JP3473710B2 - Mixed fineness reticulated body, manufacturing method and products using it - Google Patents

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION The present invention relates to a reusable heterogeneous-fine mixed reticulate body having excellent cushioning properties, heat resistance durability, and vibration absorption, and a futon using the process and the different fine-fineness mixed reticulated body, It relates to products such as furniture, beds, and cushioning materials for vehicles.

[0002]

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

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

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

Polyester hard cotton, for example, JP-A-58-3
1150, JP-A-2-154050, JP-A-3-220354, etc., but since an amorphous polymer having a brittle adhesive component of the heat-bonding fiber used is used (for example, JP-A-58). -136828, Japanese Patent Application Laid-Open No. 3-
However, there is a problem in that durability is poor such that the bonded portion is brittle and the bonded portion is easily broken during use and the form and elasticity are reduced. As an improved method, a method of entanglement treatment has been proposed in Japanese Patent Laid-Open No. 4-245965, but there is a problem that the brittleness of the bonded portion is not solved and the elasticity is largely reduced. In addition, there is complexity during processing. Further, there is a problem that the bonded portion is hard to be deformed and soft cushioning is hard to be imparted. For this reason, the polyester elastomer that is soft even at the bonded portion and recovers even if it is deformed to some extent
A heat-bonding fiber using a non-elastic polyester as a core component is disclosed in JP-A-4-240219, and a cushion material using the fiber is disclosed in WO-91 / 19032, JP-A-5-155651. It is proposed in Japanese Patent Laid-Open No. 5-163654. The adhesive component used in this fiber structure has a polyalkylene glycol content of 30 to 50 as a soft segment of polyester elastomer.
Wt%, 5% terephthalic acid as the acid component of the hard segment
It contains 0 to 80 mol% and is used as another acid component composition
As in the fiber described in Japanese Patent Publication No. 0-1404, isophthalic acid is contained to increase the amorphous property, and the melting point is 180.
The temperature is below ℃, and the heat-bonded part is well formed with a low melt viscosity to form an ameber-shaped bonded part, but it is easy to plastically deform, and because the core component is an inelastic polyester, plastic deformation especially under heating Becomes remarkable, and there is a problem that the heat resistance and compression resistance are lowered. As an improved method for these, Japanese Patent Laid-Open No.
No. 163654 proposes a structure consisting only of a polyester elastomer containing isophthalic acid as a sheath component and a heat-bonding composite fiber using an inelastic polyester as a core component. Plastic deformation becomes significant, the heat resistance and compression resistance deteriorate, and there is a problem in using it for a wadding layer or a cushion material. On the other hand, there is a method in which a silicone oil is added to a base material of hard cotton to lower the friction coefficient of fibers to improve the durability and improve the texture.
It is proposed in Japanese Patent No. 158094. However, there is a problem with the adhesiveness of the heat-adhesive fiber and the durability is poor, so it is not preferable for use in a wadding layer or cushioning material.

A thermoplastic olefin network used for civil engineering work is disclosed in JP-A-47-44839. However, unlike a cushion made of fine fibers, the surface is uneven and the touch is poor, and since the material is olefin, the heat resistance durability is extremely poor and it cannot be used as a wadding layer or cushion material. In addition, Japanese Patent Publication No. 3-1766
No. 6 discloses a method in which ejection filaments having different fineness are fused to each other to form a mold, but the mesh structure is not suitable as a cushion material. Japanese Examined Patent Publication No. 3-55583 discloses that
A method of thinning only a very surface with a thinning device such as a rotating body before cooling is described. With this method, the surface cannot be flattened and a thick thin linear layer cannot be formed. Therefore, it does not provide a comfortable cushioning material. Japanese Patent Application Laid-Open No. 1-207462 discloses a vinyl chloride floor mat, but it is not preferable as a wadding material or a cushioning material because it has poor compression recovery at room temperature and remarkably poor heat resistance. is there. Note that no consideration is given to vibration damping in the above-mentioned structure.

[0007]

To solve the above problems,
Isolates vibrations, heat resistance and durability, shape retention, is hard to stuffy and has excellent cushioning properties, heterogeneous mixed mesh made of thermoplastic elastic resin suitable for cushion material and method and futon using heterogeneous mixed mesh, It aims to provide products and manufacturing methods such as furniture, beds, and cushions for vehicles.

[0008]

Means for Solving the Problems In order to solve the above-mentioned problems, the present invention provides a continuous thick line and a thin line made of a thermoplastic elastic resin mixed with each other so as to bend and contact each other. A three-dimensional three-dimensional structure is formed by fusing most of the contact portion, and both surfaces thereof are substantially flattened, and the thick filaments and thin filaments have a cross-sectional secondary moment ratio of 5 to 5. 500 and an apparent density of 0.01 to 0.2
g / cm ³ of different fineness mixed reticulate body, a plurality of orifices having different cross-sectional areas are mixed, and a thermoplastic elastic resin is distributed to each nozzle orifice from the nozzle. A heterogeneous mixed reticulate body which is discharged downward from the nozzle at a melting temperature higher than 80 ° C., is in contact with each other in a molten state and is fused to form a three-dimensional structure, which is sandwiched by a take-up device and cooled in a cooling tank. And a product using the different fineness mixed reticulate 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. In addition, it is particularly preferable to add a flame retardant, an antioxidant, or the like, if necessary, to improve flame retardancy and durability. Examples of the flame retardant include halogen compounds, halogen compounds and inorganic substances (for example, antimony trioxide, boron oxide, etc.), phosphorus compounds, phosphorus compounds and melamine compounds, and the like.
Such as [2.3-di (2-hydroxyethoxy) -carbonylpropyl] 9-10-dihydro-9-oxa-10-phosphaphenalene-10-oxylo and bis (1.3-phenylene-diphenyl) phosphate. It is preferable to add a phosphorus compound in a phosphorus content of 5,000 ppm or more and 100,000 ppm or less to impart flame retardancy, since it is possible to suppress generation of toxic gas with a small lethal amount during combustion. If the phosphorus-based flame retardant is contained, thermal decomposition tends to occur. Therefore, it is preferable to contain an antioxidant in order to suppress thermal decomposition at a temperature of 300 ° C. or lower. The antioxidant is preferably a hindered phenol-based antioxidant and a hindered amine-based antioxidant, and a nitrogen-free hindered phenol-based antioxidant is 1% to 5%. It is particularly preferable to suppress the thermal decomposition by adding it, because the generation of toxic gas with a small lethal amount at the time of combustion can be suppressed. The soft segment content of the thermoplastic elastic resin constituting the component having the function of absorbing vibration and stress, which is the object of the present invention, is preferably 15% by weight 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. .

It is preferable that the thermoplastic elastic resin constituting the heterogeneous mixed network of the present invention 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 Average molecular weight is 5
00 or more and 5000 or less, particularly preferably 1000 or more and 3
When 000 or less of polytetramethylene glycol is copolymerized in an amount of 15% by weight or more and 70% by weight or less, more preferably 30% by weight or more and 60% by weight or less, terephthalate having rigidity in the acid component of the hard segment Acid and naphthalene 2.
6 When the content of 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 fatigue resistance are improved, but the temperature after melting heat bonding is lower than the melting point by at least 10 ° C or more. The annealing treatment improves the heat resistance and sag resistance. After applying compressive strain,
The ring further improves the heat resistance and sagging resistance. 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 present invention is a continuous thermoplastic elastic resin.
I made a mixture of thick and thin filaments,
A three-dimensional vertical structure in which most of the contact parts are fused by contacting each other.
Formed a body structure with both sides substantially flat
Apparent density is 0.01g / cm ³To 0.2 g / cm³Net
The cross section of the linear thick line and thin line that form a strip
Different fineness mixed net having a secondary moment ratio of 5 or more and 500 or less
It is a state. The function of the cushioning material is to thicken the basic fineness.
And make it a little harder to hold the body shape and moderately sink
More comfortable buttocks touch and even distribution of buttocks pressure distribution
The seat that absorbs vibration with a component that makes it and a component with good vibration damping
It is composed of components that block the vibration transmitted from the
It can be deformed and absorbed as a unit to improve the sitting comfort
It In the present invention, the body shape is maintained by mixing thick filaments.
Difference that improves function and develops a desirable cushion function
It is a finely mixed reticulate body. The network of the present invention has thermoplastic elasticity.
Since it is made of resin, it can be used to
Most of the vibration is absorbed by the vibration absorption function of thermoplastic elastic resin
Damps and acts as a vibration isolation layer. In addition, locally large changes
Even if a shape stress is applied, the surface of the mesh body will be subjected to a deformation stress.
A heat transfer that is substantially flattened and most of the contact area is fused.
Responsive to deformation stress on the surface of a net made of plastic elastic resin
Disperses the deformation stress, and the thick filaments show an appropriate compression resistance.
At the same time, deformation occurs due to compression along with the thin filaments and the fusion is integrated.
Energy conversion by transformation of the entire three-dimensional structure
Absorbs deformation stress and avoids stress concentration on individual filaments
Yes, when the stress is released, the thermoplastic elastic resin rubber bullet
Since it develops the property and easily recovers the original form,
Good and thick line resistance to compression stress
The deformation strain against it changes like a spring, and when you sit down, a thin line
Since the strips and thick lines are mixed, the buttocks are supported with low repulsive force.
Body shape retention without giving a feeling of flooring
Since it has a longevity function, it is too soft and the subsidence is large
It was possible to improve the drawbacks. Wire made only of known inelastic resin
A mesh composed of strips cannot be absorbed by the surface layer.
When it is deformed, it does not have rubber elasticity.
Plastic deformation occurs and recovery does not occur, resulting in poor durability. Mesh
If the surface of the
External force is selectively transmitted to the surface line and adhesive points
And stress concentration may occur.
As a result, fatigue due to stress concentration occurs and
It may decrease. The deformation stress is transmitted from the outside.
3D structure part when the layer to be formed is made of thermoplastic elastic resin
Since the entire structure is deformed in minutes, stress concentration is relieved,
If only non-elastic resin is used, the stress will be applied as it is.
It concentrates on the points and causes structural destruction, which makes it impossible to recover. Furthermore,
Sit when the surface is not substantially flat and uneven
When you do so, you may feel uncomfortable in your buttocks, which may make you uncomfortable to sit in.
Not good. If the linear shape is not continuous, the fineness is
In a thick net, the adhesion point becomes the stress transmission point, so the adhesion point
Severe stress concentration on the
Inferior and not preferable. If not fused, shape retention
This is not possible and the structure does not deform as a unit.
Fatigue phenomenon occurs and the durability deteriorates, and at the same time the shape changes
It is not preferable because the body shape cannot be maintained. The present invention
The more preferable degree of fusion is the area where the filaments are in contact.
Most of them are fused, most preferably contact
All parts are in a fused state. 3D fused and integrated
The whole three-dimensional structure is deformed and energy is converted into deformation stress.
Is absorbed and is recovered when the stress is released, and transmitted from the frame.
Even if it vibrates, thermoplastic elasticity has good vibration absorption and elastic recovery.
The resin wire absorbs and blocks the vibration of the resonance part of the human body.
You can improve comfort and durability. The present invention
Apparent density of reticulate body is 0.005g / cm³Then repulsion
Loss of force, insufficient vibration absorption capacity and deformation stress absorption capacity
It may be difficult to develop the cushion function.
0.20 g / cm³Above, the repulsive force is too high and the sitting heart
Since the ground may be deteriorated, vibration absorption capacity and deformation stress
The function as a cushion body is developed by utilizing the absorption function.
Easy to get 0.01g / cm³0.10 g / cm or more³The following is
Preferably, more preferably 0.03 g / cm³0.0 or more
8 g / cm³It is the following. The present invention has a thick line and a thin line.
When three-dimensional structure is formed by mixing
Can exhibit uniform anti-compression property and shows softness
Only the thin filaments do not undergo large deformation selectively in the three-dimensional network.
The entire tow structure is deformed to disperse the force well.
It If it is unevenly distributed, uniform anti-compression property cannot be expressed and local
Intensity is poor due to stress concentration on thick and thin filaments
It is not preferable. Disconnection between thick and thin filaments of the present invention
The surface secondary moment ratio is 5 to 500 (in terms of fineness ratio)
In the case of a solid round cross section, the fineness and the fineness of thick filaments
The fineness ratio of the stripes is 1.7 times or more and 8 times or less. )
It If it is less than 5, the function of the thick filament as an anti-compression component is
It is not preferable because it is difficult to develop. Thick above 500
The difference in density between the filaments and the thin filaments becomes too large, resulting in a three-dimensional
Density unevenness is likely to occur in the body structure, and the thin linear nets
Loss of tow reinforcement effect, resulting in stress concentration on thick filaments.
It is not preferable because it becomes easy to twist and durability is lowered. Thick
The cross-section secondary moment ratio between the fine and fine lines is preferably
10 to 300, more preferably 20 to 10
It is 0 or less. Thus, the wire forming the mesh body of the present invention
The fineness of the strip is preferably 100,000 denier or less. Apparent
0.2g / cm³If you do the following, 100,000
If it exceeds denier, the number of components will decrease and density unevenness will occur.
In some cases, a structure with poor durability is partially formed, and stress concentration
It is not preferable because fatigue increases and durability deteriorates.
The fineness of the filaments constituting the reticulated body of the present invention is too fine.
If so, the compressive resistance becomes too low and the stress absorption due to deformation is
Since it decreases, 100 denier or more is preferable. More preferred
More than 500 denier, which is easy to get the anti-compression effect,
Does not impair the denseness of the structural surface due to the decrease in the number of constituents 10
It is less than 000 denier. The thickness of the mesh of the present invention is
The desired thickness can be selected depending on the way and is not particularly limited,
If it is less than 5 mm, the stress absorption function and the stress dispersion function will deteriorate.
So, the preferable thickness is the surface function that distributes the force and the vibration and deformation.
A thickness of 10 mm or more that can exhibit a stress absorbing function
And more preferably 20 mm or more.

The cross-sectional shape of the filaments of the reticulate body of the present invention is not particularly limited, but the hollow section or the irregular section has the effect of mixing thick filaments and thin filaments and more preferable anti-compression property ( Repulsive force) and touch can be imparted, which is particularly preferable. The anti-compression property can be adjusted by the fineness and the modulus of the material used to make the fineness fine, or in the soft material the hollowness and the irregularity can be increased to adjust the gradient of the initial compression stress, and the fineness can be made slightly thicker or slightly. A material with a high modulus lowers the hollow ratio and the degree of irregularity to provide anti-compression property with a comfortable sitting feeling. As another effect of the hollow cross section and the irregular cross section, by increasing the hollow ratio and the degree of irregularity, if the same anti-compression property is given, the weight can be further reduced, and the energy saving can be achieved when it is used for the seat of an automobile or the like. Yes, if you have a futon,
Improves handling when lifting 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, when the thermoplastic elastic resin layer is largely deformed, the energy and the deformation stress that cannot be converted into energy are converted into energy.
In order to obtain a three-dimensional three-dimensional structure that can be converted and restored, a sheath-core structure or a side-by-side structure in which 50% or more of the linear surface is occupied by a soft thermoplastic elastic resin, and a combination thereof are mentioned. That is, in the sheath core structure, the sheath component is a thermoplastic elastic resin having a large soft segment content which is easy to energy-convert vibration and deformation stress, and the core component is a thermoplastic elastic resin having a small soft segment content, By giving anti-compression property, it is possible to give a comfortable touch to the buttocks due to an appropriate 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) It is particularly preferable that the ratio of the thermoplastic elastic resin having a large soft segment content occupying the linear surface is 80% or more, and most preferably the thermoplastic elastic resin having a large soft segment content occupying the linear surface. Is a score with the ratio of 100% as 100%. When the proportion of the thermoplastic elastic resin with a large soft segment content that occupies the linear surface is large, the flowability when melting and fusing is high, so there is the effect of strengthening the adhesion, and the structure deforms as a unit. In this case, the fatigue resistance against stress concentration at the bonding points is improved, and the heat resistance and durability are further improved.

Since thick and thin filaments made of a thermoplastic elastic resin are mixed to form a three-dimensional three-dimensional structure, most of the contact portions are fusion-bonded and the surface is substantially flattened. Other heat-adhesive components (heat-bonded non-woven fabric, heat-bonded non-woven fabric, heat-bonded non-woven fabric, heat-bonded non-woven fabric, heat-bonded non-woven fabric, non-woven fabric, knitted fabric, hard cotton, film, foam, metal, etc. (Fiber, heat-bonded film, heat-bonded resin, etc.) or adhesive to form an integrated laminated structure, which is used for vehicle seats, ship seats,
Beds for vehicles such as vehicles, ships, hospitals, etc.
If you want to get furniture chairs, office chairs, futons and other products,
Since the contact area with the adherend surface can be widened, it is possible to obtain a product that has a wide bonding area and is firmly bonded and has good adhesion durability. Incidentally, by performing the above pseudo-crystallization treatment at any stage of commercialization from the different fineness mixed reticulate body forming step, the thermoplastic elastic resin component in the structure becomes a melting curve measured by a differential scanning calorimeter. It is more preferable to have 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 filaments of the different fineness mixed reticulate body of the present invention are formed into a composite structure, and a low melting point thermoplastic elastic resin having a large soft segment content that facilitates energy conversion of vibration and deformation stress is used as a heat-bonding component and a shape-retaining component. By using a thermoplastic elastic resin having a low soft segment content, 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 heterogeneous-fineness mixed 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 to form a reticulate body, a nonwoven fabric, or a knitted fabric. , A hard cotton, film, foam, metal, etc., the contact area with the surface to be heat-bonded can be widened, so that the heat-bonded area becomes wider, and a new heat-bonded molded body and vehicle seat, ship seat,
Beds for vehicles such as vehicles, ships, hospitals, etc.
You can get furniture chairs, office chairs, and futon products. In addition, by performing pseudo crystallization at any stage until new molded products and products are commercialized, the filaments made of the thermoplastic elastic resin in the structure are melted by a differential scanning calorimeter. It is more preferable to make the curve have an endothermic peak at a temperature of room temperature or higher and melting point or lower because a product with significantly improved heat resistance and durability can be provided. When the adherend is adhered in a stretched state at the time of heat-bonding, the adhered body does not relax the stretched state due to the rubber elasticity of the adhesive layer, so that the adherend can be a molded body having tension and less likely to wrinkle.

Next, the manufacturing method of the present invention will be described. The manufacturing method of the present invention distributes the thermoplastic elastic resin to each nozzle orifice from a nozzle in which a plurality of orifices having different cross-sectional areas are mixed,
At a melting temperature higher than the melting point of the thermoplastic resin by 10 ° C. to 80 ° C., they are 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 are sandwiched by a take-up device. This is a method for producing a mixed reticulate body which can be cooled in a cooling tank, and preferably a different fineness which is annealed at a temperature of at least 10 ° C. or lower than the melting point of the thermoplastic elastic resin in the process of integrally molding after cooling to reach commercialization. It is a method for producing a mixed reticulate body and a product. The reticulate body is prepared by melting a thermoplastic elastic resin by using a general extruder and distributing it to a nozzle in which a plurality of orifices having different cross-sectional areas are mixed to obtain a melting point of 1 or more.
At a melting temperature higher than 0 ° C. to 80 ° C., a discharge amount that achieves a desired apparent density is discharged downward. When the melting temperature is higher than 80 ° C., which is higher than the melting point, thermal decomposition becomes 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 by 10 ° C. or more, melt fracture occurs and normal filament formation cannot be performed, and the temperature of the filament decreases when contacting and fusing while forming loop after discharge. The filaments may not be fused to each other and may result in a network having insufficient adhesion, which is not preferable. 2 is preferable to melting point
0 ° C to 60 ° C higher, more preferably 30 above melting point
The temperature is higher by 50 ° C to 50 ° C. When the flame retardant is kneaded at the time of melt extrusion, in a twin-screw extruder or a single-screw extruder, it is preferable to uniformly knead with a screw having a kneading function such as a dullage or a pin. In the case of multi-component, the thermoplastic elastic resin is separately melted by using a multi-component extruder for each individual component, and the thermoplastic elastic resins are jointly distributed at the nozzle back surface where a plurality of orifices having different cross-sectional areas are mixed, At the same melting temperature, which is 10-80 ° C higher than the melting point of each component,
20 ° C. to 80 ° C. higher than the melting point of the low melting point component and 15 ° C. to 40 ° C. higher than the melting point of the high melting point component,
More preferably from the melting point of the low melting point component to 40 ° C to 70 ° C
It is discharged at a higher discharge temperature below the orifice with a discharge amount that gives a desired apparent density at the same melting temperature, which is 20 ° C. to 30 ° C. higher than the melting point of the high melting point component. Unless the melting temperature difference immediately before joining is 10 ° C. or less, abnormal flow may occur and the formation of the composite morphology may be impaired. In the sheath core, the core component is supplied from the center, and the sheath component is merged from around the core component and discharged. On the side-by-side, the respective components are combined at the melting temperature and discharged from the left and right or the front and back. The nozzle of the present invention in which a plurality of orifices having different cross-sectional areas are mixed,
For example, an effective width of 50 mm in the longitudinal direction and an effective width of 50 in the width direction.
In the case of 0 mm, the pitch between the holes in the row in the width direction of the nozzle is constant at 5 mm, and in the case of an orifice shape with a round cross section with a constant pitch between rows, if the cross-sectional area of the orifice is changed, the pressure loss difference at the time of discharge is given Using the principle that the molten thermoplastic resin is extruded from the same nozzle at a constant pressure with a smaller pressure loss in orifices, the orifice diameter for making thick filaments is φ1 mm and the orifice diameter for making thin filaments is φ0. Nozzles in which φ1 mm and φ0.7 mm are alternately arranged by staggered arrangement in which each row has a diameter of 1 mm and φ0.7 mm is shifted by 2.5 mm for each row in the longitudinal direction, and the first row is from φ1 mm If arranged, the second row is φ0.7
An example is a nozzle in which φ1 mm and φ0.7 mm are arranged in a straight line and are arranged in a straight line alternately in each column. Of course, a combination of two thin holes and one thick hole or three thin holes and one thick hole can be selected as needed. The shape of the orifice is not particularly limited, but may be a hollow cross section (for example, a triangular hollow shape, a round hollow shape, a shape with a protrusion, etc.) and / or an irregular cross section (for example, a triangular, Y-shaped, star-shaped cross-section secondary mode). In addition to the above effects, it is difficult for the three-dimensional structure formed by the discharge filaments in the molten state to relax the flow, and on the contrary, the flow time at the contact point is maintained for a long time to strengthen the adhesion point. It is particularly preferable because it can be When heating for adhesion as described in Japanese Patent Application Laid-Open No. 1-2075, the three-dimensional structure is easily relaxed, a planar structure is formed, and a three-dimensional three-dimensional structure becomes difficult, which is not preferable. As an effect of improving the properties of the reticulate body, the apparent bulk can be increased, the weight can be reduced, the anti-compression property can be improved, and the elasticity can be improved, which is difficult to obtain. In the 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 holes of the present invention is preferably 3 mm to 20 mm, more preferably 5 mm to 1.
It is 0 mm. Of course, the cushion characteristics can be optimized by changing the hole density of a specific portion. 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. Further, it is possible to manufacture a reticulated structure having different fineness filaments between rows. Then, the liquid is discharged downward from the nozzle, and while forming a loop, they are brought into contact with each other in a molten state and fused to form a three-dimensional structure, and both sides of the reticulated structural body in a linear state are drawn. It is sandwiched by a net, and the twisted discharge line on the surface of the mesh is bent over 45 ° to deform and flatten the surface, and at the same time the contact point with the unbent discharge line is bonded to form a structure. After that, continuously 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. Basically, 10 cm to 40 cm is preferable when the discharge amount of the discharge line is large at 5 g / min or more, and 5 cm to 20 cm is preferable when the discharge amount of the discharge line is less than 5 g / min hole, but in the present invention, Since the thick filaments and the thin filaments are mixed, it is preferable to set the distance between the nozzle surface and the take-off point according to the discharge amount of the thin filaments. 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, it is difficult to drain and dry, and the thermoplastic elastic resin swells, 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 pair of take-up conveyors with adjustable intervals installed on the cooling medium sandwiches and holds the molten discharge filaments so that the parts that are in contact with each other are fused and continuously drawn into the cooling medium to solidify By adjusting the interval of the conveyor when forming the body,
The thickness can be adjusted while the fused network is in a molten state, and a desired thickness can be obtained. If the conveyor speed is too high, the formation of contact points may be insufficient, or the contact point may be cooled until the fusion point is sufficiently formed, resulting in insufficient fusion of the contact portion. Further, if the speed is too slow, the melt will stay too much and the density will increase, so it is necessary to set the conveyor speed suitable for the desired apparent density. As a preferred method of the present invention, after cooling once, in any step leading to product formation by integral molding, a pseudo-crystallization treatment by annealing is performed at a temperature of at least 10 ° C. or lower than the melting point of the thermoplastic elastic resin to carry out a different fineness. A more preferred method is to obtain a mixed reticulate or product. 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. By this treatment, the heat-resistant sag resistance is remarkably improved as compared with the one having no endothermic peak (having no endothermic peak) having an endothermic peak below the melting point. The preferred pseudo-crystallization treatment temperature of the present invention is (Tαcr + 10 ° C) to (Tm-20 ° C). If it is pseudo-crystallized by simple heat treatment, heat resistance and sag resistance are improved. However, it is more preferable to impart compressive deformation of 10% or more and anneal to significantly improve the heat resistance and sag resistance. When the drying step is performed after cooling once, the pseudo crystallization treatment can be performed at the same time by setting the drying temperature to the annealing temperature. Also, a pseudo crystallization treatment can be separately performed in the process of commercialization.

When the different fineness mixed reticulate body of the present invention is used as a cushioning material, it is necessary to select the resin, fineness, loop diameter and bulk density to be used depending on the purpose and site of use. For example, in order to impart a soft touch, moderate depression and bulging with tension, it is preferable to have a low density and fine fineness and a fine loop diameter. A layer with medium density, thick fineness, and a slightly larger loop diameter to lower the frequency, improve linearity of moderate hardness and compression hysteresis to improve body retention, and maintain durability. It is preferable to have a structure in which layers having low density, fine fineness, and fine loop diameter are laminated and integrated. Further, it can be used for vehicle seats, boat seats, beds, chairs, furniture, etc. by molding it into a shape suitable for the purpose of use by using a molding die or the like to the extent that the three-dimensional structure is not impaired. Of course, it is also possible to use it in combination with other materials such as a different mesh body, a hard cotton cushion material composed of a short fiber aggregate, a non-woven fabric or the like so as to meet the required performance in relation to the application. In addition, other than the resin manufacturing process, the molded product is processed from the manufacturing process to the extent that performance is not deteriorated, and at any stage of commercialization, it becomes flame retardant, insecticidal, antibacterial, heat resistant, water / oil repellent, colored, aroma, etc. It is possible to perform the processing such as the addition of chemicals to add the function.

[0016]

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) Cross section secondary moment ratio of filaments and fineness Each filament portion was cut out from 10 places of the sample, embedded with acrylic resin, the cross section was cut out to create a section, and a cross section photograph was taken. obtain. The cross-sectional photograph of each part is enlarged to show the cross-sectional area (Si) and cross-section secondary moment (Ii) of each part of thick and thin filaments.
Ask for. Next, the secondary secondary cross-section moment (Il
The ratio (IΔ) between i) and the secondary moment of cross section (Isi) of the thin filament is calculated by the following equation. (Average of each part n = 5) IΔ = Σ (Ili) / Σ (Isi) Further, a section obtained in the same manner was dissolved in acrylic resin with acetone, vacuum defoamed, and heated to 40 ° C. using a density gradient tube. The specific gravity (SGi) measured by Then, a linear weight of 9000 m is obtained from the following equation. (Unit: cgs) Fineness = [(1 / n) ΣSi × SGi] × 900000 Whether or not the fusion-bonded sample is fused by visual judgment is determined by whether or not the fibers adhering to each other can be pulled out by hand and removed. It is determined that something that does not come off is fused. Heat resistance and durability (residual strain at 70 ° C) Cut a sample into a size of 15 cm x 15 cm, compress it by 50%, leave it in dry heat at 70 ° C for 22 hours, then cool to remove compression strain and leave it for 1 day (b) Is calculated, and is calculated from the thickness (a) before processing by the following equation, that is, (ab) / a × 100. Unit% (average value of n = 3) Cyclic compression strain sample is cut into a size of 15 cm x 15 cm, and is 50% in a RH room at 25 ° C and 65% in a Shimadzu Servo Pulser.
The thickness (b) after leaving the sample for 20,000 times after repeating compression recovery at a cycle of 1 Hz up to the thickness of 1 is calculated from the thickness (a) before the treatment, that is, (ab) / ax Calculated from 100. Unit% (average value of n = 3) A composition in which a flame retardant was not added to a thermoplastic elastic resin A-1 described later was used as a sheath component and A-2 by a known composite spinning machine by a conventional sitting comfort method. The composition containing no flame retardant was individually melted to form the core component and distributed immediately before the orifice. Each discharge amount was 50/50 by weight, and 1.6 g / min. Min: 0.8 g / min) and spinning temperature 245
At a spinning rate of 3500 m / min, the yarn having a fineness of 4.1 denier and a shrinkage rate of 8% at a dry heat of 160 ° is converged into a tow-shaped crimp. Is given, 64
It was cut into mm to obtain a heat-bonding fiber made of a thermoplastic elastic resin having a cross section of sheath core. As the base material fiber, PET having an intrinsic viscosity of 0.63 and 0.56 was distributed at a weight ratio of 50/50 by a conventional method, and the discharge amount per single hole was 3.0 g / min (1.5 g / min.
Min: 1.5 g / min) at a spinning temperature of 285 ° C., discharged from a C type orifice, composite spinning at a spinning speed of 1300 m / min, and then drawn in two stages at 70 ° C. and 180 ° C. to obtain a drawn yarn. A three-dimensional crimped yarn having a denier of 6 denier and an initial tensile resistance of 38 g / denier was obtained by cutting into 64 mm and causing crimping at a dry heat of 160 ° C. The resulting heat-bonded fiber (30% by weight) and the base material fiber (70% by weight) were mixed to form an opener.
A web obtained by pre-opening with a card and opening with a card and having a basis weight of 500 g / m ² was laminated to form a carded web on the surface side of a multi-layer mesh body cut into the shape of a bucket sheet. The apparent bulk density of the cushion is 0.05 g / cm ³
To be laminated into a thermoforming female mold, compressed with an oyster mold, and packed and heat-bonded with hot air at 200 ° C for 5 minutes to form a bucket sheet-shaped cushion. Cover the side of polyester moquette consisting of, and set it on the seat frame to create a seat with 4 side seats and 6 side backs and 30 ° C RH7
5% A paneler was allowed to sit on the seat created in the room and the following evaluation was performed. (N = 5) (1) Feeling on the floor: The degree of "dosun" when sitting and the feeling of hitting the floor were qualitatively and qualitatively evaluated. Not felt; ◎, hardly felt; ○, slightly felt; △, felt; × (2) Feeling of stuffiness: Feeling stuffy when sitting for 2 hours and the buttocks and the part of the crotch that contacts the seat inside the crotch Qualitatively evaluated. Almost no feeling: ◎, slightly stuffy; ○, slightly stuffy; △, significantly stuffy; × (3) How long you can sit in the seat within 8 hours: within 1 hour; × within 2 hours; △ within 4 hours;
○ 4 hours or more; ◎ (4) A qualitative qualitative evaluation was performed on the degree of waist fatigue when the user sat in the seat for 4 hours. None; ◎, hardly tired; ○, slightly tired; △, very tired; × (5) Overall evaluation: 4 points from ◎ of the evaluations from (1) to (4), ○
3 points, △ is 2 points, × is 1 point and does not include Δ with 12 points or more; very good (⊚), that with 12 points or more; Good (○), 10 points or more is x It was evaluated as those which did not contain; those which were somewhat bad (Δ) and those which contained x; bad (x).

Example 1 As a polyester elastomer, dimethyl terephthalate (DMT) or dimethyl naphthalate (DM) was used.
N) and 1.4 butanediol (1.4 BD) were charged with a small amount of a catalyst, and after transesterification by a conventional method, polytetramethylene glycol (PTMG) was added and polycondensation was performed while heating and depressurizing. -Terester block copolymer elastomer is produced, and then Asahi Denka Adekastab PFR is added as a flame retardant at a phosphorus content of 10000 ppm and Asahi Denka Adekastab AO330 is added as 2%, and the mixture is kneaded and pelletized. Table 1 shows the formulation of the thermoplastic elastic resin raw material obtained by vacuum drying at 50 ° C. for 48 hours.

[0019]

[Table 1]

With a 50 cm wide and 5 cm long nozzle effective surface, the hole-to-hole pitch in the width direction is 5 mm, and the orifice shape is 2 mm in outer diameter and 1.6 mm in inner diameter at intervals of 5 mm in the length direction, and the hollow forming property of triple bridge is formed. A thermoplastic elastic resin raw material (A) obtained by using a nozzle in which cross-sections and circular cross-section orifices with a diameter of 0.5 mm are alternately arranged -1 and A-2) are separately melted in two extruders, and A-1 and A-2 are melted through a gear pump.
Triple bridge with A-1 as the sheath component and A-2 as the core component immediately before the orifice (seed / core: 50/50 weight ratio, single hole discharge rate 2.0 g / min) To the hollow forming orifice, and to the round hole orifice, only A-1 (single hole discharge amount 0.5 g / minute hole) is supplied and discharged below the nozzle at a melting temperature of 240 ° C., 10 cm below the nozzle surface. Cooling water is placed in the chamber, and stainless steel endless nets 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 are exposed above the water surface. -While forming a ridge and fusing the contact portion, 3
While forming a three-dimensional mesh structure, both sides are sandwiched by a take-up conveyor, drawn into cooling water at 25 ° C at a speed of 1 m / min to be solidified, cut into a predetermined size, and then compressed to 80% of the thickness. The cross-sectional shape of the thick filament obtained by pseudo-crystallization treatment with hot air at 100 ° C. for 20 minutes is a triangular rice ball-shaped hollow cross-section with a sheath core structure having a hollow ratio of 38% and a fineness of 9
It is made up of 000 denier filaments. The fine filaments have a round cross section with a fineness of 2200 denier, a cross sectional secondary moment ratio of 172, and an average apparent density of 0.056 g / cm.
Table 2 shows the properties of the heterogeneous mixed reticulate body in which the surface of the three-dimensional reticulated structure of ³ is substantially flattened. Example 1 of Example 1 is a dense reticulated mixed reticulate body that takes advantage of the characteristics of a soft elastic resin and the characteristics of a slightly hard elastic resin, and thus is excellent in heat resistance, durability at room temperature, comfortable to sit on, and flame retardant. It was an excellent cushioning material with excellent safety. It can be seen that the seat created for evaluation also has excellent performance.

[0021]

[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.
A 50 cm wide and 5 cm long nozzle effective surface has a hole-to-hole pitch of 5 mm, and orifices of 1 mm in diameter and 0.7 mm in round cross section are alternately arranged at intervals of 5 mm in the length direction. Of the thermoplastic elastic resin A-
No. 3 was distributed to the nozzle, and the total discharge amount was 1590 g / min at a melting temperature of 210 ° C. and the take-up conveyor speed was 1.
Thick filaments having a fineness of 10400 denier and fine filaments having a fineness of 250 were obtained in the same manner as in Example 1 except that the fineness was 3 m / min.
Table 2 shows the characteristics of a heterogeneous mixed reticulate body having a denier of 0, a cross-sectional secondary moment ratio of 73, and an apparent density of 0.048 g / cm ^3.
Shown in. As is clear from Table 2, Example 2 is a cushioning material that is practically usable in terms of heat resistance and durability at room temperature, has improved body retention, and is comfortable to sit on. It turns out to be 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. After mixing and kneading, pelletizing, vacuum drying, and prescription of the polyether urethane polymer are shown in Table 3.

[0024]

[Table 3]

The thermoplastic elastic resin thus obtained was used with B-1 as a sheath component of a thick filament, B-2 as a core component, B-1 as a thin filament, and a melting temperature of 210.degree. Other than that, the cross-sectional shape of the thick filament obtained in the same manner as in Example 1 is a triangular rice ball type hollow cross-section with a sheath core structure, the hollow ratio is 40%, and the fineness is 1
1000 denier, fine filament with round cross section has fineness of 2500
Table 2 shows the characteristics of the denier, the cross sectional secondary moment ratio of 230 and the average apparent density of 0.055 g / cm ³ of the mixed fineness reticulated body. Example 4 is a heterogeneous mixed reticulate body using urethane as a thermoplastic elastic resin, which has heat resistance, durability at room temperature,
It was a cushioning material with excellent sitting comfort. It can be seen that the seat created for evaluation is also excellent.

Comparative Examples 1 and 2 In Comparative Example 1, PET having an intrinsic viscosity of 0.63 was used and discharged at a melting temperature of 280 ° C. In Comparative Example 2, PP having a melt index of 12 was used and the melting temperature was 240 ° C. Table 2 shows the characteristics of the different fineness mixed reticulate body obtained in the same manner as in Example 2 except that the pseudo crystallization treatment was not performed. In the reticulate body of Comparative Example 1, the thick filaments had a fineness of 8900 denier in a solid round section, the fine filaments had a fineness of 2100 denier in a solid round section, and the secondary moment ratio of the cross section was 76. Apparent density is 0.054g
It was / cm ³ . In the reticulate body of Comparative Example 2, the thick filament has a solid round cross section with a fineness of 21,000 denier, the fine filament has 5300 denier, the secondary moment ratio of cross section is 62, and the average apparent density is 0.053 g / It was cm ³ . Comparative Example 1 is an example of a cushioning material that is poor in heat resistance and durability because it is a net-like body made of non-elastic polyester and is hard and uncomfortable to sit on. Comparative example 2
This is an example of a cushion material that is hard and uncomfortable to sit on because it is a reticulate body made of non-elastic olefin with a slightly finer fineness, and has poor heat resistance and durability.

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 some of the properties of the reticulate body obtained by the same method as described in (1). In addition, since the fusion state is poor and the shape retention is poor, 50
% Repulsive force at compression, apparent density, residual strain at 70 ° C., repeated compressive strain, and sitting comfort were 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 All orifices had a diameter of 1 mm and the total discharge amount was 55 mm.
The fineness was 2000-2, which was obtained in the same manner as in Example 2 except that 0 g / min was set and a take-up conveyor net was placed 10 cm below the nozzle surface and no pseudo-crystallization treatment was performed.
Table 2 shows the characteristics of the reticulate body having a denier of 400, a secondary sectional moment ratio of 1.7, and an average apparent density of 0.022 g / cm ³ . Since Comparative Example 4 uses a thermoplastic elastic resin, it has a good touch, but it is an example of a cushioning material having a small cross-section secondary moment ratio and inferior body retention, and slightly inferior heat resistance and durability.

Comparative Example 5 Orifice shape was φ1 mm at intervals of 5 mm in the longitudinal direction.
Arrange 0.5mm round cross-section orifices alternately, discharge at a total discharge rate of 2100g / min, arrange a take-up conveyor net 10cm below the nozzle surface and take-off at 1m / min for pseudo-crystallization treatment. The thick filaments obtained in the same manner as in Example 2 had a fineness of 32,000 denier, a secondary cross-section moment ratio of 4000, and an average apparent density of 0.085.
Table 2 shows the properties of the gauze / cm ³ mixed fineness reticulate body. In Comparative Example 5, the fineness of the thick filaments is remarkably large, and the secondary moment ratio in cross section with the thin filaments is remarkably large. Therefore, since the heterogeneous mixed reticulate body has density unevenness, the heat resistance and durability are deteriorated, and sitting comfort is improved. This is an example of a cushion material that becomes slightly worse.

COMPARATIVE EXAMPLE 6 A take-up conveyor net is a wire mesh having irregularities on both sides,
The thick filaments obtained in the same manner as in Example 2 except that the pseudo crystallization treatment was not performed had a solid round cross section, a fineness of 10,000 denier, a cross sectional secondary moment ratio of 72, and an average apparent density of 0.048.
Table 2 shows the properties of the gauze / cm ³ mixed fineness reticulate body. 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. It is an example of a material.

Comparative Example 7 Thick filaments obtained in the same manner as in Example 2 except that the total discharge rate was 500 g / min, the take-up conveyor net speed was 4 m / min, and no pseudo-crystallization treatment was performed. Has a fineness of 290
Table 2 shows the characteristics of a heterogeneous mixed reticulate body having a denier of 0, a cross sectional secondary moment ratio of 51, and an apparent density of 0.005 g / cm ^3.
Shown in. Comparative Example 7 has a low apparent density, and therefore is a cushioning material having inferior sitting comfort, heat resistance and durability.

Comparative Example 8 A thick sample obtained in the same manner as in Example 2 except that the total discharge amount was 4500 g / min, the take-up conveyor net speed was 0.8 m / min, and no pseudo-crystallization treatment was performed. Table 2 shows the characteristics of the heterogeneous mixed reticulate body having a filament fineness of 28,000 denier, a sectional secondary moment ratio of 66, and an apparent density of 0.23 g / cm ³ . Comparative Example 7 has a high apparent density and therefore is a cushioning material which is slightly inferior in sitting comfort and inferior in heat resistance and durability.

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 different fineness mixed reticulated body obtained in Example 1 was laminated on the reticulated body surface cut to a length of 120 cm, and the apparent density was 0.06 g.
/ Cm ³ and compressed with hot air of 180 ° C. for 5 minutes and then cooled to obtain a non-woven fabric laminated mesh body having flat both sides. Then, compress it by 10% of the thickness and quasi-crystallize it with hot air at 100 ° C for 20 minutes to make a cushion with a thickness of 7 cm.
I made one. The obtained cushion has a thickness of 7 cm and a width of 120.
cm, a length of 200 cm was quilted every 50 cm, and the mattress was made by putting it in a lateral area of 120 cm in width and 200 cm in length. This mattress was placed on a bed, and a paneler-4 person used it for 7 hours in a room at 25 ° C. RH 65% to sensory-evaluate the sleeping comfort.
The bed was covered with sheets, the comforter was 1.8 kg of down / feather: 90/10, and the pillow was the one used by the paneler every day. As a result of the evaluation, the bed was highly safe and passed the flame retardancy according to the 45 ° mesenamin method with no feeling of flooring, moderate depression, and comfortable sleeping without feeling stuffiness. For comparison, a similar mattress was prepared from a urethane foam plate with a density of 0.04 g / cm ³ and a thickness of 10 cm, and the mattress was placed on a bed and the sleeping comfort was evaluated. It was a bed that made me feel stuffy and didn't feel comfortable to sleep.

Example 6 A net body was prepared by laminating nonwoven fabrics of the mixed fineness network obtained in Example 1 in the same manner as in Example 5, and the width was 38 cm and the length was 4 cm.
The corner was cut at 0 cm to make the corner 10 cm, and the polyester moquette used for sitting comfort evaluation was placed on the side of the office chair frame, and the commercially available polyurethane was used for the cushion. As a result of evaluating the sitting comfort for 4 hours in comparison with a chair, the feeling of stuffiness, the feeling of being on the floor, and the time that the patient can endure while sitting are remarkable when using the heterogeneous-fineness mixed reticulate body in which the nonwoven fabric of the present invention is laminated. Was excellent.

[0035]

EFFECTS OF THE INVENTION The continuous filaments made of thermoplastic elastic resin and having a mixture of thick filaments and thin filaments form a three-dimensional network structure and are fused together to form a substantially flat surface. The different fineness reticulated body has improved vibration isolation, heat resistance and durability, bulkiness, and body shape retention, and has improved sitting comfort.
A cushioning material that is resistant to stuffiness, and is used in combination with other materials to give the above-mentioned preferable characteristics to vehicle seats, boat seats, vehicles, boats, commercial beds such as hospitals and hotels,
Products such as furniture cushions and bedding can be provided. Furthermore, it is also useful as an interior material and a heat insulating material for vehicles and building materials.

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ Identification code FI D01F 6/62 303 D01F 6/62 303D 6/86 301 6/86 301B 6/92 304 6/92 304H (56) References Kaihei 2-92214 (JP, A) JP 7-189105 (JP, A) JP 1-213454 (JP, A) JP 58-109670 (JP, A) JP 58-149362 ( JP, A) JP 55-17527 (JP, A) Actual flat 1-16326 (JP, U) Actual flat 2-18300 (JP, U) Actual flat 2-18371 (JP, U) (58 ) Fields surveyed (Int.Cl. ⁷ , DB name) D04H 1/00-18/00 B68G 1/00-15/00 D01D 1/00-13/02 D01F 1/00-13/04

Claims (7)

(57) [Claims] 1. A three-dimensional three-dimensional structure in which a continuous thick filament and a thin filament made of a thermoplastic elastic resin are mixed and bent to be in contact with each other to melt most of the contact portion, Both sides thereof are substantially flattened, and the thick and thin filaments have a cross-section secondary moment ratio of 5 to 5.
It is 500, and the apparent density is 0.01 to 0.2 g / cm ^3.
A mixed reticulate body characterized by being: 2. The mixed fineness reticulated body according to claim 1, wherein the continuous filaments have a hollow cross section and / or a modified cross section. 3. Phosphorus in the thermoplastic elastic resin is 5000 pp
The reticulated mixed reticulate body according to claim 1, wherein the reticulated body contains m or more. 4. The heterogeneous mixed reticulate body according to claim 1, wherein the thermoplastic elastic resin constituting 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. 5. A thermoplastic elastic resin is distributed to each nozzle orifice from a nozzle in which a plurality of orifices having different cross-sectional areas coexist, and the temperature is lower than the nozzle at a melting temperature 10 to 80 ° C. higher than the melting point of the thermoplastic resin. A method for producing a different fineness mixed reticulate body in which a three-dimensional structure is formed by ejecting toward each other and contacting each other in a molten state and fusing them to form a three-dimensional structure, which is sandwiched by a drawing device and cooled in a cooling tank. 6. The method for producing a mixed fineness reticulated body according to claim 5 , wherein annealing is performed at a temperature of at least 10 ° C. or lower than the melting point of the thermoplastic elastic resin in a step of integrally molding after cooling and commercialization. 7. A seat for a vehicle, a seat for a ship, a seat for a vehicle, a seat for a vehicle, a seat for a ship, a commercial bed for home use, a chair for furniture, an office work, etc., which uses the mixed fineness reticulated body according to claim 1. The product described on either the chair or the futon.