JP3444375B2 - Multilayer net, manufacturing method and products using the same - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a multilayer mesh body having excellent cushioning property, heat resistance durability and vibration absorption property, reinforced by a recyclable non-woven fabric, a manufacturing method and a futon using the multilayer mesh body. , Furniture, beds, cushioning materials for vehicles, etc. and manufacturing method.

[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, hard cotton mother
A method of adding a silicone oil agent to the R> material to lower the friction coefficient of the fiber to improve the durability and improve the texture is disclosed in Japanese Patent Laid-Open No. Sho 63-63.
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. Note that no consideration is given to vibration damping in the above-mentioned structure.

[0007]

To solve the above problems,
A multi-layer suitable for cushioning material that is reinforced with a non-woven fabric that is a net-like body that is laminated with a thermoplastic elastic resin layer and a thermoplastic non-elastic resin layer, which has excellent heat resistance and durability, shape retention and cushioning properties An object of the present invention is to provide a product and a manufacturing method such as a futon, furniture, a bed, and a cushion for a vehicle using a net-like body and a manufacturing method and a multilayer net-like body.

[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 a three-dimensional three-dimensional structure fused to each other are laminated and fused, and the surface of the thermoplastic elastic resin layer is substantially flattened. A nonwoven fabric made of continuous fibers is bonded to one surface of the plastic elastic resin layer, and the density is 0.01.
g / cm ³ to 0.2 g / cm ³ multi-layer mesh body, multi-row nozzles with multiple orifices to distribute thermoplastic elastic resin and thermoplastic inelastic resin to each nozzle orifice in each layer, At a melting temperature higher than the melting point of the plastic resin by 10 to 120 ° C., a non-woven fabric composed of continuous fibers is formed on one side while being discharged downward from the nozzle, contacting each other in a molten state and fusing to form a three-dimensional structure. It is a method for producing a multi-layer net body that is joined and sandwiched by a take-up device and cooled in a cooling tank, and a product using the multi-layer net 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. 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 elastic network of the present invention is preferably 15% by weight or more and 80% by weight or less, more preferably 30% by weight or more and 70% by weight or less. .

The component composed of the thermoplastic elastic resin constituting the multilayer reticulate body 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. 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 has a fineness of 100,000 denier or less.
The lower continuous filaments are bent and brought into contact with each other
A heat-sensitive structure that forms a three-dimensional structure in which most of the parts are fused
The plastic elastic resin layer and the thermoplastic inelastic resin layer are fusion-bonded to each other.
Substantially flat surface of thermoplastic elastic resin layer
A non-woven fabric made of continuous fibers is bonded to the back surface of the reticulated body.
The density is 0.01 g / cm³To 0.2 g / cm³Multi-layer
It is a mesh. The function of the cushion material is that the cushion layer
The basic fineness is made thicker and made a little harder, and it is responsible for body shape retention
Vibration absorption with a slightly higher density due to layers and components with good vibration damping
It is composed of a layer that collects and blocks vibrations, and the surface layer has a slightly fineness.
Suitable as a slightly soft layer with a large number of thin lines
Depth of degree gives a comfortable buttocks touch to the buttocks
Uniformly distributes pressure distribution and absorbs with cushion layer
It absorbs vibrations that could not be made and blocks vibrations in the resonant parts of the human body.
By integrating the layers to be disconnected, stress and vibration can be changed together.
It can be shaped and absorbed to improve sitting comfort. Furthermore
In addition, the surface in contact with the frame is reinforced with a reinforcing material to cushion it.
The surface that is integrated with the layer and supports the cushioning material (reinforcing layer)
And the cushion keeps its shape to keep you comfortable
And it will be a durable seat. In the present invention, the cushion layer
The function of the continuous filament with fineness of 100,000 denier or less
Most of the contact parts are melted by bending and making contact with each other.
Thermoplastic elastic resin layer forming a worn three-dimensional structure
And the thermoplastic non-elastic resin layer are fusion bonded to each other
The plastic elastic resin layer surface has a substantially flat mesh surface.
Having the function of a reinforcing layer in a nonwoven fabric made of continuous fibers
And a multi-layer reticulated structure exhibiting the above-mentioned preferable cushioning function.
It is the body. The multilayer reticulate body of the present invention is for reinforcing the cushion layer.
Made of continuous fiber that is strong and has a strong reinforcing effect even if it is thin
Non-woven fabric is bonded and integrated. Bonded with cushion layer
If not, the cushioning layer reinforcement effect will be lost, so it is preferable.
Not good. Nonwoven fabric thickness when the reinforcing material is monofilament nonwoven fabric
Since the reinforcing effect of the hit is bad, the weight becomes heavy and it is not preferable.
Yes. The preferred nonwoven fabric of the present invention is a spunbond nonwoven fabric.
And the basis weight is 20 g / m²~ 500g / m²Is. Eye
Attached 20g / m²If it is less than 5, the reinforcing effect will be poor and 5
00 g / m²If it exceeds, the moldability is deteriorated, which is not preferable.
Yes. The fineness of continuous fiber is less than 1 denier that can maintain shape.
Above 100 denier from the range that does not impair the moldability.
preferable. Reinforcing layer made of continuous fibers to maintain shape
Needle punching, heat embossing and bonding.
It is preferable to use a non-woven fabric strongly reinforced with a binder.
The material of the cushion layer and the reinforcement layer is, for example, polyester.
If you unify all the seats, you will have to sort them when recycling the seats.
Therefore, it is preferable. Furthermore, it is better to use flame-retardant materials.
preferable. On the other hand, the mesh body having a cushion layer function is
The connecting line forms a three-dimensional structure and melts at most of the contact area.
Thermoplastic elastic resin layer and thermoplastic inelastic resin integrated
The fat layer is laminated so that both sides are substantially flat.
The back side is a non-woven fabric made of continuous fibers with a reinforcing layer function.
Since the surfaces are joined together, the shape of the cushion layer is retained.
The vibration given from the outside is the vibration of the thermoplastic elastic resin.
Most of the vibrations are absorbed and damped by the absorption function to create a vibration isolation layer.
Work. When a large deformation stress is applied locally
However, the deformation stress causes the net surface to be substantially flattened.
A net made of thermoplastic elastic resin with most of the contact part fused.
The deformation stress is received by the surface of the body and dispersed,
A structure in which a plastic elastic resin layer is deformed and fused and integrated.
The whole is deformed, energy is converted, and most of the deformation stress is
Deformation that was absorbed and could not be absorbed by the thermoplastic elastic resin layer
Is a three-dimensional fusion-integrated structure with a thermoplastic elastic resin layer
The net-like structure is deformed as a whole while maintaining the shape with the reinforcement layer.
Response to individual filaments in layers composed of thermoplastic inelastic resin
Elasticity of thermoplastic inelastic resin filaments can be avoided because force concentration can be avoided
A thermoplastic non-elastic resin that easily absorbs stress even within the limit
Deforms as long as it exhibits anti-compression but does not exceed the elastic limit
However, when the stress is released, the thermoplastic inelastic resin filament layer also
Elastic recovery, and the thermoplastic elastic resin layer also exhibits rubber elasticity
It easily recovers to its original form, so it has good sag resistance.
In both cases, the deformation strain with respect to the stress during compression changes linearly,
When sitting, it supports the buttocks with a low repulsive force and moderately sinks.
It does not give a feeling of being on the floor because it causes
It A mesh made of only thermoplastic elastic resin has a softness
The present invention solves the problem that the subduction is slightly increased.
The mold holding function was improved. Only made of known inelastic resin
A mesh composed of linear filaments cannot be absorbed by the surface layer.
It does not have rubber elasticity when subjected to threshold deformation
The plastic deformation is more likely to occur and the recovery is lost, resulting in poor durability. network
If the surface of the body is not substantially flattened,
External force is selectively applied to the surface line and the adhesive point.
Transmission and stress concentration may occur.
Fatigue caused by stress concentration due to external force
There is a case where the sex is deteriorated. Note that the deformation stress is transmitted from the outside.
If the layer to be reached is made of thermoplastic elastic resin, it has a three-dimensional structure.
Stress concentration is relaxed because the entire structure is deformed in the building part
However, if it consists of non-elastic resin only, the stress
Concentrated at the bonding point, structural destruction occurs and recovery is not possible. Further
The surface is not substantially flat and has
When you sit down, you feel uncomfortable in your buttocks
Not preferable. If the line is not continuous,
In the case of a thick net, the adhesion point becomes the stress transmission point and
Extreme stress concentration at the point of contact causes structural destruction and heat resistance and durability
It is inferior in properties and is not preferable. If not fused, keep the shape
Since it cannot be held and the structure does not deform integrally, stress concentration
Fatigue phenomenon occurs due to
It is not preferable because it is deformed and the body shape cannot be maintained. Book
The more preferred degree of fusion of the invention is that the filaments are in contact
Most of the part is fused, most preferably
All the contact parts are in a fused state. Thus, continuous line
Forming a three-dimensional three-dimensional structure in which the contact portions of the stripes are mostly fused.
Thermoplastic with good vibration absorption and elastic recovery integrated with fusion
A layer of elastic resin and a layer of thermoplastic inelastic resin with anti-compression properties
Are laminated and fused together to form a flat surface.
The mesh with the cushion layer function is transmitted from the surface layer.
The deformation stress that is generated is received on the surface and the dispersion of stress is improved,
The stress applied to each line is reduced and the reinforcement layer maintains its shape.
The entire structure deforms while holding it, absorbs the deformation stress, and
The cushioning that supports the parts is also improved, and the stress is released
The vibration transmitted from the frame through the reinforcing layer is also recovered.
The thermoplastic elastic resin part with good dynamic absorption and elastic recovery absorbs
It sits comfortably in order to cut off the vibration of the resonance part of the human body.
The durability can be improved. From this purpose,
The fineness of the filaments forming the bright mesh is determined by the thermoplastic elastic resin layer.
And thermoplastic non-elastic resin layer for both 100,000 denier or less
Below. Apparent density 0.2g / cm ³If you
If the number exceeds 100,000 denier, the number of components will be small.
Structure, resulting in uneven density and partial poor durability.
Fatigue due to stress concentration, resulting in reduced durability.
It is not preferable. Fibers of filaments that form the mesh body of the present invention
As for the degree, if the fineness is too fine, the compression resistance becomes too low and the deformation
As the stress absorbability due to
is there. The preferred range of the thermoplastic elastic resin layer is anti-compression.
More than 300 denier, which is effective, to reduce the number of components
50,000 denier or less, which does not impair the structural precision
Below. More preferably 500 denier or more, 100
It is not more than 00 denier. Thermoplastic inelastic resin layer preferred
The new range is less than 500 denier, where the effect of anti-compression property is easy to appear.
In addition, the structure does not lose its compactness due to the decrease in the number of components.
It is below 50,000 denier. More preferably 100
It is 0 denier or more and 10,000 denier or less. Starting
The apparent density of the bright mesh is determined by the thermoplastic elastic resin layer and the
0.005 g / cm for both plastic and inelastic resin layers³Then repulsive force
Is lost and the vibration absorption capacity and deformation stress absorption capacity are insufficient.
It may become difficult to develop the cushion function,
0.25g / cm³Above, the repulsive force is too high and the sitting comfort
As it may worsen, vibration absorption capacity and deformation stress absorption
The function as a cushion body is expressed by utilizing the function.
0.01 g / cm³0.20 g / cm or more³I like the following
And more preferably 0.03 g / cm³0.08g or more
/cm³It is the following. The reticulate body in the present invention has different fineness.
Different fibers that have an optimal configuration in combination with the apparent linear density
A method of forming a laminated structure can be selected as a preferred embodiment.
Wear. The thickness of the reticulate body of the present invention is not particularly limited,
If the thickness of the plastic elastic resin layer is less than 5 mm, it has a stress absorbing function.
Since the stress distribution function is reduced, the preferred thickness is the distribution of force.
A thickness that can develop the surface function to perform vibration and the function to absorb vibration and deformation stress
Only 10 mm or more, more preferably 20 mm or more
Is. The thickness of the thermoplastic inelastic resin layer is
When the thickness is 5 mm or more, and the thickness of reticulate body is 50 mm,
In this case, leave a thickness that allows the function of the thermoplastic elastic resin layer to be expressed.
Is preferably 30 mm or less, more preferably 10 mm or more,
It is less than 20 mm. Consisting of the reticulate body of the present invention and continuous fibers
Apparent Density as a Multi-Layered Mesh Formed by Fusion Bonding Nonwoven Fabrics
Is 0.01 g / cm³To 0.2 g / cm ³Is. 0.0
1 g / cm³If less than, cushioning such as body shape retention and vibration absorption
It is not preferable because it will reduce the function. 0.2 g / cm³To
If you exceed it, the impact resilience will increase and you will feel uncomfortable.
Not preferable. Preferred apparent density is 0.02g / cm³
~ 0.1g / cm³And more preferably 0.03 g /
cm³~ 0.06g / cm³Is. Mesh and non-woven fabric are joined
If not integrated, reinforced when subjected to shear deformation
Since there is no support for the shape retention function of the layer, it can be connected to the frame.
May become defective and the thermoplastic inelastic layer may break.
Less preferred.

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.

The multilayer reticulate body in which the thermoplastic elastic resin layer and the thermoplastic non-elastic resin layer are fusion-bonded has a substantially flat surface, and most of the contact portions are fused, and the back surface is Is a bonded and integrated non-woven fabric made of continuous fibers having a high reinforcing effect, and since both sides are substantially flattened, the multi-layer net and other nets, non-woven fabric, knitted fabric, hard cotton,
In order to bond the film, foam, metal, etc. to be heat-bonded, it is integrated by using other heat-bonding components (heat-bonding nonwoven fabric, heat-bonding fiber, heat-bonding film, heat-bonding resin, etc.) and adhesives. When a laminated structure is used to obtain products such as vehicle seats, ship seats, vehicle seats, ship seats, hospital beds and other commercial and household beds, furniture chairs, office chairs, futons, etc. Since the contact area with the can be widened, the adhesive area can be widened, and a product with strong adhesion and good adhesion durability can be obtained. In addition, by performing the above-mentioned pseudo-crystallization treatment at any stage of commercialization from the multilayer network forming step, the thermoplastic elastic resin component in the structure has a melting curve measured by a differential scanning calorimeter at room temperature or higher. Having an endothermic peak at a temperature equal to or lower than the melting point is more preferable because the heat resistance and durability of the product is remarkably improved. The linear structure of the thermoplastic elastic resin layer of the multilayer reticulate body of the present invention has a composite structure, and a low melting point thermoplastic elastic resin having a large soft segment content that facilitates energy conversion of vibrations and deformation stresses is a thermal adhesive component, By using a thermoplastic elastic resin having a low content of the soft segment as the shape-retaining component, a heat-adhesion function can be imparted. In order to impart a preferable heat-adhesive function, for example, in a sheath-core structure, a thermoplastic elastic resin having a large soft segment content that facilitates energy conversion of vibration and deformation stress of a sheath component is used as a heat-adhesive component and a core component is used. A thermoplastic elastic resin with a low soft segment content is used as a high melting point component to have a net-like shape holding function.
The function of the heat-bonding layer can be imparted by using the one whose temperature is lowered by 0 ° C. or more. The melting point of the heat-bonding component is preferably 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. The multilayer reticulate body of the present invention having a heat-bonding function, which is a preferred embodiment, has a substantially flat surface, and most of the contact portions are fused, so that the reticulate body, the nonwoven fabric, the knitted fabric, the hard fabric Since the contact area with the surface of the heat-bonded material such as cotton, film, foam, metal, etc. can be widened, the heat-bonded area becomes wider, and a new molded article with strong heat-bonding and seats for vehicles, seats for ships, vehicles ,
Products such as commercial and domestic beds for ships and hospitals, furniture chairs, office chairs, and futons can be obtained. 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. In the manufacturing method of the present invention, 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.
A non-woven fabric made of continuous fibers is bonded on one side while being discharged from the nozzle downward at a melting temperature higher than 0 ° C. and lower than 120 ° C., contacting each other in a molten state and fusing to form a three-dimensional structure. It is a method of manufacturing a multi-layer mesh body that is sandwiched by a take-up device and cooled in a cooling tank. The reticulated body is a manufacturing method of. 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 present invention, for example, the effective width in the longitudinal direction is 50 mm, and the pitch between the holes in the rows in the width direction is 10 mm.
In the case of a circular cross-section orifice shape with a constant pitch of 5 mm between rows, the thermoplastic elastic resin layer is arranged in one row to the seventh row when arranged on one side, and in the first row to six rows when arranged on both sides. Distribute into the 10th to 11th rows and the thermoplastic non-elastic resin into the other rows, preferably 10 ° C from the melting point of each component.
As described above, at the same melting temperature of 120 ° C. or less, the discharge amount at which the layers of the respective components have the desired apparent density, for example, the single hole discharge amount is 2.5 g / min for the thermoplastic elastic resin layer portion, The portion which becomes the non-elastic resin layer is preferably 2 g / min, and each component is preferably fed with a 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. A preferable melting temperature is 20 ° C. to 100 ° C. higher than the melting point of the low melting point component, more preferably 30 ° C. to 80 ° C. higher than the melting point, and 15 ° C. higher than the melting point of the high melting point component.
To 40 ° C. higher, more preferably 20 ° C. to 30 ° C. higher than the melting point, at the same melting temperature. According to the present invention, however, since the melted linear shapes are brought into contact with each other and fused to form a three-dimensional structure, the nonwoven fabric made of continuous fibers is bonded to one surface of the melted linear shapes. If the temperature is not higher than the temperature that can be applied by 5 ° C. or more, the linear fusion bonding with the nonwoven fabric becomes insufficient. The preferred melting temperature is 20 ° C. to 100 ° C. higher than the melting point of the low melting point component, more preferably 30 ° C. to 80 ° C. higher than the melting point, and 15 ° C. to 40 ° C. higher than the melting point of the high melting point component, more preferably Discharge at the same melting temperature, which is 20 ° C. to 30 ° C. higher than the melting point. 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 a hollow cross section (for example, triangular hollow,
In addition to the above effects, the melted state can be achieved by using a round hollow shape, a hollow shape with protrusions, etc.) This is particularly preferable because the three-dimensional structure formed by the discharge line makes it difficult to relax the flow, and conversely holds the flow time at the contact point for a long time to strengthen the adhesion point. Japanese Patent Laid-Open No. 1-2075
In the case of heating for adhesion as described in Japanese Patent Publication, it is not preferable because the three-dimensional structure is likely to be relaxed, a planar structure is formed, and a three-dimensional three-dimensional structure becomes difficult. As an effect of improving the properties of the reticulate body, the apparent bulk can be increased, the weight can be reduced, the anti-compression property can be improved, and the elasticity can be improved, which is difficult to obtain. In the hollow cross section, if the hollow ratio exceeds 80%, the cross section tends to be crushed. Therefore, it is preferably 10% or more and 70% or less, more preferably 20% or more and 60% or less, which can exhibit the effect of weight reduction. 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 hole pitch in the first to sixth rows is 5 mm, and the hole pitch in the tenth and eleventh rows is If the total discharge amount of each component is made to be the same while changing to 6.67 mm, the apparent density of the thermoplastic elastic resin layer becomes 0.0
55 g / cm ^3, and 0.067 g / cm ^3, increased the apparent density of the thermoplastic non-elastic resin layer 2 fold configuration number without changing leave 0.041 g / cm ^3, and about 1.5 times A dense thermoplastic elastic resin layer can be formed. 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 diameter in the 7th to 8th rows is 0.7 mm, and the hole pitch is 5 mm.
By setting the orifice diameters of the other rows to 1.0 mm, two layers of inelastic resin can be formed to improve sitting comfort and dispersion of deformation stress. Then, it is discharged downward from the nozzle, and 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 a nonwoven fabric made of continuous fibers is continuously supplied to one surface. , Both sides of the multi-layer network structure in which the linear state is melted, joined to a three-dimensional three-dimensional structure in the molten state, are sandwiched by a take-up net, and the winding twisted discharge line on the surface of the network body is bent by 45 ° or more. To flatten the surface at the same time to form a structure by adhering the contact points with the discharge line that is not bent, to form a structure, and then continuously use a cooling medium (usually water at room temperature can increase the cooling rate. However, it is preferable in terms of cost), so that the three-dimensional three-dimensional net-structured laminated net body of the present invention is obtained. 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. When the discharge amount of the discharge line is large at 5 g / min or more, 10 cm to 40 cm is preferable, and when the discharge amount of the discharge line is less than 5 g / min hole, 5 cm to 20 cm is preferable. The thickness of the laminated network is determined by the opening width of the take-up net (interval between the take-up nets) that sandwiches 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. Then, it is cut into a desired length or shape and used as a cushion material.
The desired loop diameter and wire diameter can be determined by the distance between the nozzle surface and the take-up conveyor installed on the cooling medium for solidifying the resin, the melt viscosity of the resin, the orifice hole diameter and the discharge amount, and the like. A non-woven fabric composed of continuous fibers that are continuously supplied while fusing the portions in contact with each other by sandwiching and holding the discharge filaments in a molten state with a pair of take-up conveyors with adjustable spacing installed on the cooling medium. Fusion bonding,
When forming a net-like structure by continuously drawing and solidifying in a cooling medium, by adjusting the interval of the conveyor, it is possible to adjust the thickness while the fused net-like body is in a molten state,
A desired thickness is 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. It should be noted that if the supply speed of the nonwoven fabric made of continuous fibers is not the same as the surface speed of the take-up conveyor, pulling or loosening will occur and the reinforcing function of the cushion will deteriorate, which is not preferable.
As a preferred method of the present invention, after cooling once, 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 into a product to obtain a multi-layer network. Obtaining a body or product is a more preferred method of preparation. 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. In this process,
It has an endothermic peak below the melting point, and its heat resistance and sag resistance are remarkably improved as compared with those without pseudo-crystallization treatment (without endothermic peak). 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.

When the multilayer reticulate body of the present invention is used as a cushion, it is necessary to select a resin to be used, a fineness, a loop diameter and a bulk density depending on the purpose of use and the site of use. For example,
In order to give a soft touch, moderate depression and bulging with tension, it is preferable to have a low density, fine fineness, and a fine loop diameter, and in order to develop the cushion function of the middle layer, the resonance frequency Is lowered, and moderate hardness and hysteresis at the time of compression are changed linearly to improve body retention.
In order to maintain durability, it is preferable to have a structure in which a layer having a medium density and a large fineness, a layer having a relatively large loop diameter and a layer having a low density and a fineness and a fine loop diameter are laminated and integrated. Also,
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.

[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. Reinforcing effect Sample is cut into a size of 30 cm x 30 cm, and the diameter is 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) Heat resistance durability (70 ° C residual strain) A sample was cut into a size of 15 cm x 15 cm, compressed by 50%, left at 70 ° C in dry heat for 22 hours, and then cooled to remove compression strain. The thickness (b) after standing for a day is obtained, and is calculated from the thickness (a) before the treatment by the following formula, that is, (ab) / a × 100. Unit% (average value of n = 3) Cyclic compression strain sample is cut into a size of 15 cm x 15 cm, and is 50% in a RH room at 25 ° C and 65% in a Shimadzu Servo Pulser.
The thickness (b) after leaving the sample for 20,000 times after repeating compression recovery at a cycle of 1 Hz up to the thickness of 1 is calculated from the thickness (a) before the treatment, that is, (ab) / ax Calculated from 100. Unit% (average value of n = 3) By a conventional composite spinning machine by a conventional sitting comfort method, the thermoplastic elastic resin A-1 described below is individually used as a sheath component and A-2 as a core component. Melt and distribute immediately before the orifice, and the discharge amount is 50/50 by weight, and the spinning temperature is 245, with 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).

Examples 1 and 2 Dimethyl terephthalate (DMT) or dimethyl naphthalate (DM) was used as the polyester elastomer.
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 A-2) and PET having an intrinsic viscosity of 0.63 are separately melted by three extruders, A-1 and A-2 are immediately before the orifice, and A-1 is a sheath component. A-2 is distributed as the core component (seeds / core: 50/50 weight ratio) from the 1st to 6th rows, the 10th to 11th rows, and the PET from 7th to 9th rows. Distributing to the eyes, and at a melting temperature of 280 ° C., the discharge rate of the first to sixth rows is 758 g / min, the discharge rate of the seventh to ninth rows is 304 g / min, and the tenth and eleventh rows. Discharge to the lower side of the nozzle at a discharge rate of 253 g / min.
Cooling water is placed below 0 cm, and a pair of take-up conveyors with a width of 60 cm are arranged in parallel at intervals of 5 cm so that a part of the pair of take-up conveyors appears on the water surface. A spunbonded non-woven fabric with a basis weight of 100 g / m ² made of PET fibers slit into a width of 50 cm while forming a loop to form a three-dimensional network structure while fusing the contact portions and nipping it on one conveyor. Continuously supply from one side, then draw the molten discharge line shape,
While fusing the contact part, it is also fused with the spunbonded non-woven fabric, sandwiching both sides of the laminate having a net-like structure composed of the spunbonded non-woven fabric on one side, and at a speed of 1 m / min.
Table 2 shows the properties of the multilayer reticulate body obtained by pulling into cooling water at 5 ° C. to solidify, then performing pseudo crystallization treatment for 20 minutes in a hot air dryer at 100 ° C., and cutting into a predetermined size.
The reticulate body of the thermoplastic elastic resin layer on the surface of Example 1 is formed by a linear stripe having a triangular rice ball type hollow cross section having a cross core structure 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 reticulate body of the thermoplastic elastic resin layer on the back side is a triangular rice ball type hollow cross section having a cross-section structure with a hollow ratio of 38% and a fineness of 7,500 denier. The average apparent density is 0.067 g / cm ³ , and the mesh of the thermoplastic non-elastic resin layer in the middle is a triangular rice ball type hollow cross section with a hollow ratio of 40% and a fineness. Is formed of 9000 denier filaments, the average apparent density is 0.041 g / cm ³ , and the average apparent density of the entire multilayer reticulated body fused and integrated with the spunbond nonwoven fabric is 0.056 g / cm 3. ^{Was 3} . As is clear from Table 2, in Example 1, the cushioning material is excellent in heat resistance, durability at room temperature, and sitting comfort due to the laminated net structure that makes use of the characteristics of the soft elastic resin and the characteristics of the slightly hard elastic resin. Was also able to withstand practical use. 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
80 mol% and 1.4 butanediol (1.4 BD)
Obtained in the same manner as in Example 1 except that a small amount of catalyst was charged.
Table 1 shows the formulation of the polyester-based thermoplastic elastic resin.
The obtained A-3 is used as the sheath component, and the hole shape of the orifice
Nozzle with a round cross section with a hole diameter of 1 mm
mm cross section with 10 mm pitch between holes in width direction
Using a nozzle with a staggered arrangement with a hole-to-hole pitch of 5 mm,
A-3 is used as the thermoplastic elastic resin for the 1st to 7th rows
Dispensed and discharged at a rate of 710 g / min, thermoplastic inelastic
Distributing from the 8th row to the 11th row using PET as the resin
The same as Example 1 except that the discharge rate was 410 g / min.
The multi-layer reticulate body obtained in this manner had a layer A-3 reticulate solid circle
Surface has a fineness of 9000 denier and an average apparent density of 0.0
44 g / cm³The PET layer mesh has a solid round cross section and fineness.
9100 denier, average apparent density 0.047 g /
cm³So, the average apparent density when fused and integrated with the reinforcement layer is
0.048g / cm ³Table 2 shows the characteristics of the multi-layer reticulate body.
As is clear from Table 2, Example 2 has heat resistance and room temperature resistance.
Persistence is practically usable, body retention is improved, and sitting
It is a cushioning material with excellent comfort, and the reinforcing effect is practically used.
Was possible. The seats created for evaluation are also excellent
I know that

Example 4 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]

Table 2 shows the characteristics of the multilayer reticulate body obtained in the same manner as in Example 1 except that B-1 was used as the sheath component and B-2 was used as the core component in the obtained thermoplastic elastic resin. In Example 3, the linear cross-sectional shape of the surface side of the composite thermoplastic elastic resin layer of B-1 and B-2 is a triangular rice ball type hollow cross-section with a sheath core structure, the hollow ratio is 40%, and the fineness is 6200 denier. -The average apparent density is 0.055 g / cm ³ , and the back side is a triangular rice ball type hollow cross-section with a linear cross-section. The hollow ratio is 40%, the fineness is 8300 denier, average. Has an apparent density of 0.066 g / cm ³ , and the intermediate PET layer has a fineness of 9000 denier and an average apparent density of 0.041.
In g / cm ^3, the average apparent density of the whole reinforcement and fused integral net-like body was 0.056 g / cm ^3. In addition, B
-1 was used as the sheath component, B-2 was used as the core component, and the spinning temperature was 200 ° C. -Le,
The sitting comfort was evaluated in the same manner as in the sitting comfort evaluation method except that a heat-bonding fiber having a shrinkage ratio at 150 ° C. of 9% was used. Example 4 is a cushioning material which is a multilayer reticulate body using urethane as a thermoplastic elastic resin and which is excellent in heat resistance, durability at room temperature, and sitting comfort, and has a reinforcing effect that can be used practically. It can be seen that the seat created for evaluation is also excellent.

Comparative Examples 1-2 In Comparative Example 1, PBT having a relative viscosity of 1.0 is used in the first to seventh rows.
And PET with an intrinsic viscosity of 0.63 from the 8th row to the 11th row
Dispense and discharge at a melting temperature of 280 ° C.
Toindex 5 polyethylene in rows 1 to 7,
Melt index 12 PP from 8th row to 11th row
Distributing and setting the melting temperature to 240 ° C.
Except for using pan bond and not performing pseudo crystallization,
The characteristics of the multilayer reticulate body obtained in the same manner as in Example 2 are shown in Table 2.
You The reticulate body of Comparative Example 1 is a solid round cross-section of the PBT layer reticulate body.
Surface has a fineness of 8900 denier and an average apparent density of 0.0
44 g / cm³The PET layer mesh has a solid round cross section and fineness.
9000 denier, average apparent density 0.047 g /
cm³The average appearance of the net body fused and integrated with the reinforcing layer
Density is 0.048g / cm³Met. Reticulated body of Comparative Example 2
The PE layer mesh has a solid round cross section with a fineness of 21,000 denier.
-Le, average apparent density is 0.043g / cm ³And PP
The layer mesh has a solid round cross section with a fineness of 25,000 denier and flat
Uniform apparent density of 0.046 g / cm³And the fusion with the reinforcement layer
The average apparent density of the reticulated body integrated by wearing is 0.051 g.
/cm³Met. Comparative Example 1 is made of non-elastic polyester
Since it is a net-like body that has a poor heat resistance and durability, it is hard and comfortable to sit on.
In the test of the reinforcement effect with a cushioning material, the structure was considerably damaged.
This is a broken example. Comparative Example 2 has a slightly finer inelasticity.
Since it is a net consisting of fins, it has poor heat resistance and durability
With the cushion material, the structure is completely broken in the test of the reinforcement effect.
This is a broken example.

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 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 3 is an example that is not suitable for a cushioning material because its shape is not fixed.

Comparative Example 4 A wire obtained in the same manner as in Example 2 except that a take-up conveyor net was placed 25 cm below the nozzle surface to form a net without supplying spunbonded nonwoven fabric and no pseudo-crystallization treatment was performed. The fineness of the strip is 9100 denier, and the average apparent density is 0.0.
The properties of the laminated network of 45 g / cm ³ are shown in Table 2. In Comparative Example 4, the thermoplastic elastic resin layer is laminated, so that it is comfortable to sit on, but it is inferior in heat resistance and durability and lacks a reinforcing material, so it is not preferable as a cushioning material with poor shape retention of the mesh structure. is there.

Comparative Example 5 A nozzle having a width of 50 cm and a length of 5 cm and having a staggered arrangement of 10 mm in the width direction and a pitch of 20 mm in the length direction on the effective surface of the nozzle and having orifice diameters of 2 mm were used. Distribute A-3 on the 3rd row and PET on the 4th to 7th rows, and discharge at a discharge rate of 25 g / min per single hole, and the nozzle surface is 30 cm.
The fineness of the filaments obtained in the same manner as in Example 2 was 113,000 denier, except that a take-up conveyor net was placed below and taken up at 1 m / min, and no pseudo-crystallization treatment was performed, with an average apparent density. Table 2 shows the characteristics of 0.157 g / cm ³ of the multilayer network. Comparative Example 5 is a cushion material having a remarkably fineness and a thick multi-layered mesh having density unevenness, resulting in poor heat resistance durability and slightly poor sitting comfort, and also an example of poor shape retention of the reinforcing material.

Comparative Example 6 The spacing (opening width) of the take-up conveyor net was 15 cm,
One side of the take-up conveyor net is arranged so that the melted discharge line does not come into contact with the side to which the spunbonded non-woven fabric is not supplied, and the A-3 layer mesh formed in the same manner as in Example 2 except that the pseudo crystallization treatment is not performed. The body has a solid round cross section with a fineness of 9000 denier, an average apparent density of 0.038 g / cm ³ , and P
The net of the ET layer has a solid round cross section with a fineness of 9100 denier,
The average apparent density is 0.036 g / cm ³ , and the average apparent density of the net body fused and integrated with the reinforcing layer is 0.037 g.
The properties of the multilayer network in which the surface of / cm ³ is not substantially flattened are shown in Table 2. In Comparative Example 6, since the surface of the net-like body is uneven, the apparent density is low, but the durability is poor, the thermal adhesion with the surface layer is insufficient, and the cushion feels a little inferior and is slightly inferior in sitting comfort. This is an example in which the shape retention of the reinforcing material is poor.

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-3 layer has a filament fineness of 13,000 denier and an apparent density of 0.22 g /
cm ³ PET 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 mesh body is a multilayer mesh of 0.223 g / cm ³ Characteristics Is shown in Table 2. Comparative Example 7 is a cushion material having a slightly poorer sitting comfort, insufficient heat resistance and durability because of its high apparent density, and also an example of the shape retention of the reinforcing material being poor.

Example 5 The thermoplastic elastic resin A-1 obtained in Example 1 was individually melted so as to be the sheath component and A-2 to be the core component by a known composite spinning machine by a conventional method. At a weight ratio of 50/50, with 1.6 g / min per hole (0.8 g / min: 0.8 g / min) as the spinning temperature.
A yarn having a fineness of 4.1 denier obtained at a spinning speed of 3500 m / min at a spinning speed of 3500 m and a shrinkage rate of 10% at a dry heat of 160 ° is converged into a tow shape and mechanically wound by a crimper. Give contraction,
It was cut into 64 mm to obtain a heat-bonded fiber made of a thermoplastic elastic resin having a sheath core cross section. As the base material fiber, PET having an intrinsic viscosity of 0.63 and 0.56 is used in a weight ratio of 50/50 by a conventional method.
3.0g / min per hole (1g / min: 1g
/ Min) is discharged from a C-shaped orifice at a spinning temperature of 265 ° C., composite spinning is performed at a spinning speed of 1300 m / min, and then the drawn yarn obtained by two-stage drawing at 70 ° C. and 180 ° C. is cut into 64 mm. Free heat treatment at 170 ° C. to develop three-dimensional crimps, fineness 6 denier with a sheath core structure having a hollow ratio of 32% in hollow section, initial tensile resistance 38 g / denier
A base material fiber having a crimp degree of 20% and a crimp number of 18 / inch was obtained. The heat-bonded fibers thus obtained and the base material fibers were mixed at a weight ratio of 40/60, pre-opened with an opener and then opened with a card, and the web obtained was laminated to have a basis weight of 1000 g / m ² . Then, the multilayer net body obtained in Example 1 was laminated on the surface of the net body cut to a length of 120 cm to give an apparent density of 0.05 g / cm ^3.
It was compressed so that it was heated to 180 ° C. for 5 minutes and then cooled to obtain a nonwoven fabric laminated mesh body having flat both sides.
Then, compress it by 10% of its thickness, and heat it with hot air at 100 ° C for 20
Pseudo cushioning with a thickness of 7 cm was prepared by pseudo crystallization. The cushion obtained is quilted every 7 cm in thickness, 120 cm in width and 50 cm in length, and the width is 120 cm and the length is 200 cm.
I put it in the lateral area of cm and made a mattress. This mattress is installed on the bed and the panel is placed in a room at 25 ° C and RH 65%.
Sensory evaluation of sleeping comfort was carried out by allowing 4 people to use it for 7 hours. In addition,
The bed was covered with sheets, the comforter was a 1.8 kg down / feather: 90/10 batting, and the pillow was a paneler's daily use. The evaluation result is
It was a bed with no feeling of flooring, moderate subsidence, and a comfortable feeling of sleep without stuffiness. For comparison, density 0.0
A similar mattress was made from a urethane foam plate with a thickness of 4 g / cm ³ and a thickness of 10 cm, and the mattress was placed on a bed and the sleeping comfort was evaluated. Met.

Example 6 A non-woven fabric laminated network was prepared from the multilayer network obtained in Example 1 in the same manner as in Example 5 and had a width of 38 cm, a length of 40 cm and a corner of 10 cm. Cut into pieces and set it on the office chair frame with the polyester moquette used for sitting comfort evaluation as the side, and compare it with the office chair using commercially available polyurethane as a cushion, and let it sit for 4 hours for evaluation. As a result, the feeling of dampness, the feeling of flooring, and the time during which the patient can stand while sitting were remarkably excellent in those using the multilayer net body laminated with the nonwoven fabric of the present invention.

[0035]

EFFECTS OF THE INVENTION A thermoplastic elastic resin layer having good absorption of vibrations and stress and a thermoplastic non-elastic resin layer having anti-compression property, which are formed by fusion-bonding continuous filaments forming a three-dimensional network structure, are fusion bonded. The multilayered reticulate body of the present invention, in which the thermoplastic elastic resin layer on the front surface is substantially flattened and the back surface is reinforced with a nonwoven fabric of continuous fibers, is further improved in vibration isolation, heat resistance durability, bulkiness, and sitting comfort. Also, it is a cushioning material that does not easily get damp, and is provided with the above-mentioned preferable characteristics by using it together with other materials.Vehicle seats, boat seats, vehicles, boats, commercial beds such as hospitals and hotels, and cushions for furniture, Products such as bedding products 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 having a three-dimensional three-dimensional structure in which continuous filaments having a fineness of 100 to 100,000 denier are bent and brought into contact with each other to fuse most of the contact portions to each other. A thermoplastic non-elastic resin layer is laminated and fused, the thermoplastic elastic resin layer surface is substantially flattened, and a nonwoven fabric made of continuous fibers is bonded to one surface of the thermoplastic elastic resin layer. Is 0.01 g / cm ³
To 0.2 g / cm ³ of multi-layer mesh. 2. The multi-layer mesh body according to claim 1, wherein the cross-sectional shape of the continuous filaments is a hollow cross section and / or a modified cross section. 3. The multilayer reticulated body 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. At a temperature, it is discharged downward from the nozzle, and in a molten state, they are brought into contact with each other and fused to form a three-dimensional structure, and a nonwoven fabric made of continuous fibers is joined on one side and sandwiched by a take-up device in a cooling tank. A method for producing a multi-layer mesh body that can be cooled. 5. The method for producing a multilayer 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 the step of integrally molding after cooling and commercialization. 6. A vehicular seat, a vehicular seat, a vehicular, a marine, a hospital, etc. commercial and household bed, a furniture chair, an office chair, and the like, which use the multilayer mesh body according to claim 1. The product described on one of the futons.