JP3444372B2 - Multilayer 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. Multilayer laminated net with a net made of a resin and manufacturing method, and a futon, furniture, bed using the multilayer laminated net,
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 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,
Vibration-proof, heat-resistant durability, shape retention and cushioning properties that prevent stuffiness, thermoplastic elastic resin layer and thermoplastic non-elastic resin layer are fused and integrated To provide a product and a method for manufacturing a multilayer laminated network and a manufacturing method which are optimal for a cushioning material in which short fiber nonwoven fabrics made of an inelastic resin are laminated and bonded, and a product such as a futon, furniture, bed, and vehicle cushion using the multilayer laminated network. To aim.

[0008]

Means for Solving the Problems The means for solving the above problems, that is, the present invention, is to make continuous filaments having a fineness of 100 to 100,000 denier meander and contact with each other, and most of the contact portions are contacted with each other. The thermoplastic elastic resin layer and the thermoplastic non-elastic resin layer forming the three-dimensional three-dimensional structure fused to each other are laminated and fused to each other to form a laminated net having a substantially flat surface. , Thermo-adhesive short fibers made of a thermoplastic elastic resin and a thermoplastic non-elastic resin are opened on the surface of the thermoplastic elastic resin layer of the laminated network to form a three-dimensional structure, and most of the contact portion is formed by the heat-adhesive component. Non-woven fabrics that are fused and integrated and whose surfaces are substantially flat are joined and integrated to form a multi-layer laminated mesh body having a density of 0.01 g / cm ³ to 0.2 g / cm ³ and a plurality of orifices having a plurality of orifices. Heatable with thermoplastic elastic resin from the row nozzle Non-elastic resin is distributed to each nozzle orifice so as to form each layer, and is discharged downward from the nozzle at a melting temperature 10 to 120 ° C. higher than the melting point of the thermoplastic resin, and they are brought into contact with each other in a molten state. After being fused and forming a three-dimensional structure, sandwiched by a take-up device and cooled in a cooling tank, the thermo-adhesive short fibers made of a thermoplastic elastic resin and a thermoplastic non-elastic resin are opened on the thermoplastic elastic resin layer surface. And a product using the multilayer laminated net body, in which webs having a three-dimensional structure are laminated, and by compression thermoforming, most of the contact portions are fused and integrated with a thermal adhesive component. is there.

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. . 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. . Thermal adhesion, hydrolysis resistance, stretchability,
Considering heat resistance and the like, terephthalic acid is used as the dicarboxylic acid, or naphthalene 2.6 dicarboxylic acid, 1.4 butanediol is used as the diole component, and polytetramethylene glycol is used as the polyalkylenediol. The terpolymer block copolymer or the terpolymer block copolymer of polylactone as the polyester diol is particularly preferable. In a special case, it is possible to use the one in which a polysiloxane-based soft segment is introduced. In addition, the above elastomer is blended with a non-elastomer component,
Those obtained by copolymerization and those obtained by softening the polyolefin component are also included in the thermoplastic elastic resin of the present invention. As a polyamide elastomer, the hard segment is nylon 6, nylon 66, nylon 610,
Polyethylene glycol, polypropylene glycol, polytetramethylene glycol, ethylene oxide having an average molecular weight of about 300 to 5000 is used as the soft segment in the skeleton of nylon 612, nylon 11, nylon 12, etc. and their copolymerized nylon. -A block copolymer composed of at least one kind of polyalkylenediol such as glycol composed of 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 (A) Polyester, Polyester
The tellers have an average molecular weight of about 1000 to 6000,
Preferably from 1300 to 5000 polybutylene adipates
Copolyester, polyethylene glycol, polypropylene glycol, polytetramethylene glycol
Polyalkylenediol such as glycol and ethylene oxide-propylene oxide copolymer glycol is preferable, and as the polyisocyanate of (B), a conventionally known polyisocyanate can be used. An isocyanate mainly composed of 4'diisocyanate may be used, and if necessary, a trace amount of conventionally known triisocyanate may be added and used. 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,
It is more preferable to use a material having a temperature of 160 ° C. or higher because the 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 multilayer 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 multilayer 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,
Heat resistance and sag resistance are remarkably improved as compared with 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 9
5 mol% or more, particularly preferably 100 mol% and glyco-
After transesterification of the monomer component, polymerization is performed to a required degree of polymerization, and then, as the polyalkylene diol, the average molecular weight is preferably 500 or more and 5000 or less, particularly preferably 10
00 to 3000 polytetramethylene glycol in an amount of 15% to 70% by weight, more preferably 30% by weight.
When the amount of copolymerization is not less than 60% by weight and not less than 60% by weight, the crystallinity of the hard segment is improved when the content of terephthalic acid or naphthalene 2.6 dicarboxylic acid, which has rigidity in the acid component of the hard segment, is large. However, plastic deformation is less likely to occur and the heat resistance and sag resistance is improved, but the heat resistance and sag resistance is further improved by performing annealing treatment at a temperature lower than the melting point by at least 10 ° C. or more after melt heat bonding. 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 the differential scanning calorimeter of the multilayer laminated network 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. 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.

The present invention is a thermoplastic elastic resin in which a continuous linear filament having a fineness of 100 to 100,000 denier is bent and brought into contact with each other to form a three-dimensional solid structure in which most of the contact portions are fused. Layer and thermoplastic non-elastic resin layer, both surfaces of which are substantially flattened, and the thermoplastic elastic resin layer surface of the net-like body is opened with short fibers made of thermoplastic elastic resin and thermoplastic non-elastic resin to form a three-dimensional structure. The non-woven fabric, which has been flattened and whose surface where most of the contact portion has been fused and integrated by the thermal adhesive component is substantially flattened, has a density of 0.
It is a multi-layer laminated network of 01 g / cm ³ to 0.2 g / cm ³ . The function of the cushioning material is that the cushioning layer is composed 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 and absorbs vibrations and blocks vibrations. However, the surface layer is a soft layer with a fineness and a large number of constituent fibers, which gives a comfortable touch to the buttocks due to a proper subsidence to evenly disperse the buttocks pressure distribution and vibration that could not be absorbed by the cushion layer. By integrating the layer that absorbs and absorbs the vibration of the resonance part of the human body, the stress and the vibration can be integrally deformed and absorbed to improve the sitting comfort. In the present invention, the function of the cushion layer is given to the net-like body formed with the fused three-dimensional three-dimensional structure composed of the thermoplastic elastic resin layer and the thermoplastic non-elastic resin layer, and the function of the surface layer is changed to the thermoplastic elastic resin. A non-woven fabric (short-fiber non-woven fabric) in which short fibers made of a thermoplastic non-elastic resin are opened to form a three-dimensional structure, and most of contact portions are fused and integrated with the thermoplastic elastic resin to substantially flatten the surface. ), And is joined and integrated to give a preferable cushioning material function. The short fiber non-woven fabric having a surface layer function constituting the laminated laminated network of the present invention provides a comfortable buttocks touch due to an appropriate depression as a soft layer, and therefore the heat-adhesive component is made of a thermoplastic elastic resin (preferably , 40% by weight or more, which can satisfy the vibration absorption function and the deformation stress absorption function, and when it exceeds 70% by weight, the shape retention of the short fibers deteriorates and the subsidence increases, so 70% by weight or less) Short fibers made of thermoplastic non-elastic resin and having a fineness of 20 denier or less are opened to form a three-dimensional structure, and most of the contact parts are substantially flattened by the heat-adhesive component. It is made of a non-woven fabric. The fineness of the thermal bonding fibers 20 denier - To below 0.01 g / cm ³ or more 0.05 g / cm ³ can be imparted over the the preferred surface layer features apparent density of the short fiber nonwoven fabric Le, configuration number is reduced , It is not preferable because it does not show the characteristics as a dense structure and impairs a comfortable touch. In addition, as the fineness of the heat-bonding fiber becomes smaller, the number of constituents decreases, the heat-bonding points decrease, the dispersion of the deformation stress deteriorates, and the stress concentration at the bonding points increases and the sag resistance decreases, which is preferable. Absent. On the other hand, if the fineness is too small, the anti-compression property is lowered, large deformation is easily caused, and the thermoplastic non-elastic resin portion is plastically deformed, resulting in a marked deterioration in durability, which is not preferable. The fineness of the preferred short fibers is 1 denier to 10
Denier, more preferably 3 to 6 denier. The short fibers are opened to form a three-dimensional structure, and the surface where most of the contact portions are fused and integrated by heat bonding (preferably all of the contact points are fused and integrated) is substantially flattened. The non-woven fabric receives the local pressure of the buttocks on the surface and evenly distributes the pressure distribution, and the three-dimensional structure of short fiber non-woven fabric is fused and integrated with the thermoplastic elastic resin of the heat-adhesive component. Since the thermal bonding fibers and thermal bonding points undergo large deformation, the entire structure deforms and absorbs the deformation stress by energy conversion, and when the deformation stress is released, the rubber elasticity of the thermoplastic elastic resin facilitates the deformation. Since it has a function to restore the original form, it has good sag resistance. 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 component is made of a thermoplastic elastic resin having a good vibration absorption property, it also functions as a layer that absorbs vibrations that could not be absorbed by the cushion layer and blocks vibrations at 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. Although the thickness of the short fiber non-woven fabric layer is not particularly limited, it is preferably 3 mm to 30 mm for exhibiting the surface layer function, and 5 mm to 20 mm.
Is particularly preferable. On the other hand, the net-like body having a cushion layer function is formed by laminating a thermoplastic elastic resin layer and a thermoplastic non-elastic resin layer, in which continuous filaments form a three-dimensional three-dimensional structure and are fused and integrated at most of contact portions. Since both surfaces are substantially flattened and the surface is joined with the short fiber non-woven fabric with the thermoplastic elastic resin layer surface, most of the vibration applied from the outside is absorbed by the vibration absorption function of the thermoplastic elastic resin. Acts as a vibration isolation layer by absorbing and damping. Even when a large deformation stress is locally applied, the deformation stress dispersed and reduced in the non-woven fabric layer is substantially flattened on the surface of the netting body and most of the contact portion is fused, resulting in thermoplastic elasticity. The deformation stress is received by the surface of the mesh made of resin and the deformation stress is dispersed, and the thermoplastic elastic resin layer deforms and the fusion-integrated structure deforms as a whole and undergoes energy conversion to convert most of the deformation stress. The deformation that could not be absorbed by the thermoplastic elastic resin layer is due to the deformation of the entire three-dimensional network structure fused and integrated through the thermoplastic elastic resin layer and the layer formed of the thermoplastic inelastic resin. Since it is possible to avoid stress concentration on individual filaments, it becomes easier to absorb stress even within the elastic limit of the thermoplastic non-elastic resin filaments, and within the range where the thermoplastic inelastic resin exhibits anti-compression and does not exceed the elastic limit. Deforms and heats when released from stress The elastic non-elastic resin filament layer also elastically recovers, and the thermoplastic elastic resin layer also develops rubber elasticity and easily recovers to its original form, so it has good sag resistance and deformation strain against stress during compression. It changes linearly, and when sitting, it supports the buttocks with a low repulsive force and causes a certain degree of depression, so it does not give a feeling of being on the floor and develops a body shape retention function. 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. A known net-like body composed of filaments made only of non-elastic resin does not have rubber elasticity when subjected to a large deformation that cannot be absorbed by the surface layer, and therefore plastic deformation due to compressive deformation does not occur and recovery is inferior. 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 layer to which the deformation stress is transmitted from the surface layer is made of thermoplastic elastic resin, the entire structure is deformed in the three-dimensional structure portion, so the stress concentration is relieved.
In the case of using only the non-elastic resin, the stress concentrates on 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 because the sitting comfort is poor. 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, a thermoplastic elastic resin layer having good vibration absorption and elastic recovery, which is formed by forming a three-dimensional three-dimensional structure in which the contact portions of continuous filaments are mostly fused, and fusion-bonded, and a thermoplastic having anti-compression The net-like body having a cushion layer function in which the layers of the non-elastic resin are laminated and fusion-bonded to each other and the surface is substantially flattened is a surface layer composed of a short fiber non-woven fabric whose thermo-adhesive fiber is a thermoplastic elastic resin. The deformation stress transmitted from is received on the surface, the distribution of stress is improved, the stress applied to each line is reduced, the entire structure is deformed to absorb the deformation stress, and the cushioning property to support the buttocks is also improved. It recovers when the stress is released, and the vibrations transmitted from the frame are absorbed by the thermoplastic elastic resin part, which has good vibration absorption and elastic recovery, and blocks the vibration of the resonance part of the human body, thus providing comfort and durability. Can be improved. For this purpose, the fineness of the filaments forming the mesh body of the present invention is 100 for both the thermoplastic elastic resin layer and the thermoplastic non-elastic resin layer.
It is less than 000 denier. Apparent density 0.2g / cm
^{When it is} less than ^{3, the} number of constituents is reduced when it exceeds 100,000 denier, a structure with poor durability is partially formed due to density unevenness, fatigue due to stress concentration increases and durability is reduced, which is not preferable. . The fineness of the filaments constituting the reticulated 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 is lowered. The preferred range of the thermoplastic elastic resin layer is 300 denier or more, where the effect of anti-compression property is likely to be exhibited, and 5000 is not impaired in the denseness of the structural surface due to the decrease in the number of constituents.
It is 0 denier or less. More preferably, it is at least 500 denier and at most 10,000 denier. The preferable range of the thermoplastic non-elastic resin layer is that the effect of anti-compression property is easily obtained.
It is 0 denier or more and 50,000 denier or less, which does not impair the denseness of the structural surface due to the decrease in the number of constituents. More preferably, it is not less than 1000 denier and not more than 10,000 denier. The apparent density of the reticulate body of the present invention is 0.005 g / cm for both the thermoplastic elastic resin layer and the thermoplastic non-elastic resin layer.
^{In 3} , the repulsive force is lost, and the vibration absorbing ability and the deformation stress absorbing ability are insufficient, and it may be difficult to develop the cushioning function. At 0.25 g / cm ³ or more, the repulsive force is too high and the sitting comfort becomes poor In some cases, the vibration absorbing ability and the deformation stress absorbing function can be fully utilized to easily develop the function as a cushioning body 0.01 g / cm ³ or more 0.20 g / cm
^It is preferably ³ or less, more preferably 0.03 g / cm ³ or more and 0.08 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 of the thermoplastic elastic resin layer is less than 5 mm, the stress absorbing function and the stress dispersing function are deteriorated. Therefore, the preferable thickness is a surface function for dispersing force and vibration or deformation. The thickness capable of exhibiting the stress absorbing function is 10 mm or more, and more preferably 20 mm or more. The thickness of the thermoplastic inelastic resin layer is
5mm or more, which can maintain body shape, and reticulate thickness is 50
In the case of mm, it is preferably 30 mm or less, more preferably 1 mm or less, leaving a thickness capable of exhibiting the function of the thermoplastic elastic resin layer.
It is 0 mm or more and less than 20 mm. The apparent density of the laminated structure in which the mesh body and the short fiber nonwoven fabric of the present invention are integrally bonded is 0.01 g / cm ³ to 0.2 g / cm ³ . 0.
If it is less than 01 g / cm ³ , the cushioning function such as body shape retention and vibration absorption is deteriorated, which is not preferable. 0.2 g / cm ³
If it exceeds, the impact resilience becomes large and the sitting comfort becomes poor, which is not preferable. Preferred apparent density is 0.02g / cm
^{3 to} 0.1 g / cm ³ , more preferably 0.03 g
/ Cm ^{3 to} 0.06 g / cm ³ . If the mesh body and the short fiber non-woven fabric are not joined and integrated with each other, if they are not joined and integrated by shear deformation, the entire structure cannot be deformed, so that the short fiber non-woven fabric is significantly damaged and the structure is destroyed. In some cases, even if the structure is not destroyed, there is no support for the body shape-retaining layer, which is not preferable because the body shape-holding is poor.

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, in particular, 50% or more of the linear surface is softly heat-treated in order to form a three-dimensional three-dimensional structure capable of energy-converting and recovering vibration and deformation stress that cannot be energy-converted even if the thermoplastic elastic resin layer is largely deformed. Examples thereof include a sheath core structure or a side-by-side structure occupied by a plastic elastic resin, and a combination thereof. That is, see
In the score structure, the sheath component is a thermoplastic elastic resin with a large soft segment content that facilitates energy conversion of vibrations and deformation stresses, and the core component is a thermoplastic elastic resin with a small soft segment content to provide anti-compression properties. By giving it, it is possible to give a comfortable touch to the buttocks due to a proper depression. In 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 made lower than that of a thermoplastic elastic resin with a low soft segment content that exhibits anti-compressibility. 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) ), The proportion of the thermoplastic elastic resin occupying the linear surface and having a large soft segment content is 80
% Or more is particularly preferable, and most preferably, it is a sheath core in which the proportion of the thermoplastic elastic resin having a large soft segment content occupying the linear surface is 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.

Since a net-like body in which a thermoplastic elastic resin layer and a thermoplastic non-elastic resin layer are laminated and fused and a short fiber non-woven fabric are joined and integrated to form a multilayer laminated net body in which both sides are substantially flattened. Other heat-bonding components (heat-bonding non-woven fabric, heat-bonding fiber, heat-bonding film) for bonding with other materials to be heat-bonded such as other reticulate body, non-woven fabric, knitted fabric, hard cotton, film, foam and metal. , Heat-bonding resin, etc.) or adhesive to form an integrated laminated structure, for vehicle seats, ship seats, vehicle seats, ship seats, hospital beds, etc. for business and household beds, furniture chairs, office work When obtaining products such as chairs and duvets, the contact area with the surface to be adhered can be widened, so that a product having a wide adhesive area and firmly adhered can also be obtained with good durability. In addition, by performing the above-mentioned pseudo crystallization treatment at any stage from the step of forming the net and the laminated net to the product, the component composed of the thermoplastic elastic resin in the multilayer net is measured 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. The back surface of the reticulate body forming the multi-layer laminated reticulate body of the present invention can also be provided with a thermal adhesive function as a thermoplastic elastic resin layer, and a reinforcing material or the like can be integrated into the thermal adhesive structure. As the heat-adhesive component, a more preferable function of the heat-adhesive layer can be imparted by using a thermoplastic elastic resin having a large content of soft segments, which is easy to energy-convert vibration and deformation stress. Further, the short-fiber non-woven fabric of the surface layer of the multilayer laminated network of the present invention is composed of a heat-bonding fiber, and can be used as the heat-bonding layer thereof, but preferably the heat-bonding component has a high soft segment content and 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-adhesive component forming the filaments or fibers in the multilayer laminated network preferable for exhibiting the heat-adhesion function is 15 ° C. to 80 ° C. lower than the melting point of the high-melting component,
More preferably, the melting point is 20 ° C. to 60 ° C. lower. The multilayer laminated reticulate body 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 reticulate body, a nonwoven 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 treatment at any stage until new molded products and products are commercialized, the lines made of thermoplastic elastic resin in the structure are converted into melting curves measured with a differential scanning calorimeter. Having an endothermic peak at a temperature of room temperature or higher and melting point or lower is more preferable 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. A thermoplastic elastic resin and a thermoplastic non-elastic resin are distributed to each nozzle orifice so as to form each layer from a multi-row nozzle having a plurality of orifices, and the melting point of the thermoplastic resin is higher by 10 ° C. or more.
After being discharged downward from the nozzle at a melting temperature higher than 0 ° C., 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. A web in which short fibers made of a thermoplastic elastic resin and a thermoplastic non-elastic resin are spread on the surface of the plastic elastic resin layer to form a three-dimensional structure, and most of the contact portion is bonded by a heat-adhesive component by compression thermoforming. This is a method for producing a multi-layer laminated network body that is fused and integrated. The reticulated body uses a general multi-component extruder to melt the thermoplastic elastic resin and the thermoplastic non-elastic resin separately for each individual component, and the thermoplastic elastic resin is applied to one or both sides of the reticulated body on the back surface of the nozzle. The thermoplastic inelastic resin is distributed to other parts and discharged 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. In a preferred embodiment of the invention, for example,
When the effective width in the longitudinal direction is 50 mm, the pitch between the holes in the row in the width direction of the nozzle is 10 mm, and the pitch between the rows is 5 mm, the orifice shape has a circular cross section. 1st to 7th rows, in the case of arranging on both sides, it is distributed to 1st to 6th rows and 10th to 11th rows, and the thermoplastic non-elastic resin is distributed to other rows, preferably, At the same melting temperature of 10 ° C to 120 ° C below the melting point of each component,
Discharge rate at which the layer of each component has a desired apparent density, for example,
The single hole discharge rate is 2.5 g / for the thermoplastic elastic resin layer.
As for the portion which becomes the thermoplastic non-elastic resin layer, preferably, each component is fed with the molten thermoplastic resin to the nozzle by each gear pump and discharged downward from each orifice. 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 with insufficient adhesion, which is not preferable. The preferred melting temperature is 2 than the melting point of the low melting point component.
0 ° C to 100 ° C higher, more preferably 3 above melting point
The temperature is 0 ° C. to 80 ° C. higher, 15 ° C. to 40 ° C. higher than the melting point of the high melting point component, and more preferably 2 ° C. higher than the melting point.
Discharging is carried out at the same melting temperature, which is 0 ° C. to 30 ° C. higher. In the case of composite spinning, unless the difference in melting temperature immediately before joining is 10 ° C. or less, abnormal flow may occur and the formation of 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. 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. According to a more preferred embodiment of the present invention, when the number of constituents is increased by the thermoplastic elastic resin layer, for example, the inter-hole pitch in the first to sixth rows is set to 5
mm, the pitch between the holes in the 10th and 11th rows was changed to 6.67 mm, and the total discharge amount of each component was the same, and the apparent density of the thermoplastic elastic resin layer was 0.055 g / cm ³ , And 0.067 g / cm ³ , and the number of components is 2 without changing the apparent density of the thermoplastic non-elastic resin layer to 0.041 g / cm ^3.
It is possible to obtain a dense thermoplastic elastic resin layer that is doubled and increased about 1.5 times. Of course, the cushion characteristics can be optimized by changing the pore density of a specific portion of the thermoplastic non-elastic resin layer. 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 difference in pressure loss at the time of discharge is given by changing the cross-sectional area of the orifice, the discharge amount of the molten thermoplastic resin extruded from the same nozzle at a constant pressure will decrease as the orifice with the larger pressure loss is used. It is also possible to manufacture a net-like structure composed of filaments of different fineness between the rows. For example, when the thermoplastic inelastic resin is distributed in the 7th to 9th rows as described above, the orifice diameters in the 7th to 8th rows are 0.7 mm, the hole pitch is 5 mm, and the orifices in the other rows are By setting the diameter to 1.0 mm, 2 layers of inelastic resin can be used.
By forming layers, it is possible to improve sitting comfort and dispersion of deformation stress. 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, and are sandwiched by a take-up net, and the winding winding filaments in the molten state on the surface of the mesh body are bent by 45 ° or more. After deforming to flatten the surface and at the same time form a structure by adhering the contact points with the discharge line that is not bent, a cooling medium (usually using room temperature water can increase the cooling rate, It is preferable because it is cheap in terms of cost), and is rapidly cooled to obtain the three-dimensional three-dimensional net-structured net-like body of the present invention. 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. If the discharge amount of the discharge line is 5g / hole or more, 10cm-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 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. still,
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 that solidifies the resin, the melt viscosity of the resin, the hole diameter of the orifice 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 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. Next, in the present invention, it is joined and integrated with a short-fiber non-woven fabric made of a heat-bonding fiber having a surface layer function. Thermoadhesive fibers having a fineness of 20 denier or less, which are composed of a thermoplastic elastic resin and a thermoplastic non-elastic resin, are obtained by individually melting a low-melting thermoplastic elastic resin and a high-melting thermoplastic non-elastic resin. The composite yarn is spun and stretched to obtain a finished yarn. 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 a heat-bonded fiber. The composite form of the heat-adhesive fiber used in the present invention is not particularly limited, but it is preferable that the low melting point component occupies 50% or more of the surface of the fiber in a side-by-side or sheath core since the function as the heat-adhesive fiber is required. More preferably, the low melting point component occupies 100% or more of the surface of the fiber. Next, the heat-bonded fibers are pre-opened with an opener or the like and then opened with a card or the like, and an open web having a three-dimensional structure is laminated and compressed on the surface of the mesh 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 multilayer laminated network obtained by once cooling the network or integrally molding. It is a more preferable production method to obtain a multilayer laminated network or product by carrying out 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 multilayer laminated network of the present invention is used as a cushion, a resin used depending on its purpose and site of use,
It is necessary to select the fineness, the loop diameter, and the bulk density. 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 multi-layer laminate 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 by using a molding die or the like to the extent that the three-dimensional structure is not impaired 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, 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.

[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:%) Cyclic compressive strain sample is cut into a size of 15 cm x 15 cm, and it is 50% in a RH chamber at 25 ° C and 65% with a Shimadzu Servo Pulsar.
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:%) Sit comfort Cover the surface of the multi-layer laminated network cut into the shape of a bucket sheet with the side of polyester moquette made of Toyobo Co., Ltd. and set on the seat frame to set the seat. 4 seats and 6 seats on the back were provided with side ground stoppers, and a paneler was seated on the seats prepared in a room at 30 ° C RH75% 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. .

[0020]

[Table 1]

On the effective surface of the nozzle having a width of 50 cm and a length of 5 cm, the pitch between the holes in the width direction is set to 5 mm for 1 to 6 rows, 10 mm for 7 to 9 rows, and 6.67 mm for 10 and 11 rows. The orifice shape of the staggered arrangement with the hole-to-hole pitch of 5 mm in the direction of 2 mm is the outer diameter of 2 mm and the inner diameter is 1.6 mm.
-1) and PBT having a relative viscosity of 1.0 are melted by separate extruders, A-1 is distributed to the 1st to 6th rows, 10th and 11th rows, and PBT is the 7th row. To the 9th row, and at a melting temperature of 260 ° C., the discharge amount of the 1st to 6th rows is 758
g / min, discharge amount of 7th to 9th rows is 304 g / min, 1
The discharge rate of the 0th and 11th rows was 253 g / min, and was discharged below the nozzle. Cooling water was placed 10 cm below the nozzle surface, and the width was 6
A pair of take-up conveyors with 0 cm stainless steel endless nets arranged in parallel at intervals of 5 cm are arranged so as to partly come out above the water surface, and the melted discharge line is bent to form a loop to form a contact portion. After forming a three-dimensional network structure by fusing, the two sides of the molten network are sandwiched by a take-up conveyor and drawn into cooling water at 25 ° C. at a speed of 1 m / min to be solidified and then flattened. The net-like body of the thermoplastic elastic resin layer on the surface side obtained by cutting into a predetermined size is formed by a linear cross section having a triangular rice ball type hollow cross section with a hollow ratio of 38% and a fineness of 5,600 denier. The average apparent density is 0.055 g / cm ³ , and the net-like body of the thermoplastic elastic resin layer on the back side has a triangular cross-sectional hollow section with a hollow ratio of 38% and a fineness of 7,500 denier. The average appearance Density 0.067 g / cm ^3, the mesh-like body of the intermediate thermoplastic non-elastic resin layer hollow ratio of 40% cross-sectional shape hollow cross section of the triangular rice ball type, fineness 9000
Denier - forms Le striatum, the apparent density of the average at 0.041 g / cm ^3, the average apparent density of the whole mesh body fused integral was 0.053 g / cm ^3. Separately,
The thermoplastic elastic resin A is produced by a conventional composite spinning machine by a conventional method.
-1 is melted individually as a sheath component and PBT as a core component and distributed just before the orifice, and each discharge amount is 50 /
At a weight ratio of 50, 1.6 g / minute hole (0.8 g / hole)
Min: 0.8 g / min), the yarn was discharged at a spinning temperature of 265 ° C., and a yarn having a fineness of 4.1 denier and a shrinkage rate of 4% at a dry heat of 160 ° C. was converged at a spinning speed of 3500 m / min. Then, mechanical crimping was applied with a crimper in a tow shape and cut into 64 mm to obtain a heat-bonded fiber made of a thermoplastic elastic resin having a cross section of sheath core. The resulting heat-bonded fiber was pre-opened with an opener and then opened with a card, and a web was obtained.
g / m ² , laminated on the net, compressed to an apparent density of 0.05 g / cm ³ , heat-treated with hot air at 180 ° C. for 5 minutes and then cooled to form a multi-layered laminate having flat surfaces. A reticulate body was obtained. Then compress 10% of the thickness to 100 ° C
Table 2 shows the characteristics of the multilayer laminated network of the present invention obtained by performing pseudo-crystallization for 20 minutes with the hot air. As is clear from Table 2, Example 1 is a cushioning material having excellent heat resistance and durability at room temperature, which is a multilayered reticulated body that takes advantage of the characteristics of the soft elastic resin, and which has an improved body retention and is comfortable to sit on. Met. 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.
The orifice shape has a round cross section with a hole diameter of 1 mm, the nozzle pitch is 10 mm in the width direction, and the hole pitch in the length direction is 5 mm.
No. 2 is used and the discharge amount is 710 g /
A-2 layer obtained in the same manner as in Example 1 except that PBT was used as the thermoplastic inelastic resin, PBT was used for distribution in the 8th to 11th columns, and the discharge rate was 410 g / min. Of the solid round cross section has a fineness of 9,000 denier and an average apparent density of 0.044 g / cm ³ , while the PBT layer reticulate has a solid round cross section of a fineness of 9,100 denier and an average apparent density of At 0.047 g / cm ³ , the average apparent density of the fusion-bonded and integrated reticulate body was 0.045 g / cm ³ . Next, Table 2 shows the characteristics of the multilayer laminated network obtained in the same manner as in Example 1. As is clear from Table 2, in Example 2, the heat resistance and the durability at room temperature were practically usable, and the body shape retention was improved.
It is clear that the cushioning material is comfortable to sit on, and 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.

[0025]

[Table 3]

On the surface side of the B-1 layer obtained in the same manner as in Example 1 except that the obtained thermoplastic elastic resin (B-1) was used, the linear cross section of the layer was a triangular rice ball type hollow cross section. Rate 4
0%, fineness is 6200 denier, average apparent density is 0.055 g / cm ³ , and the back side has a triangular cross-section of filaments with a hollow cross section of 40% hollowness and fineness of 8300.
Denier, with an average apparent density of 0.066 g / cm ³ ,
Intermediate PBT layer fineness 9000 denier - le, the apparent density of the average at 0.041 g / cm ^3, the average apparent density of the whole mesh body fused integral was 0.053 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 as the core component, and the spinning temperature was 265 ° C, the fineness was 4.5 denier. 1
The shrinkage ratio at 50 ° C. was 4%. This heat-bonded fiber was 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 to obtain a multilayer laminated mesh having flat both sides. Obtained.
Then, compress it by 10% of its thickness, and heat it with hot air at 100 ° C for 20
Table 2 shows the characteristics of the multilayer laminated network of the present invention obtained by the minute pseudo crystallization treatment. Example 3 was a cushioning material which was a multilayer laminated network utilizing the characteristics of soft urethane and which was excellent in heat resistance, durability at room temperature, good shape retention and comfortable sitting. It can be seen that the seat created for evaluation is also excellent.

Comparative Examples 1 and 2 In Comparative Example 1, the PBT used in Example 1 was distributed to the 1st to 7th rows, and the PET having an intrinsic viscosity of 0.63 was distributed to the 8th to 11th rows. The mixture was discharged at 280 ° C., and in Comparative Example 2, polyethylene of melt index 5 was used in the first to seventh rows,
The mesh used in Comparative Example 1 obtained in the same manner as in Example 2 except that PP having a melt index of 12 was distributed to the 8th to 11th rows and the melting temperature was 240 ° C. The solid round cross section has a fineness of 8900 denier and an average apparent density of 0.044 g / cm ³ , and the PET layer mesh has a solid round cross section of a fineness of 9000 denier and an average apparent density of 0.047 g / cm ^3. In cm ³ , the average apparent density of the fusion-bonded reticulated body was 0.045 g / cm ³ . In the mesh used in Comparative Example 2, the PE layer mesh has a solid round cross section and a fineness of 2
1000 denier, average apparent density 0.043 g /
In cm ^3, fineness reticulated body solid round cross-section of the PP layer 25000
Denier, with an average apparent density of 0.046 g / cm ³ ,
The average apparent density of the reticulated body fused and integrated is 0.045.
It was g / cm ³ . Next, Table 2 shows the characteristics of the multilayer laminate network obtained in the same manner as in Example 2 except that the pseudo crystallization treatment was not performed. 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. It is a hard and uncomfortable cushioning material. 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 multilayer laminated network obtained by laminating the short fiber non-woven fabric prepared in the same manner as in Example 1 on the surface layer except that no pseudo crystallization treatment was performed using No. Comparative Example 4
Was a cushioning material that was comfortable to sit on, but had slightly poor heat resistance and durability.

COMPARATIVE EXAMPLE 5 A nozzle having a diameter of 2 mm and having a staggered arrangement with a hole-to-hole pitch of 20 mm in the width direction and a hole-to-hole pitch of 10 mm on the effective surface of a nozzle having a width of 50 cm and a length of 5 cm was used. 2 is distributed from the first row to the third row, PBT is distributed from the fourth row to the sixth row, and the discharge amount of A-2 is 1925 g / min and the discharge amount of PBT is 1
The fineness of the filament obtained in the same manner as in Example 2 except that the filament was discharged at 900 g / min, a take-up conveyor net was placed under the nozzle surface of 30 cm, and the filament was taken at 1 m / min, was A-2 component and The PBT component is 112,000 denier, and the average apparent density of both the A-2 layer and the PBT layer is 0.154 g / cm.
Example 2 except that the reticulate body of ³ was used and no pseudo-crystallization treatment was performed.
Table 2 shows the characteristics of the multilayer laminated network produced in the same manner as in (1). Comparative Example 5 was a cushioning material having a remarkably fineness and a multi-layer laminated netting having a density unevenness, and thus the heat resistance and durability were poor and the sitting comfort was slightly poor.

Comparative Example 6 An A-2 layer reticulate body obtained in the same manner as in Example 2 except that the spacing (opening width) of the take-up conveyor net was 15 cm was a solid round cross section with a fineness of 9000 denier. The average apparent density is 0.038 g / cm ³ , the PBT layer mesh has a solid round cross section with a fineness of 9100 denier and an average apparent density of 0.03.
The average apparent density of the reticulated body fused and integrated at 6 g / cm ³ was 0.037 g / cm ³ , and the reticulated body whose surface was not substantially flattened was used. Table 2 shows the characteristics of the multilayer laminated network produced in the same manner as in (1). Comparative Example 6 was a cushioning material with a slightly inferior durability because of its low apparent density due to the uneven surface of the reticulate body, insufficient thermal bonding, and a slightly inferior 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. The A-2 layer has a filament fineness of 13,000 denier and an apparent density of 0.22 g /
cm ^3, PBT layer streak fineness 13000 denier - le, with an apparent density of 0.23 g / cm ^3, an apparent density of the average of the fused integral net-like body with a 0.22 g / cm ^3, pseudo-crystalline Table 2 shows the characteristics of the multilayer laminated network produced in the same manner as in Example 2 except that the chemical 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 0.5 mm was used. -2 to 1
27 g / min is supplied from the 10th to the 10th lines, 22 g / min of PBT is supplied from the 11th to 18th lines to be discharged, and a take-up conveyor net is arranged 5 cm below the nozzle surface to provide 0.15 m / min.
A-obtained in the same manner as in Example 2 except that
The second layer has a fineness of 97 denier and an apparent density of 0.013 g.
/ Cm ³ , the PBT layer has a fineness of 98 denier, an apparent density of 0.014 g / cm ³ , and a fusion-integrated average apparent density of 0.013 g / cm ³ is used. 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 apparent density was compressed to 0.015 g / cm ³ . Comparative Example 8 was a cushioning material which was slightly inferior in sitting comfort because the linear fineness was too fine and the depression was large and the feeling of flooring was large even when a fine mesh-like body was used as the cushioning layer.

Comparative Example 9 220 g / min of A-2 is supplied from the 1st to the 7th rows for comparison
The PET used in Example 1 was 125 g / in the 8th to 11th rows.
Minute supply and discharge at a melting temperature of 280 ° C.
Bare net is arranged and collected at 1.6m / min.
The A-2 layer obtained in the same manner as in Example 2 had a fineness of 2800 data.
Neil, apparent density 0.008g / cm ³, PBT layer is
Fineness of 2600 denier, apparent density of 0.009 g /
cm³And the average apparent density after fusion bonding is 0.009.
g / cm³Using the reticulated body of
Degree is 0.008g / cm³Except that it was compressed to
The characteristics of the multi-layer laminated network produced in the same manner as in Comparative Example 7 are shown.
2 shows. In Comparative Example 9, the apparent density was too low and the subduction occurred.
It becomes bigger and the feeling of being on the floor becomes larger and the comfort of sitting is slightly inferior.
It was a cushion material.

Example 5 The multilayer laminated elastic network obtained in Example 1 was cut into a length of 120 cm and put into 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. Place this mattress on the bed,
The panel comfort was sensory-evaluated by allowing 4 panelists to use it in a room at 25 ° C RH 65% for 7 hours. The bed is covered with sheets, and the comforter is 1.8 kg down / feather: 90 /
10 was used as the batting, and the pillow was worn by the paneler, which is used 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 density of 0.04 g / cm ³ and a thickness of 1
A similar mattress was made from a 0 cm urethane foam plate, and the mattress was placed on a bed and the sleeping comfort was evaluated. As a result, it was a bed with a small feeling of flooring but a large sinking and a slight stuffiness, which was uncomfortable to sleep.

Example 6 The multilayer laminated net body obtained in Example 1 was prepared to have a width of 38 cm and a length of 40 cm.
The corner was cut into a shape with an arc of 10 cm, and the polyester moquette used for sitting comfort evaluation was installed on the office chair frame with the side ground, and a commercial polyurethane chair was used as a cushion. In comparison with the above, the sitting comfort was evaluated by sitting for 4 hours. As a result, the feeling of stuffiness, the feeling of flooring, and the time that the patient can endure while sitting was significantly excellent in the one using the multilayer laminated reticulate body of the present invention.

[0037]

EFFECTS OF THE INVENTION A surface in which a filament in which a thermoplastic elastic resin having good vibration and stress absorption and a thermoplastic non-elastic resin for improving body-holding property are laminated in multiple layers forms a three-dimensional structure and is fused and integrated. Is a flattened reticulate body as a cushion layer, a thermal adhesive component as a thermoplastic elastic resin with good vibration and stress absorption, and a short fiber non-woven fabric with a thermoplastic non-elastic resin as a shape-retaining component as a surface layer. The multilayer laminated reticulate body of the present invention, which is joined and integrated, is a cushioning material having good vibration comfortability, heat resistance durability, bulkiness, and sitting comfort with improved body shape retention, and which is covered with the side fabric as it is or , Products such as vehicular seats, marine seats, vehicular seats, vehicular seats, commercial beds for hospitals and hotels, furniture cushions, bedding products, etc., which are used in combination with other materials. 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 6/00 D01F 6/00 A 6/62 303 303 6/62 303D 6/86 301 6/86 301B (56) References JP 55-17527 (JP, A) JP 1-213454 (JP, A) JP 58-109670 (JP, A) JP 58-149362 (JP, A) SAIHAI 1-16326 (JP, U) Actual development 2-18300 (JP, U) Actual development 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. A thermoplastic elastic resin layer in which continuous filaments having a fineness of 100 to 100,000 denier are bent and brought into contact with each other, and most of the contact portions are fused to form a three-dimensional solid structure. A thermoplastic non-elastic resin layer is laminated and fusion-bonded to each other to form a laminated network having a substantially flat surface. The thermoplastic elastic resin layer and the thermoplastic elastic resin are formed on the thermoplastic elastic resin layer surface of the laminated network. A non-woven fabric in which thermo-adhesive short fibers made of a plastic non-elastic resin are opened to form a three-dimensional structure, and most of the contact portions are fused and integrated by a thermo-adhesive component and the surface is substantially flattened. multilayer laminate meshwork of 0.2 g / cm ³ density that is integrally joined from 0.01 g / cm ^3. 2. The multilayer laminated net body according to claim 1, wherein the cross-sectional shape of the filament is a hollow cross section and / or a modified cross section. 3. The multilayer laminated network according to claim 1, wherein the thermoplastic elastic resin forming the continuous filament has an endothermic peak at a temperature of room temperature or higher and melting point or lower in a melting curve measured by a differential scanning calorimeter. 4. A thermoplastic elastic resin and a thermoplastic inelastic resin are distributed to each nozzle orifice so as to form each layer from a multi-row nozzle having a plurality of orifices, and the melting point is 10 to 120 ° C. higher than the melting point of the thermoplastic resin. It is discharged downward from the nozzle at a temperature, 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 thermoplastic elastic resin is applied to one side. And heat-adhesive short fibers made of thermoplastic non-elastic resin are spread to form a three-dimensional structured open web, and most of the contact parts are fused and integrated by compression thermoforming by compression thermoforming. A method for producing a multi-layer laminated netting material. 5. The method for producing a multi-layer laminate network 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, and the like, which use the multilayer laminated mesh according to claim 1. And the product described in any of the futons.