JP3588893B2 - Easy to recycle bed mat - Google Patents

Description

【化３】

式（２）（３）中、Ｒは高分子主鎖または有機残基、Ｒ_１ は炭素数８〜１８のアルキル基、Ｒ_２ は炭素数１〜１８のアルキル基、フェニル基または置換アリール基を示す。
【００４６】
上記（２）または（３）で示される第４アンモニウム塩化されたリン酸エステル基を有するビニル系重合体または共重合体は優れた抗菌性を有している。しかも、両性を有する高分子物質であるため、合成繊維や天然繊維に強固に付着させることができる。このため、持続性、洗濯耐久性に優れた抗菌性を得ることができる。また、水溶液や水−アルコール混合溶液として得られるため、繊維材料への適用が容易であり、かつ装置を腐蝕させることがないという利点を有している。
【００４７】
次に、本発明で使用するメラミン系化合物の例としては、下記（４）の一般式で示されるものがあげられる。
【００４８】
【化４】

ただし、式中、Ｒ_０ 〜Ｒ_２ ：−Ｈ、−ＯＨ、−Ｃ_６ Ｈ_５ 、Ｃ_ｎ Ｈ_２ｎ＋１（_ｎ ：１〜１０）、−ＣＯＯＣｎＨ_２ｎ＋１（_ｎ ：１〜２０）、−ＣＯＮＲ_３ Ｒ_４ 、−ＮＲ_３ Ｒ_４ （Ｒ_３ 、Ｒ_４ ：−Ｈ、−ＯＨ）、−ＯＣｎＨ_２ｎ＋１、−ＣＨ_２ ＯＣ_ｎ Ｈ_２ｎ＋１、−ＣＨ_２ ＣＯＯｎＨ_２ｎ＋１（ｎ：１〜２０）、−ＣＨ_２ ＯＨ、−ＣＨ_２ ＣＨ_２ ＯＨ、−ＣＯＮＨ_２ 、−ＣＯＮＨＣＨ_２ ＯＨ、−Ｏ（Ｘ−Ｏ）_ｎ Ｒ_５ （Ｘ：−Ｃ_２ Ｈ_４ −、−Ｃ_３ Ｈ_６ −、−Ｃ_４ Ｈ_８ −、_ｎ ：１〜１５００、Ｒ_４ ：−Ｈ、−ＣＨ_３ 、−Ｃ_２ Ｈ_５ 、−Ｃ_３ Ｈ_７ ）
上記一般式の中でも好ましい化合物は、Ｒ_０ 、Ｒ_１ が−ＮＲ_３ Ｒ_４ である化合物であり、その中でもＲ_２ が−ＣＯＮＲ_３ Ｒ_４ 、−ＮＲ_３ Ｒ_４ であるものがより好ましい。さらに、Ｒ_３ 、Ｒ_４ が−ＣＨ_２ ＯＨ、−ＣＨ_２ ＣＨ_２ ＯＨ、−ＣＯＮＨ_２ 、−ＣＯＮＨＣＨ_２ ＯＨである化合物が特に好適である。
【００４９】
かかるこれらの化合物は一例であり、上記以外の化合物や誘導体も用い得ることはいうまでもない。
【００５０】
メラミン系化合物は、重合性官能基を少なくとも２個有するものが繊維表面で形成される樹脂被膜の耐久性が向上し好適である。
【００５１】
かくして、抗菌成分として前記抗菌単独成分あるいは抗菌成分が酸性基含有重合体および／または共重合体と反応した抗菌性反応生成物と被膜形成主要成分としてのメラミン系化合物とからなる抗菌性被膜が繊維の表面に形成されるものであるが、該膜の耐久性に対する作用機構としては、上記被膜形成主要成分であるメラミン系化合物が、繊維基質ポリマ内で重合あるいは架橋し、２次元または３次元構造化すると同時に、その一部が繊維基質ポリマの官能基とも化学結合し、網状不溶化して繊維に強固に固着するための該膜の耐久性を著しく向上させて、優れた耐温水洗濯性およびドライクリーニング性を発揮させることができるのである。
【００５２】
上記抗菌成分と被膜形成主要成分を繊維に付与する方法の代表例としては、上記成分を含有する水溶液に重合開始剤あるいは架橋触媒を添加した同一処理浴で繊維をパディングまたはスプレー処理した後、湿潤下で反応処理する方法がある。反応は室温以上の温度で行うことができるが、通常は蒸熱処理する。上記２成分を別浴で処理することもできる。すなわち、まず抗菌成分を含有する処理浴で繊維をパディングまたはスプレー処理した後、乾熱または蒸熱処理し、次に被膜形成主要成分含む水溶液に重合開始剤または架橋触媒を添加した別処理浴で繊維をパディングまたはスプレー処理し、蒸熱処理することもできる。
【００５３】
重合開始剤は、アルキレングリコール単位を有するアクリル系化合物を重合反応させるときに使用される。具体例としては、過硫酸アンモン、過硫酸カリ、アゾビスイソブチロニトリル等、一般的なビニル重合開始剤でよく、またかかる重合開始剤の種類を選択することにより、適宜所望条件処理で被膜処理することができる。
【００５４】
一方、触媒はメラミン系化合物を架橋反応させる時に使用され、具体例としては、ギ酸、酢酸をはじめとする各種の有機カルボン酸及びそれらのアンモニウム、ナトリウム、カリウム等の有機塩及び硫酸、過硫酸、塩酸、リン酸、硝酸等のアンモニウム、ナトリウム、カリウム、マグネシウム、亜鉛、アルミニウム、鉄等の無機塩及びこれらの複塩などが挙げられる。勿論、上記した化合物は限定されない。
【００５５】
前記蒸熱処理は８０〜１４０℃、好ましくは１００〜１３０℃で０．５〜３０分間の条件で行なうことができる。乾熱処理は８０〜１５０℃、好ましくは１００〜１３０℃で乾燥した後、１００〜２２０℃、好ましくは１４０〜１９０℃で０．５〜５分間の条件で行なうことができる。
【００５６】
本発明方法に従って、パディングまたはスプレー処理するのに用いる処理液中には、柔軟剤、撥水剤、吸水剤、帯電防止剤、硬仕上げ剤等、他の薬剤を添加してもよい。
【００５７】
さらに、ベッドマットのマット中材繊維は、繊度が０．５〜３０デニール、繊維長が１０〜１００ｍｍの短繊維が好ましく用いられる。繊度かあまりに細くなると詰め綿として必要な集合体としての嵩が低くなったり、圧縮に対する反発性や嵩の回復性も低下する恐れがある。また、あまりにも太いと触感が粗硬になりがちである。また、繊維長が短かすぎると繊維間の絡合性が悪くなり綿切れが生じやすいし、また長くなりすぎると開繊性や製綿性が悪くなる恐れがある。
【００５８】
巻縮は、適宜選択すればよいが、嵩高性、ソフト感、圧縮に対する反発性や回復性あるいは製綿性をよくするために、機械巻縮を与えることが好ましく、詰め綿繊維製糸時の非対称冷却処理し、繊維１本１本に構造差を与えて３次元巻縮化したものがより好ましい。巻縮数は３山／２５ｍｍ以上、巻縮度が５％以上であることが好ましい。
【００５９】
また、この他、ベッドマットのマット中材繊維は、必要に応じて酸化チタン、カーボンブラック等の顔料のほか従来公知の抗酸化剤、着色防止剤、耐光剤、帯電防止剤等を添加することも好ましい。
【００６０】
本発明に使用するベッドマットのマット中材繊維の断面形状は丸のみでなく、多角などの異形断面で、中空化したものがさらに好ましい。
【００６１】
複合繊維ＣはポリエステルＲ１およびＲ２の２成分からなり、ポリエステルＲ１としては、例えば、ポリエチレン、ポリプロピレン、エチレンプロピレン共重合体、エチレンブテン共重合体、エチレン酢酸ビニル共重合体等のポリオレフィンあるいはオレフィン共重合体、ポリヘキサメチレンテレフタレート、ポリヘキサメチレンブチレンテレフタレート、ポリヘキサメチレンテレフタレートイソフタレート等のポリエステルあるいは共重合ポリエステル等の熱可塑性ポリマーから選ばれる、少なくとも一種類のポリマーを挙げることができる。
【００６２】
Ｒ２は特に限定されないが、例えば、テレフタル酸、２，６−ナフタレンジカルボン酸あるいはそれらのエステルを主たるジカルボン酸成分とし、エチレングリコールもしくはテトラメチレングリコールを主たるグリコール成分とするポリエチレンテレフタレート、ポリブチレンテレフタレート、あるいはポリエチレン２，６−ナフタレートなどのポリエステルが挙げられる。
【００６３】
Ｒ１の選択においては、前記の抗菌ポリエステル繊維Ａ、ポリエステル繊維Ｂおよび複合繊維ＣのポリエステルＲ２のうちで、最も融点が低いものより融点が低いものが使用され、熱接着性の観点からは２０℃以上低いのが好ましく、２５℃以上低いのがより好ましい。
【００６４】
また、接着の効果や熱劣化を防止する観点からＲ１の融点は８０〜１７０℃の範囲に含まれるのが好ましく、１００〜１７０℃の範囲に含まれるのはより好ましい。
【００６５】
複合繊維Ｃにおける重量比Ｒ１／Ｒ２は２０／８０〜６０／４０とするものである。好ましくは２０／８０〜５０／５０である。Ｒ１の重量比が少ないと、繊維間の熱接着性が十分に得られなくなり、製造したベッドマット中材の形態固定性が悪くなることがある。
【００６６】
一方、Ｒ１の重量比が高くなりすぎると、ベッドマット中材のソフト感が損なわれ、さらに圧縮残留歪が大きくなることがある。
【００６７】
複合繊維Ｃには、この他必要に応じてＲ１，Ｒ２以外の酸化チタン、カーボンブラック等の顔料のほか、抗酸化剤、着色防止剤、耐光剤、帯電防止剤などが添加されていても勿論よい。このような複合繊維Ｂは通常の複合紡糸法によって製造することができる。
【００６８】
次に、本発明に用いるベッドマット中材に嵩高性、ソフト感を付与し、圧縮に対する回復性を向上させるため、複合繊維Ｃは機械捲縮等を有するのが好ましい。この捲縮数は適宜選択すればよいが、捲縮数は少なくとも３山／２５ｍｍで捲縮度が少なくとも５％となるのが好ましい。
【００６９】
マット中材を構成する複合繊維Ｃとしては、嵩高性、ソフト感付与の観点から繊度が０．５〜３０デニール、繊維長が１０〜１００ｍｍの短繊維が好ましく用いられる。
【００７０】
次に、本発明に用いるマット中材の製造方法例について説明する。本発明に用いるマット中材を製造するに際しては、まず前記した重量比の抗菌ポリエステル繊維Ａと複合繊維Ｃ、または抗菌ポリエステル繊維Ａ、ポリエステル繊維Ｂおよび複合繊維Ｃとを、通常の紡績工程で使用する給綿機、混綿機、開繊機によって、十分に混綿、開繊し、目的に応じた形状の通気性型枠に送綿ファンによる空気流などの気体と共に吹き込んで充填する。前記のようにそれぞれの繊維を吹き込んで充填するためには、型枠が適度の通気性を有するものを使用する。例えば、ＪＩＳ Ｌ １０７９−１９６６フラジール型通気性試験機により測定した際においては、通気性は５〜２００ｃｃ／ｃｍ^２ ・ｓｅｃの範囲にあることが好ましい。
【００７１】
このような型枠としては、例えば、パンチング金属板で構成された金型を用いることができる。通気性型枠内に吹き込まれたそれぞれの繊維は、タテ、ヨコ、厚み方向にランダムに配列した状態となる。
【００７２】
次に、充填した繊維混合物を圧縮して、ベッドマット中材に適した密度にするものである。密度は０．０２５〜０．１０ｇ／ｃｍ^３ が好ましい。密度があまりに低いと、得られる繊維成形体がソフトすぎて使用感が悪くなることがあり、希望の形状に裁断、成形し難くなる。また密度があまりに高くなるとソフト感が低下し、使用感が悪くなることがある。
【００７３】
さらに、充填し、圧縮した繊維混合物を熱処理して複合繊維Ｃ相互間および複合繊維Ｃと抗菌ポリエステル繊維Ａやポリエステル繊維Ｂとの接点の一部を接着して形態を固定する。熱処理の温度は繊維ＣのＲ１が溶融する温度であればよく、一般的には８０〜２００℃が好ましい。熱処理時間は繊維混合物の密度等によって適宜選択するのが好ましい。
【００７４】
抗菌性はベッドマットのマット中材繊維に抗菌ポリエステル繊維をすればよいが、ベッドマットのカバーに抗菌性を付与することも好ましい。
【００７５】
【実施例】
次に本発明を実施例によりさらに詳細に説明する。本発明に記載した諸特性の測定法は次の通りである。
【００７６】
（１）撓み量
幅１０ｃｍ、厚み４ｃｍ、長さ５０ｃｍの長方形のマット中材試験片を３個準備し、水平な台上にのせ、試験片をすべらせて台の端から長さ３０ｃｍ出した状態で１分間放置後、台の上面と試験片の先端の下面の高さの差（撓み量）をスケールで読みとり、３回の平均値で表わした。
【００７７】
（２）抗菌性
黄色ブドウ状球菌（Ｓｔａｐｈｙｌｏｃｏｃｃｓｕ Ａｕｒｅｕｓ ＡＴＴＣ６５３８ｐ）のブイヨン懸濁液とし、布団の詰め綿をウエッブ状としたものに注加して、密閉容器中で３７℃、１８時間培養後の生菌数を計測し、殖菌数に対する菌数を測定して、菌数増減値差Ｋ＝ｌｏｇ（Ｂ／Ｃ）で求めた。
【００７８】
ただし、菌培養条件はｌｏｇ（Ｂ／Ａ）＞２であること。Ａは抗菌加工していない通常のポリエステルの綿のウエッブ状としたものに前記菌を注加して、注加直後分散回収した菌数。Ｂは抗菌加工していない通常のポリエステルの綿のウエッブ状としたものに前記菌を注加して、１８時間培養後分散回収した菌数。Ｃは詰め綿をウエッブ状としたものに前記菌を注加して、１８時間培養後分散回収した菌数。
【００７９】
なお、洗濯後の抗菌性は、ドラム染色機を用い、中性洗剤“ザブ”（花王）２ｇ／ｌ、過酸化水素３ｃｃ／ｌ、過酸化ソーダ１．５ｇ／ｌ、温度８５±２℃、浴比１：２０で１５分間洗濯し、その後排液、脱水後、水洗を１０分間実施する。水洗後タンブラー・ドライヤーを用いて２０分間で乾燥させる。これを洗濯１回とする。
【００８０】
抗菌性はＫが１．６以上を合格レベルとした。また、ＭＲＳＡに対する抗菌性は（財）日本食品分析センターに評価を依頼した。
【００８１】
（３）繊度
ＪＩＳ Ｌ１０１５−７−５１Ａの方法に準じて測定した。
【００８２】
（４）平均繊維長（カット長）
ＪＩＳ Ｌ１０１５Ａ法（ステープルダイヤグラム法）に準じて測定した。
【００８３】
（５）巻縮数および巻縮度
巻縮数および巻縮度はＪＩＳ Ｌ１０１５−７−１２−１およびＪＩＳ Ｌ１０１５−７−１２−２の方法に準じて測定した。
【００８４】
（６）充填密度
試験片（タテ：２０ｃｍ、ヨコ：２０ｃｍ、厚さ：２０ｃｍ）を２０℃×６５％ＲＨの雰囲気中に２４時間放置した後の重量（ｗ）を測定し、次式で求めた。
密度（ｇ／ｃｍ^３ ）＝ｗ／８０００
［実施例１〜３および比較例１〜２］
ベッドマットのマット中材用抗菌ポリエステル繊維Ａとして、通常のポリエチレンテレフタレートのチップを用いて、紡糸温度２８０℃、引取り速度１３５０ｍ／分、紡糸口金直下で通常の非対称冷却処理をして、未延伸糸を紡糸した。
【００８５】
次いで、該未延伸糸を、延伸倍率３．０倍、延伸浴温度８０℃で延伸し、クリンパで機械巻縮を付与・仕上げ油剤付与してカットした後、１４５℃の熱セッターでセット・乾燥して、繊度約１２デニール、カット長３０ｍｍ、捲縮数５．３山／２５ｍｍ、捲縮度２５．２％の中空率３０％、中空円形断面のステープルとした。
【００８６】
さらに、第４アンモニウム塩化した１価のリン酸エステル基を有するビニル系重合体からなる抗菌性樹脂を３２％含む抗菌剤の２．５％水溶液を調整した。また、メラミン系化合物であるＳｕｍｉｔｅｘ Ｍ−３（住友化学工業（株）製）１．０％水溶液、架橋剤であるＳｕｍｉｔｅｘ Ａｃｘ（住友化学工業（株）製）０．３％水溶液、軟化剤０．７％水溶液調整した。これら水溶液を混合、撹拌後、前記ポリエステル中空繊維ステープルを浸漬し、絞って１３０℃で１分間キュアリングさせて抗菌ポリエステル繊維Ａを得た。得られた抗菌繊維の抗菌成分付着量は０．５２％ｏｗｆ、メラミン系化合物付着量は０．６５％ｏｗｆ、黄色ブドウ状球菌の抗菌性Ｋは洗濯前４．３、洗濯５０回後４．１、ＭＲＳＡに対する抗菌性は洗濯前４．３、洗濯５０回後３．３と良好であった。
【００８７】
これとは別に、マット中材用複合繊維Ｃとして、Ｒ２は融点が２５５℃の通常ポリエチレンテレフタレートチップを使用し、Ｒ１はイソフタル酸４０モル％共重合した融点が１１０℃のポリエチレンテレフタレート系ポリエステルを用いて、紡糸温度２８５℃、引取り速度１３５０ｍ／分、Ｒ１／Ｒ２で表される重量比が５０／５０のＲ２を芯部とし、Ｒ１を鞘部とした同心円状の未延伸糸を紡糸した。
【００８８】
次いで、この未延伸糸を、延伸倍率３．０倍、延伸浴温度８０℃で延伸し、クリンパで機械捲縮を付与した。さらに、７０℃の熱セッターで乾燥した後、仕上げ油剤を付与して、カット長６４ｍｍに切断して、繊度約４．２デニール、表面層の融点が約１１０℃の複合繊維Ｃを得た。
【００８９】
前記繊維Ａおよび繊維Ｃを表１の混綿割合で混綿し、ローラカードでさらに混綿・開繊し、図２のような金型の吹込口から、各面にパンチングが施された、内面の幅×長さ×深さが８２×８４×１００ｃｍの下金型３に、空気流と共に吹き込んで充填した。吹き込まれた繊維混合物４を各面にパンチングが施された上金型２で圧縮し、充填密度０．０４ｇ／ｃｍ^３ 、厚さ５０ｃｍで固定した。金型に充填圧縮した繊維混合物４を、紡績糸のセットに使用するヒートセッターを用いて、蒸熱１３０℃×２５分間熱セットし、繊維成形体を得た。
【００９０】
次に、得られた前記繊維成形体の圧縮方向に対し垂直な方向を上下方向（厚み方向）として厚さ７ｃｍにスライスし、該スライスシートを横にならべて互いに接着した後裁断して、幅８２ｃｍ、長さ１９２ｃｍ、厚さ７ｃｍのベッドマット中材とした。さらに、表１のように実施例１、２および比較例２のベッドマット中材については大型油圧機を用いて室温状態で厚さ方向に圧縮率５０％で５回仕上げ圧縮処理した。
【００９１】
さらに、ベッドマットのカバー（側地）としてはポリエステル７５デニールの仮撚加工糸を用いた両面丸編地をポリエステルのスパン縫糸で縫製し、品質や取扱表示ラベルにはポリエステルスパンボンドを使用してベッドマットとした。
【００９２】
このベッドマットを１年間使用したところ、実施例１〜３のベッドマットは撓み量が５．１〜１９．８ｃｍで、ギャッジベツドの電動変化に良く追従し、屈曲性の良好なもので、抗菌性や洗濯等での取扱性も良好であって、かつ洗濯での水切れ性に優れ、透湿性、透水性が良好で快適な使用感を有するものであった。
【００９３】
これに対し、比較例１は、撓み量が４．３ｃｍでギャッジベツド用としての屈曲性がやや不良であって、座位での座り心地が劣り、抗菌性も劣るものであった。
【００９４】
また、比較例２は、屈曲性や抗菌性は良好であるが、撓み量が２４．２ｃｍでやや曲がり易く、マット中材をカバーに挿入しにくいと同時に、洗濯等でマットを移動させる場合の取扱性がやや劣るものであった。
【００９５】
実施例１〜３の使用後のベッドマットを回収し、反毛機にかけて解繊した後、この開繊繊維を溶融ペレット化し、再度溶融紡糸・延伸して、８デニール、３０ｍｍのポリエステルステープルとした。得られたステープルはやや灰色味を帯びたポリエステルステープルで、市販の通常ポリエステルステープルに比べてやや強度が低いものの、詰綿として十分使用可能なものであった。
【００９６】
実施例１〜３および比較例１〜２のベッドマット中材の加工方法や性質を表１に示す。
【００９７】
［実施例４］
実施例１で、抗菌ポリエステル繊維Ａを製造する際、抗菌加工を施さないステープルをポリエステル繊維Ｂとし、抗菌ポリエステル繊維Ａを４０重量％、抗菌加工を施さないポリエステル繊維Ｂを２０重量％、複合繊維Ｃを４０重量％混綿するほかは実施例２と同様にしてベッドマットとし、１年間使用した。該ベッドマットは屈曲性、防虫性、洗濯等での取扱性も良好であって、洗濯での水切れ性に優れ、透湿性、透水性が良好で快適な使用感を有するものであった。
【００９８】
実施例４の使用後のベッドマットを回収し、反毛機にかけて解繊した後、この開繊繊維を溶融ペレット化し、再度溶融紡糸・延伸して、１２デニール、３０ｍｍのポリエステルステープルとした。得られたステープルはやや灰色味を帯びたポリエステルステープルで、市販の通常ポリエステルステープルに比べてやや強度が低いものの、詰綿として十分使用可能なものであった。
【００９９】
実施例４のベッドマット中材の加工方法や性質を表１に示す。
【０１００】
【表１】

【０１０１】
【発明の効果】
本発明によれば、効率的にリサイクル化でき、医療用ベッドなどに必要な屈曲性や抗菌性があつて、透湿性・透水性が高く快適な使用感を有し、しかも環境面で問題を生じ難いベッドマットを得ることができる。
【図面の簡単な説明】
【図１】本発明に用いるブロック形状繊維成形体の一例を示す斜視図。
【図２】本発明に用いる繊維成形体の製造装置の一例を示す縦断面図。
【符号の説明】
１：下金型
２：上金型
３：気体の吹き込み口
４：繊維混合物[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a bed mat that is easy to recycle, has excellent flexibility required for a medical bed mat, has antibacterial properties, and has a comfortable feeling of use with high moisture permeability and water permeability.
[0002]
[Prior art]
In recent years, due to the two needs of environmental protection of the earth and efficient use of resources, the problem of the treatment and reuse of industrial waste and general household waste has been increasing in importance, and in many fields and many People are showing interest. However, in the field of bed mats, most used bed mats have been incinerated or landfilled, and recycling technology is still in the development stage.
[0003]
Conventionally, the recycling technologies proposed for textile products are roughly classified into the following three.
[0004]
The first is thermal recycling. In this method, products are cut into appropriate forms, burned, and reused as in-house power generation and various types of heat energy. However, this method is not preferable from the viewpoint of resource reuse.
[0005]
The second is material recycling. This method is different from the following chemical recycling in that it is physically and mechanically pelletized. When this recycled pellet is reused, it is divided into two cases. One is to develop a product as a new material in consideration of the fact that various materials are mixed, such as flower beds, bonsai pots, and sidewalk decorative piles. The other is a case in which 100% identical material is used as described in JP-A-5-219935 and JP-A-6-123052, collected, pelletized, melted and reused. . However, in this method, in order to make all components the same, in the case of 100% nylon disclosed in Japanese Patent Application Laid-Open No. Hei 5-212935, the tufted base fabric, the sealing layer, and the backing layer are changed from inexpensive materials to expensive materials. Is essential and may not be economical.
[0006]
Third is chemical recycling. The chemical recycling that best fits the basic concept of recycling is chemical recycling, in which products are collected, decomposed, and returned to their original raw materials. However, fiber products are generally rarely produced as a single material, and the composition of the materials is diverse. Therefore, it takes a while to develop an economical depolymerization system. Means for solving this problem, for example, in the case of a carpet product, is described in Japanese Patent Application Laid-Open No. 5-117441. As an auxiliary means for improving the efficiency of depolymerization, the carpet is cut into small pieces, separated into small pieces containing nylon 6 which is a pile material and other small pieces with a separator, and the small pieces containing nylon 6 are supplied to a depolymerization system. Ε-caprolactam as a raw material. However, even if the fiber product is divided into small pieces and separated by mechanical means, for example, due to a difference in specific gravity due to a cyclone, it has been difficult to efficiently recycle the product.
[0007]
On the other hand, as a mat material of a bed mat, a resin foam such as polyurethane has generally been mainly used. However, resin foams have environmental problems such as the use of chlorofluorocarbon gas or a substitute gas during foaming and the generation of toxic gases during combustion. In addition, air permeability and moisture permeability are low, and they are easily stuffy. In addition, when a solution such as water or urine is applied, the water permeability is low.
[0008]
Cushion materials (fiber stuffing materials) as mat materials for solving these problems are disclosed in, for example, JP-B-62-2155, JP-B-1-18183, JP-B-4-33478, and JP-A-3-140185. It has been proposed in gazettes and the like. These cushioning materials are composed of a core-sheath composite fiber using a low-melting fiber as a heat-adhesive fiber or a high-melting thermoplastic resin as a core and a low-melting thermoplastic resin as a sheath. The use of has produced some results, but further improvement is desired.
[0009]
[Problems to be solved by the invention]
The object of the present invention is easy to recycle, and has antibacterial properties and bendability, is hard to set against compression, is soft, has high moisture permeability and high water permeability, has a comfortable feeling of use, and is environmentally friendly. An object of the present invention is to provide a bed mat that does not easily cause a problem.
[0010]
[Means for Solving the Problems]
The bed mat of the present invention has the following configuration to solve the above-mentioned problem.
That is, the mat material of the bed mat is a bed mat which is a fiber molded body containing at least the antibacterial polyester fiber A, and most of the constituent fibers of the material of the mat have a cross section (bdef) in the thickness direction of the mat material. The fiber axis directions are arranged substantially parallel to each other, and are arranged in a random direction within a cross section (bdef) in the thickness direction of the mat material, and the mat material has a deflection amount of 5 measured by the method described in the text. An easy-to-recycle bed mat having a size of about 20 cm, and wherein a mat material, a mat cover, and a sewing thread of the mat constituting the bed mat are all made of fibers made of a polyester-based polymer.
[0011]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, the bed mat of the present invention will be described in detail with reference to the drawings and embodiments.
[0012]
The present invention is an easily recyclable bed mat. As described above, a general bed mat has a structure in which a resin foam such as polyurethane is used as an inner material of the bed mat, and the core material is wrapped with a cover such as cotton or polyester. Further, the cover is made of a cloth such as cotton or polyester with sewing threads, fasteners and quality indicating labels having different chemical compositions. Although it is not easy to recycle a bed mat composed of these various materials, the bed mat of the present invention is intended to obtain a bed mat that can be easily recycled while maintaining the required quality of the bed mat.
[0013]
The bed mat of the present invention is a bed mat that is made of a fiber molded body, and furthermore, the fabric and the sewing thread that constitute the cover of the bed mat are all made of fibers made of a polyester polymer to make the bed mat easy to recycle. is there. If necessary, accessories such as fasteners and quality labels are also made of polyester polymer fibers.
[0014]
The bed mat of the present invention can be recycled by any of material recycling, chemical recycling, and thermal recycling. However, since the bed mat material, the cloth constituting the cover of the bed mat, and the sewing thread are made of polyester fiber, the bed mat is collected. It is easy and preferable because the bed mat is cut, opened, melted and pelletized and recycled.
[0015]
FIG. 1 is a perspective view showing an example of a fiber arrangement in a block shape of a fiber molded body for a mat middle material of a bed mat of the present invention.
[0016]
The fibrous molded article is a fibrous molded article composed of two or more kinds of fibers and contains at least an antibacterial polyester fiber A, usually has polyester (R2) as a core component, and has a melting point of the antibacterial polyester fiber A or antibacterial processed. A composite fiber C and an antibacterial polyester fiber A having at least a polyester-based thermoplastic polymer (R1) on the fiber surface side at least 20 ° C. lower than that of the polyester fibers B and R2 which have not been treated, or a composite fiber C and an antibacterial A polyester fiber A and a polyester fiber B which has not been subjected to antibacterial treatment, and at least a part of the contact points between the composite fibers C and between the composite fiber C and the polyester fibers A and B are bonded and molded; Most of the constituent fibers of the mat material are arranged so that the fiber axis direction is substantially parallel to the cross section (bdef) in the thickness direction of the mat material. In the thickness direction of the mat in material cross-section (BDEF) in which are arranged in a random direction.
[0017]
Here, in order to increase the flexibility of the mat material, most of the constituent fibers are arranged such that the fiber axis direction is substantially parallel to the cross section (bdef) in the thickness direction of the fiber molded body as shown in FIG. The fibers are arranged in a random direction in a cross section (bdef) in the thickness direction of the molded body, and the number of fibers arranged substantially parallel to the thickness direction when used as a cushion body, that is, the direction subjected to a compressive action is increased. And a structure that enhances compression recovery and resilience.
[0018]
Most of the constituent fibers are arranged such that the fiber axis direction is substantially parallel to the cross section (bdef) in the thickness direction of the fiber molded body as shown in FIG. The main purpose of arranging in a different direction is, for example, in a bed of a type that can change the bed from a sleeping position to a sitting position, such as a medical bed, the bed mat also deforms in a similar manner according to the change of the bed Another object of the present invention is to prevent only the bed mat from floating from the bed body. To this end, the longitudinal direction of the mat material (cushion material) for the bed mat is made to coincide with the ab line direction of the fiber molded body, and the fiber axis direction is substantially parallel to the cross section (bdef) in the thickness direction of the mat material. It is important that the fiber axis direction is arranged in a random direction with a cross section (bdef) in the thickness direction so that the long direction of the bed mat is easily bent. It is important that the degree of flexibility is such that the amount of deflection measured by a characteristic evaluation method described later is 5 to 20 cm. If it is less than 5 cm, the mat is unpreferably because the mat is lifted from the bed or wrinkled due to poor flexibility. If it exceeds 20 cm, problems arise such as poor handling when the mat is moved by washing or the like.
[0019]
Further, most of the constituent fibers are arranged so that the fiber axis direction is parallel to the cross section (bdef) in the thickness direction of the fiber molded body, and are arranged in a random direction in the cross section (bdef) in the thickness direction of the fiber molded body. By doing so, it is possible to obtain a fiber molded article having high durability due to washing and use, high moisture permeability and high water permeability, and high comfort in use, even though the flexibility is good.
[0020]
Here, there are a large number of cross sections in the thickness direction, such as a plane having an angle along the ae line in FIG. 1 and a plane having an angle along the ab line in FIG. 1, but the cross section in the thickness direction (bdef) in which the fibers are arranged substantially in parallel is shown. Since the fibers are arranged substantially parallel to the plane at this angle only at the plane along the be line, when the fiber molded body is pulled or distorted, it is relatively easy to peel off as compared to the plane at other angles. It is an angle plane.
[0021]
As the structure of the middle material of the bed mat, the middle material having the above-mentioned fiber arrangement is preferable, but in addition, the fibers to be used are mixed and opened, and further mixed and opened with a card to form a web, and laminated by a cotton forming machine. After forming the web, the web is folded into a wave shape, and the wave height of the wave is set to the thickness of the mat, and is fixed by the low melting point fiber in the used fiber, so that the inner material of the bed mat having increased flexibility can be obtained. .
[0022]
The proportion of the antibacterial polyester fiber A, the polyester fiber B not subjected to the antibacterial treatment and the composite fiber C is 40% by weight or more in terms of antibacterial properties, and the polyester fiber B not subjected to the antibacterial treatment is the aforementioned antibacterial polyester fiber. Those containing less than 80% by weight in total with polyester fiber A are preferred. It is preferable that the content of the conjugate fiber C be 20% by weight or more and less than 60% by weight from the viewpoints of shape retention, durability, cushioning property, soft feeling, antibacterial property and the like of the fiber molded body in the bed mat. . In particular, the range of 20 to 50% by weight is preferable.
[0023]
The composite fiber C is composed of the two components R1 and R2, and R1 is, for example, a polyolefin or olefin copolymer such as polyethylene, polypropylene, ethylene propylene copolymer, ethylene butene copolymer, and ethylene vinyl acetate copolymer. And at least one polymer selected from thermoplastic polymers such as polyesters such as polyhexamethylene terephthalate, polyhexamethylene butylene terephthalate, and polyhexamethylene terephthalate isophthalate, and copolymerized polyesters. R2 is not particularly limited. For example, polyethylene terephthalate, polybutylene terephthalate, or terephthalic acid, 2,6-naphthalenedicarboxylic acid or an ester thereof as a main dicarboxylic acid component, and ethylene glycol or tetramethylene glycol as a main glycol component. Polyesters such as polyethylene 2,6-naphthalate are exemplified.
[0024]
In the selection of R1, the melting point of the fiber A, the other fibers B and R2 is lower than that of the lowest fiber, and is preferably 20 ° C. or higher, and more preferably 50 ° C. or higher from the viewpoint of thermal adhesion. Is more preferred.
[0025]
Further, the melting point of R1 is preferably in the range of 80 to 170 ° C, more preferably in the range of 100 to 170 ° C, from the viewpoint of the effect of adhesion and prevention of thermal deterioration.
[0026]
The weight ratio represented by R1 / R2 in the conjugate fiber C is from 20/80 to 20/80 in view of shape retention, durability, cushioning property, recycling efficiency in the case of recycling, cost, etc. It is preferably in the range of 60/40.
[0027]
In addition to the pigments such as titanium oxide and carbon black other than R1 and R2, if necessary, the conjugate fiber C may be added with an antioxidant, an anti-coloring agent, a light-proofing agent, an antistatic material, or the like. Good. Such a composite fiber C can be produced by a usual composite spinning method.
[0028]
Next, the composite fiber C preferably has mechanical crimping or the like in order to impart bulkiness and softness to the fiber molded article of the present invention and to improve recovery from compression. The number of crimps may be appropriately selected depending on the use of the fiber molded body, but it is preferable that the number of crimps be at least three peaks / 25 mm and the degree of crimp be at least 5%.
[0029]
As the composite fiber C constituting the fiber mixture, short fibers having a fineness of 0.5 to 30 denier and a fiber length of 10 to 100 mm are preferably used from the viewpoint of bulkiness and softness.
[0030]
The antibacterial polyester fiber A used for the mat material of the bed mat of the present invention may be a type in which an antibacterial component is kneaded into a polyester polymer, or a method of applying the antibacterial component by processing. The antimicrobial polyester fiber A preferably has, for example, 0.05 to 3.0% owf of an antimicrobial component adhered to the fiber. More preferably, it is 0.1 to 2.0% owf. If the amount of the antibacterial component is too small, the antibacterial performance may be insufficient. On the other hand, if the amount is too large, the fibers become too stiff, resulting in reduced resilience to compression and a problem in cost, which is not preferable in practical use.
[0031]
The melamine-based compound forms a crosslinked network structure on the fiber surface, and is therefore effective for improving washing durability, particularly industrial washing durability. The melamine-based compound is preferably adhered to the fiber at 0.05 to 2.0% owf, preferably 0.1 to 1.2% owf.
[0032]
Various compounds are used as the antibacterial component. For example, a compound having a basic group such as an amidine group or a guanidin group or a salt thereof such as a sodium salt, a potassium salt, or an ammonium salt, and a quaternary ammonium salt may be used.
[0033]
Compounds containing an amidine group include 4,4'-stilbene-dicarboxamidine-diisethionate (i.e., stilbamine isethionate), N '-(4-chloro-2-methyl-phenyl) -N, N Dimethyl-methanimide (ie, chlordimeform) and the like, and compounds containing a guanidin group include 1,17-diguanidino-9-aza-heptadecane (ie, guazatine), p- (chlorophenyldiguanide) -hexane. (Ie, chlorhexidine), p-benzoquinone-amidino-hydrazone-thiosemicanevazone (ie, ambazone), and the quaternary ammonium salts include benzalkonium chloride, benzethonium chloride, and the like. Of course, these compounds are merely examples, and it goes without saying that compounds other than those described above can be used. Among these compounds, p- (chlorophenyldiguanide) -hexane or a salt thereof is preferable because it has high safety and the antibacterial property does not decrease even when proteins and the like are present.
[0034]
The antibacterial component having such a basic functional group is preferably used after reacting with an acidic group-containing polymer (which may be a homopolymer or a copolymer) which reacts with the acid.
[0035]
Examples of the acidic group-containing monomer constituting the acidic group-containing polymer include a sulfone group, a carboxyl group, a phosphone group, each acidic group such as a phenolic hydroxyl group, or a salt thereof such as a sodium salt, a potassium salt, and an ammonium salt. Monomers.
[0036]
Examples of the monomer having a sulfone group include styrenesulfonic acid, vinylsulfonic acid, allylsulfonic acid, sulfopropyl acrylate, sulfopropyl methacrylate, 3-chloro-4-vinylbenzenesulfonic acid, and 2-acrylamide-2-methylpropane sulfone. Acid, 2-acryloyloxybenzenesulfonic acid, 2-acryloyloxynaphthalene-2-sulfonic acid, 2-methacryloyloxynaphthalene-2-sulfonic acid, 2-hydroxy-3-methacryloyloxypropyl sulfonic acid, etc. Examples of the monomer having a phosphonic group include acrylic acid, methacrylic acid, itaconic acid, crotonic acid, maleic acid, maleic anhydride, 3-butene-1,2,3-tricarboxylic acid, and 4-pentenoic acid. As a monomer Allylphosphonic acid, acid phosphoxyethyl methacrylate, 3-chloro-2-acid phosphoxypropyl methacrylate, 1-methylvinylphosphonic acid, 1-phenylvinylphosphonic acid, 2-phenylvinylphosphonic acid, 2-methyl-2-phenyl Examples of monomers having a phenolic hydroxyl group, such as vinylphosphonic acid, 2- (3-chlorophenyl) vinylphosphonic acid, and 2-diphenylvinylphosphonic acid, include o-oxystyrene and o-vinylanisole. .
[0037]
Such monomers may be used alone or in combination of two or more. Further, other monomers copolymerizable with the monomer having an acidic group may be used in combination. Such monomers include, for example, acrylonitrile, acrylates, methacrylates, vinyl chloride, vinyl acetate, vinyl propionate, vinylidene chloride, ethylene, propylene, styrene and its derivatives, butadiene, acrylamide and its derivatives, hydroxyethyl Acrylate, hydroxyethyl methacrylate and the like can be mentioned.
[0038]
As a polymerization method, any of ordinary polymerization methods such as an emulsion polymerization method, a solution polymerization method, and a bulk polymerization method can be employed. Among them, the emulsion polymerization method is preferably used because a large amount of acidic groups tend to be distributed on the particle surface of the obtained polymer.
[0039]
An antimicrobial reaction product is obtained by reacting an acidic group-containing polymer obtained by polymerizing such a monomer with a basic group-containing antimicrobial component.
[0040]
Further, among the quaternary ammonium salts, the compound represented by the above formula (1) is particularly preferably used as a compound exhibiting a highly safe antibacterial and deodorant effect. In the formula (1), R ₁ Is an alkyl group having 12 to 16 carbon atoms. If the number of carbon atoms is 11 or less or 17 or more, the antibacterial properties are insufficient.
[0041]
In the formula (1), R ₂ , R ₃ , R ₄ Is an alkyl group having 1 to 2 carbon atoms, and when the number of carbon atoms is 3 or more, the clay rises and the production state is not preferable, and the solubility in water decreases.
[0042]
As the anion used for neutralizing the quaternary ammonium salt, an alkyl phosphate ion is selected from the viewpoint of rust prevention. Further, an alkyl group having 4 carbon atoms, that is, a butyl group is selected. As the butyl group, any of an n-butyl group, an iso-butyl group and a tert-butyl group are preferably used. When the number of carbon atoms of the alkyl group is 3 or less, it is not preferable from the viewpoint of safety. When the number of carbon atoms of the alkyl group is 5 or more, the viscosity becomes high and the synthesis becomes difficult. It becomes a mixture of acid ions, which is not preferable in terms of safety.
[0043]
Also, when used in combination with a melamine-based compound, the antibacterial resin has an antibacterial property with excellent durability, can safely and easily impart antibacterial properties to fiber materials, and does not corrode processing equipment. Is more preferred.
[0044]
In the present invention, the antibacterial resin comprises a vinyl polymer or copolymer having a quaternary ammonium chloride-containing monovalent or divalent phosphate ester group represented by the following formula (2) or (3). I have.
[0045]
Embedded image

Embedded image

In the formulas (2) and (3), R is a polymer main chain or an organic residue; ₁ Is an alkyl group having 8 to 18 carbon atoms, R ₂ Represents an alkyl group having 1 to 18 carbon atoms, a phenyl group or a substituted aryl group.
[0046]
The vinyl polymer or copolymer having a quaternary ammonium chloride phosphate group represented by the above (2) or (3) has excellent antibacterial properties. In addition, since the polymer material is amphoteric, it can be firmly attached to synthetic fibers and natural fibers. For this reason, antibacterial properties excellent in durability and washing durability can be obtained. Further, since it is obtained as an aqueous solution or a water-alcohol mixed solution, it has an advantage that it can be easily applied to a fiber material and does not corrode the device.
[0047]
Next, examples of the melamine-based compound used in the present invention include those represented by the following general formula (4).
[0048]
Embedded image

However, in the formula, R ₀ ~ R ₂ : -H, -OH, -C ₆ H ₅ , C _n H _{2n + 1} ( _n : 1 to 10), -COOCnH _{2n + 1} ( _n : 1 to 20), -CONR ₃ R ₄ , -NR ₃ R ₄ (R ₃ , R ₄ : -H, -OH), -OCnH _{2n + 1} , -CH ₂ OC _n H _{2n + 1} , -CH ₂ COOnH _{2n + 1} (N: 1 to 20), -CH ₂ OH, -CH ₂ CH ₂ OH, -CONH ₂ , -CONHCH ₂ OH, -O (XO) _n R ₅ (X: -C ₂ H ₄ -, -C ₃ H ₆ -, -C ₄ H ₈ −, _n : 1 to 1500, R ₄ : -H, -CH ₃ , -C ₂ H ₅ , -C ₃ H ₇ )
A preferred compound among the above general formulas is R ₀ , R ₁ Is -NR ₃ R ₄ Wherein R is ₂ Is -CONR ₃ R ₄ , -NR ₃ R ₄ Is more preferable. Further, R ₃ , R ₄ Is -CH ₂ OH, -CH ₂ CH ₂ OH, -CONH ₂ , -CONHCH ₂ Compounds that are OH are particularly preferred.
[0049]
These compounds are merely examples, and it goes without saying that compounds and derivatives other than those described above can also be used.
[0050]
Melamine-based compounds having at least two polymerizable functional groups are suitable because the durability of the resin film formed on the fiber surface is improved.
[0051]
Thus, the antimicrobial coating comprising the antimicrobial single component or the antimicrobial reaction product obtained by reacting the antimicrobial component with the acidic group-containing polymer and / or copolymer as the antimicrobial component and the melamine-based compound as the main component for forming the film is a fiber. The mechanism of action on the durability of the film is as follows. The melamine compound, which is a main component of the film, is polymerized or crosslinked in the fiber matrix polymer to form a two-dimensional or three-dimensional structure. At the same time, a part of the film is chemically bonded to the functional group of the fiber matrix polymer, and the durability of the film for insolubilizing in a network and firmly fixing the fiber is remarkably improved. The cleaning property can be exhibited.
[0052]
As a typical example of the method of applying the above antibacterial component and the film-forming main component to the fiber, padding or spraying the fiber in the same treatment bath in which a polymerization initiator or a crosslinking catalyst is added to an aqueous solution containing the above component, and then wet There is a method of performing reaction treatment below. The reaction can be carried out at a temperature of room temperature or higher, but usually a steam heat treatment is performed. The above two components can be treated in separate baths. That is, first, the fibers are padded or sprayed in a treatment bath containing an antibacterial component, then dried or steamed, and then the fibers are treated in a separate treatment bath in which a polymerization initiator or a cross-linking catalyst is added to an aqueous solution containing a main component for forming a film. Can be padded or sprayed and steamed.
[0053]
The polymerization initiator is used when polymerizing an acrylic compound having an alkylene glycol unit. As a specific example, a common vinyl polymerization initiator such as ammonium persulfate, potassium persulfate, azobisisobutyronitrile, etc. may be used. Can be processed.
[0054]
On the other hand, the catalyst is used when a melamine-based compound is subjected to a cross-linking reaction, and specific examples thereof include formic acid, various organic carboxylic acids including acetic acid and their ammonium, sodium, potassium and other organic salts and sulfuric acid, persulfuric acid, Inorganic salts such as ammonium, sodium, potassium, magnesium, zinc, aluminum, and iron such as hydrochloric acid, phosphoric acid, and nitric acid, and double salts thereof, and the like. Of course, the above compounds are not limited.
[0055]
The steaming heat treatment can be performed at 80 to 140 ° C, preferably 100 to 130 ° C, for 0.5 to 30 minutes. The dry heat treatment can be performed at 80 to 150 ° C, preferably 100 to 130 ° C, and then at 100 to 220 ° C, preferably 140 to 190 ° C for 0.5 to 5 minutes.
[0056]
According to the method of the present invention, other chemicals such as a softening agent, a water repellent, a water absorbing agent, an antistatic agent and a hard finishing agent may be added to the processing liquid used for padding or spraying.
[0057]
Further, short fibers having a fineness of 0.5 to 30 denier and a fiber length of 10 to 100 mm are preferably used as the medium fiber of the bed mat. If the fineness is too small, there is a possibility that the bulk as an aggregate required for wadding decreases, and the resilience to compression and the recoverability of the bulk also decrease. Also, if it is too thick, the feel tends to be coarse and hard. On the other hand, if the fiber length is too short, the entanglement between fibers deteriorates, and cotton breakage is likely to occur. If the fiber length is too long, the fiber opening property and cotton-forming property may deteriorate.
[0058]
The crimping may be selected as appropriate, but it is preferable to provide mechanical crimping in order to improve bulkiness, softness, resilience to compression, resilience to cotton, or cotton-forming property, and asymmetrical yarns at the time of yarn filling. It is more preferable that the fibers are subjected to a cooling treatment and three-dimensionally crimped by giving a structural difference to each fiber. The number of crimps is preferably 3 peaks / 25 mm or more, and the degree of crimp is preferably 5% or more.
[0059]
In addition, in addition to the pigments such as titanium oxide and carbon black, conventionally known antioxidants, anti-coloring agents, light-proofing agents, anti-static agents, etc. may be added to the mat medium fiber of the bed mat, if necessary. Is also preferred.
[0060]
The cross-sectional shape of the fiber in the mat of the bed mat used in the present invention is not limited to a circle, but is more preferably a hollow cross-section such as a polygonal shape.
[0061]
The conjugate fiber C is composed of two components of polyesters R1 and R2. Examples of the polyester R1 include polyolefins such as polyethylene, polypropylene, ethylene propylene copolymer, ethylene butene copolymer, and ethylene vinyl acetate copolymer, and olefin copolymers. At least one polymer selected from polyesters such as coalesced, polyhexamethylene terephthalate, polyhexamethylene butylene terephthalate, and polyhexamethylene terephthalate isophthalate, and thermoplastic polymers such as copolymerized polyesters.
[0062]
R2 is not particularly limited. For example, polyethylene terephthalate, polybutylene terephthalate, or terephthalic acid, 2,6-naphthalenedicarboxylic acid or an ester thereof as a main dicarboxylic acid component, and ethylene glycol or tetramethylene glycol as a main glycol component. Polyesters such as polyethylene 2,6-naphthalate are exemplified.
[0063]
In the selection of R1, among the above-mentioned antimicrobial polyester fibers A, polyester fibers B and polyester fibers R2 of the composite fibers C, those having a lower melting point than those having the lowest melting point are used. Or lower, more preferably 25 ° C. or higher.
[0064]
Further, the melting point of R1 is preferably in the range of 80 to 170 ° C, more preferably in the range of 100 to 170 ° C, from the viewpoint of the effect of adhesion and prevention of thermal deterioration.
[0065]
The weight ratio R1 / R2 in the composite fiber C is set to 20/80 to 60/40. Preferably it is 20 / 80-50 / 50. If the weight ratio of R1 is small, sufficient thermal adhesiveness between fibers may not be obtained, and the shape fixability of the manufactured middle material of the bed mat may be deteriorated.
[0066]
On the other hand, if the weight ratio of R1 is too high, the softness of the middle material of the bed mat may be impaired, and the compression set may be further increased.
[0067]
In addition to the pigments such as titanium oxide and carbon black other than R1 and R2, if necessary, the conjugate fiber C may contain an antioxidant, an anti-coloring agent, a light-proofing agent, an antistatic agent, and the like. Good. Such a conjugate fiber B can be produced by an ordinary conjugate spinning method.
[0068]
Next, the composite fiber C preferably has mechanical crimping or the like in order to impart bulkiness and softness to the middle material of the bed mat used in the present invention, and to improve recovery from compression. The number of crimps may be appropriately selected, but it is preferable that the number of crimps is at least 3 peaks / 25 mm and the degree of crimp is at least 5%.
[0069]
As the composite fiber C constituting the mat material, short fibers having a fineness of 0.5 to 30 denier and a fiber length of 10 to 100 mm are preferably used from the viewpoint of bulkiness and softness.
[0070]
Next, an example of a method for producing a mat material used in the present invention will be described. In producing the mat material used in the present invention, first, the antibacterial polyester fiber A and the conjugate fiber C, or the antibacterial polyester fiber A, the polyester fiber B, and the conjugate fiber C in the weight ratio described above are used in a normal spinning process. The cotton is sufficiently mixed and spread by a cotton feeder, a cotton blender, and a fiber opening machine, and the air-permeable mold having a shape suitable for the purpose is blown and filled together with a gas such as an air flow by a cotton fan. In order to blow and fill each fiber as described above, a mold having a proper air permeability is used. For example, when measured by a JIS L 1079-1966 Frazier-type air permeability tester, the air permeability is 5 to 200 cc / cm. ² • It is preferably within the range of sec.
[0071]
As such a mold, for example, a mold composed of a punched metal plate can be used. The fibers blown into the air-permeable mold are in a state of being randomly arranged in the length, width, and thickness directions.
[0072]
Next, the filled fiber mixture is compressed to a density suitable for the material in the bed mat. Density is 0.025 to 0.10 g / cm ³ Is preferred. If the density is too low, the obtained fiber molded product may be too soft, resulting in poor usability, and it may be difficult to cut and mold into a desired shape. On the other hand, if the density is too high, the soft feeling is reduced, and the usability may be deteriorated.
[0073]
Further, the filled and compressed fiber mixture is subjected to heat treatment to bond a part of the contact points between the composite fibers C and between the composite fibers C and the antibacterial polyester fibers A and polyester fibers B to fix the form. The temperature of the heat treatment may be a temperature at which R1 of the fiber C is melted, and is generally preferably 80 to 200 ° C. The heat treatment time is preferably selected as appropriate depending on the density of the fiber mixture and the like.
[0074]
The antibacterial property may be an antibacterial polyester fiber in the mat material fiber of the bed mat, but it is also preferable to impart antibacterial property to the cover of the bed mat.
[0075]
【Example】
Next, the present invention will be described in more detail with reference to examples. The measuring methods of various characteristics described in the present invention are as follows.
[0076]
(1) Deflection amount
Prepare three rectangular mat medium test pieces of 10 cm in width, 4 cm in thickness, and 50 cm in length, put them on a horizontal table, slide the test pieces, and leave them 30 cm in length from the end of the table for 1 minute. Thereafter, the difference (bending amount) between the height of the upper surface of the table and the lower surface of the tip of the test piece was read on a scale, and expressed as an average of three measurements.
[0077]
(2) Antibacterial properties
A bouillon suspension of Staphylococcus aureus ATTC6538p was added to a web of futon wadding, and the viable cell count was measured after culturing at 37 ° C for 18 hours in a closed container. , The number of bacteria with respect to the number of cultured bacteria was measured, and the difference in the number of bacteria was calculated as K = log (B / C).
[0078]
However, the culture conditions of the bacteria must be log (B / A)> 2. A is the number of bacteria dispersed and recovered immediately after the above-mentioned bacteria were poured into a web of ordinary polyester cotton which had not been subjected to antibacterial treatment. B is the number of bacteria which were dispersed and recovered after 18 hours of culturing by pouring the bacteria into a web of ordinary polyester cotton which had not been subjected to antibacterial processing. C is the number of bacteria which were dispersed and recovered after 18 hours of culturing by pouring the above-mentioned bacteria into a stuffed cotton web.
[0079]
The antibacterial properties after washing were measured using a drum dyeing machine using a neutral detergent "Zab" (Kao) 2 g / l, hydrogen peroxide 3 cc / l, sodium peroxide 1.5 g / l, temperature 85 ± 2 ° C, Wash for 15 minutes at a bath ratio of 1:20, and then perform drainage, dehydration, and water washing for 10 minutes. After washing with water, it is dried for 20 minutes using a tumbler dryer. This is one wash.
[0080]
The antibacterial property was determined to be acceptable when K was 1.6 or more. The antibacterial property against MRSA was evaluated by the Japan Food Research Laboratories.
[0081]
(3) Fineness
It measured according to the method of JIS L1015-7-51A.
[0082]
(4) Average fiber length (cut length)
The measurement was performed according to the JIS L1015A method (staple diagram method).
[0083]
(5) Number and degree of crimp
The number of crimps and the degree of crimp were measured according to the methods of JIS L1015-7-12-1 and JIS L1015-7-12-2.
[0084]
(6) Packing density
A test piece (vertical: 20 cm, horizontal: 20 cm, thickness: 20 cm) was allowed to stand in an atmosphere of 20 ° C. × 65% RH for 24 hours, and the weight (w) was measured and determined by the following equation.
Density (g / cm ³ ) = W / 8000
[Examples 1-3 and Comparative Examples 1-2]
As an antibacterial polyester fiber A for a mat material in a bed mat, a normal polyethylene terephthalate chip was used, and a normal asymmetric cooling treatment was performed immediately below a spinneret at a spinning temperature of 280 ° C. and a take-up speed of 1350 m / min. The yarn was spun.
[0085]
Next, the undrawn yarn is drawn at a draw ratio of 3.0 times at a drawing bath temperature of 80 ° C., subjected to mechanical crimping with a crimper, applied with a finishing oil agent, cut, and then set and dried with a 145 ° C. heat setter. Then, a staple having a fineness of about 12 deniers, a cut length of 30 mm, a number of crimps of 5.3 / 25 mm, a hollow rate of 30% with a crimp degree of 25.2%, and a hollow circular cross section was obtained.
[0086]
Further, a 2.5% aqueous solution of an antibacterial agent containing 32% of an antibacterial resin made of a vinyl polymer having a quaternary ammonium chloride and a monovalent phosphate ester group was prepared. Further, a 1.0% aqueous solution of Sumitex M-3 (manufactured by Sumitomo Chemical Co., Ltd.), a melamine-based compound, a 0.3% aqueous solution of Sumitex Acx (manufactured by Sumitomo Chemical Co., Ltd.), a softening agent, A 0.7% aqueous solution was prepared. After mixing and stirring these aqueous solutions, the polyester hollow fiber staple was immersed, squeezed and cured at 130 ° C. for 1 minute to obtain antibacterial polyester fiber A. The obtained antimicrobial fiber had an antimicrobial component adhesion amount of 0.52% owf, a melamine-based compound adhesion amount of 0.65% owf, and antibacterial K of Staphylococcus aureus 4.3 before washing and 50 after washing 50 times. 1. The antibacterial properties against MRSA were as good as 4.3 before washing and 3.3 after washing 50 times.
[0087]
Separately, as the composite fiber C for mat middle material, R2 uses a normal polyethylene terephthalate chip having a melting point of 255 ° C., and R1 uses polyethylene terephthalate-based polyester having a melting point of 110 ° C. and copolymerized with 40 mol% of isophthalic acid. Then, a spinning temperature of 285 ° C., a take-up speed of 1350 m / min, and a weight ratio represented by R1 / R2 of 50/50 were spun to form a concentric undrawn yarn having R2 as a core and R1 as a sheath.
[0088]
Next, the undrawn yarn was drawn at a draw ratio of 3.0 times at a drawing bath temperature of 80 ° C., and mechanically crimped with a crimper. Furthermore, after drying with a heat setter at 70 ° C., a finishing oil agent was applied and cut into a cut length of 64 mm to obtain a composite fiber C having a fineness of about 4.2 denier and a melting point of the surface layer of about 110 ° C.
[0089]
The fibers A and C were mixed at the mixing ratio shown in Table 1, further mixed and opened with a roller card, and the width of the inner surface where each surface was punched from the mold inlet as shown in FIG. The lower mold 3 having a length of 82 × 84 × 100 cm in length × length × depth was blown and filled together with an air flow. The blown fiber mixture 4 is compressed by an upper mold 2 having a punched surface, and a packing density of 0.04 g / cm. ³ And fixed at a thickness of 50 cm. The fiber mixture 4 filled in a mold and compressed was heat-set at 130 ° C. for 25 minutes using a heat setter used for setting a spun yarn to obtain a fiber molded body.
[0090]
Next, the obtained fiber molded body was sliced to a thickness of 7 cm with the direction perpendicular to the compression direction as the up-down direction (thickness direction), and the sliced sheets were cut side by side, adhered to each other, and cut. The bed mat was 82 cm in length, 192 cm in length and 7 cm in thickness. Furthermore, as shown in Table 1, the middle materials of the bed mats of Examples 1 and 2 and Comparative Example 2 were subjected to finish compression processing at a compression ratio of 50% in the thickness direction at room temperature five times using a large hydraulic machine.
[0091]
Furthermore, as a cover (side material) of the bed mat, a double-sided circular knitted fabric using 75 denier false twisted yarn is sewn with a polyester spun sewing thread, and a polyester spun bond is used for a quality and handling label. Bed mat.
[0092]
When this bed mat was used for one year, the bed mats of Examples 1 to 3 had a deflection amount of 5.1 to 19.8 cm, followed the electric change of the gadget well, had good flexibility, and had antibacterial properties. It had good handleability in washing and washing, etc., was excellent in drainage in washing, had good moisture permeability and water permeability, and had a comfortable feeling of use.
[0093]
On the other hand, in Comparative Example 1, the bending amount was 4.3 cm, the flexibility for gadget bedding was slightly poor, the sitting comfort in the sitting position was poor, and the antibacterial property was also poor.
[0094]
Comparative Example 2 has good flexibility and antibacterial properties, but has a bending amount of 24.2 cm, is slightly bent, and it is difficult to insert the mat material into the cover, and at the same time the mat is moved by washing or the like. The handleability was somewhat poor.
[0095]
The used bed mats of Examples 1 to 3 were collected and defibrated by a napping machine. Then, the opened fibers were melt-pelletized, melt-spun and drawn again to obtain 8 denier and 30 mm polyester staples. . The obtained staple was a slightly grayish polyester staple, which was slightly lower in strength than a commercially available normal polyester staple, but was sufficiently usable as a cotton wad.
[0096]
Table 1 shows the processing methods and properties of the materials in the bed mats of Examples 1 to 3 and Comparative Examples 1 and 2.
[0097]
[Example 4]
In Example 1, when producing the antibacterial polyester fiber A, the staples not subjected to the antibacterial treatment are referred to as polyester fibers B, the antibacterial polyester fiber A is 40% by weight, the polyester fiber B not subjected to the antibacterial treatment is 20% by weight, and the conjugate fiber is used. A bed mat was prepared in the same manner as in Example 2 except that 40% by weight of C was mixed, and used for one year. The bed mat had good flexibility, insect repellency, handleability in washing and the like, was excellent in drainage in washing, had good moisture permeability and water permeability, and had a comfortable feeling of use.
[0098]
The used bed mat of Example 4 was collected and defibrated by an anti-hair machine, then the opened fiber was melt-pelletized, melt-spun and drawn again to obtain 12 denier, 30 mm polyester staple. The obtained staple was a slightly grayish polyester staple, which was slightly lower in strength than a commercially available normal polyester staple, but was sufficiently usable as a cotton wad.
[0099]
Table 1 shows the processing method and properties of the middle material of the bed mat of Example 4.
[0100]
[Table 1]

[0101]
【The invention's effect】
ADVANTAGE OF THE INVENTION According to this invention, it can be recycled efficiently, has the flexibility and antibacterial properties required for medical beds, etc., has high moisture permeability and water permeability, has a comfortable feeling of use, and has environmental problems. It is possible to obtain a bed mat that hardly occurs.
[Brief description of the drawings]
FIG. 1 is a perspective view showing an example of a block-shaped fiber molded product used in the present invention.
FIG. 2 is a longitudinal sectional view showing an example of an apparatus for producing a fiber molded body used in the present invention.
[Explanation of symbols]
1: Lower mold
2: Upper mold
3: Gas inlet
4: fiber mixture

Claims (11)

A mat in which the mat material of the bed mat is a fiber molded product containing at least the antibacterial polyester fiber A, wherein most of the constituent fibers of the mat material have a fiber axis with respect to a cross section (bdef) in the thickness direction of the mat material. The directions are arranged substantially parallel to each other, and are arranged in random directions within a cross section (bdef) in the thickness direction of the mat material. The mat material has a deflection amount of 5 to 20 cm measured by the method described in the text. And an easy-to-recycle bed mat, wherein the mat material, the cover of the mat, and the sewing thread of the cover that constitute the bed mat are all made of fibers made of a polyester polymer. The easily recyclable bed mat according to claim 1, wherein the ratio of the antibacterial polyester fiber A contained in the mat material of the bed mat is 40% by weight or more. The mat material of the bed mat is a fiber molded article containing a composite fiber C of polyester R2 and polyester R1 having a lower melting point than any of antibacterial polyester fiber A and polyester R2. The easily recyclable bed mat according to claim 1 or 2, wherein at least a part of a contact point between the conjugate fiber C and the polyester fiber A is formed by bonding. The easily recyclable bed mat according to claim 3, wherein the composite fiber C contained in the mat material of the bed mat is a composite fiber having polyester R2 as a core component and polyester R1 as a sheath component. The easily recyclable bed mat according to claim 3 or 4, wherein the weight ratio of the composite fiber C represented by R1 / R2 is in the range of 20/80 to 60/40. The easily recyclable bed mat according to any one of claims 3 to 5, wherein the ratio of the composite fiber C contained in the mat material of the bed mat is 20% by weight or more and less than 60% by weight. The mat material of the bed mat is a fibrous molded article composed of two or more kinds of fibers, and the antibacterial polyester fiber A is 40% by weight or more, and the polyester fiber B is usually 80% by weight in total with the antibacterial polyester fiber A %. The easily recyclable bed mat according to any one of claims 1 to 6, which is a fiber molded body containing less than 10% by weight. The easily recyclable bed mat according to any one of claims 1 to 7, wherein the antibacterial component of the antibacterial polyester fiber A has an amidine group or a guanidine group. The easily recyclable bed mat according to any one of claims 1 to 7, wherein the antibacterial component is a fourth ammonium salt. The easily recyclable bed mat according to claim 9, wherein the quaternary ammonium salt is represented by the following formula (1).

(However, R ₁ represents an alkyl group having 12 to 16 carbon atoms, R ₂ , R ₃ and R ₄ represent an alkyl group having 1 to 2 carbon atoms, and Bu represents a butyl group.) 9. The antibacterial resin according to claim 1, wherein the antibacterial component is an antibacterial resin comprising a vinyl polymer or a vinyl copolymer having a quaternary ammonium chloride-containing monovalent or divalent phosphate group. An easy-to-recycle bed mat as described in.

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