed by a configuration in which the pitch between rows or the pitch between holes is also changed, or a method in which the pitch between both rows and holes is also changed. In addition, if the cross-sectional area of the orifice is changed to give a pressure loss difference at the time of discharge, the melted thermoplastic resin is extruded from the same nozzle with a constant pressure, and the discharge amount decreases as the orifice loses more pressure. It is possible to manufacture a net-like structure composed of filaments of different fineness by using a nozzle having at least a plurality of rows having different cross-sectional areas of orifices in a section in the direction. Then, the liquid is discharged downward from the nozzle, and while forming a loop, they are brought into contact with each other in a molten state to be fused to form a three-dimensional structure, and are sandwiched by a take-up net to melt the surface of the net-like body. Bending the twisted discharge line of 45 degrees or more to deform it to flatten the surface and at the same time bond the contact points with the unbent discharge line to form a structure, and then continuously cool the medium (usually at room temperature). It is preferable to use the water of (1) because the cooling rate can be increased and the cost can be reduced). The distance between the nozzle surface and the take-off point is preferably at least 40 cm or less to prevent the discharge filament from being cooled and the contact portion not being fused. 1 if the discharge rate of discharge line is 5g / hole or more
0 cm to 40 cm is preferable, and 5 cm to 20 cm is preferable when the discharge amount of the discharge filament is less than 5 g / hole. The thickness of the net-like body is determined by the opening width (interval between the take-up nets) of the take-up net sandwiching both surfaces of the three-dimensional structure in the molten state.
In the present invention, the opening width of the take-up net is 5 mm for the above reason.
That is all. Next, it is drained and dried, but if a surfactant or the like is added to the cooling medium, draining and drying may be difficult, or the thermoplastic elastic resin may swell, which is not preferable. The desired loop diameter and wire diameter can be determined by the distance between the nozzle surface and the take-up conveyor installed on the cooling medium for solidifying the resin, the melt viscosity of the resin, the orifice hole diameter and the discharge amount, and the like. A pair of take-up conveyors with adjustable spacing installed on the cooling medium sandwiches and holds the melted discharge filaments to fuse the portions that are in contact with each other and continuously draw in the cooling medium to solidify. By adjusting the distance between the conveyors when forming the body, the thickness can be adjusted while the fused net-like body is in a molten state, and a desired thickness can be obtained. If the conveyor speed is too fast,
In some cases, the contact points may be insufficiently formed, or the contact points may be cooled by sufficient cooling until the fusion points are sufficiently formed. Further, if the speed is too slow, the melt will stay too much and the density will increase, so it is necessary to set the conveyor speed suitable for the desired apparent density. Then in the present invention,
It is joined and integrated with a short fiber non-woven fabric that has the function of a surface layer. A short fiber composed of a thermoplastic elastic resin and a thermoplastic non-elastic resin is preferably a composition in which the thermoplastic elastic resin of the heat-adhesive component has a low melting point and the thermoplastic non-elastic resin has a high melting point, which are individually melted The finished yarn can be obtained by spinning and stretching with the composite spinning of. However, in this method, since the melting point of the heat-adhesive component is low, heat setting at a high temperature at the time of stretching cannot be performed, so that only a high shrinkage rate of 30% to 80% can be obtained.
When the web is thermoformed, shrinkage of the web causes defective molding. In the present invention, in order to solve this problem,
It is preferable to obtain it by a method in which the shrinkage rate is reduced to 10% or less by high-speed spinning at a speed of 00 m / min or more and the finished yarn is obtained all at once. Next, crimping is applied and cut into a desired cut length to obtain short fibers. Although the composite form of the short fibers used in the present invention is not particularly limited, it is preferable that the low melting point component occupies 50% or more of the surface of the fiber in the side-by-side or the score, since the function as the heat-bonding fiber is required. More preferably, the low melting point component occupies 100% or more of the surface of the fiber. The short fibers thus obtained are pre-opened with an opener or the like and then opened with a card or the like, and a web having a three-dimensional structure is laminated and compressed on the surface of the reticulated body and bonded by thermoforming. It is also possible to integrate them, or to form a short-fiber non-woven fabric by laminating and compressing only the open webs and thermoforming to form a short-fiber non-woven fabric, and then joining and integrating the net body and the short-fiber non-woven fabric. In this case, a thermal adhesive layer or an adhesive may be separately used between the reticulate body and the short fiber non-woven fabric for bonding and integration, or the thermal rebonding function of the reticulate body or the short fiber non-woven fabric may be used for bonding and integration. Good. As a preferred method of the present invention, a temperature of at least 10 ° C. or lower than the melting point of the thermoplastic elastic resin is used in any step leading to commercialization of the nonwoven fabric laminated network obtained by once cooling the network or integrally molding. It is a more preferable production method to obtain a non-woven fabric laminated network or product by performing pseudo crystallization treatment by annealing. The pseudo-crystallization treatment temperature is at least 10 ° C. lower than the melting point (Tm), and is higher than the α dispersion rising temperature (Tαcr) of Tan δ. This treatment has an endothermic peak below the melting point and does not have pseudo-crystallization treatment (no endothermic peak)
The heat resistance and sag resistance are remarkably improved. The preferred pseudo-crystallization treatment temperature of the present invention is from (Tαcr + 10 ° C.) to (Tαcr + 10 ° C.).
m-20 ° C). If it is pseudo-crystallized by simple heat treatment, heat resistance and sag resistance are improved. However, it is more preferable to impart compressive deformation of 10% or more and anneal to significantly improve the heat resistance and sag resistance. Further, when the reticulate body is once cooled and then subjected to a drying step, the pseudo crystallization treatment can be simultaneously performed by setting the drying temperature to the annealing temperature. Also, a pseudo crystallization treatment can be separately performed in the process of commercialization. Then, it is cut into a desired length or shape and used as a cushion material.

When the non-woven fabric laminated network of the present invention is used as a cushion, it is necessary to select the resin to be used, the fineness, the loop diameter and the bulk density depending on the purpose of use and the site of use. For example, in order to give a soft touch, moderate depression and bulging with tension, a dense structure with a slightly high density and fine fineness is preferable, and in order to exert the cushion function of the middle layer, the resonance frequency is low. However, in order to improve the body shape retention by linearly changing the appropriate hardness and hysteresis at the time of compression, in order to maintain durability, medium density, thick fineness, a layer with a slightly larger loop diameter and low density It is preferable to have a structure in which layers having a fine fineness and a fine loop diameter are laminated and integrated. Since the nonwoven fabric-laminated network of the present invention has the functions of both the surface layer and the cushion layer at the same time, it can be formed into a shape suitable for the purpose of use using a molding die or the like so as not to impair the three-dimensional structure, and the side cloth is covered. It can be used for vehicle seats, boat seats, beds, chairs, furniture and the like. Of course, it is also possible to use it in combination with another material that should meet the required performance in relation to the application, for example, a different mesh body, a hard cotton cushion material composed of a short fiber aggregate, a non-woven fabric, or the like. In addition, other than the resin manufacturing process, it is processed into a molded product from the manufacturing process within a range that does not deteriorate the performance,
Flame retardant, insect repellent antibacterial, heat resistant, at any stage of commercialization
Water and oil repellency, coloring, aroma and other functions can be processed by adding chemicals.

[0017]

EXAMPLES The present invention will be described in detail below with reference to examples.

The evaluations in the examples were carried out by the following methods. Melting point (Tm) and endothermic peak below melting point TA50, DSC50 type differential thermal analyzer manufactured by Shimadzu Corporation was used, and the endothermic peak (melting peak) was measured from the endothermic curve measured at a temperature rising rate of 20 ° C./min. ) The temperature was determined. Tαcr polymer is heated to the melting point + 10 ° C and the thickness is about 300 μm.
Film was prepared and measured using a Vibron DDVII type manufactured by Orientec Co., Ltd. at a rate of 110 Hz and a heating rate of 1 ° C./min. Tan δ (the ratio of the imaginary elastic modulus M ″ to the real part M ′ of the elastic modulus M ″ / The rising temperature of α dispersion corresponding to the transition temperature from the rubber elastic region to the melting region of M ′). The apparent density sample is cut into a size of 15 cm × 15 cm, the heights at four locations are measured, the volume is determined, and the weight of the sample is divided by the volume. (Average value of n = 4) Each fine line sample is cut out from 10 places of fine line fineness, embedded with an acrylic resin, a cross section is cut out, and a section is prepared to obtain a cross section photograph. The cross-sectional area (Si) of each part is obtained from the cross-sectional photograph of each part. In addition, a piece obtained in the same manner was dissolved in acrylic resin with acetone, degassed in vacuum, and a density gradient tube was used to 40 ° C.
Determine the specific gravity (SGi) measured in. Then, a linear weight of 9000 m is obtained from the following equation. (Unit: cgs) Fineness = [(1 / n) ΣSi × SGi] × 900000 Whether or not the fusion-bonded sample is fused by visual judgment is determined by whether or not the fibers adhering to each other can be pulled out by hand and removed. It is determined that something that does not come off is fused. Heat resistance and durability (residual strain at 70 ° C) Cut a sample into a size of 15 cm x 15 cm, compress it by 50%, leave it in dry heat at 70 ° C for 22 hours, then cool to remove compression strain and leave it for 1 day (b) Is calculated, and is calculated from the thickness (a) before processing by the following equation, that is, (ab) / a × 100. Unit% (average value of n = 3) Cyclic compression strain sample is cut into a size of 15 cm x 15 cm, and is 50% in a RH room at 25 ° C and 65% in a Shimadzu Servo Pulser.
The thickness (b) after leaving the sample for 20,000 times after repeating compression recovery at a cycle of 1 Hz up to the thickness of 1 is calculated from the thickness (a) before the treatment, that is, (ab) / ax Calculated from 100. Unit% (average value of n = 3) Seating comfort A non-woven fabric laminate sheet cut into a sheet shape is covered with a polyester moquette hem made of Toyobo Co., Ltd. on the surface layer side to form a seat frame. Set the seats to 4 seats and 6 seats on the back, and create side seats.
The following evaluations were performed. (N = 5) (1) Feeling on the floor: The degree of "dosun" when sitting and the feeling of hitting the floor were qualitatively and qualitatively evaluated. Not felt; ◎, hardly felt; ○, slightly felt; △, felt; × (2) Feeling of stuffiness: Feeling stuffy when sitting for 2 hours and the buttocks and the part of the crotch that contacts the seat inside the crotch Qualitatively evaluated. Almost no feeling: ◎, slightly stuffy; ○, slightly stuffy; △, significantly stuffy; × (3) How long you can sit in the seat within 8 hours: within 1 hour; × within 2 hours; △ within 4 hours;
○ 4 hours or more; ◎ (4) A qualitative qualitative evaluation was performed on the degree of waist fatigue when the user sat in the seat for 4 hours. None; ◎, hardly tired; ○, slightly tired; △, very tired; × (5) Overall evaluation: 4 points from ◎ of the evaluations from (1) to (4), ○
3 points, △ is 2 points, × is 1 point and does not include Δ with 12 points or more; very good (⊚), that with 12 points or more; Good (○), 10 points or more is x It was evaluated as those which did not contain; those which were somewhat bad (Δ) and those which contained x; bad (x).

Example 1 As a polyester elastomer, dimethyl terephthalate (DMT) or dimethyl naphthalate (DM) was used.
N) and 1.4 butanediol (1.4 BD) were charged with a small amount of a catalyst, and after transesterification by a conventional method, polytetramethylene glycol (PTMG) was added and polycondensation was performed while heating and depressurizing. -Formation of terester block copolymer elastomer, then addition and mixing of 2% of antioxidant, kneading, pelletizing, and vacuum drying at 50 ° C for 48 hours are shown in Table 1. .

[0020]

[Table 1]

Orifice shapes having a staggered arrangement with a hole-to-hole pitch of 5 mm in the width direction and a hole-to-hole pitch of 10 mm in the length direction on an effective surface of a nozzle having a width of 50 cm and a length of 5 cm have an outer diameter of 2 mm and an inner diameter of 1.6 mm.
With a nozzle with a triple bridge hollow forming cross section,
The obtained thermoplastic elastic resin raw materials are melted by different extruders, A-1 is distributed as a sheath component, and PBT having a relative viscosity of 1.0 is distributed just before the orifice so as to become a core component, and the melting temperature is changed. Discharge rate per single hole at 260 ° C: 2.0 g / min (A-
(1: 1 g / min, PBT: 1 g / min), and the cooling water is placed 12 cm below the nozzle surface, and stainless steel endless nets with a width of 60 cm are arranged in parallel with a pair of take-up conveyors at intervals of 5 cm. It is arranged so that it partially appears on the surface of the water, and the discharge line in the molten state is bent to form a loop, and the contact portion is fused to form a three-dimensional network structure. While sandwiching both sides of the body with a take-up conveyor, the body was drawn into cooling water at 25 ° C. at a speed of 1 m / min to be solidified and flattened on both sides, and then cut into a predetermined size. -It has a triangular cross section with a score structure and a hollow cross section with a hollowness of 40% and a fineness of 9000 denier, and an average apparent density of 0.046 g.
It was / cm ³ . Separately, the thermoplastic elastic resin A-1 is melted individually by a conventional method so that the thermoplastic elastic resin A-1 becomes the sheath component and the PBT becomes the core component and distributed immediately before the orifice. 50/50 weight ratio, 1.6g / min per hole (0.8g / min: 0.8g / min) was discharged at a spinning temperature of 265 ° C, and the fineness obtained at a spinning speed of 3500m / min. 4.1 denier, 4% shrinkage at 160 ° C dry heat is converged, crimped in a tow shape and mechanically crimped, cut into 64 mm and thermoplastic elasticity of sheath core cross section A heat-bonded fiber made of resin was obtained. The resulting heat-bonded fiber was pre-opened with an opener and then opened with a card to obtain a web, which was laminated to a basis weight of 1000 g / m ² and laminated on the reticulated body to give an apparent density of 0. It was compressed to 0.05 g / cm ³ , heat-treated for 5 minutes with hot air at 180 ° C., and then cooled to obtain a nonwoven fabric laminated mesh body having flat both sides. Next, the characteristics of the nonwoven fabric laminated network of the present invention obtained by compressing 10% of the thickness and performing pseudo-crystallization treatment with hot air of 100 ° C. for 20 minutes are shown in Table 2.
Shown in. As is clear from Table 2, Example 1 was a cushioning material having excellent heat resistance and durability at room temperature and excellent sitting comfort because it was a nonwoven fabric laminated reticulate body which made the best use of the characteristics of the soft elastic resin. It can be seen that the seat created for evaluation also has excellent performance.

[0022]

[Table 2]

Example 2 20 mol% of dimethyl isophthalate (DMI) and DMT
Table 1 shows the formulation of the 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. Example 1 except that a nozzle having a circular cross section with a hole diameter of 1 mm was used as the orifice and A-3 was used as the sheath component.
The reticulate body obtained in the same manner as in (1) had a solid round cross section and was formed from filaments having a fineness of 9000 denier, and had an average apparent density of 0.045 g / cm ³ . Next, Table 2 shows the characteristics of the nonwoven fabric laminated network obtained in the same manner as in Example 1. As is clear from Table 2, it can be seen that Example 2 is a cushioning material which is practically usable in terms of heat resistance and durability at room temperature and has an excellent sitting comfort, and the seat prepared for evaluation is also excellent.

Example 3 As a polyurethane elastomer, 4,4'-diphenylmethane diisocyanate (MDI), PTMG and 1.4BD as a chain extender were added and polymerized, and then 2% of an antioxidant was added and mixed. Table 3 shows the formulation of the polyether urethane polymer after kneading, pelletizing and vacuum drying.

[0025]

[Table 3]

The thermoplastic elastic resin thus obtained (seed component:
In the same manner as in Example 1 except that B-1) was used, the cross-sectional shape of the linear filaments of the linear filaments was a triangular rice ball type hollow cross section with a hollow ratio of 40% and a fineness of 9800 denier. The average apparent density was 0.047 g / cm ³ . On the other hand,
The characteristics 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 was used as the core component, and the spinning temperature was 265 ° C., the fineness was 4.5 denier, 150 The shrinkage percentage at 9 ° C was 9%. This heat-bonded fiber and the base material obtained in Example 1 were made into a laminated web of 1000 g / m ^{2 in} the same manner as in Example 1, laminated with the mesh, heat treated with hot air at 160 ° C. for 5 minutes, and then cooled. As a result, a non-woven fabric laminated reticulate body having flat both sides was obtained. Then compress 10% of the thickness to 100 ° C
Table 2 shows the characteristics of the non-woven fabric laminated network of the present invention obtained by performing the pseudo crystallization treatment for 20 minutes with hot air. Example 3 is a non-woven laminate reticulate body that takes advantage of the characteristics of soft urethane, and has heat resistance.
It was a cushioning material with excellent durability and comfort at room temperature. It can be seen that the seat created for evaluation is also excellent.

Comparative Examples 1 and 2 The PBT used in Example 1 was used as a sheath component and an intrinsic viscosity of 0.
PET of 63 is the core component and polyethylene of melt index 5 is the sheath component, and P of melt index 12 is used.
With P as the core component, the melting temperature is 280 ° C and 240 ° C.
Except that, the reticulate body used in Comparative Example 1 obtained in the same manner as in Example 2 has a fineness of 8700 denier and an apparent density of 0.047 g / cm ³ , and the reticulate body used in Comparative Example 2 has a fineness of 24000. Denier with an apparent density of 0.047 g / cm
^{Was 3} . Then, except that the pseudo crystallization treatment was not performed
Table 2 shows the characteristics of the nonwoven fabric-laminated network obtained in the same manner as in Example 2. Comparative Example 1 has a poor heat resistance and durability because it is a reticulated body made of non-elastic polyester, and despite the fact that a short fiber non-woven fabric using a heat-bonding fiber whose thermo-bonding component is a thermoplastic elastic resin is used for the surface layer. , A cushion material that is hard and uncomfortable to sit on. In Comparative Example 2, the surface layer and the reticulate body are heat-resistant because the fine fiber is a reticulate body made of non-elastic olefin, and the heat-bonding component is a short fiber non-woven fabric made of a thermoplastic adhesive resin and made of polyester. Since it did not adhere, it was adhered with a urethane adhesive, but it was a cushioning material that had poor heat resistance and durability and was uncomfortable to sit on.

Comparative Example 3 Example 2 was repeated except that a take-up conveyor net was placed 60 cm below the nozzle surface and no pseudo crystallization treatment was performed after the take-up conveyor net was taken out.
Table 2 shows a part of the properties of the reticulate body obtained by the same method as described above.
In addition, since the non-woven fabric laminated network could not be formed due to poor adhesion and poor shape retention, repulsive force at 50% compression,
Apparent density, reinforcement effect, residual strain at 70 ℃, repeated compression strain,
Also, the sitting comfort is not evaluated. Comparative Example 3 is an example that is not suitable for a cushioning material because its shape is not fixed.

Comparative Example 4 A filament obtained in the same manner as in Example 2 except that the pseudo crystallization treatment was not performed had a fineness of 9100 denier and an average apparent density of 0.
4-45-EE manufactured by Toyobo Co., Ltd., which uses 045 g / cm ³ of reticulate body and thermoplastic non-elastic resin as a thermal bonding component in thermal bonding fiber
Table 2 shows the characteristics of the nonwoven fabric laminated network in which the short fiber nonwoven fabric prepared in the same manner as in Example 1 was laminated on the surface layer except that no pseudo crystallization treatment was performed using 7. Comparative Example 4 was a cushioning material which was comfortable to sit on but had slightly poor heat resistance and durability.

Comparative Example 5 A nozzle having a width of 50 cm and a length of 5 cm and having a staggered arrangement of holes with a pitch of 10 mm in the width direction and a pitch of 20 mm between the holes in the length direction was used as a nozzle having a diameter of 2 mm to form a single hole. Discharge at a rate of 25 g / min per nozzle, nozzle surface 30 cm
The fineness of the filament obtained in the same manner as in Example 2 was 11 except that a take-up conveyor net was arranged below and the take-up was carried out at 1 m / min.
At 2000 denier, the average apparent density is 0.154 g.
Table 2 shows the properties of the non-woven fabric laminated network prepared in the same manner as in Example 2 except that the net-like network of 1 cm ³ / cm ³ was used and no pseudo-crystallization treatment was performed. Comparative Example 5 was a cushioning material having a remarkably fineness and a non-woven fabric laminated network having unevenness in density, resulting in poor heat resistance and a little uncomfortable sitting comfort.

Comparative Example 6 The filament fineness obtained in the same manner as in Example 2 was 9000 denier, and the average apparent density of the reticulate body was 0. 0, except that the spacing (opening width) of the take-up conveyor net was 5 cm. 043 g / cm ³
Table 2 shows the characteristics of the non-woven fabric laminated network produced in the same manner as in Example 2 except that the network whose surface was not substantially flattened was used and the pseudo crystallization treatment was not performed. Comparative Example 6
Since the surface of the net-like body was uneven, the apparent density was low, but the durability was poor, the thermal adhesion was insufficient, and the cushioning material was a little inferior in sitting comfort with a feeling of foreign matter.

Comparative Example 7 Obtained in the same manner as in Example 2 except that the amount of discharge per single hole was 3 g / min, the speed of the take-up conveyor net was 0.3 m / min, and no pseudo-crystallization treatment was performed. Streak fineness of 13
000 denier, the average apparent density of the reticulate body is 0.21.
Table 2 shows the characteristics of the non-woven fabric-laminated network prepared in the same manner as in Example 2 except that the network of g / cm ³ was used and the pseudo-crystallization treatment was not performed. Since Comparative Example 7 had a high apparent density, it was a cushioning material having a good touch but a little inferior sitting comfort, and insufficient heat resistance and durability.

COMPARATIVE EXAMPLE 8 A nozzle having a width of 50 cm and a length of 5 cm and having a staggered arrangement of 4 mm pitch between holes in the width direction and 3 mm pitch between holes in the length direction and having an orifice diameter of 1 mm was used for each single hole. Of a filament obtained in the same manner as in Example 2 except that the discharge rate was 0.012 g / min, a take-up conveyor net was placed 5 cm below the nozzle surface, and the rate was 1.5 m / min. Fineness is 4
The net density of the non-woven fabric laminated net is 0.009 by using the net of 0 denier and the apparent density of 0.008 g / cm ^3.
Table 2 shows the characteristics of the non-woven fabric-laminated network produced in the same manner as in Comparative Example 7 except that the composition was compressed to have g / cm ³ . Comparative Example 8 is a cushion material having a fine mesh with a fine linear fineness as a cushion layer, and the apparent density is too low to cause a large sinking, a large floor feeling, and a slightly inferior sitting comfort. .

Example 5 The nonwoven laminated elastic mesh obtained in Example 1 was cut into a length of 120 cm and put in a side cloth having a width of 120 cm and a length of 200 cm which was quilted every 5 cm in thickness, 120 cm in width and 50 cm in length. Created a mattress. This mattress was placed on a bed, and a paneler-4 person used it for 7 hours in a room at 25 ° C. RH 65% to sensory-evaluate the sleeping comfort. In addition, the bet is
The quilt is hung and the comforter is 1.8kg down / feather: 9
0/10 batting was used, and the pillow was worn by the paneler every day. As a result of the evaluation, the bed was a bed which had no feeling of flooring, had a moderate depression, and did not feel stuffy and had a comfortable sleeping comfort. For comparison, a similar mattress was prepared from a urethane foam plate with a density of 0.04 g / cm ³ and a thickness of 10 cm, and the mattress was placed on a bed and the sleeping comfort was evaluated. It was a bed that made me feel stuffy and didn't feel comfortable to sleep.

Example 6 The non-woven fabric laminated net body obtained in Example 1 has a width of 38 cm and a length of 40.
The corner was cut into a shape with 10 cm of the corner, and the polyester moquette used for sitting comfort evaluation was set on the side of the office chair frame, and the commercially available polyurethane was used for the cushion. Compared to a chair, it provides a comfortable sitting 4
As a result of evaluation by sitting for a while, the stuffy feeling, the feeling of flooring, and the time to be able to stand while sitting were significantly excellent in those using the nonwoven fabric laminated reticulate body of the present invention.

[0036]

EFFECTS OF THE INVENTION The surface formed by fusion-bonding the filament formed by combining the thermoplastic elastic resin having good vibration and stress absorption property and the thermoplastic non-elastic resin improving the body-holding property forms a three-dimensional structure. A substantially flat mesh body is used as a cushion layer, a thermoplastic elastic resin with good vibration and stress absorption is used as a heat-adhesive component, and a thermoplastic inelastic resin is used as a fiber shape-retaining component for short-fiber heat-adhesive integration. The nonwoven fabric laminated network of the present invention in which the above nonwoven fabric is bonded and integrated as a surface layer is improved in vibration isolation, heat resistance durability, bulkiness, and sitting comfort.
It is a cushioning material that does not get stuffy easily, and it is covered with a side material as it is, or is used in combination with other materials, so that the seats for vehicles, seats for boats, seats for boats, for vehicles, boats, hospitals, hotels, etc. Products such as commercial beds, furniture cushions, and bedding can be provided. Furthermore, it is also useful as an interior material and a heat insulating material for vehicles and building materials.

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ Identification code FI D01F 8/04 D01F 8/04 Z // D01F 6/00 6/00 A 6/62 303 303 6/62 303D 6/86 301 6 / 86 301B (56) Reference JP-A 55-17527 (JP, A) JP-A 1-213454 (JP, A) JP-A 58-109670 (JP, A) JP-A 58-149362 (JP, A) Actual Kai 1-18326 (JP, U) Actual Kai 2-18300 (JP, U) Actual Kai 2-18371 (JP, U) (58) Fields surveyed (Int.Cl. ⁷ , DB name) ) D04H 1/00-18/00 B68G 1/00-15/00 B32B 1/00-35/00 D01D 1/00-13/02 D01F 1/00-13/04

Claims (6)

(57) [Claims] 1. A continuous composite filament having a fineness of 100 to 100,000 denier, which is a composite of a thermoplastic elastic resin and a thermoplastic non-elastic resin, is made to meander and is brought into contact with each other, and most of the contact portion is fused. Is formed into a three-dimensional three-dimensional structure, both sides of which are substantially flattened, and one side of the three-dimensional thermoadhesive composite short fibers made of a thermoplastic elastic resin and a thermoplastic inelastic resin is three-dimensionally formed. Non-woven fabric that is structured and most of the contact parts are fused and integrated with thermoplastic elastic resin and the surface of which is substantially flat is joined and integrated, and the density is 0.01 g / cm ³ to 0.2 g / A non-woven fabric laminated network characterized by having a size of cm ³ . 2. The nonwoven fabric laminated reticulate body according to claim 1, wherein the cross-sectional shape of the continuous composite filaments is a hollow cross section and / or a modified cross section. 3. The nonwoven fabric laminated reticulated body according to claim 1, which has an endothermic peak at a temperature of not less than room temperature and not more than the melting point in a melting curve measured by a differential scanning calorimeter of a component made of a thermoplastic elastic resin constituting a laminated reticulate structure. 4. A thermoplastic elastic resin and a thermoplastic non-elastic resin are distributed in front of each nozzle orifice so that they can be compounded from a multi-row nozzle having a plurality of orifices, and the melting point of the thermoplastic resin is higher by 10 to 120 ° C. It is discharged downward from the nozzle at the melting temperature, and while being in contact with each other in a molten state and fused to form a three-dimensional structure, it is sandwiched by a take-up device and cooled in a cooling tank, and then thermoplastic elasticity is applied to one side. Thermo-adhesive composite short fibers made of resin and thermoplastic non-elastic resin are opened to form a three-dimensional structured web, which is laminated by compression thermoforming, and most of the contact parts are fused and integrated with thermoplastic elastic resin. A method for producing a non-woven laminate network, comprising: 5. The method for producing a non-woven fabric reticulated body according to claim 4, wherein annealing is performed at a temperature of at least 10 ° C. or lower than the melting point of the thermoplastic elastic resin in the step of integrally molding after cooling and commercialization. 6. A vehicle seat, a ship seat, a vehicle, a ship, a hospital bed, etc. for commercial and household beds, furniture chairs, office chairs, etc., which use the nonwoven fabric laminated mesh according to claim 1. And the product described in any of the futons.