JP3431098B2 - Flame-retardant reinforced mesh, manufacturing method and products using the same - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION The present invention relates to a flame-retardant reinforced mesh body having excellent cushioning properties, heat resistance durability and vibration absorption properties, reinforced with a flame-retardant and recyclable non-woven fabric, and a method for producing the same. Futon, furniture, bed using flame retardant reinforced mesh,
The present invention relates to products such as vehicle cushioning materials and manufacturing methods.

[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 wadding layer or a cushioning material, it has poor moisture permeability and heat storage property and is apt to be stuffy.
Moreover, since it is not thermoplastic, it becomes difficult to recycle, and when it is incinerated, the damage to the incinerator is large and the cost for removing the 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 significant, the heat resistance and compression resistance deteriorate, and there is a problem in using it for a wadding layer or 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 the durability and improve the texture.
It is proposed in Japanese Patent No. 158094. 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 in a wadding layer or 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. Japanese Patent Application Laid-Open No. 1-207462 discloses a vinyl chloride floor mat, but it is not preferable as a wadding material or a cushioning material because it has poor compression recovery at room temperature and remarkably poor heat resistance. is there. In addition, the above-mentioned structure does not consider flame retardancy or vibration damping at all.

[0007]

To solve the above problems,
Vibration-isolating, heat-resistant durability, shape retention, cushioning, non-steaming, flame retardancy, low toxicity index of combustion gas and high safety are reinforced with a non-woven thermoplastic elastic resin mesh. An object of the present invention is to provide a flame-retardant reinforcing mesh body suitable for a cushioning material and a manufacturing method, and a product and a manufacturing method using the mesh body such as a futon, furniture, bed and cushion for vehicles.

[0008]

[Means for Solving the Problems] Means for solving the above problems, that is, the present invention, has a soft segment amount (A wt%) and a phosphorus content (Bppm) of 60 A + 200 ≦ B ≦ 1.
A continuous linear filament having a fineness of 100,000 denier or less made of a thermoplastic elastic resin satisfying the relationship of 00000 is bent and brought into contact with each other, and most of the contact portions are fused to form a three-dimensional three-dimensional structure. A continuous fiber nonwoven fabric made of a thermoplastic inelastic resin having a phosphorus content of 1000 ppm or more and 20000 ppm or less is joined to one surface of the reticulated body, the surface of the thermoplastic elastic resin layer is flattened, and the apparent density is 0.01 to 0.2 g / cm ³ flame-retardant reinforcing mesh body, multi-row nozzle with multiple orifices, phosphorus content (Bppm) is soft segment amount (A wt%) 60A + 200 ≦ B ≦ A thermoplastic elastic resin satisfying 100,000 is distributed to each nozzle orifice, and directed downward from the nozzle at a melting temperature 20 to 80 ° C. higher than the melting point of the thermoplastic resin. And a discharge device, and in a molten state, they are brought into contact with each other and fused to form a three-dimensional structure, and a continuous fiber nonwoven fabric made of a thermoplastic inelastic resin having a phosphorus content of 1000 ppm or more and 20000 ppm or less is bonded to one surface of the take-up device. It is a method for producing a flame-retardant reinforcing mesh body which is sandwiched between and cooled in a cooling tank, and a product using the flame-retardant reinforcing mesh body.

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.
It is a ternary block copolymer composed of at least one of polyalkylenediol such as propylene, 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 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,
You can also use a kotatsu that has a polysiloxane-based soft segment 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, the hard segment includes nylon 6, nylon 66, nylon 610, nylon 612,
Polyethylene glycol, polypropylene glycol, polytetramethylene glycol having an average molecular weight of about 300 to 5000 is used as the soft segment in the skeleton of nylon 11, nylon 12, etc. and their copolymerized nylon.
A block copolymer composed of at least one kind of polyalkylenediol such as 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.
The polyurethane-based elastomer is (A) number average molecular weight of 1000 to 60 in the presence or absence of a usual solvent (dimethylformamide, dimethylacetamide, etc.).
00 has a hydroxyl group-terminated polyether and / or polyester, and (B) an organic diisocyanate-based polyisocyanate as a main component.
As a typical example, a polyurethane elastomer in which a chain-extended polyamine having a diamine (C) as a main component is added to a prepolymer which is a group having a hydroxyl group can be exemplified. The polyester or polyether of (A) has an average molecular weight of about 1,000.
To 6000, preferably 1300 to 5000, polybutylene adipate copolyester, polyethylene glycol, polypropylene glycol, polytetramethylene glycol, glycol composed of ethylene oxide-propylene oxide copolymer, etc. Polyalkylenedio-
Are preferred, and as the polyisocyanate of (B),
Although a conventionally known polyisocyanate can be used, an isocyanate mainly composed of diphenylmethane 4,4 ′ diisocyanate may be used, and if necessary, a conventionally known triisocyanate and the like may be added in a small amount. (C)
As the polyamine, a known diamine such as ethylenediamine or 1.2-propylenediamine is mainly used, and if necessary, a trace amount of triamine or tetraamine may be used in combination. These polyurethane elastomers are used alone or
You may use it in mixture of 2 or more types. 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. Since the reticulated body of the present invention contains a phosphorus compound in order 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 to improve heat resistance and durability, if necessary. The antioxidant is preferably a hindered antioxidant, which includes a hindered phenol type and a hindered amine type, and does not contain nitrogen.
It is particularly preferable to add 1% to 5% of a dophenol-based antioxidant to suppress thermal decomposition, since 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.
As described above, it is more preferably 30% by weight or more, preferably 80% by weight or less, and more preferably 70% by weight or less in view of heat resistance and sag resistance. That is, the soft segment content of the component having the function of absorbing vibrations 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. .

In the flame-retardant reticulate material of the present invention, the phosphorus content (Bppm) in the thermoplastic elastic resin is 60A + 200≤B≤10 with respect to the soft segment content (A% by weight).
It is necessary to satisfy the relationship of 0000. If it is not satisfied, the flame retardance is poor, which is not preferable. 100000ppm
If it exceeds the range, the plastic deformation due to the plasticizing effect becomes large and the heat resistance of the thermoplastic elastic resin is deteriorated, which is not preferable. The preferred phosphorus content (Bppm) is the soft segment content (A
Weight%), 30A + 1800 ≦ B ≦ 100,000
And the more preferable phosphorus content (Bppm) is 16A + 2600 with respect to the soft segment content (A weight%).
≦ B ≦ 50000. For flame retardancy, there is a method to add a high level of flame retardancy by adding a large amount of halides and inorganic substances, but when burning, a large amount of toxic halogen gas with a small lethal amount is generated, and there is a problem of poisoning during fire. There is a large damage to the incinerator during incineration, which is not preferable. In the present invention, the halide content is at least 1% by weight or less, preferably the halide content is 0.5% by weight or less, more preferably the halide-free content. As the phosphorus-based flame retardant of the present invention, for example, in the case of a polyester-based thermoplastic elastic resin, a flame-retardant in the hard segment portion during resin polymerization is described, for example, in JP-A-51-82392. [2.3-di (2-hydroxyethoxy) -carbonylpropyl] 9-10-dihydro-
A method of preparing a polyester-based thermoplastic elastic resin in which a carboxylic acid such as 9-oxa-10-phosphaphenalene-10-oxylo is copolymerized as a part of the acid component of the hard segment, or a thermoplastic elastic resin is used in a subsequent step. For example, the flame retardancy can be imparted by adding a phosphorus compound such as the existing chemical substance number (3) -3735. Other flame retardants capable of imparting flame retardancy include various phosphoric acid esters, phosphorous acid esters, phosphonic acid esters (the above phosphoric acid esters containing a halogen element as necessary), or polymers derived from these phosphorus compounds. It can be illustrated. In the present invention, various modifiers, additives, colorants and the like can be added to the thermoplastic elastic resin as needed. The flame-retardant reticulate material of the present invention contains phosphorus in order to impart flame retardancy. The reason is, as described above, from the viewpoint of safety, cyan gas, halogen gas, etc. generated in a fire. The goal is to minimize the lethal dose of toxic gases. Therefore, the combustion gas toxicity index of the flame-retardant reticulate material 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 material and the wadding layer, it is preferable to use a polyester-based thermoplastic elastic resin for recycling without separation.

The filament made of thermoplastic elastic resin constituting the composite 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 The average molecular weight is 500 or more and 5000 or less, particularly preferably 100.
When 0 to 3000 polytetramethylene glycol is copolymerized in an amount of 15 to 70% by weight, more preferably 30 to 60% by weight, the acid component of the hard segment is rigid. When the content of a certain terephthalic acid or naphthalene 2.6 dicarboxylic acid is high, the crystallinity of the hard segment is improved, the plastic deformation is less likely to occur, and the heat resistance and sag resistance are improved, but the melting point is further increased after the melt heat bonding. When the annealing treatment is performed at a temperature lower by at least 10 ° C. or more, the heat resistance and sag resistance is further improved. If annealing is performed after applying compressive strain, heat resistance and sag resistance are further improved.
The endothermic peak is more clearly expressed in the melting curve measured by a differential scanning calorimeter of the linear structure of the network structure treated as described above at a temperature of room temperature or higher and melting point or lower. 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. The flame-retardant network of the present invention contains a phosphorus content of 1000 ppm or more and 20000 ppm or less in the thermoplastic non-elastic resin. 1
If it is less than 000 ppm, the flame retardance is insufficient, and
If it exceeds 000 ppm, the plastic deformation due to the plasticizing effect becomes large and the heat resistance of the thermoplastic non-elastic resin is deteriorated, which is not preferable. Preferable phosphorus content is 2000 ppm or more 100
00ppm or less, more preferably 3000ppm or more 8
It is 000 ppm. Flame retardance is a method of adding a large amount of halides and inorganic substances to impart a high degree of flame retardance,
When burned, a large amount of toxic halogen gas with a small lethal amount is generated, and there is a problem of poisoning at the time of fire, and when incinerated, the incinerator is greatly damaged, which is not preferable. Particularly, vinyl chloride has a self-extinguishing property, but when burned, a large amount of toxic gas is generated, so that it is not preferable to use it in the present invention. In the present invention, the halide content is at least 1% by weight or less, preferably the halide content is 0.5% by weight or less, more preferably the halide-free content. As the phosphorus-based flame retardant of the present invention, for example, in the case of a polyester-based thermoplastic non-elastic resin, as a flame retardant at the time of resin polymerization, it is described in, for example, JP-A-51-82392.
Polyester system in which carboxylic acid such as [2.3-di (2-hydroxyethoxy) -carbonylpropyl] 9,10-dihydro-9, oxa, 10 phosphaphenalene, 10 oxylo is copolymerized as a part of acid component A method of using a thermoplastic non-elastic resin or a thermoplastic non-elastic resin in a later step,
For example, it is possible to impart flame retardancy by adding a phosphorus compound such as existing chemical substance number (3) -3735. Other flame retardants capable of imparting flame retardancy include various phosphoric acid esters, phosphorous acid esters, phosphonic acid esters (the above phosphoric acid esters containing a halogen element as necessary), or polymers derived from these phosphorus compounds. It can be illustrated. In the present invention, various modifiers, additives, colorants and the like can be added to the thermoplastic elastic resin as needed. The flame-retardant reticulate material of the present invention contains phosphorus in order to impart flame retardancy. The reason is, as described above, from the viewpoint of safety, cyan gas, halogen gas, etc. generated in a fire. The goal is to minimize the lethal dose of toxic gases. Therefore, the combustion gas toxicity index of the flame-retardant reticulate material 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 material and the wadding layer, it is preferable to use a polyester-based thermoplastic elastic resin for recycling without separation.

The present invention is a phosphorus-containing thermoplastic elastic resin in which continuous filaments having a fineness of 100,000 denier or less are meandered and brought into contact with each other to form a three-dimensional solid structure in which most of the contact portions are fused. A continuous fiber non-woven fabric made of a phosphorus-containing thermoplastic non-elastic resin is joined to the back surface of the layer network, and the surface of the thermoplastic elastic resin layer is flattened to a density of 0.01 g /
It is a flame-retardant reinforced reticulate body of cm ³ to 0.2 g / cm ³ . Flame retardant reinforcing mesh of the present invention is fused integrally to form a three-dimensional structure the majority of the continuous filament made of phosphorus-containing thermoplastic elastomeric resin contact portion is fused, the surface taking over In the device
Flattened by sandwiching (hereinafter, substantially flat
Sometimes referred to as Since a continuous fiber non-woven fabric made of phosphorus-containing thermoplastic non-elastic resin is bonded to the back surface, most vibrations are absorbed and damped by the vibration absorption function of the thermoplastic elastic resin. , Even when a large deformation stress is locally applied, the surface of the reinforcing mesh is substantially flattened and most of the contact portion is fused, and the back surface is a continuous fiber non-woven fabric bonded to the back surface. , Reinforcing mesh is received on the surface of the reinforcing mesh to disperse the deforming stress, and the filament made of thermoplastic elastic resin forms a three-dimensional three-dimensional structure and is fused and integrated so that the entire structure is easily deformed. Then, the deformation stress is absorbed by energy conversion, and when the deformation stress is released, the rubber elasticity of the thermoplastic elastic resin has a function of easily recovering the original shape, so that the fatigue resistance is good. Since the known mesh-like body composed of filaments made only of non-elastic resin does not have rubber elasticity, it is plastically deformed by compressive deformation and does not recover, resulting in poor durability.
When the surface of the reinforced mesh is not substantially flattened, when a local external force is applied to the surface, stress concentration may occur selectively up to the filaments and bonding points of the surface. With respect to such external force, fatigue due to stress concentration may occur and sag resistance may decrease. When the filaments are made of thermoplastic elastic resin, the entire structure is deformed in the three-dimensional structure portion, so stress concentration is relieved. However, in the non-elastic resin, stress is concentrated at the bonding point and structural damage is caused. It will not occur and will not recover. 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 adhesion point serves as a stress transmission point, so that significant stress concentration occurs at the adhesion point and structural destruction occurs.
JP-A-61-137732, WO91-1903
It is not preferable because it has poor heat resistance and durability like the structure disclosed in Japanese Patent Publication No. 2 or the like. 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. The function of the cushion material is that the cushion layer is a layer that thickens the basic fineness and makes it a little harder and is responsible for body shape maintenance, and a layer with a slightly higher density with a component with good vibration damping properties that absorbs vibration and blocks vibration. Configure and
The surface layer is a slightly soft layer with a slightly finer fineness and a larger number of filaments, which gives a comfortable touch to the buttocks due to the appropriate subsidence to evenly disperse the buttocks pressure distribution and cannot 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. Further, the surface in contact with the frame is reinforced with a reinforcing material to be integrated with the cushion layer to form a surface (reinforcing layer) for supporting the cushion material, and by maintaining the shape of the cushion, a comfortable and durable seat can be obtained. . The flame-retardant reinforcing network of the present invention is also intended to provide a cushioning material having the functions of both the cushion layer and the reinforcing layer. As a reinforcing material for the cushioning layer, a thin thermoplastic resin having a high reinforcing effect is strong. Continuous fiber nonwoven fabric made of non-elastic resin is bonded and integrated. If it is not joined to the cushion layer, the reinforcing effect of the cushion layer will be lost, which is not preferable. If the reinforcing material is a monofilament non-woven fabric, the reinforcing effect per thickness of the non-woven fabric is poor and the weight becomes heavy, which is not preferable. Preferred non-woven fabric of the present invention is a spunbonded nonwoven fabric having a basis weight is ^{20g / m 2 ~500g / m 2} . If the basis weight is less than 20 g / m ² , the reinforcing effect will be poor and 500 g
If it exceeds / m ² , the moldability is deteriorated, which is not preferable. It is preferable that the cushion layer and the reinforcing layer are made of polyester, for example, because it is not necessary to separate them when the seat is recycled. Thus, continuous filaments made of a thermoplastic elastic resin having good vibration absorption and elastic recovery form a three-dimensional three-dimensional structure in which most of the contact portions are fused, and the fusion is integrated so that the surface is substantially flat. Reinforced reticulate body in which a reinforcing layer is integrally joined to the cushion layer and the back surface of the cushion layer,
The surface layer receives deformation stress on the surface and improves the dispersion of stress,
The stress applied to each individual line is reduced, the entire structure supported by the reinforcing layer deforms to absorb the deformation stress, and also improves the cushioning property to support the buttocks, recovers when the stress is released, and The cushion layer made of a thermoplastic elastic resin having good vibration absorption and elastic recovery absorbs the vibration transmitted from the body 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 the filament made of a thermoplastic elastic resin having good vibration absorption and elastic recovery forming the reinforced mesh 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 filament made of the thermoplastic elastic resin 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 is lowered, and thus the number of constituents is lowered. It is 50,000 denier or less so as not to impair the denseness of the structural surface. More preferably, it is at least 500 denier and at most 10,000 denier. The average apparent density of the reinforced reticulate body of the present invention is 0.
005g / cm ³ in repulsive force is lost, there is a case where vibration absorption capacity and deformation stress absorption capacity is less likely to express insufficient and becomes cushioning function, comfort too high repulsive force at 0.25 g / cm ³ or more May deteriorate, so that the function as a cushioning body is easily expressed by utilizing the vibration absorbing ability and the deformation stress absorbing function, and is 0.01 g / cm ³ or more and 0.20 g / cm ³ or less, preferably 0.03 g. /
It is not less than cm ^{3 and not} more than 0.08 g / cm ³ . In the present invention, a method of forming 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 as a preferred embodiment. The thickness of the reinforced 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. The thickness that can be achieved is 10 mm or more, and more preferably 20 mm or more.

The cross-sectional shape of the filament of the flame-retardant reinforced net-like body of the present invention is not particularly limited, but a preferable anti-compression property (repulsive force) and touch can be imparted by forming a hollow cross section or a modified cross section. Therefore, it is particularly preferable. 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 capable of imparting preferable anti-compression property (repulsive force) and touch, there is a method of forming the filament of the laminated network 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, in particular, 50% or more of the linear surface is made of a soft thermoplastic elastic resin in order to obtain a three-dimensional structure in which vibration and deformation stress that cannot be energy-converted even if the cushion layer is largely deformed can be energy-converted and recovered. And a side-by-side structure and a combination thereof. 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 a thermoelastic resin having a small content of soft segments exhibiting anti-compression properties. Composed of a plastic elastic resin, it can give a comfortable touch to the buttocks due to an appropriate depression. With the side-by-side structure, the melt viscosity of a thermoplastic elastic resin with a high soft segment content that facilitates energy conversion of vibration and deformation stress is lower than the melt viscosity of a thermoplastic elastic resin with a low soft segment content that exhibits anti-compression properties. A structure in which the proportion of thermoplastic elastic resin occupying a linear surface and having a large amount of soft segment is increased (metaphorically, a structure in which a thermoplastic elastic resin is arranged in an eccentric sheath-core structure) It is particularly preferable that the ratio of the thermoplastic elastic resin having a large soft segment content occupying the linear surface is 80% or more, and most preferably the thermoplastic elastic resin having a large soft segment content occupying the linear surface. Is a score with the ratio of 100% as 100%. 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.

The flame-retardant reinforcing mesh formed of filaments made of thermoplastic elastic resin has a substantially flat surface so that most of the contact portions are fused and the back surface has a reinforcing effect. The continuous fiber non-woven fabric made of high thermoplastic non-elastic resin is bonded and integrated, and both sides are substantially flattened, so the flame-retardant reinforcing net and other nets, non-woven fabric, knitted fabric, hard cotton Other heat-adhesive components (heat-bonded non-woven fabric, heat-bonded fiber, heat-bonded film, heat-bonded resin, etc.) and adhesives are used to bond heat-bonded materials such as film, foam, metal, etc. To obtain products such as vehicle seats, ship seats, vehicle beds, ship seats, hospital beds, and other commercial and household beds, furniture chairs, office chairs, futons, etc. as an integrated laminated structure Since the contact area with the body surface can be widened,
It is possible to obtain a product having a wide adhesion area and strong adhesion and good adhesion durability. In this case, since a flame-retardant integrally laminated structure can be obtained by using a flame-retardant heat-bonded body, the present invention is a particularly preferred embodiment. In addition, by performing the above-mentioned pseudo crystallization treatment at any stage from the flame retardant reinforced reticulated body forming stage to commercialization, the filaments made of the thermoplastic elastic resin in the structure are measured with a differential scanning calorimeter. It is more preferable that the 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 reinforced reticulate body of the present invention have a composite structure, a preferable heat adhesion function can be imparted.
For example, in the sheath core structure, a thermoplastic elastic resin containing a large amount of soft segment that facilitates energy conversion of vibration and deformation stress of the sheath component is used as a heat-adhesive component, and a soft segment containing the compressive property of the core component is contained. A thermoplastic adhesive resin having a small amount is used as a high melting point component to have a function of holding a net-like shape, and the melting point of the thermal bonding component is lower than the melting point of the high melting point resin by 10 ° C. or more. The function of can be added. In addition, it is also preferable to laminate the surface layer of the flame-retardant reinforcing network of the present invention with a low-melting point thermoplastic elastic resin having a high soft segment content that facilitates energy conversion of vibration and deformation stress as a heat-adhesive component. Adhesive function can be added. The melting point of the heat-bonding component that forms the filaments in the reticulate body, which is preferable for exhibiting the heat-bonding function, is 15 ° C to 50 ° C lower than the melting point of the high-melting point component, and more preferably 20 ° C to 40 ° C lower melting point. is there. The flame-retardant reinforcing mesh body of the present invention having a heat-bonding function has a substantially flat surface, and most of the contact portions are fused,
Since the contact area with the surface of the object to be heat-bonded, such as a mesh, a non-woven fabric, a knitted woven fabric, a hard cotton, a film, a foam, and a metal, can be widened, the heat-bonded area can be widened, and a new molded body and vehicle can be firmly heat-bonded. Seats, seats for ships, vehicles, ships, hospital beds, and other commercial and household beds, furniture chairs, office chairs,
You can get futon products. 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. According to the manufacturing method of the present invention, the soft segment amount (A% by weight) and the phosphorus content (Bppm) are 60 A compared with the multi-row nozzle having a plurality of orifices.
A thermoplastic elastic resin satisfying the relationship of + 200 ≦ B ≦ 100,000 is distributed to each nozzle orifice, and at a melting temperature higher than the melting point of the thermoplastic resin by 20 ° C. or more and less than 80 ° C.,
A continuous fiber non-woven fabric made of a thermoplastic non-elastic resin having a phosphorus content of 1000 ppm or more is bonded to one surface while discharging downward from the nozzle, contacting each other in a molten state and fusing to form a three-dimensional structure. This is a method for producing a flame-retardant reinforced mesh body which is sandwiched by a take-up device and cooled in a cooling tank. In the present invention, as described above, a method of adding a phosphorus compound at the time of polymerization and copolymerization and a method of adding a phosphorus compound after polymerization and mixing and kneading can be performed. The mixing and kneading can be performed by using a twin-screw kneading extruder or a single-screw extruder having a kneading function such as a dullage, a pin, or the like, which can be performed before melt extrusion or during melt extrusion. If a fixed amount of flame retardant can be supplied, kneading at the time of melt extrusion is the cheapest method. Solid flame retardant can be easily mixed with resin and supplied to the extruder so as not to segregate.However, liquid flame retardant is supplied to the kneading extruder in a fixed amount while liquid flame retardant is also measured separately. It is most desirable to take the method of kneading while supplying. For example, a method of quantitatively supplying a liquid flame retardant through a vent hole of a twin-screw kneading extruder can be exemplified. With such a method, the soft segment amount (A% by weight) and the phosphorus content (Bppm) are 6
A phosphorus content satisfying the relation of 0A + 200 ≦ B ≦ 100,000 is added to the thermoplastic elastic resin, and then melt extruded to form a reticulated body. The molten phosphorus-containing thermoplastic elastic resin is supplied to a multi-row nozzle having a plurality of orifices and discharged downward from the orifices. The melting temperature at this time is 20 ° C. to 80 ° C. higher than the melting point of the thermoplastic elastic resin. If the melting temperature is higher than 80 ° C. higher than the melting point of the thermoplastic elastic resin, thermal decomposition becomes remarkable and the rubber elastic properties of the thermoplastic elastic resin deteriorate, which is not preferable. On the other hand, unless the temperature is higher than the melting point of the thermoplastic elastic resin by 10 ° C. or more, melt fracture occurs and normal filament formation cannot be performed.
When they are contacted and fused while forming a loop after discharge, the temperature of the filaments may be lowered and the filaments may not be fused to each other, which may result in insufficient adhesion to form a reticulated body. Thus, in the present invention, the continuous linear nonwoven fabrics are bonded to one surface while the molten linear shapes are brought into contact with each other and fused to form a three-dimensional structure, so that the molten linear shapes can be fused to each other. If the temperature is not higher than 5 ° C, the non-woven fabric and the linear fusion bonding will be insufficient. The preferred melting temperature is 25 ° C to 60 ° C above the melting point
℃ higher temperature, more preferably 30 ℃ to 40 ℃ above the melting point
It is a high temperature. 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. The hollow section has a hollow ratio of 8
If it exceeds 0%, the cross section tends to be crushed, so that it is preferably 10% or more and 70% or less, more preferably 20% or more and 60% or less so that the effect of weight reduction can be exhibited. 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. Also, if the pressure loss difference at the time of discharge is given by changing the cross-sectional area of the orifice, the principle that the discharged amount of molten thermoplastic elastic resin extruded from the same nozzle at a constant pressure becomes smaller for the orifice with larger pressure loss, is used. It is possible to manufacture a reticulated 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 longitudinal direction. Then, discharge 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, while continuously feeding a continuous fiber non-woven fabric made of a thermoplastic non-elastic resin on one side to form a three-dimensional solid in a molten state. Both sides of the net-like structure joined to the structure and joined to the reinforcing layer in the molten linear state are sandwiched by a take-up net, and the twisted discharge filaments on the surface of the net-like body are bent by 45 ° or more to be deformed. The surface is flattened at the same time, and at the same time the contact points with the unbent discharge line are adhered to form the structure, and then the cooling medium is continuously used (usually using room temperature water can increase the cooling speed, which is cost-effective. However, it is cheaper, which is preferable), and is rapidly cooled to obtain the flame-retardant reinforced reticulated body of the present invention having a three-dimensional solid reticulated structure. 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 flame-retardant reinforcement mesh is the opening width of the take-up net that sandwiches both surfaces of the three-dimensional structure in the molten state (the distance between the take-up nets).
Depends on. In the present invention, the opening width of the take-up net is set to 5 mm or more for the above reason. 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. Placed on the cooling medium, a pair of take-up conveyors with adjustable spacing sandwiches the molten discharge filaments and holds them together to fuse the portions that are in contact with each other and to bond them together with the continuous fiber nonwoven fabric that is continuously supplied. When it is attached and continuously drawn into a cooling medium to form a net-like structure by solidification, by adjusting the interval of the conveyor,
The thickness can be adjusted while the fused network is in a molten state, and a desired thickness can be obtained. If the conveyor speed is too high, the formation of contact points may be insufficient, or the contact point may be cooled until the fusion point is sufficiently formed, resulting in insufficient fusion of the contact portion. 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. In addition, if the supply speed of the continuous fiber nonwoven fabric continuously supplied is not the same as the surface speed of the take-up conveyor, pulling or loosening occurs and the reinforcing function of the cushion is deteriorated, which is not preferable. As a preferred method of the present invention, after cooling once, a pseudo crystallization treatment by annealing is performed at a temperature of at least 10 ° C. or lower than the melting point of the thermoplastic elastic resin in any step leading to product formation by integrally molding and flame retardance. A more preferred method is to obtain a sex-reinforced network or product. The pseudo-crystallization treatment temperature is at least 10 ° C. lower than the melting point (Tm), and the tan α
The temperature is higher than the dispersion rising temperature (Tαcr). By this treatment, the heat-resistant sag resistance is remarkably improved as compared with the one having no endothermic peak (having no endothermic peak) having an endothermic peak below the melting point. The preferred pseudo-crystallization treatment temperature of the present invention is (Tαcr + 10 ° C) to (Tm-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. When the drying step is performed after cooling once, the pseudo crystallization treatment can be performed at the same time 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 using the cushion of the flame-retardant reinforcing net according to the present invention, 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 impart a soft touch, moderate depression and bulging with tension, it is preferable to have a low density and fine fineness and a fine loop diameter. Low frequency, moderate hardness and linear change of hysteresis at the time of compression to improve body retention, and to maintain durability, medium density, thick fineness,
It is preferable to have a structure in which a layer having a rather large loop diameter and a layer having a low density, a fine fineness, and a fine loop diameter are laminated and integrated.
Further, it can be used for vehicle seats, boat seats, beds, chairs, furniture, etc. by molding it into a shape suitable for the purpose of use by using a molding die or the like to the extent that the three-dimensional structure is not impaired. Of course, it is also possible to use it in combination with other materials such as a different mesh body, a hard cotton cushion material composed of a short fiber aggregate, a non-woven fabric or the like so as to meet the required performance in relation to the application. In addition, other than the resin manufacturing process, the molded product is processed from the manufacturing process to the extent that performance is not deteriorated, and at any stage of commercialization, it becomes flame retardant, insecticidal, antibacterial, heat resistant, water / oil repellent, colored, aroma, etc. It is possible to perform the processing such as the addition of chemicals to add the function.

[0018]

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. 1. Melting point (Tm) and endothermic peak below melting point TA50, DSC50 type differential thermal analyzer manufactured by Shimadzu Corp. was used to measure the endothermic peak (melting peak) from the endothermic curve measured at a heating rate of 20 ° C / min. -H) The temperature was determined. 2. Heat the Tαcr polymer to a melting point of + 10 ° C to a thickness of approximately 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 ′). 3. Apparent density The sample is cut into a size of 15 cm x 15 cm, the heights at four locations are measured, the volume is calculated, and the weight of the sample is divided by the volume. (Average value of n = 4) 4. Fineness of the filaments Each filament portion is cut out from 10 locations, embedded in acrylic resin, the cross section is cut out to prepare a section, and a cross-section photograph is obtained. 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] × 9000000 5. Whether or not the fusion-bonded sample is fused by visual judgment Is it not possible to pull the fibers adhering together by hand to separate them? It is judged that something that does not come off is fused. 6. Reinforcing effect Cut a sample into a size of 30 cm x 30 cm, diameter 24 cm
The degree of damage of the sample by dropping the iron ball 100 times with 0.5Hz cycle on the center of the sample with the device that the iron ball with the chain connected to the Was judged according to the following criteria. ⊚: No damage. ○: Slight damage.
Δ: The structure was partially destroyed. X: The structure is almost destroyed. (Average value of n = 3) 7. Heat resistance and durability (residual strain at 70 ° C) The sample was cut into a size of 15 cm x 15 cm, compressed by 50%, left in dry heat at 70 ° C for 22 hours, and then cooled to reduce compression strain. Except for this, the thickness (b) after standing for 1 day is calculated, and is calculated from the thickness (a) before the treatment by the following equation, that is, (ab) / a × 100. Unit% (average value of n = 3) 8. Cyclic compressive strain sample is cut into a size of 15 cm × 15 cm, and it is 50% in a RH chamber at 25 ° C. and 65% at 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) 9. Flame retardance According to the F-MVSS302 method, those satisfying the flame retardancy standard (extinguishing flame in 60 seconds or less) were judged as pass, and those not satisfying it were judged as fail. 10. Combustion gas toxicity index Shown as an integrated value of values obtained by dividing each combustion gas amount (mg) measured by the method of JIS-K-7217 by the lethal dose (mg / 10 liter) when inhaled for 10 minutes. 11. Sedentary comfort Using a known composite spinning machine, the thermoplastic elastic resin A-1 to be described later is individually melted so as to become the sheath component and A-2 as the core component, and distributed immediately before the orifice. The spinning temperature was 245, with each discharge rate being 50/50 weight ratio and 1.6 g / min per hole (0.8 g / min: 0.8 g / min).
At a spinning rate of 3500 m / min, the yarn having a fineness of 4.1 denier and a shrinkage rate of 8% at a dry heat of 160 ° is converged into a tow-shaped crimp. Is given, 64
It was cut into mm to obtain a heat-bonding fiber made of a thermoplastic elastic resin having a cross section of sheath core. As the base material fiber, PET having an intrinsic viscosity of 0.63 and 0.56 was distributed at a weight ratio of 50/50 by a conventional method, and the discharge amount per single hole was 3.0 g / min (1.5 g / min.
Min: 1.5 g / min) at a spinning temperature of 285 ° C., discharged from a C type orifice, composite spinning at a spinning speed of 1300 m / min, and then drawn in two stages at 70 ° C. and 180 ° C. to obtain a drawn yarn. A three-dimensional crimped yarn having a denier of 6 denier and an initial tensile resistance of 38 g / denier was obtained by cutting into 64 mm and causing crimping at a dry heat of 160 ° C. The resulting heat-bonded fiber (30% by weight) and the base material fiber (70% by weight) were mixed to form an opener.
A web obtained by pre-opening with a card and opening with a card and having a basis weight of 500 g / m ² was laminated to form a carded web on the surface side of a multi-layer mesh body cut into the shape of a bucket sheet. The apparent bulk density of the cushion is 0.05 g / cm ³
To be laminated into a thermoforming female mold, compressed with an oyster mold, and packed and heat-bonded with hot air at 200 ° C for 5 minutes to form a bucket sheet-shaped cushion. Cover the side of polyester moquette consisting of, and set it on the seat frame to create a seat with 4 side seats and 6 side backs and 30 ° C RH7
5% A paneler was allowed to sit on the seat created in the room and the following evaluation was 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. .

[0021]

[Table 1]

Orifice shapes having a staggered arrangement with a hole-to-hole pitch of 10 mm in the width direction and a hole-to-hole pitch of 5 mm on the 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 existing chemical substance number (3) -3735 was added as a flame retardant to the obtained A-1 and A-2 as a flame retardant while supplying them in a fixed amount separately in an extruder having two kneading functions, and a phosphorus content of 10,000 p
It is added so as to be pm and melt-kneaded, and A-1 and A-
Dispense 2 into the rear face of the orifice so that A-1 is the sheath component and A-2 is the core component immediately before the orifice (sees / core: 50/50 weight ratio), and a single hole is made at 245 ° C. A discharge amount of 2.0 g / min per discharge is made below the nozzle, cooling water is arranged 10 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 on the water surface. While arranging so that a part of it is exposed and nipping it on one conveyor, dimethyl terephthalic acid and 10 [2.3 · di (2-hydroxyethoxy) -carbonylpropyl] 9 · 10 · 10 as an acid component slit into a width of 50 cm. Dihydro ・ 9 ・ oxa ・ 10 phosphaphenalene ・ 10
Relative viscosity of 1.0 obtained by charging oxylo with a phosphorus content of 5000 ppm and a small amount of 1.4BD as a glycol component with a small amount of catalyst, transesterifying by a conventional method, and then polycondensing while heating and depressurizing. Of a copolymerized PBT fiber of 1
00 g / m ² of the needle-punched spunbonded nonwoven fabric was continuously supplied from one side, and then the discharge line in the molten state was taken out, and the spunbonded nonwoven fabric was also fused while melting the contact portion. One side per minute while sandwiching both sides of a laminate having a net-like structure formed of spunbonded nonwoven fabric on one side
of the flame-retardant reinforced reticulate body obtained by pulling it into cooling water at 25 ° C. at a speed of m to solidify it, then performing pseudo-crystallization treatment for 20 minutes in a hot air dryer at 100 ° C., and then cutting it into a predetermined size. The characteristics are shown in Table 2. The flame-retardant reinforced reticulate body of Example 1 has a triangular rice ball-shaped hollow cross section having a sheath core structure, a hollow ratio of 40%, a fineness of 9000 denier, and a phosphorus content of 10
It is formed by filaments of 000 ppm (60 A + 200 = 2780 ppm), and the average apparent density is 0.047 g /
It was cm ³ . Example 1 has a flame-retardant reinforced net structure that makes use of the characteristics of the soft elastic resin, and thus has a cushioning function that is excellent in heat resistance, durability at room temperature, and sitting comfort, and is also flame-retardant and has a combustion gas toxicity index. It is a cushioning material with low safety and a reinforcing effect that can withstand practical use. It can be seen that the seat created for evaluation also has excellent performance.

[0023]

[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.
Properties of the elastic composite reticulate body obtained in the same manner as in Example 1 except that a flame retardant was added to A-3 so that the phosphorus content was 8000 ppm, and a nozzle having a circular cross section with an orifice hole shape of φ1 mm was used. Is shown in Table-2. The fineness of the solid round cross section is 9000 denier and the phosphorus content is 8000 ppm (60
A + 200 = 3320 ppm), and the average apparent density of the reticulate body was 0.046 g / cm ³ . As is clear from Table 2, Example 2 has practically usable heat resistance and durability at room temperature, has a cushioning function with excellent sitting comfort, is flame-retardant, and has a low combustion gas toxicity index. It was a cushioning material with high properties, and its reinforcing effect could be used practically. It can be seen that the seat created 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.

[0026]

[Table 3]

A flame retardant was added to the obtained thermoplastic elastic resin B-1 only so that the phosphorus content would be 12000 ppm.
Table 2 shows the properties of the elastic composite network obtained in the same manner as in Example 1 except that the melting temperature was 220 ° C. In Example 3, the cross-sectional shape of the filament is a triangular rice ball-shaped hollow cross-section and the hollow ratio is 41.
%, Fineness 9800 denier, phosphorus content 12000 pp
The average apparent density of the mesh body formed of filaments of m (60A + 200 = 2480 ppm) and joined to the reinforcing layer having a phosphorus content of 12000 ppm was 0.047 g / cm ³ . Example 3 is a flame-retardant reinforced reticulate body that takes advantage of the characteristics of soft urethane, has a cushioning function that is excellent in heat resistance, durability at room temperature, and sitting comfort, is flame-retardant, and has a low toxicity index of combustion gas. It is a cushion material with high safety, and the reinforcing effect was that it could withstand practical use. It can be seen that the seat created for evaluation is also excellent.

COMPARATIVE EXAMPLE 1 The phosphorus content was adjusted to 5000 ppm so that the content was 10 [2.3.
Di (2-hydroxyethoxy) -carbonylpropyl]
Polyethylene terephthalate (PET) having an intrinsic viscosity of 0.63 copolymerized with 9,10, dihydro, 9, oxa, 10 phosphaphenalenes, 10 oxylo is melted at 28
The fineness of the filament obtained in the same manner as in Example 2 was 8800 deniers except that the temperature was 5 ° C. and the pseudo-crystallization treatment was not performed.
And phosphorus content is 5000ppm, phosphorus content 5000p
The apparent density of the mesh body joined to the pm reinforcement layer is 0.04.
Table 2 shows the characteristics of the flame-retardant reinforced reticulate body of 7 g / cm ³ . Comparative Example 1 is an example in which the structure is broken in the test of the reinforcing effect by the cushioning material which is hard and uncomfortable to sit in because it is flame-retardant, but the heat resistance and durability are poor because it is a reticulated body made of thermoplastic inelastic polyester. .

Comparative Example 2 A filament obtained in the same manner as in Example 2 except that the continuous fiber non-woven fabric used for the reinforcing layer was not used and the pseudo-crystallization treatment was not performed had a fineness of 9000 denier and a phosphorus content of 8000ppm (6
0A + 200 = 3320ppm), apparent density is 0.0
The net-like body with a reinforcing layer of 44 g / cm ³ passed the flame retardancy and had a good sitting comfort, but was slightly inferior in heat resistance and durability.
Since there is no reinforcing material, the structure was destroyed in the test of the reinforcing effect.

Comparative Example 3 10 [2.3-di (2-hydroxyethoxy) -carbonylpropyl] 9 so that the phosphorus content was 100 ppm
Obtained in the same manner as in Example 2 except that the continuous fiber nonwoven fabric composed of PBT copolymerized with 10-dihydro-9-oxa-10-phosphaphenalene-10-oxylo was used as a reinforcing layer and no pseudo-crystallization treatment was performed. The fineness of the streaks is 9000
Denier and phosphorus content is 8000ppm (60A + 200
= 3320 ppm), the net-like body joined to the reinforcing layer having a phosphorus content of 100 ppm and having an apparent density of 0.048 g / cm ³ has good sitting comfort, but is slightly inferior in heat resistance and durability and is difficult to reinforce. Since it is not combusted, flame retardancy is an example of failure.

Comparative Example 4 A filament was obtained in the same manner as in Example 2 except that a flame retardant was added to A-3 so that the phosphorus content was 200 ppm and the pseudo-crystallization treatment was not performed. Denier and phosphorus content is 200ppm (60A + 200 = 3320pp
m), a net-like body having an apparent density of 0.048 g / cm ³ joined to a reinforcing layer having a phosphorus content of 5000 ppm has good sitting comfort, but is slightly inferior in heat resistance and durability, and the net-like body is flame-retardant. Flame retardancy is an example of failure because it has not been converted.

Comparative Example 5 A discharge amount of 210 g / min, a take-up conveyor net placed 5 cm below the nozzle surface, and a take-up speed of 1.2 m / min. The fineness obtained in the same manner as in Example 2 is 1800 denier and the phosphorus content is 9000.
A reticulate body having an average apparent density of 0.09 g / cm ³ in which a reinforcing layer having a phosphorus content of 5000 ppm is joined to a reticulate body of ppm (60A + 200 = 3320 ppm) passes flame retardancy, but the density is too low. This is an example of a cushioning material that is extremely inferior in sitting comfort, has insufficient heat resistance and durability, and has poor shape retention of the reinforcing material.

Comparative Example 6 Obtained in the same manner as in Example 2 except that the discharge amount per single hole was 3 g / min, the take-up conveyor net speed was 0.3 m / min, and no pseudo-crystallization treatment was performed. Streak fineness of 13
000 denier and phosphorus content of 9000ppm (60A
+ 200 = 3320ppm) A-3 layer has a phosphorus content of 50
The average apparent density when the reinforcing layer of 00 ppm is joined is 0.
The 21 g / cm ³ mesh is flame-retardant, but has a high apparent density, which makes it slightly inferior to sitting comfort, and is a cushioning material with insufficient heat resistance and durability. is there.

Comparative Example 7 Using a nozzle having a diameter of 2 mm and a staggered arrangement with a hole-to-hole pitch of 10 mm in the width direction and a hole-to-hole pitch of 20 mm on the effective surface of a nozzle having a width of 50 cm and a length of 5 cm, a single hole was used. The fineness of the filaments obtained in the same manner as in Comparative Example 2 was 113 except that the discharge rate was 25 g / min and the take-up conveyor net was placed 30 cm below the nozzle surface and the rate was 1 m / min.
Phosphorus content of 9000 denier and 9,000 ppm (60 A +
200 = 3320ppm) A-3 layer has a phosphorus content of 500
The average apparent density when the reinforcing layer of 0 ppm is joined is 0.1
The 5 g / cm ³ mesh is flame-retardant, but its fineness is remarkably thick and it has density unevenness, so it is a cushioning material that has poor heat resistance and durability, and is somewhat uncomfortable to sit on. This is an inferior example.

Comparative Example 8 The linear fineness obtained in the same manner as in Example 2 was 9000, except that the take-up conveyor net on the side where the spunbonded nonwoven fabric was not supplied was used and the surface of the take-up conveyor was uneven. Denier phosphorus content 9000ppm (60A +
Since 200 = 3320ppm) average apparent density of the mesh-like body of 0.048 g / cm ³ to A-3 layer and the reinforcing layer are integrated fused phosphorus content 5000ppm of the surface of the mesh body has become uneven, This is an example of a cushioning material which has a low apparent density but is inferior in durability, insufficient thermal bonding, gives a feeling of foreign matter to the buttocks and is uncomfortable to sit on, and inferior in shape retention of the reinforcing material.

Comparative Example 9 Example 2 was repeated except that the take-up conveyor net was placed 60 cm below the nozzle surface and the pseudo-crystallization treatment was not performed after the take-up conveyor net was taken.
Table 2 shows a part of the properties of the reticulate body obtained by the same method as described above.
In addition, since the adhesive state is poor and the non-woven fabric does not adhere and the shape retention is poor, the repulsive force at 50% compression, apparent density, reinforcing effect, residual strain at 70 ° C., repeated compressive strain, and sitting comfort are not evaluated. . Comparative Example 9 is an example that is not suitable for a cushioning wadding layer because the shape is not fixed.

Reference Example 1 A nozzle having a width of 50 cm and a length of 5 cm and having an orifice diameter of 1 mm in a staggered arrangement with a hole-to-hole pitch of 5 mm in the width direction and a hole-to-hole pitch of 5 mm in the length direction on a nozzle effective surface of 22 mm was used to discharge 22 g. /
The fineness of the filament obtained in the same manner as in Comparative Example 2 was 92 denier, except that the take-up conveyor net was placed 5 cm below the nozzle surface and the take-up was carried out at 0.2 m / min. Phosphorus content is 9000ppm (60A + 200 = 3320pp
The reticulate body having an average apparent density of 0.015 g / cm ³ in which a reinforcing layer having a phosphorus content of 5000 ppm is joined to the A-3 layer of m) has flame retardancy, but has a slightly poor heat resistance and durability, and has a fineness. This is an example of a cushioning material whose seating comfort is remarkably deteriorated due to its extremely thin shape, and the shape retention of the reinforcing material is also poor.

Reference Example 2 A filament was obtained in the same manner as in Example 2 except that a flame retardant was added to A-3 so that the phosphorus content was 110000 ppm and the pseudo-crystallization treatment was not performed. Denier,
Phosphorus content is 110000ppm (60A + 200 = 33
20 ppm), a net body having an apparent density of 0.048 g / cm ³ of a net body joined with a reinforcing layer having a phosphorus content of 5000 ppm is a thermoplastic elastic resin by adding too much flame retardant to the A-1 layer. This is an example of an inferior cushioning material that is inferior in sitting comfort, heat resistance, and durability because the characteristics are remarkably deteriorated.

Reference Example 3 Copolymerized to have a phosphorus content of 11,000 ppm
Example except that the strong layer was used and the pseudo-crystallization treatment was not performed
The fineness of the filament obtained in the same manner as in No. 2 is 9000 denier and phosphorus.
Content is 8000ppm (60A + 200 = 3320p
pm), joined with a reinforcing layer having a phosphorus content of 11000 ppm
Apparent density of mesh is 0.048g / cm ³The net of
It is comfortable to sit on and flame-retardant, but the reinforcement layer contains many flame-retardants.
If added too much, the properties of the thermoplastic inelastic resin have deteriorated.
Therefore, the heat resistance and durability are slightly inferior and there is no reinforcement effect.
Here is an example.

Example 5 The composite reticulate body obtained in Example 1 was cut into a length of 120 cm,
On both sides, 30 pieces of Toyobo's thermal bonding fiber 4-64-TE5 and Toyobo's three-dimensional crimp staple 10-64-745 are used.
A card web obtained by mixing and opening at a weight ratio of / 70 is laminated and compressed on the surface side so that the total weight is 0.05 g / cm ^3, and thermoformed integrally with hot air at 200 ° C. for 10 minutes to obtain a thickness of 7 cm. I made 4 cushions. The obtained cushion was quilted at a thickness of 7 cm, a width of 120 cm, and a length of 50 cm, and the mattress was put in a side cloth having a width of 120 cm and a length of 200 cm. This mattress is placed on the bed and at 25 ℃ RH6
The panel comfort was sensory-evaluated by allowing the paneller to be used by 4 people for 7 hours in a 5% room. The bed was covered with sheets, the comforter was 1.8 kg of down / feather: 90/10, and the pillow was the one used 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.

[0041]

Industrial Applicability The present invention in which filaments made of a phosphorus-containing thermoplastic elastic resin form a three-dimensional network structure and are fused and integrated to form a substantially flat surface, and the back surface is reinforced with a nonwoven fabric of phosphorus-containing continuous fibers. The flame-retardant reinforced mesh is a cushioning material with high safety that is vibration-proof, heat-resistant and durable, bulky, has a cushioning function that is comfortable to sit in and does not easily get damp, and is flame-retardant and has a low combustion gas toxicity index. Yes, vehicle seats, boat seats, which have been given the above-mentioned preferable characteristics by being used in combination with other materials,
Products such as vehicles, ships, commercial beds for hospitals and hotels, furniture cushions, bedding products, etc. 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 ID FI D01F 6/92 304 D01F 6/92 304H // D01F 6/00 6/00 A 6/62 303 6/62 303D 6/86 301 6/86 301B (56) Reference JP-A-7-52332 (JP, A) JP-A-6-207317 (JP, A) JP-A-6-173115 (JP, A) JP-A-5-272043 (JP , A) JP 55-17527 (JP, A) JP 1-213454 (JP, A) JP 58-109670 (JP, A) JP 58-149362 (JP, A) 1-16326 (JP, U) Actual flat 2-18300 (JP, U) Actual flat 2-18371 (JP, U) (58) Fields investigated (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. The soft segment amount (A wt%) and phosphorus content (Bppm) are 60A + 200 ≦ B ≦ 100,000.
The fineness of the thermoplastic elastic resin satisfying the above relation is 10
A continuous linear filament having a density of 0000 denier or less is bent and brought into contact with each other so that most of the contact portions are fused and the phosphorus content is 1000 on one surface of the reticulated body forming a three-dimensional three-dimensional structure.
A continuous fiber nonwoven fabric made of a thermoplastic non-elastic resin of not less than ppm and not more than 20000 ppm is joined, the surface of the thermoplastic elastic resin layer is flattened, and the apparent density is 0.01 to
A flame-retardant reinforced reticulate body characterized by having a content of 0.2 g / cm ³ . 2. The flame-retardant reinforced net-like body according to claim 1, wherein the cross-sectional shape of the continuous filament is a hollow cross section and / or a modified cross section. 3. The flame-retardant reinforced reticulated body according to claim 1, wherein the thermoplastic elastic resin forming the continuous filaments has an endothermic peak at a temperature above room temperature and below the melting point in the melting curve measured by a differential scanning calorimeter. . 4. A thermoplastic elastic resin having a phosphorus content (Bppm) and a soft segment amount (A weight%) of 60A + 200 ≦ B ≦ 100000 is distributed to each nozzle orifice from a multi-row nozzle having a plurality of orifices. , At a melting temperature 20 to 80 ° C. higher than the melting point of the thermoplastic resin, discharged downward from the nozzle, and in a molten state, they are brought into contact with each other to be fused to form a three-dimensional structure, and a phosphorus content on one side. Of 1000 ppm or more and 20000 ppm or less of a continuous fiber non-woven fabric made of thermoplastic non-elastic resin, joined by a take-up device and cooled in a cooling tank. 5. The method for producing a flame-retardant reinforced reticulate 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 a step of integrally molding after cooling and commercialization. . 6. A vehicular seat, a vehicular seat, a vehicular seat, a vehicular seat, a commercial or domestic bed, a chair for furniture, office work, etc., which uses the flame-retardant reinforced mesh according to claim 1. The product described in either the chair or the futon.