JP3637929B2 - Mat and its manufacturing method - Google Patents
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- JP3637929B2 JP3637929B2 JP15447995A JP15447995A JP3637929B2 JP 3637929 B2 JP3637929 B2 JP 3637929B2 JP 15447995 A JP15447995 A JP 15447995A JP 15447995 A JP15447995 A JP 15447995A JP 3637929 B2 JP3637929 B2 JP 3637929B2
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Description
【０００１】
【産業上の利用分野】
本発明は、蒸れ難く、保温性、体型保持性に優れ寝心地が良好で、耐久性、折り曲げ性にも優れ洗濯が可能で常に清潔性を保持でき、リサイクルが可能な一般家庭用、病院用及びホテル用等のベットに最適なベットマット及び、敷布団、座蒲団、家具、枕等のクッション材にも適したマット及びその製法に関する。
【０００２】
【従来技術】
現在、ベッド用のベットマットはクッション層に硬鋼線スプリング又は発泡スチロール等の発泡体を用い、ワディング層に発泡ウレタンや非弾性捲縮繊維を接着した樹脂綿や硬綿などが積層一体化されたもの、及びクッション体が同一組成のウレタン等の発泡体や非弾性捲縮繊維を接着した樹脂綿又は硬綿のみで構成されたものが使用されている。
【０００３】
しかしながら、クッション層に硬鋼線スプリングを用いたものは、サポ−ト性は著しく優れているが、折り曲げ性に劣り、又、廃棄時に硬鋼線スプリングを分離して処理するための煩雑さが大きい問題となっている。クッション層又はワディング層又はクッション体に発泡−架橋型ウレタンを用いたものは、クッション体としての耐久性は極めて良好だが、透湿透水性に劣り蓄熱性があるため蒸れやすく、折り曲げ性もやや劣り、かつ、熱可塑性では無いためリサイクルが困難となり焼却される場合、焼却炉の損傷が大きく、かつ、有毒ガス除去に経費が掛かる。このため埋め立てされることが多くなったが、地盤の安定化が困難なため埋め立て場所が限定され経費も高くなっていく問題がある。また、加工性は優れるが製造中に使用される薬品の公害問題などもある。また、最近、病院用ベットがＭＲＳＡ等の温床となる問題からベットマットの洗濯が必要だが、透水性に劣るウレタンは洗濯ができないため社会問題になっている。
【０００４】
クッション層又はワディング層又はクッション体がポリエステル繊維を接着剤で接着した樹脂綿、例えば接着剤にゴム系を用いたものとして特開昭６０−１１３５２号公報、特開昭６１−１４１３８８号公報、特開昭６１−１４１３９１号公報等がある。又、架橋性ウレタンを用いたものとして特開昭６１−１３７７３２号公報等がある。これらをクッション層又はワディング層に用いたものは、通気性をよくして蒸れを軽減できるが、耐久性と折り曲げ性に劣り、且つ、熱可塑性でなく、単一組成でもないためリサイクルも出来ない等の問題、及び加工性の煩雑さや製造中に使用される薬品の公害問題などもある。また、洗濯は可能だが、水切り性が悪い問題がある。
【０００５】
クッション層又はワディング層又はクッション体にポリエステル硬綿、例えば特開昭５８−３１１５０号公報、特開平２−１５４０５０号公報、特開平３−２２０３５４号公報等があるが、用いている熱接着繊維の接着成分が脆い非晶性のポリマ−を用いるため（例えば特開昭５８−１３６８２８号公報、特開平３−２４９２１３号公報等）接着部分が脆く、使用中に接着部分が簡単に破壊されて形態や弾力性が低下するなどの耐久性が劣る問題がある。更に折り曲げ性が劣るものである。また、洗濯は可能だが、水切り性が悪い問題がある。耐久性の改良法として、交絡処理する方法が特開平４−２４５９６５号公報等で提案されているが、接着部分の脆さは解決されず弾力性の低下が大きく、折り曲げ性も劣る問題がある。また、加工時の煩雑さもある。更には接着部分が変形しにくくソフトなクッション性を付与しにくい問題もある。このため、接着部分を柔らかい、且つある程度変形しても回復するポリエステルエラストマ−を用い、芯成分に非弾性ポリエステルを用いた熱接着繊維が特開平４−２４０２１９号公報で、同繊維を用いたクッション体がＷＯ−９１／１９０３２号公報、特開平５−１５６５６１号公報、特開平５−１６３６５４号公報等で提案されている。この繊維構造物に使われる接着成分がポリエステルエラストマ−のソフトセグメントとしてはポリアルキレングリコ−ルの含有量が３０〜５０重量％、ハ−ドセグメントの酸成分にテレフタル酸を５０〜８０モル％含有し、他の酸成分組成として特公昭６０−１４０４号公報に記載された繊維と同様にイソフタル酸を含有して非晶性が増すことになり、融点も１８０℃以下となり低溶融粘度として熱接着部分の形成を良くしてアメーバー状の接着部を形成しているが塑性変形しやいため、及び芯成分が非弾性ポリエステルのため、特に加熱下での塑性変形が著しくなり、耐熱抗圧縮性が低下する問題点、及び折り曲げ性が劣り、洗濯は可能だが、水切り性が悪い問題点がある。耐久性を更なる改良法として、特開平５−１６３６５４号公報にシ−ス成分にイソフタル酸を含有するポリエステルエラストマ−、コア成分に非弾性ポリエステルを用いた熱接着複合繊維のみからなる構造体が提案されているが上述の理由で加熱下での塑性変形が著しくなり、耐熱抗圧縮性が低下し、クッション体に使用するには問題がある。又、硬綿の母材にシリコ−ン油剤を付与して繊維の摩擦係数を下げて耐久性を向上し、風合いを良くする方法が特開昭６３−１５８０９４号公報で提案されている。が、熱接着繊維の接着性に問題があり、耐久性が劣るのでクッション体に使用するには好ましくない。他方、折り曲げ性の改良法として、折り畳み構造にする方法が特開昭５５−３６３７３号公報、特開平２−１４２５１３号公報、特開平５−３８９４号公報等で提案されているが、折り曲げ性は改良されたが、耐久性や洗濯時の問題は何ら改良されず、クッション体として用いるには問題が多いものである。又、折り曲げ部分に空洞を作って折り曲げ性を改良したものとして、例えば特開平５−２８５０３１号公報等があるが、ウレタン等の発泡体の問題、又は硬綿の問題を何ら解決できていない。
【０００６】
土木工事用に使用する熱可塑性のオレフィン網状体が特開昭４７−４４８３９号公報に開示されている。それらを用いたクッション体として、実開昭５８−９３２７０号公報に硬い構造と柔らかな構造を積層されたものが実開昭５８−９５７６０号公報には、硬い構造の網状体内部に空調部を有するもの、実開昭５８−１０５７１４号公報には硬い構造と推測される網状体を用いたもの記載されているが、耐熱耐久性や寝心地及び軽量化や洗濯性などの取扱性には何ら配慮されていない。特開昭５８−１０９６７０号公報には、片面に凹凸を有する網状体が提案されているが、細い繊維から構成したクッションとは異なり表面が凸凹でタッチが悪く、耐熱耐久性や寝心地及び軽量化や洗濯性などの取扱性には何ら配慮されていない。特開平６−３２７７２３号公報には、洗浄パイプや通気管等を装着可能な孔部を有する網状体が開示されているが、素材がオレフィンのため耐熱耐久性が著しく劣り、軽量化や洗濯性などの取扱性にも何ら配慮されておらずワディング層やクッション材には使用ができないものである。また、特公平３−１７６６６号公報には繊度の異なる吐出線条を互いに融着してモ−ル状物を作る方法も開示されているがクッション材には適さない網状構造体である。特公平３−５５５８３号公報には、ごく表面のみ冷却前に回転体等の細化装置で細くする方法が記載されている。この方法では表面をフラット化できず、厚みのある細い線条層を作ることできない。したがって座り心地の良好なクッション材にはならない。特開平１−２０７４６２号公報では、塩化ビニ−ル製のフロアマットの開示があるが、室温での圧縮回復性が悪く、耐熱性は著しく悪いので、クッション材としては好ましくないものである。なお、上述構造体はベットマットに関する配慮が全くなされていない。
【０００７】
特開平６−２６９３４５号公報には、遠赤外線輻射機能を持つ不織布等の寝具用部材を被う、綿材をシ−トで挟みキルトした布団用パッドが開示されているが、体型保持機能や蒸れ防止機能等の寝心地改良、耐熱耐久性、水切り性や乾燥性等の洗濯性、及び折り曲げ性に関する配慮がなされていない問題がある。実開平６−４８４５３号公報には、折り目をつけた硬綿をキルティングを施した詰綿充填包布に包まれた敷布団が開示されている。敷布団としては、折り畳み性と保温性は良いが、通気性に劣り蒸れ易く、体型保持性が不充分で、耐熱耐久性、水切り性や乾燥性等の洗濯性の配慮がなされていない問題がある。
【０００８】
【発明が解決しようとする課題】
上記問題点を解決し、蒸れ難く、保温性、形態保持性等の寝心地を良くし、耐熱耐久性、折り曲げ性も良好で使い易く、ＭＲＳＡ等の雑菌を除去するための洗濯が可能な構造とし、更には、分別すればリサイクルも可能にしたベット、敷布団、座蒲団、家具用クッションに最適なマット及びその製法を提供することを目的とする。
【０００９】
【課題を解決するための手段】
上記課題を解決するための手段、即ち、本発明は、クッション層の少なくとも上面にワディング層が積層され、且つ、全体面が側地で被われ縫製されたマットであり、クッション層は熱可塑性弾性樹脂からなる線径が５mm以下の連続した線条を曲がりくねらせランダムループを形成し、それぞれのループの接触部の大部分が融着されてなる三次元立体構造網状体で形成され、該三次元立体構造網状体は上、下両面が実質的にフラット化されており、見掛け密度が０．００５〜０．１０ｇ／cm3 、厚みが５mm以上であり、ワディング層は、ポリエステル繊維のウェブからなり、見掛け密度が０．１ｇ／cm3 以下であることを特徴とするマットである。更には、クッション層を構成する熱可塑性弾性樹脂が、室温での３００％伸長後の回復率（室温伸長回復率）が２０％以上、７０℃での１０％伸長を２４時間保持した後の回復率（７０℃伸長回復率）が３０％以上であるマットであり、クッション層を構成する網状体の線径が０．０１mm以上、見掛けの密度が０．０１ｇ／cm3 から０．０８ｇ／cm3 、厚みが１０mm以上１００mm以下であるマットであり、クッション層を構成する網状体の線径が０．１mm以上２mm以下、見掛けの密度が０．０２ｇ／cm3 から０．０６ｇ／cm3 、厚みが２０mm以上８０mm以下であるマットであり、熱可塑性弾性樹脂からなる成分を示差走査型熱量計で測定した融解曲線に室温以上融点以下の温度に吸熱ピ−クを持つ網状体を用いたマットであり、クッション層を構成する網状体の該線条の断面形状が中空断面又は及び異形断面であるマットであり、ワディング層がニードルパンチされ、厚みが３mm以上１５mm以下であり、見掛け密度が０．０１ｇ／cm3 以上０．０６ｇ／cm3 以下のマットであり、熱可塑性弾性樹脂がポリエステルであるマットであり、天然繊維が絹からなるマットであり、繊維表面にポリエチレングリコ−ル成分を０．０５重量％以上含有するポリエステル繊維を主たるマトリックスとするウエッブからなるマットであり、複数のオリフィスを持つ多列ノズルより熱可塑性弾性樹脂をその融点より２０〜８０℃高い溶融温度で、該ノズルより下方に向けて吐出させ、溶融状態で連続線条のループを形成し、それぞれのループを互いに接触させて融着させ３次元構造を形成しつつ、引取り装置で挟み込み冷却槽で冷却せしめた後、得られた３次元構造体の上、下両面又は片面にポリエステル繊維のウェッブを積層し、全面を側地で被うマットの製法であり、製品化に至る任意の工程で網状体を構成する熱可塑性弾性樹脂の融点より少なくとも１０℃以下の温度でアニ−リングよる疑似結晶化処理を行うマットの製法であり、ポリエチレングリコ−ルを１重量％以上、１０重量％混合して繊維化したポリエステル繊維を主たるマトリックスとしたウエッブを用いるマットの製法である。
【００１０】
本発明における熱可塑性弾性樹脂とは、ソフトセグメントとして分子量３００〜５０００のポリエ−テル系グリコ−ル、ポリエステル系グリコ−ル、ポリカ−ボネ−ト系グリコ−ルまたは長鎖の炭化水素末端をカルボン酸または水酸基にしたオレフィン系化合物等をブロック共重合したポリエステル系エラストマ−、ポリアミド系エラストマ−、ポリウレタン系エラストマ−、ポリオレフィン系エラストマ−などが挙げられる。熱可塑性弾性樹脂とすることで、再溶融により再生が可能となるため、リサイクルが容易となる。例えば、ポリエステル系エラストマ−としては、熱可塑性ポリエステルをハ−ドセグメントとし、ポリアルキレンジオ−ルをソフトセグメントとするポリエステルエ−テルブロック共重合体、または、脂肪族ポリエステルをソフトセグメントとするポリエステルエステルブロック共重合体が例示できる。ポリエステルエ−テルブロック共重合体のより具体的な事例としては、テレフタル酸、イソフタル酸、ナフタレン２・６ジカルボン酸、ナフタレン２・７ジカルボン酸、ジフェニル４・４’ジカルボン酸等の芳香８ジカルボン酸、１・４シクロヘキサンジカルボン酸等の脂環族ジカルボン酸、琥珀酸、アジピン酸、セバチン酸ダイマ−酸等の脂肪族ジカルボン酸または、これらのエステル形成性誘導体などから選ばれたジカルボン酸の少なくとも１種と、１・４ブタンジオ−ル、エチレングリコ−ル、トリメチレングリコ−ル、テトレメチレングリコ−ル、ペンタメチレングリコ−ル、ヘキサメチレングリコ−ル等の脂肪族ジオ−ル、１・１シクロヘキサンジメタノ−ル、１・４シクロヘキサンジメタノ−ル等の脂環族ジオ−ル、またはこれらのエステル形成性誘導体などから選ばれたジオ−ル成分の少なくとも１種、および平均分子量が約３００〜５０００のポリエチレングリコ−ル、ポリプロピレングリコ−ル、ポリテトラメチレングリコ−ル、エチレンオキシド−プロピレンオキシド共重合体からなるグリコ−ル等のポリアルキレンジオ−ルのうち少なくとも１種から構成される三元ブロック共重合体である。ポリエステルエステルブロック共重合体としては、上記ジカルボン酸とジオ−ル及び平均分子量が約３００〜５０００のポリラクトン等のポリエステルジオ−ルのうち少なくとも各１種から構成される三元ブロック共重合体である。熱接着性、耐加水分解性、伸縮性、耐熱性等を考慮すると、ジカルボン酸としてはテレフタル酸、または、及びナフタレン２・６ジカルボン酸、ジオ−ル成分としては１・４ブタンジオ−ル、ポリアルキレンジオ−ルとしてはポリテトラメチレングリコ−ルの３元ブロック共重合体または、ポリエステルジオ−ルとしてポリラクトンの３元ブロック共重合体が特に好ましい。特殊な例では、ポリシロキサン系のソフトセグメントを導入したものも使うこたができる。また、上記エラストマ−に非エラストマ−成分をブレンドされたもの、共重合したもの、ポリオレフィン系成分をソフトセグメントにしたもの等も本発明の熱可塑性弾性樹脂に包含される。ポリアミド系エラストマ−としては、ハ−ドセグメントにナイロン６、ナイロン６６、ナイロン６１０、ナイロン６１２、ナイロン１１、ナイロン１２等及びそれらの共重合ナイロンを骨格とし、ソフトセグメントには、平均分子量が約３００〜５０００のポリエチレングリコ−ル、ポリプロピレングリコ−ル、ポリテトラメチレングリコ−ル、エチレンオキシド−プロピレンオキシド共重合体からなるグリコ−ル等のポリアルキレンジオ−ルのうち少なくとも１種から構成されるブロック共重合体を単独または２種類以上混合して用いてもよい。更には、非エラストマ−成分をブレンドされたもの、共重合したもの等も本発明に使用できる。ポリウレタン系エラストマ−としては、通常の溶媒（ジメチルホルムアミド、ジメチルアセトアミド等）の存在または不存在下に、（Ａ）数平均分子量１０００〜６０００の末端に水酸基を有するポリエ−テル及び又はポリエステルと（Ｂ）有機ジイソシアネ−トを主成分とするポリイソシアネ−トを反応させた両末端がイソシアネ−ト基であるプレポリマ−に、（Ｃ）ジアミンを主成分とするポリアミンにより鎖延長したポリウレタンエラストマ−を代表例として例示できる。（Ａ）のポリエステル、ポリエ−テル類としては、平均分子量が約１０００〜６０００、好ましくは１３００〜５０００のポリブチレンアジペ−ト共重合ポリエステルやポリエチレングリコ−ル、ポリプロピレングリコ−ル、ポリテトラメチレングリコ−ル、エチレンオキシド−プロピレンオキシド共重合体からなるグリコ−ル等のポリアルキレンジオ−ルが好ましく、（Ｂ）のポリイソシアネ−トとしては、従来公知のポリイソシアネ−トを用いることができるが、ジフェニルメタン４・４’ジイソシアネ−トを主体としたイソシアネ−トを用い、必要に応じ従来公知のトリイソシアネ−ト等を微量添加使用してもよい。（Ｃ）のポリアミンとしては、エチレンジアミン、１・２プロピレンジアミン等公知のジアミンを主体とし、必要に応じて微量のトリアミン、テトラアミンを併用してもよい。これらのポリウレタン系エラストマ−は単独又は２種類以上混合して用いてもよい。なお、本発明の熱可塑性弾性樹脂の融点は耐熱耐久性が保持できる１４０℃以上が好ましく、１６０℃以上のものを用いると耐熱耐久性が向上するのでより好ましい。なお、本発明のベットマットを構成する網状体は好ましい実施形態として難燃性を付与するため燐系化合物を含有させるので、熱安定性が難燃剤を含有しないものよりやや劣るので、必要に応じ、抗酸化剤等を添加して耐熱性や耐久性を向上させるのが特に好ましい。抗酸化剤は、好ましくはヒンダ−ド系抗酸化剤としては、ヒンダ−ドフェノ−ル系とヒンダ−ドアミン系があり、窒素を含有しないヒンダ−ドフェノ−ル系抗酸化剤を１％〜５％添加して熱分解を抑制すると燃焼時の致死量が少ない有毒ガスの発生を抑えられるので特に好ましい。本発明の目的である好ましい耐久性とクッション性を兼備できるマット類になるクッション層を構成する熱可塑性弾性樹脂の後述する方法で測定した伸長回復性は、室温での３００％伸長後の回復率（室温伸長回復率）は２０％以上、７０℃での１０％伸長を２４時間保持した後の回復率（７０℃伸長回復率）は３０％以上であり、より好ましくは、室温伸長回復率が３０％以上、７０℃伸長回復率が４０％以上であり、最も好ましくは、室温伸長回復率が４０％以上、７０℃伸長回復率が５０％以上とする。このような伸長回復性を付与する成分を構成する熱可塑性弾性樹脂のソフトセグメント含有量は好ましくは１５重量％以上、より好ましくは３０重量％以上であり、耐熱耐へたり性からは８０重量％以下が好ましく、より好ましくは７０重量％以下である。即ち、本発明の弾性網状体の振動や応力の吸収機能をもたせる成分のソフトセグメント含有量は好ましくは１５重量％以上８０重量％以下であり、より好ましくは３０重量％以上７０重量％以下である。
【００１１】
本発明マットの好ましい実施形態として難燃性を付与する必要から、熱可塑性弾性樹脂中に燐含有量（Ｂｐｐｍ）がソフトセグメント含有量（Ａ重量％）に対し、６０Ａ＋２００≦Ｂ≦１０００００の関係を満足するのが良い。満足しない場合は難燃性が劣る場合がある。１０００００ｐｐｍを越えると可塑化効果による塑性変形が大きくなり熱可塑性弾性樹脂の耐熱性が劣るので好ましくない。好ましい燐含有量（Ｂｐｐｍ）はソフトセグメント含有量（Ａ重量％）に対して、３０Ａ＋１８００≦Ｂ≦１０００００であり、より好ましい燐含有量（Ｂｐｐｍ）はソフトセグメント含有量（Ａ重量％）に対し、１６Ａ＋２６００≦Ｂ≦５００００である。難燃性は多量のハロゲン化物と無機物を添加して高度の難燃性を付与する方法があるが、燃焼時に致死量の少ない有毒なハロゲンガスを多量に発生し、火災時の中毒の問題があり、焼却時には、焼却炉の損傷が大きくなるので、本発明では、好ましいハロゲン化物の含有量は１０重量％以下、より好ましいハロゲン化物の含有量は５重量％以下、最も好ましくはハロゲン化物を含有しないものである。本発明の燐系難燃剤としては、例えば、ポリエステル系熱可塑性弾性樹脂の場合、樹脂重合時に、ハ−ドセグメント部分に難燃剤として、例えば特開昭５１−８２３９２号公報等に記載された１０〔２・３・ジ（２・ヒドロキシエトキシ）−カルボニルプロピル〕９・１０・ジヒドロ・９・オキサ・１０ホスファフェナレンス・１０オキシロ等のカルボン酸をハ−ドセグメントの酸成分の一部として共重合したポリエステル系熱可塑性弾性樹脂とする方法や、熱可塑性弾性樹脂に後工程で、例えば、トリス（２・４−ジ−ｔ−ブチルフェニル）フスファイト等の燐系化合物を添加して難燃性を付与することができる。その他、難燃性を付与できる難燃剤としては、各種燐酸エステル、亜燐酸エステル、ホスホン酸エステル（必要に応じハロゲン元素を含有する上記燐酸エステル類）、もしくはこれら燐化合物から誘導される重合物が例示できる。本発明は、熱可塑性弾性樹脂中に各種改質剤、添加剤、着色剤等を必要に応じて添加できる。本発明ベットマットを構成するクッション層の網状体やワディング層の接着成分に難燃性を付与するために燐を含有させており、この理由は、上記している如く、安全性の観点から、火災時に発生するシアンガス、ハロゲンガス等の致死量の少ない有毒ガスをできるだけ少なくすることにある。このため、本発明マット類を構成する網状体の燃焼ガスの毒性指数は、好ましくは６以下、より好ましくは５．５以下である。ワディング層の燃焼ガスの毒性指数も好ましくは６以下、より好ましくは５．５以下、最も好ましくは５以下である。クッション層の網状体を構成する熱可塑性弾性樹脂は、同一種類に統一するのが好ましい。例えばポリエステル系熱可塑性弾性樹脂とすることで、クッション層は個々に分別せずに再生リサイクルができる。
【００１２】
本発明のマットを構成する熱可塑性弾性樹脂からなる成分は、示差走査型熱量計にて測定した融解曲線において、融点以下に吸熱ピ−クを有するのが好ましい。融点以下に吸熱ピ−クを有するものは、耐熱耐へたり性が吸熱ピ−クを有しないものより著しく向上する。例えば、本発明の好ましいポリエステル系熱可塑性樹脂として、ハ−ドセグメントの酸成分に剛直性のあるテレフタル酸やナフタレン２・６ジカルボン酸などを９０モル％以上含有するもの、より好ましくはテレフタル酸やナフタレン２・６ジカルボン酸の含有量は９５モル％以上、特に好ましくは１００モル％とグリコ−ル成分をエステル交換後、必要な重合度まで重合し、次いで、ポリアルキレンジオ−ルとして、好ましくは平均分子量が５００以上５０００以下、特に好ましくは１０００以上３０００以下のポリテトラメチレングリコ−ルを１５重量％以上７０重量％以下、より好ましくは３０重量％以上６０重量％以下共重合量させた場合、ハ−ドセグメントの酸成分に剛直性のあるテレフタル酸やナフタレン２・６ジカルボン酸の含有量が多いとハ−ドセグメントの結晶性が向上し、塑性変形しにくく、かつ、耐熱抗へたり性が向上するが、溶融熱接着後更に融点より少なくとも１０℃以上低い温度でアニ−リング処理するとより耐熱抗へたり性が向上する。圧縮歪みを付与してからアニ−リングすると更に耐熱抗へたり性が向上する。このような処理をした網状体を示差走査型熱量計で測定した融解曲線に室温以上融点以下の温度で吸熱ピークをより明確に発現する。なおアニ−リングしない場合は融解曲線に室温以上融点以下に吸熱ピ−クを発現しない。このことから類推するに、アニ−リングにより、ハ−ドセグメントが再配列され、疑似結晶化様の架橋点が形成され、耐熱抗へたり性が向上しているのではないかとも考えられる。（この処理を疑似結晶化処理と定義する）この疑似結晶化処理効果は、ポリアミド系弾性樹脂やポリウレタン系弾性樹脂にも有効である。
【００１３】
本発明におけるポリエステル繊維とは、例えば、ポリエチレンテレフタレ−ト（ＰＥＴ）、ポリエチレンナフタレ−ト（ＰＥＮ）、ポリシクロヘキシレンジメチレンテレフタレ−ト（ＰＣＨＤＴ）、ポリシクロヘキシレンジメチレンナフタレ−ト（ＰＣＨＤＮ）、ポリブチレンテレフタレ−ト（ＰＢＴ）、ポリブチレンナフタレ−ト（ＰＢＮ）、ポリアリレ−ト等、及びそれらの共重合ポリエステル等が例示できる。本発明ではガラス転移点温度が少なくとも４０℃以上のものを使用するのが好ましい。本発明に用いるマットの側地にポリエステルを用いる場合は、廃棄する場合に分離せずにリサイクルが可能で、耐熱性も良好なＰＥＴ、ＰＥＮ、ＰＢＮ、ＰＣＨＤＴ等のポリエステルが特に好ましい。更には、ＰＥＴ、ＰＥＮ、ＰＢＮ、ＰＣＨＤＴ等と重縮合して燐含有エステル形成性化合物を共重合または燐含有難燃剤を含有してなる難燃性ポリエステル（以下難燃性ポリエステルと略す）が好ましく、例えば、特開昭５１−８２３９２号公報、特開昭５５−７８８８号公報、特公昭５５−４１６１０号公報等に例示されたものが挙げられる。なお、塩化ビニ−ルは自己消火性を有するが燃焼すると有毒ガスを多く発生すること、及び耐熱耐久性が劣るので本発明に用いるのは好ましくない。本発明では、ポリエステル繊維を用いる他の目的の一つは、繊維の水分率を低下させるためであるが、発汗した水分は速やかに皮膚面より移動させる必要から繊維表面は親水化して放水性を高めるのが好ましく、例えば、ポリエチレンオキサイド（ＰＥＯ）やポリエチレングリコ−ル（ＰＥＧ）等のポリエ−テル類及びそれらの共重合体や燐化合物との反応物を少なくとも０．０５重量％以上繊維表面に存在することが好ましい。より好ましくは０．１重量％以上１重量％以下である。２重量％以上存在させると繊維の摩擦係数が高くなり、開繊性が劣るので好ましくない。後加工で付与してもよいが、洗濯耐久性を保持するためには、ポリエステルに混合するのが好ましい。混合方法は、重合時に添加する方法やポリマ−ブレンドして練り込む方法、紡糸時に溶融ブレンドして練り込む方法が使える。混合する場合の添加量は、ＰＥＧでは、分子量５０００以上２００００以下のものを１重量％以上１０重量％以下添加するのが好ましい。１重量％未満では充分な放水性が付与できず、１５重量％以上では、繊維のモジュラスが低下するので好ましくない。更には、繊維断面を異形断面又は中空異形断面にしてサイホン効果でより効率的に放水性を付与するのがより好ましい。異形断面の場合は後加工でも耐久性が付与できるので好ましい実施形態である。
【００１４】
本発明マットの基本のクッション層は、繊径が５mm以下の熱可塑性弾性樹脂からなる連続した線条を曲がりくねらせ互いに接触させて該接触部の大部分が融着一体化された３次元立体構造体を形成し、両面が実質的にフラット化された網状体のため、ワディング層を介して外部から与えられた変形、特には局部的に大きい変形応力が与えられた場合でも、フラット化された網状体の面で変形応力を受け止め変形応力を分散させ、熱可塑性弾性樹脂からなる線条が３次元立体構造体を形成し融着一体化されているので、構造体全体が変形してエネルギ−変換により変形応力を吸収させることによりゴム弾性による低い反発力で変形応力を受け止めるので、極端な局部的沈み込みを防止し、人体に対し柔らかな把持力で体型を支えることができる好ましい体型保持機能を発現する。ベット用マットでは振動吸収機能も要求される。本発明の網状体からなるクッション層は、ベットイン時や寝返り時に外部から与えられた振動を熱可塑性弾性樹脂の振動吸収機能で大部分の振動を吸収減衰し、好ましい振動吸収機能も発現する。変形応力が解除されると熱可塑性弾性樹脂のゴム弾性で容易に元の形態に回復する機能があるので耐へたり性も良好である。更に、空隙率が高く、通気孔径が著しく大きいので通気抵抗が低く通気性が著しく良好であり、寝返り等による変形応力の変化を受けると熱可塑性弾性樹脂のゴム弾性を有する線条が３次元立体構造体を形成し融着一体化されているので、構造体全体が変形により圧縮回復してワディング層を介して透過したクッション層中に溜まった蒸気や熱を含む空気を圧縮時排出し、回復時新鮮な外気と入替えるポンプ機能を有するため、ワディング層とクッション層間の熱及び蒸気の移動が容易となり蒸れ難くい快適な寝心地を提供できるマットである。この目的から、本発明の網状体を形成する振動吸収性と弾性回復性の良い熱可塑性弾性樹脂からなる線条の線径は５mm以下である。見掛け密度を０．２ｇ／cm2 以下にした場合、５mmを越えると構成本数が少なくなり、密度斑を生じて部分的に耐久性の悪い構造ができ、応力集中による疲労が大きくなり耐久性が低下するので好ましくない。本発明の熱可塑性弾性樹脂からなる線条の線径が細すぎると抗圧縮性が低くなり過ぎて変形による応力吸収性が低下するので０．０１mm以上であり、構成本数の低下による構造面の緻密性を損なわない３mm以下である。より好ましくは０．０５mm以上、２mm以下である。本発明の網状体を形成する連続線条のランダムループの平均直径は、好ましくは５０mm以下、特に２〜２５mmとするのが目的を達成するためには好ましい。本発明の網状体の見掛け密度は、０．００５ｇ／cm3 では反発力が失われ、変形応力吸収能力や振動吸収能力が不充分となりクッション機能を発現させにくくなる場合があり、０．２５ｇ／cm3 以上では反発力が高すぎて座り心地が悪くなる場合がある。本発明では、軽量化して取扱性を向上させる目的で、本発明の網状体の見掛け密度は０．１０ｇ／cm3 以下である。振動吸収能力や変形応力吸収機能が生かせてクッション体としての機能が発現されやすい０．０１ｇ／cm3 以上０．０８ｇ／cm3 以下が好ましく、より好ましくは０．０２ｇ／cm3 以上０．０６ｇ／cm3 以下である。本発明における網状体は線径の異なる線状を見掛け密度との組合せで最適な構成とする異繊度積層構造とする方法も好ましい実施形態として選択できる。本発明の網状体の厚みは５mm以上が必要である。厚みが５mm未満では応力吸収機能と応力分散機能が低下するので好ましくない。好ましい厚みは力の分散をする面機能と振動や変形応力吸収機能が発現できる厚みとして１０mm以上５００mm以下であり、より好ましくは２０mm以上２００mm以下である。短板の厚みが５００mm以上になると後述する折り曲げ性がなくなる。より厚いクッション層を所望する場合は、所望に応じて２００mm以下の薄い厚みのクッション層、好ましくは１００mm以下の網状体を非接合の状態で積層することで折り曲げ性を損なうことを抑え、厚みのあるクッション層のマットを得ることもできる。厚みが２００mm以下となるように積層する場合、界面を接合しても良く、非接合でも面がフラットなので応力の伝達が面で伝達されるので変形対応性に支障はない。網状体の表面が実質的にフラット化されてない場合、側地を介してワディング層から伝達される局部的な外力は、変形応力を面で受けることが出来ず、表面の線条及び接着点部分までに選択的に伝達され、変形応力を分散させる機能が低下するので、応力集中が発生する場合があり、このような外力に対しては応力集中による疲労が発生して耐へたり性が低下する場合がある。なお、該線条が熱可塑性弾性樹脂からなる場合は３次元構造部分で構造全体が変形するので応力集中は緩和されるが、へたりが進行するに伴い体型保持機能も低下する。非弾性樹脂では、そのまま応力が接着点に集中して構造破壊を生じ回復しなくなる。更には、表面が実質的にフラット化されてなく凸凹があると、寝た時背部や臀部等に異物感を与えるため寝心地が悪くなり好ましくない。なお、線状が連続していない場合は、線条の接着点が応力の伝達点となるため接着点に著しい応力集中が起こり構造破壊を生じ耐熱耐久性が劣り好ましくない。構造破壊しない段階でも抗圧縮性が劣り、体型保持性が劣る問題があり、この問題を解決するため密度を高くすると、空隙率の低下と共に通気性も低下して快適性が低下し、重量も重くなり取扱性が著しく劣る。融着していない場合は、形態保持が出来ず、構造体が一体で変形しないため、応力集中による疲労現象が起こり耐久性が劣ると同時に、形態が変形して体型保持ができなくなるので好ましくない。本発明クッション層のより好ましい融着の程度は、線条が接触している部分の大半が融着した状態であり、もっとも好ましくは接触部分が全て融着した状態である。公知の非弾性樹脂のみからなる線条で構成した網状体では、表面層で吸収できない大きい変形応力を受けるとゴム弾性を持たないので変形しにくく大きい反発力を示すため、適度の沈み込みが起こらず、強い反発力を示すので不快な体型支持感を与え好ましくない体型保持機能を発現すると共に圧縮回復によるポンプ機能が殆ど有しないので蒸れ低減化機能が劣る。又、圧縮変形により塑性変形を生じて回復しなくなり耐久性も劣る。架橋性発泡ポリウレタンでは、振動吸収機能や耐へたり性は弾性樹脂のため良好であるが、応力伝達が容易な構造のため、局部的な変形に容易に追随して極端な局部的沈み込みを発生し、体型保持機能が劣る。又、発泡ポリウレタンは通気性が極めて劣るため蒸れ易く、快適な寝心地が得られないマットとなるクッション層である。本発明のマットはクッション層の表面側又は、及び裏面側に、見掛け密度が０．１ｇ／cm3 以下のポリエステル繊維のウェブからなるワディング層を積層し、全面を側地で被われたマットである。ポリエステル繊維は特に限定されないが前述のように、汗や湿気をできるだけ早く皮膚面からワディング層を介して移動させ蒸れ感を与えず、適正な保温性と好ましいフィット感で体型を保持して快適な眠りを永続的に提供するため、好ましくは繊維表面を親水化し、より好ましくは異形断面化して放水性を高めたポリエステル繊維を主たるマトリックスとしたウェッブを用いることで、皮膚面で体温まで温度が上昇した汗や水蒸気は、側地を介して皮膚面からワディング層へ移動し、ワディング層からただちにクッション層表面に移動する。次いでクッション層が新鮮な空気と入れ換えるポンプ機能を持つので、クッション層表面に移動した熱と水分はクッション層を介して外部に放出される相乗効果で皮膚面が乾燥すると、水分蒸発による皮膚面の温度低下も伴い蒸れ感を低減させる。ワディング層を構成するウエッブ中のポリエステル繊維は、親水化したポリエステル繊維の混合率は好ましくは少なくとも５０重量％以上であり、より好ましくは７５重量％、最も好ましくは１００重量％である。見掛け密度は、０．１ｇ／cm3 を越えるとワディング層は通気性が低下し透湿性が低下するので、透湿性からの見掛け密度は、好ましくは０．０６ｇ／cm3 以下、より好ましくは０．０４ｇ／cm3 以下である。かくして、ワディング層とクッション層の相乗効果で蒸れにくく、且つ保温性も優れたマット機能を発現できる。本発明マットのウェッブからなるワディング層は個々の繊維が固定されていないので、個々の繊維は変形応力に対する自由度が大きく、側地を介して伝達された局部的な変形応力を受けると繊維の移動を起こしつつ圧縮変形されて、クッション層に変形応力を伝達する。クッション層は伝達された変形応力を熱可塑性弾性樹脂の伸縮性で構造体全体が変形しつつエネルギ−変換により変形応力が吸収されることによりゴム弾性による低い反発力で変形応力を受け止められるので、人体に対し柔らかな把持力で体型を支えられる相乗効果で人体と接する局所的な高圧縮応力点が形成されにくくなり、より鬱血しにくいワディング機能を発現できる。この機能は側地を介して新鮮な空気を皮膚面に送ることにより、更なる相乗効果として床擦れ防止にも有効に作用する。特に顕著なこの様な効果を付与するには、側地を介してワディング層からクッション層側面へ排気される空気の通気度を１０cc／cm2 秒以上となる構成にするのが望ましい。なお、本発明のマットを被う側地の通気度は特には制限されないが、床擦れ防止効果を付与するには、側地を構成する編織物の通気度は、好ましくは３０cc／cm2 秒以上である。本発明のマットを構成する側地は、マットの側面を編織物のみで構成し、クッション層と外気間の通気性を向上させることで、クッション層のポンプ機能をより効果的に活用できるので好ましい。本発明のワディング層を構成するウエッブの見掛け密度は高過ぎると高圧縮応力支持面積の増加による鬱血防止機能の低下と通気性が劣り蒸れ防止効果も低下するので見掛け密度が０．１ｇ／cm3 以下が必要である。見掛け密度が低すぎると抗圧縮性が低下してワディング層の機能が低下するので、好ましい見掛け密度は０．０１ｇ／cm3 以上０．０６ｇ／cm3 以下、より好ましくは見掛け密度は０．０３ｇ／cm3 以上０．０５ｇ／cm3 以下である。ワディング層の厚みは、２mm未満ではワディング層機能が低下する。３０mm以上ではクッション層との相乗効果の有用な前記機能や適度の沈み込みと柔らかい把持力で体を支える体型保持機能や振動吸収機能を低下させる。好ましい厚みは３mm以上１５mm以下、より好ましくは５mm以上１０mm以下である。本発明マットのワディング層に用いるポリエステル繊維の繊度は所望に応じて選択されるが、通常のカ−ド開繊で使用できる繊度としては、０．５デニ−ルから１００デニ−ルであるが、好ましくは２デニ−ルから３０デニ−ル、より好ましくは４デニ−ルから１５デニ−ルである。特別な場合は５００デニ−ルまでの繊度が選択できる。また、本発明マットのワディング層に用いるポリエステル繊維の断面形状は特に限定されないが、異形断面で異形度が１．２以上や中空断面で中空率が１０％以上、または中空異形断面で異形度１．２以上、中空率５％以上とすることで、嵩高性、保温性、抗圧縮性が向上するので好ましい。巻縮形態は開繊ウエッブとなり絡合性が保持できれば機械巻縮でも立体巻縮でも特には限定されないが、立体巻縮で巻縮度が５％以上３０％以下で巻縮数が５個／インチ以上１５個／インチ以下とすることで柔らかな嵩高性が向上するので好ましく、立体巻縮で巻縮度が５％以上２０％以下で巻縮数が１６個／インチ以上３０個／インチ以下とすることで抗圧縮性が向上できるので好ましい。繊維長は１５mm以上１５０mm以下であればカ−ド開繊またはエア−開繊でき、特には制限されないが、好ましくは開繊しやすく絡合状態が良い３０mm以上１００mm以下を用いる。やや柔らかい風合いとするには２デニ−ルから８デニ−ルの細い繊度を用い、やや硬い風合いとするには６デニ−ルから３０デニ−ルの太い繊度を用いるのが好ましい。腰がありタッチが柔らかな風合いとするには、０．５デニ−ルから５デニ−ルの繊度のものと、６デニ−ルから１５デニ−ルの繊度のものを１／９から５／５を混繊して用いるのが好ましい。巻縮形態が機械巻縮で易滑処理したものと立体巻縮で親水加工したものを混繊して嵩高性を抑制しつつ柔らかさと耐へたり性および放水性を付与できる。ワディング層に他の特性を付加するために、例えば、防ダニ剤、抗菌剤、消臭剤、難燃剤、芳香剤等を親水化と同時に付与したポリエステル繊維を用いる又は、別途にそれらを含有するポリエステル繊維を混繊して機能を高めたり、撥水性、疎水性等の特性を利用して水切り乾燥性を改善して欠点のかバ−や特徴を倍加する等の機能付与できる繊維を混繊するのが望ましい。好みに応じてポリエステル繊維からなる所望の異なるワディング層をクッション層面に積層して夏冬使い分ける等の使用形態もとれる。又、本発明の基本機能を失わない範囲において、クッション層及び、又はワディング層に他の素材が積層されてもかまわない。本発明マットは公知のマット類に較べて洗濯性が良い。即ち、通常の繊維からなるクッション層の繊維径０．００１mm以下のもの較べ、本発明のクッション体の大部分を構成するクッション層の線径が０．０１mm以上であり、ワディング層のウェッブは繊維の表面積は大きいが、クッション体全体での平均の構成本数が少ないため、線条の表面積が著しく少ないため線条表面の付着水分が少なくできるので、水切り性に優れる。水切り性が良いので乾燥時間を短縮できる。なお、所望に応じ、側地とクッション体はボタン止めで接続される。ボタン止めの好ましい密度は２個／ｍ2 以上８個／ｍ2 であり、ボタン止め部分の厚みは所定の厚みの８０％以上を保持できるように止められているのが好ましい。ボタン止めを施しされても、本発明のワディング層を構成するウェッブは個々の繊維が充分に固定されていないので自由度が大きく、洗濯時の揉み圧縮が著しく加えられるとフェルト化する場合があるので、好ましくはワディング層を構成するウェッブに軽くニードルパンチ等による絡合処理を施しフェルト化を防止するのが好ましい。ニードルパンチしたウェッブをワディング層に用いた場合、丸洗い洗濯でもウェッブの偏りや絡みつきによるフェルト化が生じにくい。ニ−ドルパンチの密度は特には限定されないが、パンチ密度が高すぎるとウェッブ中の繊維の自由度が消失して、上記効果がなくなるので、好ましくは５本／cm2 以上３０本／cm2 以下がよい。この処理で本発明のマットは頻繁に洗濯でき、結果として、清潔なマットを常に使用できる。また、本発明のマットは、クッション層の熱可塑性弾性樹脂の伸縮性と、クッション層と変形自由度の高いウェッブからなるワディング層が積層されているので、折り曲げ性をより向上させている。この機能は、頭部や上半身を起こす必要がある介護用等のベットに使用することができる。厚みが薄い敷布団として使用する場合は、折り畳んで収納することも可能である。クッション層が非弾性樹脂で構成された硬い素材で構成されたものは無理に折り曲げると折り曲げ部が破壊する場合があり、柔らかい非弾性樹脂素材で構成されたものは塑性変形してクッションが折り曲げ部付近が凹み、繰り返し折り曲げると屈曲疲労で破断するが、変形に対する自由度の高いウェッブからなるワディング層が熱可塑性弾性樹脂からなる本発明のクッション層が非接合した積層構造のため、ワディング層が面剛性機能を持たず、折り曲げが可能で、繰り返し折り曲げに対しても、側地とクッション層に挟まれたワディング層も自由に変形をするので、塑性変形しにくく耐久性に優れる点が本発明と硬綿類と大きく異なる点である。硬綿の折り曲げ性を改良するために、折り曲げ構造とするものが提案されているが、本発明のクッション層と異なりクッション層に非弾性樹脂が使用されているため耐久性が劣るものである。業務用ベットでは、必要に応じて殺菌する場合がある。殺菌は１００℃未満のエチレンオキサイドガス又は１３０℃の蒸気を用いるのが一般的である。本発明マットは圧縮応力を付与しないで１３０℃の蒸気で９０分未満で殺菌することで変形させずに殺菌することが可能であるが、公知のオレフィン系や塩化ビニ−ル系素材を用いた場合は、耐熱性が劣り殺菌時の加熱で塑性変形し嵩減りを生じる点が本発明と異なる点である。なお、網状体形成段階から製品化される任意の段階で上述の疑似結晶化処理を施すことにより、網状体中の熱可塑性弾性樹脂からなる成分を示差走査型熱量計で測定した融解曲線に室温以上融点以下の温度に吸熱ピークを持つようにすると熱可塑性弾性樹脂の伸縮性と耐熱性が著しく向上し、製品の耐熱耐久性も格段に向上するのでより好ましい。
【００１５】
本発明のクッション層を構成する網状体の線条の断面形状は特には限定されないが、中空断面や異形断面にすることで好ましい抗圧縮性（反発力）やタッチを付与することができるので特に好ましい。抗圧縮性は繊径や用いる素材のモジュラスにより調整して、線径を細くしたり、柔らかい素材では中空率や異形度を高くし初期圧縮応力の勾配を調整できるし、線径をやや太くしたり、ややモジュラスの高い素材では中空率や異形度を低くして寝心地が良好な抗圧縮性を付与する。中空断面や異形断面の他の効果として中空率や異形度を高くすることで、同一の抗圧縮性を付与した場合、より軽量化が可能となり、ベット用マットの交換や布団、座布団などの場合は、上げ下ろし時の取扱性が向上する。好ましい抗圧縮性（反発力）やタッチを付与することができる他の好ましい方法として、本発明の網状体の線条を複合構造とする方法がある。複合構造としては、シ−スコア構造またはサイドバイサイド構造及びそれらの組合せ構造などが挙げられる。が、特にはクッション層が大変形してもエネルギ−変換できない振動や変形応力をエネルギ−変換して回復できる立体３次元構造とするために線状の表面の５０％以上を柔らかい熱可塑性弾性樹脂が占めるシ−スコア構造またはサイドバイサイド構造及びそれらの組合せ構造などが挙げられる。シ−スコア構造ではシ−ス成分は振動や変形応力をエネルギ−変換が容易なソフトセグメント含有量が多い熱可塑性弾性樹脂とし、コア成分は抗圧縮性を示すソフトセグメント含有量が少ない熱可塑性弾性樹脂で構成し適度の沈み込みによる背部や臀部等の接触部への快適なタッチを与えることができる。サイドバイサイド構造では振動や変形応力をエネルギ−変換が容易なソフトセグメント含有量が多い熱可塑性弾性樹脂の溶融粘度をソフトセグメント含有量が少ない抗圧縮性を示す熱可塑性弾性樹脂の溶融粘度より低くして線状の表面を占めるソフトセグメント含有量が多い熱可塑性弾性樹脂の割合を多くした構造（比喩的には偏芯シ−ス・コア構造のシ−スに熱可塑性弾性樹脂を配した様な構造）として線状の表面を占めるソフトセグメント含有量が多い熱可塑性弾性樹脂の割合を８０％以上としたものが特に好ましく、最も好ましくは線状の表面を占めるソフトセグメント含有量が多い熱可塑性弾性樹脂の割合が１００％のシ−スコアである。ソフトセグメント含有量が多い熱可塑性弾性樹脂の線状の表面を占める割合が多くなると、溶融して融着するときの流動性が高いので接着が強固になる効果があり、構造が一体で変形する場合、接着点の応力集中に対する耐疲労性が向上し、耐熱性や耐久性がより向上する。本発明のマットは、クッション層の片面に親水化したポリエステル繊維を主たるマトリックスとしたポリエステル繊維からなるウェッブを積層し、他面に硬綿、天然繊維ウエッブ、不織布、編み物、布帛類等を設置し、編織物からなる側地で被い一体化することもできる。本発明マットは、船舶用座席、車両用、船舶用、病院用等の業務用及び家庭用ベット、布団、座蒲団、家具用マット類等に特に有用であるが、車両用座席、家具用椅子、事務用椅子等のクッション体としても有用である。
【００１６】
次に本発明の製法を述べる。複数のオリフィスを持つ多列ノズルより熱可塑性弾性樹脂をその融点より２０℃から８０℃高い溶融温度で、該ノズルより下方に向けて吐出させ、溶融状態で互いに接触させて融着させ３次元構造を形成しつつ、引取り装置で挟み込み冷却槽で冷却せしめた後、両面又は片面にポリエステル繊維のウェッブを積層し、全面を側地で被うマットの製法であり、製品化に至る任意の工程で網状体を構成する熱可塑性弾性樹脂の融点より少なくとも１０℃以下の温度でアニ−リングよる疑似結晶化処理を行うマットの製法であり、ポリエチレングリコ−ルを１重量％以上、１０重量％混合して繊維化したポリエステル繊維を主たるマトリックスとするウエッブ用いるマットの製法である。本発明の網状体は、熱可塑性弾性樹脂を一般的な溶融押出機を用いて溶融し、複数のオリフィスを持つ多列ノズルに供給し、オリフィスより下方へ吐出する。この時の溶融温度は、熱可塑性弾性樹脂の融点より２０℃〜８０℃高い温度である。熱可塑性弾性樹脂の融点より８０℃を越える高い溶融温度にすると熱分解が著しくなり熱可塑性弾性樹脂のゴム弾性特性が低下するので好ましくない。他方、熱可塑性弾性樹脂の融点より１０℃以上高くしないとメルトフラクチャ−を発生し正常な線条形成が出来なくなり、また、吐出後ル−プ形成しつつ接触させ融着させる際、線条の温度が低下して線条同士が融着しなくなり接着が不充分な網状体となる場合があり好ましくない。好ましい溶融温度は融点より２０℃から６０℃高い温度、より好ましくは融点より２５℃から４０℃高い温度である。オリフィスの形状は特に限定されないが、中空断面（例えば三角中空、丸型中空、突起つきの中空等となるよう形状）及び、又は異形断面（例えば三角形、Ｙ型、星型等の断面二次モ−メントが高くなる形状）とすることで前記効果以外に溶融状態の吐出線条が形成する３次元構造が流動緩和し難くし、逆に接触点での流動時間を長く保持して接着点を強固にできるので特に好ましい。特開平１−２０７５号公報に記載の接着のための加熱をする場合、３次元構造が緩和し易くなり平面的構造化し、３次元立体構造化が困難となるので好ましくない。網状体の特性向上効果としては、見掛けの嵩を高くでき軽量化になり、また抗圧縮性が向上し、弾発性も改良できへたり難くなる。中空断面では中空率が８０％を越えると断面が潰れ易くなるので、好ましくは軽量化の効果が発現できる１０％以上７０％以下、より好ましくは２０％以上６０％以下である。オリフィスの孔間ピッチは線状が形成するル−プが充分接触できるピッチとする必要がある。緻密な構造にするには孔間ピッチを短くし、粗密な構造にするには孔間ピッチを長くする。本発明の孔間ピッチは好ましくは３mm〜２０mm、より好ましくは５mm〜１０mmである。本発明では所望に応じ異密度化や異繊度化もできる。列間のピッチ又は孔間のピッチも変えた構成、及び列間と孔間の両方のピッチも変える方法などで異密度層を形成できる。また、オリフィスの断面積を変えて吐出時の圧力損失差を付与すると、溶融した熱可塑性弾性樹脂を同一ノズルから一定の圧力で押し出される吐出量が圧力損失の大きいオリフィスほど少なくなる原理を使って長手方向の区間でオリフィスの断面積が異なる列を少なくとも複数有するノズルを用い異繊度線条からなる網状構造体を製造することができる。次いで、該ノズルより下方に向けて吐出させ、ル−プを形成させつつ溶融状態で互いに接触させて融着させ３次元構造を形成しつつ、引取りネットで挟み込み、網状体の表面の溶融状態の曲がりくねった吐出線条を４５°以上折り曲げて変形させて表面をフラット化すると同時に曲げられていない吐出線条との接触点を接着して構造を形成後、連続して冷却媒体（通常は室温の水を用いるのが冷却速度を早くでき、コスト面でも安くなるので好ましい）で急冷して本発明の３次元立体網状構造体化した網状体を得る。ノズル面と引取り点の距離は少なくとも４０cm以下にすることで吐出線条が冷却され接触部が融着しなくなることを防ぐのが好ましい。吐出線条の吐出量５ｇ／分孔以上と多い場合は１０cm〜４０cmが好ましく、吐出線条の吐出量５ｇ／分孔未満と少ない場合は５cm〜２０cmが好ましい。網状体の厚みは溶融状態の３次元立体構造体両面を挟み込む引取りネットの開口幅（引取りネット間の間隔）で決まる。本発明では上述の理由から引取りネットの開口幅は５mm以上とする。次いで水切り乾燥するが冷却媒体中に界面活性剤等を添加すると、水切りや乾燥がしにくくなったり、熱可塑性弾性樹脂が膨潤することもあり好ましくない。尚、ノズル面と樹脂を固化させる冷却媒体上に設置した引取りコンベアとの距離、樹脂の溶融粘度（網状体形成時の溶融粘度は好ましくは５００ポイズから１００００ポイズであり、２００００ポイズを越えるとル−プ形成速度が遅くなり、緻密な網状構造を形成しにくくなるので好ましくない。）、オリフィスの孔径と吐出量などにより所望のループ径や線径をきめられる。冷却媒体上に設置した間隔が調整可能な一対の引取りコンベアで溶融状態の吐出線条を挟み込み停留させることで互いに接触した部分を融着させつつ、連続して冷却媒体中に引込み固化させ網状体を形成する時、上記コンベアの間隔を調整することで、融着した網状体が溶融状態でいる間で厚み調節が可能となり、所望の厚みのものが得られる。コンベア速度も速すぎると、接触点の形成が不充分になったり、融着点が充分に形成されるまでに冷却され、接触部の融着が不充分になる場合がある。また、速度が遅過ぎると溶融物が滞留し過ぎ、密度が高くなるので、所望の見掛け密度に適したコンベア速度を設定する必要がある。次いで本発明では、該網状体を一旦冷却後、連続して、又は、非連続に疑似結晶化処理を行い所定の大きさに切断して、又は、切断後疑似結晶化処理される。他方、ワディング層のポリエステル繊維は公知の方法で得られるステープルなら良いが、本発明では、親水化剤としてポリエ−テル等を繊維表面に付与したポリエステル繊維を用いるのが好ましく、親水化剤としてポリエ−テル等を練り込まれたポリエステルを用いた繊維が特に好ましい。本発明の特に好ましい実施形態である親水化剤を練り込む方法としては、重合時に混合する方法、ポリエステル樹脂に混練り機能を有する押出機を用いて練り込んだレジンを作成して使用する方法及び、溶融紡糸時に直接混合練り込みする方法がある。本発明での、例えば、紡糸時直接混合練り込みする方法では、押出機のスクリュ−のコンプレッション部や先端メタ−リング部にダルメ−ジやクロスソ−等の混練り機能をもつ二軸押出機または単軸押出機を用いて、ポリエステルと共に所定量を定量供給しつつポリエステルの融点より１０℃以上３０℃未満の温度で溶融混練りする方法や、ポリエステル樹脂をその融点より２０℃以上５０℃未満の温度で溶融し、次いで押出機のコンプレッション部から先端メタ−リング部の間で、該ポリエステルの溶融温度で溶融して親水化剤のポリエチレングリコ−ルを定量供給して練り込む方法（直接メルトブレンド法）があり、本発明では後者がより望ましい。親水化剤の練り込み量は１重量％以上１０重量％添加し、例えばポリエチレングリコ−ルでは溶融混合ができる粘度を保持できる数平均分子量５０００以上５００００未満が好ましく、８０００以上２００００未満がより好ましい。混練り状態はポリエステルを主たるマトリックスとした非相溶混合になる。かくして親水化剤を混練りされた溶融ポリエステル樹脂は、定量ポンプで計量しつつノズルよりポリエステルの融点より１０℃以上５０℃未満の温度で紡糸しポリエステル繊維を得る。本発明では、繊維断面を好ましくは異形断面又は中空断面とできるノズルのオリフィス形状を選択する。より好ましくは、異形中空断面となるノズルのオリフィス形状を選択する。ポリエステル繊維は非対象冷却法又は複合紡糸法により潜在捲縮能を付与し、延伸後熱処理により立体捲縮を発現させて切断または、切断後熱処理して立体捲縮を発現させて得るのが好ましい。該ポリエステル繊維は耐へたり性と耐熱性も要求されるので、初期引張り抵抗度が少なくとも３５ｇ／デニ−ル以上で、７０℃での初期引張り抵抗度が少なくとも１０ｇ／デニ−ル以上にしたものが好ましい。嵩高性と抗圧縮性からの立体捲縮の捲縮度は１５％以上、捲縮数は１０〜２５個／インチが好ましい。かくして得られた親水化したポリエステル繊維はワディング層の主たるマトリックスとして他のポリエステル繊維と所望の配合量にて混合開繊する。親水化ポリエステル繊維と他のポリエステル繊維の混合比率を１００／０〜５０／５０重量比として、オ−プナ−等で予備開繊混合した後カ−ド等で開繊し、３次元化構造とした開繊ウエッブを形成し、厚みが３mmから１０mmとした時、見掛け密度が０．１ｇ／cm3 以下、好ましくは、見掛け密度が０．０１ｇ／cm3 から０．０６ｇ／cm3 となるように積層したウェッブをワディング層として、好ましくは、次いで常法により厚みが３mmから１０mmとした時見掛け密度が０．０１ｇ／cm3 から０．０６ｇ／cm3 となるようにウェッブにパンチ密度５本／cm2 以上３０本／cm2 以下でニードルパンチして形態を安定化したワディング層として、該網状体の表面及び、又は裏面に積層し、次いで、全面を側地となる編織物で被い、見掛け密度が０．１ｇ／cm3 以下、好ましくは、見掛け密度が０．０１ｇ／cm3 から０．０６ｇ／cm3 となるように圧縮しながら挿入縫製され、本発明のマットを得る。本発明マットは、マットの側面が編織物のみが設置されるように構成することで、側面の通気性を高めて新鮮な外気を入替えるクッション層のポンプ機能をより高められるので好ましい。側地は、先にマットの所定の形状に縫製されたものを、クッション層とワディング層を積層したクッション体に被せて挿入口を綴じ、次いで、ボタン止めを所望に応じて施してもよい。ボタン止めは、マットの面積当たり２から８個／ｍ2 とするのが好ましい。ボタン止めは、厚みの８０％以上を保てるよう押さえながら行うのが好ましい。側面の側地の処理は角部を他の布帛を被せてパイピング縫いにしてもよい。なお、本発明における結晶化処理は、製品化に至る任意の工程で熱可塑性弾性樹脂の少なくとも融点（Ｔｍ）より１０℃以上低く、Ｔａｎδのα分散立ち上がり温度（Ｔαｃｒ）以上で行う。この処理で、融点以下に吸熱ピ−クを持ち、疑似結晶化処理しないもの（吸熱ピ−クを有しないもの）より耐熱耐へたり性が著しく向上する。本発明の好ましい疑似結晶化処理温度は（Ｔαｃｒ＋１０℃）から（Ｔｍ−２０℃）である。単なる熱処理により疑似結晶化させると耐熱耐へたり性が向上する。が更には、１０％以上の圧縮変形を付与してアニ−リングすることで耐熱耐へたり性が著しく向上するのでより好ましい。
また、該網状体を一旦冷却後、乾燥工程を経する場合、乾燥温度をアニ−リング温度とすることで同時に疑似結晶化処理を行うができる。また、製品化する工程で別途疑似結晶化処理を行うができる。
【００１７】
本発明のマットは、ベット、敷布団、座蒲団、家具用マット等以外に、クッション体のみをその機能を利用して用いることが出来る。例えば、クッション層を３次元構造を損なわない程度に成形型等を用いて使用目的にあった形状に成形し、次いでワディング層を積層し側地を被せて縫製することで車両用座席、船舶用座席、椅子、家具等に用いることができる。勿論、用途との関係で要求性能に合うべき他の素材、例えば、異なる網状体、短繊維集合体からなる硬綿クッション材、不織布等と組合せて用いることも可能である。また、樹脂製造過程以外でも性能を低下させない範囲で製造過程から成形体に加工し、製品化する任意の段階で難燃化、防虫抗菌化、耐熱化、撥水撥油化、着色、芳香等の機能付与を薬剤添加等の処理加工ができる。
【００１８】
【実施例】
以下に実施例で本発明を詳述する。
【００１９】
なお、実施例中の評価は以下の方法で行った。
1. 融点（Ｔｍ）および融点以下の吸熱ピ−ク
島津製作所製ＴＡ５０，ＤＳＣ５０型示差熱分析計を使用し、昇温速度２０℃／分で測定した吸発熱曲線から吸熱ピ−ク（融解ピ−ク）温度を求めた。
2. Ｔαｃｒ
ポリマ−を融点＋１０℃に加熱して、厚み約３００μm のフイルムを作成して、オリエンテック社製バイブロンＤＤＶII型を用い、１１０Ｈｚ、昇温速度１℃／分で測定したＴａｎδ（虚数弾性率Ｍ”と弾性率の実数部分Ｍ’との比Ｍ”／Ｍ’）のゴム弾性領域から融解領域への転移点温度に相当するα分散の立ち上がり温度。
3. 室温伸長回復率
ポリマ−を融点＋１０℃に加熱して、厚み約３００μm のフイルムを作成して、オリエンテック社製テンシロンＵＴＭ４型を用い、伸長速度１００％にて３００％伸長後歪みを０％に戻し、２分間放置後再度破断まで伸長させた時の、再度伸長時に応力が発現する伸長率を３００％から差し引いた伸長率を３００％で除した値を％で示す。（ｎ＝３）
4. ７０℃伸長回復率
ポリマ−を融点＋１０℃に加熱して、厚み約３００μm のフイルムを作成して、オリエンテック社製テンシロンＵＴＭ４型を用い、７０℃雰囲気にした加熱オーブン中で伸長速度１００％にて１０％伸長歪みを付与して２４時間保持した後、歪みを０％に戻し、５分間放置後再度破断まで伸長させた時の、再度伸長時に応力が発現する伸長率を１０％から差し引いた伸長率を１０％で除した値を％で示す。（ｎ＝３）
5. 見掛け密度
試料を１５cm×１５cmの大きさに切断し、４か所の高さを測定し、体積を求め試料の重さを体積で徐した値で示す。（ｎ＝４の平均値）
6. 線条の繊径
試料を１０箇所から各線条部分を切り出し、アクリル樹脂で包埋して断面を削り出し切片を作成して断面写真を得る。拡大した断面写真より線径を求め、拡大倍率で叙した値（ｎ＝１０の平均値）
7. 融着
試料を目視判断で融着しているか否かを接着している繊維同士を手で引っ張って外れないか否かで外れないものを融着していると判断する。
8. 耐熱耐久性（７０℃残留歪）
試料を１５cm×１５cmの大きさに切断し、５０％圧縮して７０℃乾熱中２２時間放置後冷却して圧縮歪みを除き１日放置後の厚みと処理前の厚みの差と処理前の厚みとの比を％で示す（ｎ＝３の平均値）
9. 繰返し圧縮歪
試料を１５cm×１５cmの大きさに切断し、島津製作所製サ−ボパルサ−にて、２５℃６５％ＲＨ室内にて５０％の厚みまで１Ｈｚのサイクルで圧縮回復を繰り返し２万回後の試料を１日放置後の厚みと処理前の厚みの差と処理前の厚みとの比を％で示す。（ｎ＝３の平均値）
10.通気度
側地は、直接側地を株式会社テクノワ−ルド社製（コスモ計器設計品）通気量測定器、高圧タイプを用い測定した通気量（cc／cm2 秒）を通気度として示す。側地からワディング層を介して網状体に排出できる通気量は、ワディング層の片面を編織物で被われた試料を直径１０cmの円筒状に打ち抜き、側面をシ−ルできる試料厚みに相当する高さの内径１０cmの金属筒に５％圧縮した状態で入れ、上下を５％圧縮厚み分のパッキンでシ−ルして横漏れしないようにしたサンプルを作成し、株式会社テクノワ−ルド社製（コスモ計器設計品）通気量測定器、高圧タイプを用い測定した通気量（cc／cm2 秒）を通気度として示す。
11.折り曲げ性
作成したマットを水平面から片端を抑えて押し出し、４５°に切り欠いた勾配面に接するまでの長さを以下の基準で示す。１００cm未満：◎、１３０cm未満：○、１５０cm未満：△、１５０cm以上：×
12.水切り性
作成したマットの重量を測定後に水槽に浸して１０分後に取り出し、できるだけ水切りして、３０℃ＲＨ６５％の雰囲気の室内で壁に立てかけ２４時間放置後の重量を測定して残留水分の量を求め、以下の基準で評価した。残留水分が５％以下：◎、残留水分が７％以下：○、残留水分が１０％以下：△、残留水分が１０％以上：×
13.寝心地
作成したマットをベットフレ−ムにセットして、２８℃ＲＨ７５％室内でパネラ−を寝かせて以下の評価をおこなった。（ｎ＝５）なお、ベットマット上にはシ−ツを敷き、掛け布団にはダウン／フェザ−：９０／１０混合羽毛１．８kg入り、枕は自宅で使用中のものを使用させた。
(1) 違和感：寝たときの「背中に感じる違和感」の程度を感覚的に定性評価した。感じない；◎、殆ど感じない；○、やや感じる；△、感じる；×
(2) 沈み込み：寝たときの体型保持状況の程度を感覚的に定性評価した。適度の沈み込みで非常に心地よい；◎、沈み込みやや少又はやや大で心地良い；○、沈み込み小又は大で心地よさにやや欠ける；△、沈み込み過ぎ又は沈み込まないで心地よさを感じない；×
(3) 蒸れ感：２時間寝ていて、臀部や背中等のベットマットと接する部分に感じる蒸れ感を感覚的に定性評価した。殆ど感じない：◎、僅かに蒸れを感じる；○、やや蒸れを感じる；△、蒸れを著しく感じる；×
(4) 体圧の圧迫感：寝てから動かないでどの程度我慢していられるか：３０分以内；×、１時間以内；△、２時間以内；○、２時間以上；◎
【００２０】
実施例１
ポリエステル系エラストマ−として、ジメチルテレフタレ−ト（ＤＭＴ）又は、ジメチルナフタレ−ト（ＤＭＮ）と１・４ブタンジオ−ル（１・４ＢＤ）を少量の触媒と仕込み、常法によりエステル交換後、ポリテトラメチレングリコ−ル（ＰＴＭＧ）を添加して昇温減圧しつつ重縮合せしめポリエ−テルエステルブロック共重合エラストマ−を生成させ、次いで抗酸化剤１％及び難燃剤１０％（燐含有量５０００〜１００００ｐｐｍ）を添加混合後ペレット化し、５０℃４８時間真空乾燥して得られた熱可塑性弾性樹脂原料の処方を表−１に示す。
【００２１】
【表１】
幅１２０cm、長さ１０cmのノズル有効面に幅方向の孔間ピッチ５mm、長さ方向の孔間ピッチ１０mmの千鳥配列としたオリフィス形状は外径２mm、内径１．６mmでトリプルブリッジの中空形成性断面としたノズルに、得られた熱可塑性弾性樹脂原料を別々の押出機にて溶融し、Ａ−１をシ−ス成分に、Ａ−２をコア成分となるようにオリフィス直前で分配し、溶融温度２４５℃にて単孔当たりの吐出量２．０ｇ／分（Ａ−１：１ｇ／分、Ａ−２：１ｇ／分）にてノズル下方に吐出させ、ノズル面１２cm下に冷却水を配し、幅１４０cmのステンレス製エンドレスネットを平行に１０cm間隔で一対の引取りコンベアを水面上に一部出るように配して、該溶融状態の吐出線状を曲がりくねらせル−プを形成して接触部分を融着させつつ３次元網状構造を形成し、該溶融状態の網状体の両面を引取りコンベア−で挟み込みつつ毎分１ｍの速度で２５℃の冷却水中へ引込み固化させ両面をフラット化した後引取り、水切り後、連続して１２０℃の加熱空気を循環させたセッタ−中を１５分間通過させ冷却後、所定の大きさに切断して得た網状体は断面形状がシ−スコア構造の三角おむすび型の中空断面で中空率が４０％、線径が１．２mmの融点以外に１２６℃に吸熱ピープをもつ線条が、形成するル−プの互いの接触点は殆ど融着により接合され、両面は実質的にフラット化され、平均の見掛け密度が０．０４６ｇ／cm2 、厚み９．５cm、繰返し圧縮歪み２．８％、耐熱耐久性１１．２％であった。別途、ポリエステル繊維は、コンプレッション部及びメタ−リング部先端にダルメ−ジを持つ２台の押出機にて、極限粘度０．６３と０．５６の酸成分として１０〔２・３・ジ（２・ヒドロキシエチキシ）−カルボニルプロピル〕９・１０・ジヒドロ・９・オキサ・１０ホスファフェナレンス・１０・オキシロを燐含有量で１２００ｐｐｍとなるように共重合したＰＥＴをそれぞれ供給し、２８０℃にて溶融し、コンプレッション部より２７０℃に溶融したＰＥＧを添加量５重量％となるようにプランジャーポンプにて供給して２８０℃で直接メルトブレンド法にて溶融混練りした各ポリエステルを重量比５０／５０に分配して単孔当たり３．０ｇ／分孔（１．５ｇ／分：１．５ｇ／分）として紡糸温度２８０℃にてオリフィス形状が中空で３つの突起ができる形状の繊維となるノズルより、紡糸速度１３００ｍ／分で複合紡糸し、次いで、７０℃及び１８０℃にて２段延伸して得た延伸糸を６４mmに切断し１７０℃にてフリ−熱処理して立体捲縮を発現させ、突起を３つもつ異形中空断面で異形度（外接円面積／断面積）が２．０で中空率１６％のサイドバイサイド構造の繊度６デニ−ル、初期引張り抵抗度３５ｇ／デニ−ル、捲縮度２３％、捲縮数１６個／インチのポリエステル繊維を得た。次いで、該ポリエステル繊維をオ−プナ−にて予備開繊した後カ−ドで開繊して得たウエッブを厚みが８mmとなったときの見掛け密度が０．０５ｇ／cm2 となるようにパンチ密度１０本／cm2 でニ−ドルパンチして所定の大きさに切断したワディング層を該網状体の表裏に積層したクッション体を、東洋紡績製ハイムのポリエステル繊維からなる通気度３０cc／cm2 秒のブロードを所定の大きさに縫した側地に挿入し、挿入口をとじ、やや圧縮しながら８個／ｍ2 の密度でボタン止めを施して本発明のベット用マットを得た。得られたベット用マットの評価結果を表２に示す。表２で明らかごとく、耐熱性、耐久性、折り曲げ性、水切り性に優れ、通気性も良く、寝心地の良好なベット用マットである。なお、このベット用マットは難燃性を示し、燃焼ガスの毒性指数は５．０であった。このことから、火災時の安全性も高いベット用マットであることが判る。
【００２３】
【表２】
実施例２
幅１２０cm、長さ５cmのノズル有効面に幅方向の孔間ピッチ５mm、長さ方向の孔間ピッチ１０mmの千鳥配列としたオリフィス形状は外径１mm丸断面としたノズルに、得られた熱可塑性弾性樹脂原料Ａ−５を押出機にて溶融し、溶融温度２４５℃にて単孔当たりの吐出量２．０ｇ／分にてノズル下方に吐出させ、ノズル面１５cm下に冷却水を配し、幅１４０cmのステンレス製エンドレスネットを平行に平行に４．５cm間隔で一対の引取りコンベアを水面上に一部出るように配して、該溶融状態の吐出線状を曲がりくねらせル−プを形成して接触部分を融着させつつ３次元網状構造を形成し、該溶融状態の網状体の両面を引取りコンベア−で挟み込みつつ毎分１ｍの速度で２５℃の冷却水中へ引込み固化させ両面をフラット化した後引取り、水切り後、連続して１２０℃の加熱空気を循環させたセッタ−中を１５分間通過させ冷却後、所定の大きさに切断して得た網状体は、断面形状が丸断面で、線径が０．９mmの融点以外に１２６℃に吸熱ピークをもつ線条が、形成するル−プの互いの接触点は殆ど融着により接合され、両面が実質的にフラット化され、平均の見掛け密度が０．０４８ｇ／cm2 、厚み４．５cm、繰返し圧縮歪み７．５％、耐熱耐久性１８．４％であった。次いで、極限粘度０．６３のＰＥＴを用い、常法によりオリフィス形状がＣ型の中空断面を形成するノズルより２８５℃にて単孔吐出量３．０ｇ／分孔にて紡出し、ノズル直下より非対称冷却法にて潜在巻縮能を付与した以外実施例１と同様にして得た立体巻縮をもち、中空断面で中空率が３６％、繊度６デニ−ル、初期引張り抵抗度３８ｇ／デニ−ル、捲縮度２５％、捲縮数１４個／インチのポリエステル繊維を得た。このポリエステル繊維を用い、オ−プナ−にて予備開繊した後カ−ドで開繊して得たウエッブを見掛け密度が０．０５ｇ／cm2 となるようにパンチ密度１０本／cm2 でニ−ドルパンチして所定の大きさに切断したワディング層を該網状体の表裏に積層したクッション体を、東洋紡績製ハイムのポリエステル繊維からなる通気度３０cc/cm2秒のブロードを用いて所定の形状に縫製された側地に挿入して得たベット用マットの評価結果を表２に示す。表２で明らかごとく、耐熱性、耐久性、折り曲げ性、水切り性に優れ、通気性も良く寝心地の良好なベットマットである。なお、このマットは燃焼ガスの毒性指数は５．０であった。このことから、火災時の安全性が良いマットであることが分かる。
【００２５】
実施例３
幅１２０cm、長さ５cmのノズル有効面に幅方向の孔間ピッチ５mm、長さ方向の孔間ピッチ１０mmの千鳥配列としたオリフィス形状は外径２mm、内径１．６mmでトリプルブリッジの中空形成性断面としたノズルに、得られた熱可塑性弾性樹脂Ａ−３を押出機にて溶融し、溶融温度２３５℃にて単孔当たりの吐出量２．０ｇ／分にてノズル下方に吐出させ、ノズル面１２cm下に冷却水を配し、幅１４０cmのステンレス製エンドレスネットを平行に４．５cm間隔で一対の引取りコンベアを水面上に一部出るように配して、該溶融状態の吐出線状を曲がりくねらせル−プを形成して接触部分を融着させつつ３次元網状構造を形成し、毎分１ｍの速度で２５℃の冷却水中へ引込み固化させた後引取り、水切り後、連続して１２０℃の加熱空気を循環させたセッタ−中を１５分間通過させ冷却後、所定の大きさに切断して得た両面が実質的にフラット化された網状体は、断面形状は中空おむすび型断面で、線径が１．２mmの融点以外に１２６℃に吸熱ピークをもつ線条が、形成するル−プの互いの接触点は殆ど融着により接合され、平均の見掛け密度が０．０４８ｇ／cm2 、厚み４．５cm、繰返し圧縮歪み５．８％、耐熱耐久性１０．８％であった。次いで、実施例１で得たポリエステル繊維と実施例２で得たポリエステル繊維を７０／３０重量比で混合し、実施例１と同様にして得たワディング層となるウェッブをクッション層となる網状体の表面及び裏面に積層し、東洋紡績製ハイムのポリエステル繊維からなる通気度３０cc/cm2秒のブロードを用いて所定の形状に縫製された側地に挿入して得たベット用マットの評価結果を表２に示す。表２で明らかごとく、耐熱性、耐久性、折り曲げ性、水切り性に優れ、通気性も良く寝心地の良好なベットマットである。なお、このベット用マットは燃焼ガスの毒性指数は５．１であった。このことから、火災時の安全性も良いベット用マットであることが分かる。
【００２６】
実施例４
ポリウレタン系エラストマ−として、４・４’ジフェニルメタンジイソシアネ−ト（ＭＤＩ）とＰＴＭＧ及び鎖延長剤として１・４ＢＤを添加して重合し次いで抗酸化剤２％を添加混合練込み後ペレット化し真空乾燥してポリエ−テル系ウレタンポリマ−の処方を表３に示す。
【００２７】
【表３】
得られた熱可塑性弾性樹脂（シ−ス成分：Ｂ−１、コア成分：Ｂ−２）を溶融温度２２０℃とした以外実施例１と同様にして得た網状体の線条のシ−スコア構造の断面形状が三角おむすび型の中空断面で中空率４０％、線径が１．１mmの融点以外に１２６℃に吸熱ピークをもつ線条が、形成するル−プの互いの接触点は殆ど融着により接合され、両面が実質的にフラット化され、平均の見掛け密度が０．０４７ｇ／cm2 、厚み９．５cm、繰返し圧縮歪み３．６％、耐熱耐久性７．５％であった。次いで、実施例２で使用したニ−ドルパンチしたワディング層を該クッション層に積層したクッション体を、東洋紡績製ハイムのポリエステル繊維からなる通気度３０cc/cm2秒のブロードを用いて所定の形状に縫製された側地に挿入して得たベット用マットの評価結果を表２に示す。表２で明らかごとく、耐熱性、耐久性、折り曲げ性、水切り性に優れ、通気性も良く寝心地の良好なベット用マットである。
【００２９】
比較例１
メルトインデックス１２のポリプロピレン（ＰＰ）単成分のみを溶融温度を２２０℃とした以外、実施例２と同様にして得た網状体は、中実丸断面で、線径が１．８mm、の融点以外に吸熱ピークをもたない線条が、形成するル−プの互いの接触点は殆ど融着により接合され、両面が実質的にフラット化され、平均の見掛け密度が０．０４７ｇ／cm2 、厚み４．５cm、繰返し圧縮歪み３９．６％、耐熱耐久性４９．８％であった。次いで、実施例１で得たポリエステル繊維をオ−プナ−にて予備開繊した後カ−ドで開繊して得たウエッブを厚み６mmとなるときの見掛け密度が０．０５ｇ／cm2 となるようにパンチ密度１０本／cm2 でニ−ドルパンチして所定の大きさに切断したワディング層をクッション層の表面及び裏面に積層して得たクッション体を東洋紡績製ハイムのポリエステル繊維からなる通気度３０cc/cm2秒のブロードを用いて所定の形状に縫製された側地に挿入して得たベット用マットの評価結果を表２に示す。表２で明らかごとく、非弾性オレフィンからなる網状体のため、水切り性には優れるが、耐熱性、耐久性、折り曲げ性、通気性は良いが蒸れ感以外の寝心地が著しく劣るベットマットであり、難燃性も不合格になり火災時には問題がでるベットマットである。
【００３０】
比較例２
幅１２０cm、長さ１０cmのノズル有効面に幅方向の孔間ピッチ５mm、長さ方向の孔間ピッチ１０mmの千鳥配列としたオリフィス形状は外径１mm丸断面としたノズルに、得られた熱可塑性弾性樹脂原料Ａ−５を押出機にて溶融し、溶融温度２３５℃にて単孔当たりの吐出量３．０ｇ／分にてノズル下方に吐出させ、ノズル面５cm下に冷却水を配し、幅１４０cmのステンレス製エンドレスネットを平行に平行に９．５cm間隔で一対の引取りコンベアを水面上に一部出るように配して、該溶融状態の吐出線状を曲がりくねらせル−プを形成して接触部分を融着させつつ３次元網状構造を形成し、該溶融状態の網状体の両面を引取りコンベア−で挟み込みつつ毎分１ｍの速度で２５℃の冷却水中へ引込み固化させ両面をフラット化した後引取り、水切り後、所定の大きさに切断して得た網状体は、断面形状が丸断面で、線径が５．９mmの融点以外に吸熱ピークをもたない線条が、形成するル−プの互いの接触点は殆ど融着により接合され、両面が実質的にフラット化され、平均の見掛け密度が０．０７４ｇ／cm2 、厚み９．５cm、繰返し圧縮歪み１８．３％、耐熱耐久性２８．４％であった。次いで、実施例２で得たワディング層を用いて同様にして得たベット用マットの評価結果を表２に示す。表２で明らかごとく、水切り性、蒸れ感の少ない点に優れるが、耐熱性、耐久性、折り曲げ性、蒸れ感以外の寝心地が劣るベット用マットである。なお、このベット用マットの燃焼ガスの毒性指数は５．１であった。
【００３１】
比較例３
溶融温度２４５℃にて、ノズル面３０cm下に引取りコンベアネットを配し、引き取り速度を０．３ｍ／分とした以外、比較例２と同様の方法で得た網状体は、断面形状が丸断面で、線径が１．９mmの融点以外に吸熱ピークをもたない線条が、形成するル−プの互いの接触点は殆ど融着により接合され、両面が実質的にフラット化され、平均の見掛け密度が０．２４ｇ／cm2 、厚み９．５cm、繰返し圧縮歪み１９．８％、耐熱耐久性２９．４％であった。次いで、比較例２と同様にして得たベット用マットの評価結果を表２に示す。表２で明らかごとく、水切り性、蒸れ感の少ない点に優れるが、耐熱性、耐久性、折り曲げ性、蒸れ感以外の寝心地が劣るベット用マットである。なお、このベット用マットは燃焼ガスの毒性指数は５．１であった。
【００３２】
比較例４
単孔当たりの吐出量０．３ｇ／分とし、ノズル面５cm下に引取りコンベアネットを配し、引き取り速度を１．９ｍ／分とした以外、比較例３と同様の方法で得た網状体は、断面形状が丸断面で、線径が０．４mmの融点以外に吸熱ピークをもたない線条が、形成するル−プの互いの接触点は殆ど融着により接合され、両面が実質的にフラット化され、平均の見掛け密度が０．００４ｇ／cm2 、厚み９．５cm、繰返し圧縮歪み１３．６％、耐熱耐久性２２．４％であった。次いで、比較例２と同様にして得たベット用マットの評価結果を表２に示す。表２で明らかごとく、通気性、折り曲げ性、水切り性に優れるが、耐熱性、耐久性、寝心地が劣るベット用マットである。
【００３３】
比較例５
溶融温度２３０℃にて、単孔当たりの吐出量１．５ｇ／分とし、ノズル面６０cm下に引取りコンベアネットを配し、引き取り速度を１ｍ／分とした以外、比較例２と同様の方法で得た網状体は、断面形状が丸断面で、線径が１．９mmの融点以外に吸熱ピークをもたない線条となるが、線条がル−プを形成しないで接触点が殆どできず、網状体を形成しなかった。この線条を無理に見掛け密度が０．０５ｇ／cm2 、厚み９．５cmのウエッブ状とし、次いで、比較例２と同様にして得たベット用マットの評価結果を表２に示す。表２で明らかごとく、接触点が接合されない場合は、寝心地が劣るベットマットになる。なお、このベットマットは寝心地が劣悪なため他の評価をしていない。
【００３４】
比較例６
溶融温度２４５℃にて、単孔当たりの吐出量１．５ｇ／分とし、ノズル面２０cm下に引取りコンベアネットを配し、片側のコンベアネットの表面に５mmの凹凸を付けたものとし、引き取り速度を１ｍ／分とした以外、比較例２と同様の方法で得た網状体は、断面形状が丸断面で、線径が０．９mmの融点以外に吸熱ピークをもたない線条が、形成するル−プの互いの接触点は殆ど融着により接合され、片面は実質的にフラット化されているが、他面は凹凸を有する、平均の見掛け密度が０．０３５ｇ／cm2 、最も厚い場所の厚み９．５cm、繰返し圧縮歪み１９．５％、耐熱耐久性２９．２％であった。次いで、比較例２と同様にして得たベット用マットの評価結果を表２に示す。このマットは側地の表面が凸凹の弛みとなり見栄えの悪いマットになった。表２で明らかごとく、折り曲げ性、水切り性、蒸れ感、圧迫感の少ない点に優れるが、耐熱性、耐久性がやや劣り、凸凹側を使った寝心地では違和感があり、寝心地がやや劣るベット用マットである。なお、このベット用マットの燃焼ガスの毒性指数は５．１であった。
【００３５】
比較例７
幅１２０cm、長さ１cmのノズル有効面に幅方向の孔間ピッチ５mm、長さ方向の孔間ピッチ５mmの千鳥配列としたオリフィス形状は外径１mm丸断面としたノズルを用い、単孔当たりの吐出量０．３ｇ／分とし、ノズル面５cm下に引取りコンベアネットを配し、０．４cm間隔で一対の引取りコンベアを水面上に一部出るように配して、引き取り速度を１．０ｍ／分とした以外、比較例３と同様の方法で得た網状体は、断面形状が丸断面で、線径が０．４mmの融点以外に吸熱ピークをもたない線条が、形成するル−プの互いの接触点は殆ど融着により接合され、両面が実質的にフラット化され、平均の見掛け密度が０．０６４ｇ／cm2 、厚み０．４cm、繰返し圧縮歪み１８．６％、耐熱耐久性２９．８％であった。次いで、比較例２と同様にして得たベット用マットの評価結果を表２に示す。表２で明らかごとく、折り曲げ性、水切り性に優れるが、耐熱性、耐久性が劣り、クッション層が薄すぎて寝心地が著しく劣るベットマットである。
【００３６】
比較例８
疑似結晶化処理しなかった以外実施例２と同様にして得た網状体の特性は断面形状が丸断面で、線径が０．９mmの融点以外に１２６℃に吸熱ピークをもたない線条が、形成するル−プの互いの接触点は殆ど融着により接合され、両面が実質的にフラット化され、平均の見掛け密度が０．０４８ｇ／cm2 、厚み４．５cm、繰返し圧縮歪み１６．５％、耐熱耐久性２６．４％であった。別途、実施例２で使用したポリエステル繊維をオ−プナ−にて予備開繊した後カ−ドで開繊して得たウエッブを見掛け密度が０．１２ｇ／cm2 となるようにパンチ密度１０本／cm2 でニ−ドルパンチして所定の大きさに切断したワディング層を該クッション層の表裏に積層して、比較例２と同様にして得た側地に挿入して得たベット用マットの評価結果を表２に示す。表２より明らかなごとく、ワディング層の密度が高すぎるため、通気性、折り曲げ性が悪く、寝心地も劣るベット用マットであった。
【００３７】
比較例９
精練したインド綿と実施例２で使用したポリエステル繊維を７０／３０重量比で混合し、オ−プナ−にて予備開繊した後カ−ドで開繊して得たウエッブを見掛け密度が０．０５ｇ／cm2 となるようにパンチ密度１０本／cm2 でニ−ドルパンチして所定の大きさに切断したワディング層を比較例８で得た該クッション層の表裏に積層して、比較例８と同様にして得た側地に挿入して得たベット用マットの評価結果を表２に示す。表２より明らかなごとく、寝心地は良いが、ワディング層がポリエステル繊維以外を含有するため水切り性が劣るベット用マットであった。なお、実施例１のマット及び比較例９のマットを粗砕して乾燥し、再度繊維化しようとしたが、実施例１のマットは繊維形成ができたが、比較例９のマットは紡糸時の糸切れが著しく繊維化できなかった。このことから、ポリエステル以外の素材を含むマットは直接プロダクトリサイクルが困難なことがわかる。
【００３８】
比較例１０
比較例８に用いた網状体を東洋紡績製ハイムのポリエステル繊維からなる通気度３０cc/cm2秒のブロードを用いて所定の形状に縫製された側地に挿入して得たベット用マットの評価結果を表２に示す。表２より明らかなごとく、折り曲げ性と寝心地は良いが、耐熱耐久性が劣るベット用マットであった。
【００３９】
比較例１1
見掛け密度が０．０５ｇ／cm3 の市販のポリエステル硬綿を厚み５mmにスライスし、所定の大きさに切断したものをワディング層にし、比較例８で得た該網状体に積層して比較例８と同様にして得たベット用マットの評価結果を表２に示す。表２で明らかごとく、寝心地はやや良いが、耐熱性、耐久性、折り曲げ性、水切り性が劣るベット用マットである。
【００４０】
比較例１２
米綿をカ−ドウエッブとして積層し、見掛け密度が０．０５ｇ／cm3 、厚み１０cmとなるようにした玉綿を所定の大きさに縫製されたポリエステル繊維からなる側地に挿入して得られたベット用マットの評価結果を表２に示す。表２で明らかごとく、寝心地はやや良いが、耐熱性、耐久性、折り曲げ性、水切り性が劣るベット用マットである。
【００４１】
比較例１３
厚み１０cm、見掛け密度０．０５ｇ／cm3 の市販のポリエステル硬綿をクッション材とし、所定の大きさに縫製されたポリエステル繊維からなる側地に挿入して得られたベット用マットの評価結果を表２に示す。表２で明らかごとく、寝心地はやや良いが沈み込みが少なく、耐熱性、耐久性、折り曲げ性、水切り性は劣るベット用マットである。
【００４２】
比較例１４
厚み１０cm、見掛け密度０．０５ｇ／cm3 の市販の発泡ポリウレタンをクッション材とし、比較例２と同様にして得られたベット用マットの評価結果を表２に示す。表２で明らかごとく、耐熱性、耐久性は優れているが、折り曲げ性、水切り性、通気性は良いが寝心地が劣るベットマットである。
【００４３】
実施例５
実施例２で得た網状体を厚みを変えた以外実施例１と同様にして得た敷布団の評価結果では、耐熱性、耐久性、折り曲げ性、水切り性、寝心地が共に優れた敷布団であった。
【００４４】
実施例６
実施例２で得た網状体を厚みを変えた以外実施例１と同様にして得た座蒲団のの評価結果では、耐熱性、耐久性、水切り性、座り心地共に優れた座蒲団であった。
【００４５】
【発明の効果】
伸長回復性の良い熱可塑性弾性樹脂からなる線条が融着一体化され表面をフラット化した網状体からなるクッション層にポリエステル繊維ウェッブからなるワディング層を積層したマット及び、製法であるので、蒸れ難く寝心地が良好で、耐熱耐久性、形態保持性、クッション性に優れ、折り曲げ性も良好で、火災時に有毒ガスの発生が少なく、ＭＲＳＡ等の雑菌を除去するための洗濯が可能で、リサイクルし易い、一般家庭用、病院用及びホテル用等のベット、敷布団、座蒲団及び、家具用に最適なマット、及び、製造法を提供できる。[0001]
[Industrial application fields]
The present invention is not easily stuffy, has excellent heat retention and body shape retention, is comfortable to sleep, has excellent durability and bendability, can be washed, can always maintain cleanliness, and can be recycled for general household use, hospital use and The present invention relates to a bed mat that is most suitable for a bed for a hotel or the like, a mat that is also suitable for cushion materials such as a mattress, a cushion, furniture, and a pillow, and a manufacturing method thereof.
[0002]
[Prior art]
Currently, bed mats for beds use foams such as hard steel wire springs or polystyrene foam for the cushion layer, and resin cotton or hard cotton with urethane foam and inelastic crimped fibers bonded to the padding layer are laminated and integrated. The thing and the thing comprised only by the resin cotton or the hard cotton to which the cushion body adhere | attached foams, such as urethane of the same composition, and an inelastic crimped fiber, are used.
[0003]
However, the one using a hard steel wire spring for the cushion layer is remarkably excellent in supportability, but it is inferior in bendability, and the trouble of separating and processing the hard steel wire spring at the time of disposal is low. It has become a big problem. Cushion layer or wading layer or cushion body using foam-crosslinked urethane has very good durability as a cushion body, but it is inferior in moisture permeability and heat storage, so it is easy to get stuffy and slightly bendable. In addition, when it is difficult to recycle because it is not thermoplastic, the incinerator is seriously damaged, and it takes a lot of money to remove toxic gas. As a result, landfills are often used. However, since it is difficult to stabilize the ground, there is a problem that the landfill site is limited and the cost increases. In addition, the processability is excellent, but there is a problem of pollution of chemicals used during production. Recently, bed mats need to be washed due to the problem of hospital beds becoming hotbeds such as MRSA, but urethane with poor water permeability has become a social problem because it cannot be washed.
[0004]
As a cushioning layer, a wadding layer, or a cushion body, a resin cotton in which polyester fibers are bonded with an adhesive, for example, a rubber-based adhesive is used as disclosed in JP-A-60-11352, JP-A-61-141388, Japanese Laid-Open Patent Publication No. 61-141391. Japanese Patent Application Laid-Open No. 61-137732 discloses a crosslinkable urethane. Those using these for the cushion layer or wadding layer can improve the breathability and reduce the stuffiness, but they are inferior in durability and bendability, and are not thermoplastic and not single composition, so they cannot be recycled. There are also problems such as complexity of workability and pollution problems of chemicals used during production. Moreover, although washing is possible, there is a problem that drainage is poor.
[0005]
There are polyester hard cotton, for example, Japanese Patent Laid-Open No. 58-31150, Japanese Patent Laid-Open No. 2-154050, Japanese Patent Laid-Open No. 3-220354, etc., in the cushion layer or the wadding layer or the cushion body. Since an amorphous polymer having a brittle adhesive component is used (for example, Japanese Patent Laid-Open No. 58-136828, Japanese Patent Laid-Open No. 3-249213, etc.), the bonded portion is brittle, and the bonded portion is easily broken during use. There is a problem that durability is inferior, such as lowering of elasticity and elasticity. Furthermore, the bendability is inferior. Moreover, although washing is possible, there is a problem that drainage is poor. As a method for improving durability, a method of entanglement treatment has been proposed in Japanese Patent Application Laid-Open No. 4-245965 and the like, but the brittleness of the bonded portion is not solved and there is a problem that the elasticity is greatly lowered and the bending property is also inferior. . Moreover, there is also complexity during processing. Furthermore, there is also a problem that it is difficult to impart a soft cushioning property to the bonded portion that is difficult to deform. For this reason, a heat-bonding fiber using a polyester elastomer that softens and recovers even when deformed to some extent and uses a non-elastic polyester as a core component is disclosed in Japanese Patent Laid-Open No. 4-240219. The body has been proposed in WO-91 / 19032, JP-A-5-156561, JP-A-5-163654, and the like. The adhesive component used in this fiber structure is a polyester elastomer soft segment containing 30-50% by weight of polyalkylene glycol, and the hard segment acid component containing 50-80% by mole of terephthalic acid. In addition, the other acid component composition contains isophthalic acid in the same manner as the fiber described in Japanese Patent Publication No. 60-1404, resulting in an increase in amorphousness, and the melting point is 180 ° C. or lower, resulting in a low melt viscosity. The formation of the part is improved to form an amoeba-shaped adhesive part, but it is easy to plastically deform, and the core component is non-elastic polyester. There are problems of lowering and poor bendability, and washing is possible, but there is a problem of poor drainage. As a method for further improving durability, JP-A-5-163654 discloses a structure comprising a polyester elastomer containing isophthalic acid as a sheath component and a heat-bonding conjugate fiber using an inelastic polyester as a core component. Although it has been proposed, plastic deformation under heating becomes remarkable due to the above-mentioned reasons, heat resistance and compression resistance is lowered, and there is a problem in using it for a cushion body. Japanese Laid-Open Patent Publication No. 63-158094 proposes a method of improving the durability and improving the texture by applying a silicone oil to a hard cotton base material to lower the coefficient of friction of the fibers. However, there is a problem in the adhesiveness of the heat-bonding fiber, and the durability is inferior. On the other hand, as a method for improving bendability, a method for forming a fold structure has been proposed in Japanese Patent Laid-Open Nos. 55-36373, 2-142513, and 5-3894. Although improved, durability and washing problems are not improved at all, and there are many problems when used as a cushion body. Further, for example, Japanese Patent Application Laid-Open No. 5-285031 discloses an example in which a cavity is formed in a bent portion to improve the bendability, but the problem of foams such as urethane or the problem of hard cotton cannot be solved at all.
[0006]
Japanese Unexamined Patent Publication No. 47-44839 discloses a thermoplastic olefin network used for civil engineering work. As a cushion body using them, a structure in which a hard structure and a soft structure are laminated in Japanese Utility Model Laid-Open No. 58-93270 is disclosed in Japanese Utility Model Laid-Open No. 58-95760 in which an air conditioning unit is provided inside a net structure having a hard structure. Although it has been described in Japanese Utility Model Publication No. 58-105714 using a net-like body presumed to be a hard structure, no consideration is given to heat resistance, sleeping comfort, light weight, and handleability such as washability. It has not been. Japanese Laid-Open Patent Publication No. 58-109670 proposes a net-like body having irregularities on one side, but unlike a cushion composed of thin fibers, the surface is uneven and the touch is poor, and the heat durability, sleeping comfort and light weight are reduced. No consideration is given to handling such as washing and washing. Japanese Patent Application Laid-Open No. 6-327723 discloses a mesh body having holes that can be fitted with cleaning pipes, vent pipes, etc., but the material is olefin, so the heat durability is remarkably inferior, and the weight and washability are reduced. The handling property such as is not considered at all, and it cannot be used for the wadding layer or the cushion material. Japanese Examined Patent Publication No. 3-17666 discloses a method of making a molded article by fusing discharge filaments having different finenesses to each other, but it is a network structure that is not suitable for a cushion material. Japanese Patent Publication No. 3-55583 discloses a method of thinning only the very surface with a thinning device such as a rotating body before cooling. In this method, the surface cannot be flattened, and a thick and thin line layer cannot be formed. Therefore, it does not become a cushion material with good sitting comfort. JP-A-1-207462 discloses a floor mat made of vinyl chloride, but is unpreferable as a cushioning material because of poor compression recovery at room temperature and extremely poor heat resistance. In the above structure, no consideration is given to the bed mat.
[0007]
JP-A-6-269345 discloses a futon pad that covers a bedding member such as a non-woven fabric having a far-infrared radiation function and quilts with a cotton sheet sandwiched between sheets. There is a problem that consideration is not given to improvement of sleeping comfort such as a dampness prevention function, heat resistance and durability, washing properties such as drainage and drying properties, and bendability. Japanese Utility Model Laid-Open No. 6-48453 discloses a mattress wrapped in stuffed cotton-filled wrapping quilted hard cotton with creases. As a mattress, it has good foldability and heat retention, but it has poor breathability, is easily steamed, has insufficient body shape retention, and does not have consideration for washing properties such as heat resistance, drainage and drying properties. .
[0008]
[Problems to be solved by the invention]
A structure that solves the above-mentioned problems, makes it difficult to stuffy, improves the comfort of heat retention, form retention, etc., has good heat resistance and bendability, is easy to use, and can be washed to remove germs such as MRSA. Furthermore, another object of the present invention is to provide a mat that is optimal for a bed, a mattress, a cushion, and a furniture cushion that can be recycled after sorting, and a method for producing the mat.
[0009]
[Means for Solving the Problems]
Means for solving the above-mentioned problem, that is, the present invention is a mat in which a wadding layer is laminated on at least the upper surface of a cushion layer, and the entire surface is covered and sewn on the side, and the cushion layer is thermoplastic elastic. A continuous wire having a diameter of 5 mm or less made of a resin is twisted to form a random loop, and the contact portion of each loop is formed by a three-dimensional three-dimensional structure network formed by fusing. The original three-dimensional structure network is substantially flat on the upper and lower surfaces, and the apparent density is 0.005 to 0.10 g / cm. Three The thickness is 5 mm or more, and the wadding layer is made of a polyester fiber web, and the apparent density is 0.1 g / cm. Three The mat is characterized by the following. Further, the thermoplastic elastic resin constituting the cushion layer has a recovery rate after 300% elongation at room temperature (room temperature elongation recovery rate) of 20% or more and recovery after holding 10% elongation at 70 ° C. for 24 hours. Rate (70 ° C. elongation recovery rate) of 30% or more, the mesh constituting the cushion layer has a wire diameter of 0.01 mm or more, and an apparent density of 0.01 g / cm. Three To 0.08g / cm Three The mat has a thickness of 10 mm or more and 100 mm or less, the wire diameter of the mesh constituting the cushion layer is 0.1 mm or more and 2 mm or less, and the apparent density is 0.02 g / cm. Three To 0.06g / cm Three A mat having a thickness of 20 mm or more and 80 mm or less, and a net having an endothermic peak at a temperature not lower than the room temperature and not higher than the melting point was used in a melting curve obtained by measuring a component made of a thermoplastic elastic resin with a differential scanning calorimeter. The mat is a mat in which the cross-sectional shape of the filaments constituting the cushion layer is a hollow cross-section or an irregular cross-section, the padding layer is needle punched, the thickness is 3 mm or more and 15 mm or less, and the apparent density is 0.01g / cm Three 0.06g / cm Three The following mats are mats in which the thermoplastic elastic resin is polyester, natural fibers are made of silk, and the matrix mainly includes polyester fibers containing 0.05% by weight or more of polyethylene glycol component on the fiber surface. The thermoplastic elastic resin is ejected downward from the nozzle at a melting temperature higher than its melting point by 20-80 ° C. from a multi-row nozzle having a plurality of orifices, and is a continuous line in a molten state. After forming a loop of strips and fusing each loop in contact with each other to form a three-dimensional structure, it is sandwiched by a take-up device and cooled in a cooling tank, and then the upper and lower parts of the obtained three-dimensional structure are This is a mat manufacturing method in which polyester fiber webs are laminated on both sides or one side, and the entire surface is covered with a side surface. A net is formed in any process leading to commercialization. A process for producing a mat that is subjected to pseudo-crystallization treatment by annealing at a temperature of at least 10 ° C. or less from the melting point of a thermoplastic elastic resin, and is a fiber formed by mixing polyethylene glycol in an amount of 1 to 10% by weight. This is a mat manufacturing method using a web whose main matrix is fibers.
[0010]
The thermoplastic elastic resin in the present invention refers to a polyether glycol having a molecular weight of 300 to 5000, a polyester glycol, a polycarbonate glycol or a long chain hydrocarbon terminal as a soft segment. Examples thereof include polyester elastomers, polyamide elastomers, polyurethane elastomers, polyolefin elastomers and the like obtained by block copolymerization of acid or hydroxyl group olefin compounds. By using a thermoplastic elastic resin, it becomes possible to recycle by remelting, so that recycling becomes easy. For example, as a 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 polyester ether block copolymers include terephthalic acid, isophthalic acid, naphthalene 2,6 dicarboxylic acid, naphthalene 2,7 dicarboxylic acid, aromatic 8 dicarboxylic acid such as diphenyl 4,4 'dicarboxylic acid At least one dicarboxylic acid selected from alicyclic dicarboxylic acids such as 1,4 cyclohexanedicarboxylic acid, aliphatic dicarboxylic acids such as succinic acid, adipic acid, and sebacic acid dimer acid, or ester-forming derivatives thereof. Species, aliphatic diols such as 1,4 butanediol, ethylene glycol, trimethylene glycol, tetremethylene glycol, pentamethylene glycol, hexamethylene glycol, 1,1 cyclohexane Diethanolol, alicyclic diols such as 1,4 cyclohexane dimethanol, or these At least one of diol components selected from the ester-forming derivatives, and polyethylene glycol, polypropylene glycol, polytetramethylene glycol, ethylene oxide-propylene oxide copolymer having an average molecular weight of about 300 to 5,000. It is a ternary block copolymer composed of at least one of polyalkylenediols such as glycol made of a polymer. The polyester ester block copolymer is a ternary block copolymer composed of at least one of the dicarboxylic acid, a diol and a polyester diol such as a polylactone having an average molecular weight of about 300 to 5,000. . Considering thermal adhesiveness, hydrolysis resistance, stretchability, heat resistance, etc., dicarboxylic acid is terephthalic acid, or naphthalene 2,6 dicarboxylic acid, diol component is 1.4 butanediol, poly As the alkylene diol, a polytetramethylene glycol ternary block copolymer, or as the polyester diol, a polylactone ternary block copolymer is particularly preferable. In a special case, a polysiloxane-based soft segment can also be used. 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 using a polyolefin-based component as a soft segment, and the like. As the polyamide elastomer, the hard segment has nylon 6, nylon 66, nylon 610, nylon 612, nylon 11, nylon 12, etc. and their copolymer nylon as a skeleton, and the soft segment has an average molecular weight of about 300. A block copolymer composed of at least one of polyalkylenediols such as polyethylene glycol of ˜5000, polypropylene glycol, polytetramethylene glycol, glycol composed of ethylene oxide-propylene oxide copolymer, etc. You may use a polymer individually or in mixture of 2 or more types. Further, blended or copolymerized non-elastomer components can be used in the present invention. Polyurethane elastomers include (A) a polyester and / or polyester having a hydroxyl group at the terminal with a number average molecular weight of 1000 to 6000 in the presence or absence of a normal solvent (dimethylformamide, dimethylacetamide, etc.) (B A typical example is a polyurethane elastomer in which a chain is extended with a polyamine containing (C) a diamine as a main component to a prepolymer obtained by reacting a polyisocyanate containing an organic diisocyanate as a main component with both ends being isocyanate groups. It can be illustrated as Polyesters and polyethers of (A) include polybutylene adipate copolymer polyester, polyethylene glycol, polypropylene glycol, polytetramethylene having an average molecular weight of about 1000 to 6000, preferably 1300 to 5000. Polyalkylenediols such as glycols and glycols composed of ethylene oxide-propylene oxide copolymers are preferred. As the polyisocyanate (B), conventionally known polyisocyanates can be used, but diphenylmethane can be used. An isocyanate mainly composed of 4 · 4 ′ diisocyanate may be used, and if necessary, a conventionally known triisocyanate or the like may be added in a small amount. As the polyamine (C), known diamines such as ethylene diamine and 1,2 propylene diamine are mainly used, and a trace amount of triamine and tetraamine may be used in combination as necessary. These polyurethane elastomers may be used alone or in combination of two or more. In addition, the melting point of the thermoplastic elastic resin of the present invention is preferably 140 ° C. or higher, which can maintain the heat durability, and more preferably 160 ° C. or higher because the heat durability is improved. In addition, since the net-like body constituting the bed mat of the present invention contains a phosphorus-based compound for imparting flame retardancy as a preferred embodiment, the thermal stability is slightly inferior to that containing no flame retardant, so that it is necessary. It is particularly preferable to add an antioxidant or the like to improve heat resistance and durability. The antioxidant is preferably a hindered phenol type or hindered amine type as a hindered type antioxidant, and 1% to 5% of a hindered phenol type antioxidant containing no nitrogen. Addition to suppress thermal decomposition is particularly preferable because generation of toxic gas with a small lethality during combustion can be suppressed. The elongation recovery property measured by the method described later of the thermoplastic elastic resin constituting the cushion layer that becomes a mat that can have both the preferable durability and the cushioning property, which is the object of the present invention, is the recovery rate after 300% elongation at room temperature. The (room temperature elongation recovery rate) is 20% or more, and the recovery rate (70 ° C. elongation recovery rate) after holding 10% elongation at 70 ° C. for 24 hours is 30% or more, more preferably the room temperature elongation recovery rate is 30% or more, 70 ° C. elongation recovery rate is 40% or more, and most preferably, room temperature elongation recovery rate is 40% or more and 70 ° C. elongation recovery rate is 50% or more. The soft segment content of the thermoplastic elastic resin constituting the component that imparts such extension recovery property is preferably 15% by weight or more, more preferably 30% by weight or more, and 80% by weight from the heat sag resistance. The following is preferable, and more preferably 70% by weight or less. That is, the soft segment content of the component having the vibration and stress absorbing function of the elastic network of the present invention is preferably 15% by weight to 80% by weight, more preferably 30% by weight to 70% by weight. .
[0011]
Since it is necessary to impart flame retardancy as a preferred embodiment of the mat of the present invention, the phosphorus content (Bppm) in the thermoplastic elastic resin has a relationship of 60A + 200 ≦ B ≦ 100000 to the soft segment content (A wt%). It is good to be satisfied. If not satisfied, flame retardancy may be inferior. If it exceeds 100000 ppm, the plastic deformation due to the plasticizing effect becomes large and the heat resistance of the thermoplastic elastic resin is inferior. The preferred phosphorus content (Bppm) is 30A + 1800 ≦ B ≦ 100000 relative to the soft segment content (A wt%), and the more preferable phosphorus content (Bppm) is relative to the soft segment content (A wt%). 16A + 2600 ≦ B ≦ 50000. Flame retardancy can be achieved by adding a large amount of halides and inorganics to provide a high level of flame retardancy, but it generates a large amount of toxic halogen gas that is low in lethality during combustion, causing the problem of poisoning in a fire. In the incineration, since the damage of the incinerator increases, in the present invention, the preferred halide content is 10% by weight or less, the more preferred halide content is 5% by weight or less, most preferably the halide content. It is something that does not. For example, in the case of a polyester-based thermoplastic elastic resin, the phosphorus-based flame retardant of the present invention is described in JP-A-51-82392 as a flame retardant in the hard segment portion at the time of resin polymerization. Carboxylic acids such as [2,3, di (2, hydroxyethoxy) -carbonylpropyl] 9,10, dihydro, 9, oxa, 10 phosphaphenalens, 10 oxiro as part of the acid component of the hard segment Flame retardancy by adding a phosphorous compound such as tris (2,4-di-t-butylphenyl) phosphite, for example, to a method of forming a polyester-based thermoplastic elastic resin or a post-process to the thermoplastic elastic resin Sex can be imparted. Other flame retardants that can impart flame retardancy include various phosphoric acid esters, phosphorous acid esters, phosphonic acid esters (the above phosphoric acid esters containing a halogen element as necessary), or polymers derived from these phosphorus compounds. It can be illustrated. In the present invention, various modifiers, additives, colorants and the like can be added to the thermoplastic elastic resin as necessary. Phosphorus is included in order to impart flame retardancy to the adhesive component of the cushion layer network and the wadding layer constituting the bed mat of the present invention, as described above, from the viewpoint of safety, as described above. The purpose is to reduce as little as possible toxic gases such as cyan gas and halogen gas generated in the event of a fire. For this reason, the toxicity index of the combustion gas of the nets constituting the mats of the present invention is preferably 6 or less, more preferably 5.5 or less. The toxicity index of the combustion gas in the wadding layer is also preferably 6 or less, more preferably 5.5 or less, and most preferably 5 or less. It is preferable to unify the thermoplastic elastic resins constituting the cushion layer network into the same type. For example, by using a polyester-based thermoplastic elastic resin, the cushion layer can be recycled and recycled without being individually separated.
[0012]
The component comprising the thermoplastic elastic resin constituting the mat of the present invention preferably has an endothermic peak below the melting point in the melting curve measured with a differential scanning calorimeter. Those having an endothermic peak below the melting point are significantly improved in heat and sag resistance than those having no endothermic peak. For example, as a preferable polyester-based thermoplastic resin of the present invention, those containing 90 mol% or more of terephthalic acid or naphthalene 2,6 dicarboxylic acid having a rigid hard segment acid component, and more preferably terephthalic acid or The content of naphthalene 2.6 dicarboxylic acid is 95 mol% or more, particularly preferably 100 mol% and the glycol component is polymerized to the required degree of polymerization after transesterification, and is then preferably used as a polyalkylenediol. When polytetramethylene glycol having an average molecular weight of 500 or more and 5000 or less, particularly preferably 1000 or more and 3000 or less is 15% by weight or more and 70% by weight or less, more preferably 30% by weight or more and 60% by weight or less, Terephthalic acid or naphthalene 2,6 dicarboxylic acid, which has a rigid acid component in the hard segment, When the amount is large, the crystallinity of the hard segment is improved, plastic deformation hardly occurs, and heat sag resistance is improved. However, after melting and heat bonding, annealing is performed at a temperature lower by at least 10 ° C. than the melting point. When treated, heat resistance and sag resistance are improved. Heat annealing resistance is further improved by annealing after applying compressive strain. An endothermic peak is more clearly expressed in a melting curve measured with a differential scanning calorimeter at a temperature not lower than the room temperature and not higher than the melting point of the network subjected to such treatment. When annealing is not performed, the endothermic peak does not appear in the melting curve above the room temperature and below the melting point. By analogy with this, it is considered that the hard segments are rearranged by annealing and pseudo-crystallization-like cross-linking points are formed, and the heat resistance and sag resistance are improved. (This treatment is defined as pseudo-crystallization treatment) This pseudo-crystallization treatment effect is also effective for polyamide-based elastic resins and polyurethane-based elastic resins.
[0013]
The polyester fiber in the present invention is, for example, polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polycyclohexylene dimethylene terephthalate (PCHDT), polycyclohexylene dimethylene naphthalate. (PCHDN), polybutylene terephthalate (PBT), polybutylene naphthalate (PBN), polyarylate and the like, and copolyesters thereof can be exemplified. In the present invention, it is preferable to use a glass transition temperature of at least 40 ° C. or higher. When polyester is used for the side of the mat used in the present invention, polyesters such as PET, PEN, PBN, PCHDT, etc., which can be recycled without being separated and are excellent in heat resistance, are particularly preferable. Further, a flame retardant polyester (hereinafter abbreviated as a flame retardant polyester) obtained by copolymerizing a phosphorus-containing ester-forming compound by polycondensation with PET, PEN, PBN, PCHDT or the like or containing a phosphorus-containing flame retardant is preferable. Examples thereof include those exemplified in JP-A-51-82392, JP-A-55-7888, and JP-B-55-41610. Although vinyl chloride has a self-extinguishing property, it generates a lot of toxic gas when burned, and is inferior in heat resistance and durability, so it is not preferable to use it in the present invention. In the present invention, one of the other purposes of using the polyester fiber is to reduce the moisture content of the fiber. However, since the sweated moisture needs to be quickly moved from the skin surface, the fiber surface becomes hydrophilic and has a water release property. Preferably, for example, at least 0.05% by weight or more of a reaction product of polyethers such as polyethylene oxide (PEO) and polyethylene glycol (PEG) and their copolymers and phosphorus compounds on the fiber surface. Preferably it is present. More preferably, it is 0.1 weight% or more and 1 weight% or less. If it is present in an amount of 2% by weight or more, the coefficient of friction of the fiber increases and the openability is inferior. Although it may be given by post-processing, in order to maintain washing durability, it is preferable to mix with polyester. As a mixing method, a method of adding at the time of polymerization, a method of kneading by polymer blending, and a method of melt blending at the time of spinning can be used. In the case of PEG, it is preferable to add PEG having a molecular weight of 5000 to 20000 in an amount of 1 to 10% by weight. If it is less than 1% by weight, sufficient water release cannot be imparted, and if it is 15% by weight or more, the modulus of the fiber decreases, which is not preferable. Furthermore, it is more preferable that the fiber cross-section is an irregular cross-section or a hollow irregular cross-section to impart water discharge more efficiently by the siphon effect. The modified cross section is a preferred embodiment because durability can be imparted even in post-processing.
[0014]
The basic cushion layer of the mat of the present invention is a three-dimensional solid body in which continuous filaments made of a thermoplastic elastic resin having a diameter of 5 mm or less are twisted and brought into contact with each other, and most of the contact portions are fused and integrated. Because it is a network that forms a structure and is substantially flattened on both sides, it is flattened even when subjected to externally applied deformations, especially large deformation stresses, via the padding layer. Since the deformed stress is received and dispersed on the surface of the mesh body, and the filaments made of thermoplastic elastic resin form a three-dimensional structure and are fused and integrated, the entire structure is deformed and energy is lost. -By absorbing deformation stress through transformation, it receives deformation stress with a low repulsive force due to rubber elasticity, preventing extreme local sinking and supporting the body shape with a soft gripping force against the human body Expressing Masui figure holding function. The bed mat is also required to have a vibration absorbing function. The cushion layer made of the net-like body of the present invention absorbs and attenuates most of the vibration applied from the outside at the time of bed-in or turning over by the vibration absorbing function of the thermoplastic elastic resin, and exhibits a preferable vibration absorbing function. When the deformation stress is released, the rubber elasticity of the thermoplastic elastic resin has a function of easily recovering the original form, so that the sag resistance is also good. Further, since the porosity is high and the diameter of the air hole is remarkably large, the air resistance is low and the air permeability is remarkably good. When the deformation stress is changed due to turning over or the like, the filament having the rubber elasticity of the thermoplastic elastic resin becomes a three-dimensional solid. Since the structure is formed and fused and integrated, the entire structure is compressed and recovered by deformation, and air containing steam and heat accumulated in the cushion layer permeated through the wadding layer is discharged and recovered during compression. Since the mat has a pump function to replace fresh outside air, it is easy to move heat and steam between the wadding layer and the cushion layer, and is a mat that can provide a comfortable sleeping comfort that is difficult to stuffy. For this purpose, the wire diameter of the thermoplastic elastic resin having good vibration absorption and elastic recovery that forms the network of the present invention is 5 mm or less. Apparent density 0.2g / cm 2 In the case of the following, when the thickness exceeds 5 mm, the number of components is reduced, density spots are generated, a structure with poor durability is partially formed, fatigue due to stress concentration is increased, and durability is lowered, which is not preferable. If the diameter of the filament made of the thermoplastic elastic resin of the present invention is too thin, the compressibility is too low and the stress absorption due to deformation is reduced, so that it is 0.01 mm or more. It is 3 mm or less which does not impair the denseness. More preferably, it is 0.05 mm or more and 2 mm or less. In order to achieve the object, the average diameter of the random loop of the continuous filaments forming the network of the present invention is preferably 50 mm or less, particularly 2 to 25 mm. The apparent density of the network of the present invention is 0.005 g / cm. Three In this case, the repulsive force is lost, the deformation stress absorbing ability and the vibration absorbing ability are insufficient, and it may be difficult to develop the cushion function, 0.25 g / cm. Three In the above, the repulsive force may be too high and the sitting comfort may deteriorate. In the present invention, the apparent density of the network of the present invention is 0.10 g / cm for the purpose of reducing the weight and improving the handleability. Three It is as follows. 0.01g / cm that functions as a cushion is easily developed by utilizing vibration absorption ability and deformation stress absorption function Three 0.08g / cm Three The following is preferable, more preferably 0.02 g / cm Three 0.06g / cm Three It is as follows. A method of forming a different fineness laminated structure in which the net-like body in the present invention has an optimum configuration in combination with the apparent density of linear shapes having different wire diameters can also be selected as a preferred embodiment. The thickness of the network of the present invention is required to be 5 mm or more. If the thickness is less than 5 mm, the stress absorbing function and the stress dispersing function are lowered, which is not preferable. The preferred thickness is 10 mm or more and 500 mm or less, more preferably 20 mm or more and 200 mm or less, as a thickness that can exhibit a surface function for dispersing force and a function of absorbing vibration and deformation stress. When the thickness of the short plate is 500 mm or more, the bendability described later is lost. When a thicker cushion layer is desired, a thin cushion layer of 200 mm or less, preferably a net of 100 mm or less, is laminated in a non-bonded state as desired to prevent the bending property from being impaired. A cushion layer mat can also be obtained. When the layers are laminated so as to have a thickness of 200 mm or less, the interfaces may be joined, and even if they are not joined, since the surface is flat, the transmission of stress is transmitted by the surface, so there is no problem in deformation compatibility. When the surface of the mesh body is not substantially flattened, the local external force transmitted from the wading layer through the side ground cannot receive deformation stress on the surface, and the surface stripes and adhesion points Since it is selectively transmitted to the part and the function to disperse the deformation stress is reduced, stress concentration may occur. For such external force, fatigue due to stress concentration occurs and the sag resistance is reduced. May decrease. When the filament is made of a thermoplastic elastic resin, the entire structure is deformed in the three-dimensional structure portion, so that stress concentration is alleviated. However, as the sag progresses, the body shape holding function also decreases. With an inelastic resin, the stress is concentrated at the adhesion point as it is, causing structural failure and not recovering. Furthermore, it is not preferable that the surface is not flattened and has unevenness, because the feeling of foreign matters is given to the back and the buttocks when sleeping and the sleeping comfort is deteriorated. In addition, when the linear shape is not continuous, the adhesion point of the filament becomes the transmission point of stress, so that a significant stress concentration occurs at the adhesion point, resulting in structural destruction and poor heat resistance and durability. Even if it does not break the structure, there is a problem that the anti-compression property is inferior and the body shape retention property is inferior. It becomes heavier and handleability is remarkably inferior. If it is not fused, the shape cannot be maintained, and the structure does not deform integrally. Therefore, a fatigue phenomenon due to stress concentration occurs and the durability is inferior. At the same time, the shape is deformed and the body cannot be maintained. . A more preferable degree of fusion of the cushion layer of the present invention is a state in which most of the portions in contact with the filaments are fused, and most preferably, the contact portions are all fused. In a mesh structure composed of filaments made only of known inelastic resin, it does not have rubber elasticity when subjected to a large deformation stress that cannot be absorbed by the surface layer, so it is difficult to deform and exhibits a large repulsive force. In addition, since it exhibits a strong repulsive force, it provides an unpleasant body support feeling, exhibits an unfavorable body shape holding function, and has almost no pump function due to compression recovery. Further, the plastic deformation is caused by the compressive deformation and the recovery is not achieved, so that the durability is inferior. Crosslinkable foamed polyurethane has good vibration absorption function and sag resistance due to its elastic resin, but because it has a structure that allows easy stress transmission, it can easily follow local deformation and cause extreme local sinking. Occurs and the body-holding function is inferior. In addition, polyurethane foam is a cushion layer that forms a mat that is not easily breathable due to extremely poor breathability and that does not provide a comfortable sleeping experience. The mat of the present invention has an apparent density of 0.1 g / cm on the front side or back side of the cushion layer. Three It is a mat in which a wadding layer made of the following polyester fiber web is laminated and the entire surface is covered with a side fabric. Although the polyester fiber is not particularly limited, as described above, sweat and moisture are moved from the skin surface through the wadding layer as soon as possible, and no stuffiness is felt, and the body shape is maintained with proper heat retention and a favorable fit. In order to provide a permanent sleep, the surface of the skin rises to body temperature by using a web that is mainly made of polyester fibers that have been made hydrophilic, and more preferably have a modified cross-section to increase water release. The sweat or water vapor that has moved moves from the skin surface to the wadding layer through the side surface, and immediately moves from the wadding layer to the cushion layer surface. Next, because the cushion layer has a pump function that replaces the fresh air, the heat and moisture transferred to the cushion layer surface are released to the outside through the cushion layer, and when the skin surface dries, the moisture surface evaporates. It also reduces the feeling of stuffiness with a decrease in temperature. The mixing ratio of the polyester fibers in the web constituting the wadding layer is preferably at least 50% by weight, more preferably 75% by weight, and most preferably 100% by weight. Apparent density is 0.1g / cm Three Since the air permeability of the wadding layer decreases and the moisture permeability decreases, the apparent density from the moisture permeability is preferably 0.06 g / cm. Three Or less, more preferably 0.04 g / cm Three It is as follows. Thus, it is possible to express a mat function that is hard to be stuffy due to the synergistic effect of the wadding layer and the cushion layer and has excellent heat retention. Since the individual fibers are not fixed to the wadding layer made of the web of the mat of the present invention, the individual fibers have a large degree of freedom with respect to deformation stress, and when subjected to local deformation stress transmitted through the side ground, It is compressed and deformed while moving to transmit the deformation stress to the cushion layer. The cushion layer receives the deformation stress with a low repulsive force due to rubber elasticity by absorbing the deformation stress by energy conversion while the entire structure is deformed by the stretchability of the thermoplastic elastic resin due to the elastic deformation of the cushion layer, The synergistic effect of supporting the body shape with a soft gripping force against the human body makes it difficult to form a local high compressive stress point in contact with the human body, and it is possible to express a wadding function that is less prone to congestion. This function effectively acts to prevent floor rubbing as a further synergistic effect by sending fresh air to the skin surface through the side ground. In order to give such an especially remarkable effect, the air permeability of the air exhausted from the wadding layer to the side of the cushion layer through the side ground is set to 10 cc / cm. 2 It is desirable to have a configuration that takes 2 seconds or more. Although the air permeability of the side fabric covering the mat of the present invention is not particularly limited, the air permeability of the knitted fabric constituting the side fabric is preferably 30 cc / cm in order to give an effect of preventing floor rubbing. 2 More than a second. The side fabric constituting the mat of the present invention is preferable because the side surface of the mat is composed only of a knitted fabric and the air permeability between the cushion layer and the outside air is improved, so that the pump function of the cushion layer can be utilized more effectively. . If the apparent density of the web composing the wadding layer of the present invention is too high, the apparent density is 0.1 g / cm because the anti-congestion function and the breathability are deteriorated due to the increase in the support area of the high compressive stress, and the anti-steaming effect is also reduced. Three The following is required: If the apparent density is too low, the compressibility is lowered and the function of the wadding layer is lowered. Therefore, the preferred apparent density is 0.01 g / cm. Three 0.06g / cm Three Or less, more preferably the apparent density is 0.03 g / cm Three 0.05g / cm Three It is as follows. When the thickness of the wadding layer is less than 2 mm, the wadding layer function is deteriorated. If it is 30 mm or more, the above-mentioned function having a synergistic effect with the cushion layer, a body holding function and a vibration absorbing function for supporting the body with a moderate sinking force and a soft gripping force are lowered. The preferred thickness is 3 mm or more and 15 mm or less, more preferably 5 mm or more and 10 mm or less. The fineness of the polyester fiber used for the wadding layer of the mat of the present invention is selected as desired. The fineness that can be used in normal card opening is from 0.5 denier to 100 denier. , Preferably 2 denier to 30 denier, more preferably 4 denier to 15 denier. In special cases, a fineness of up to 500 denier can be selected. Further, the cross-sectional shape of the polyester fiber used for the wadding layer of the mat of the present invention is not particularly limited, but the deformed section has a deformed degree of 1.2 or more, the hollow section has a hollow ratio of 10% or more, or the hollow deformed section has a deformed degree of 1 .2 or more and a hollowness of 5% or more are preferred because the bulkiness, heat retention and anti-compressibility are improved. As long as the wound form is a spread web and the entanglement can be maintained, there is no particular limitation on either mechanical or three-dimensional crimping. However, the degree of crimping is 5% to 30% and the number of crimps is 5 / More than 15 inches / inch or less is preferable because the soft bulkiness is improved, and the degree of reduction is 3% or more and 20% or less by three-dimensional winding and the number of crimps is 16 / inch or more and 30 / inch or less. It is preferable because the anti-compressibility can be improved. If the fiber length is 15 mm or more and 150 mm or less, card opening or air-opening can be performed, and the fiber length is not particularly limited, but preferably 30 mm or more and 100 mm or less that is easy to open and in good entanglement is used. It is preferable to use a fine fineness of 2 to 8 denier for a slightly soft texture, and a thick fineness of 6 to 30 denier for a slightly hard texture. In order to create a soft texture with a waist and a touch, a fineness of 0.5 to 5 denier and a fineness of 6 to 15 denier should be 1/9 to 5 / It is preferable to use 5 in a mixed fiber. It is possible to impart softness, sag resistance, and water release while suppressing bulkiness by mixing a squeezed form that is easily slipped by mechanical squeezing and a hydrophilic process that is three-dimensional squeezed. In order to add other characteristics to the wadding layer, for example, a polyester fiber to which an acaricide, an antibacterial agent, a deodorant, a flame retardant, a fragrance, etc. are imparted at the same time as the hydrophilization is used or separately contained. Polyester fibers are mixed to enhance the function, or fibers that can be given functions such as improving drainage drying characteristics by using characteristics such as water repellency and hydrophobicity and doubling the defects and features are mixed. Is desirable. Depending on the preference, different desired padding layers made of polyester fibers may be laminated on the cushion layer surface to be used separately in summer and winter. Further, other materials may be laminated on the cushion layer and / or the wadding layer as long as the basic functions of the present invention are not lost. The mat of the present invention has better washability than known mats. That is, the diameter of the cushion layer constituting the majority of the cushion body of the present invention is 0.01 mm or more, compared to a cushion layer made of ordinary fibers having a fiber diameter of 0.001 mm or less. Although the surface area of the cushion body is large, since the average number of constituents in the entire cushion body is small, the surface area of the filaments is remarkably small, so that the moisture adhering to the surface of the filaments can be reduced, and the drainage is excellent. Drying time can be shortened because of good drainage. If desired, the side ground and the cushion body are connected by a button stop. The preferred density of button stops is 2 / m 2 More than 8 pieces / m 2 It is preferable that the thickness of the button stop portion is stopped so as to hold 80% or more of the predetermined thickness. Even when buttoning is applied, the web constituting the wadding layer of the present invention has a large degree of freedom because the individual fibers are not sufficiently fixed, and may be felted if squeezing compression during washing is applied significantly. Therefore, it is preferable that the web forming the wadding layer is lightly entangled with a needle punch or the like to prevent felting. When a needle-punched web is used for the wadding layer, felting due to web bias and entanglement is less likely to occur even with round washing. The density of the needle punch is not particularly limited, but if the punch density is too high, the degree of freedom of the fibers in the web is lost and the above effect is lost. 2 More than 30 / cm 2 The following is good. With this treatment, the mat of the present invention can be washed frequently, and as a result, a clean mat can always be used. In addition, the mat of the present invention further improves the bendability because the cushioning layer has a thermoplastic elastic resin stretchable and a cushioning layer and a wadding layer made of a web having a high degree of freedom of deformation. This function can be used for nursing care beds that require the head and upper body to wake up. When used as a thin mattress, it can be folded and stored. If the cushion layer is made of a hard material made of non-elastic resin, the bent part may break if it is forcibly bent, and if the cushion layer is made of a soft non-elastic resin material, the cushion will be bent. The wadding layer is a laminated structure in which the cushioning layer of the present invention made of a thermoplastic elastic resin is non-bonded because the wadding layer made of a web having a high degree of freedom in deformation is not bonded, but the wadding layer is a surface. It does not have a rigid function and can be bent, and even with repeated bending, the side padding and the wadding layer sandwiched between the cushion layers can be freely deformed, so that the present invention is difficult to plastically deform and has excellent durability. This is a very different point from hard cotton. In order to improve the folding property of hard cotton, a folding structure has been proposed. However, unlike the cushion layer of the present invention, an inelastic resin is used for the cushion layer, so that the durability is inferior. Commercial bets may be sterilized as necessary. The sterilization generally uses ethylene oxide gas of less than 100 ° C or steam of 130 ° C. The mat of the present invention can be sterilized without being deformed by sterilizing with steam at 130 ° C. in less than 90 minutes without applying compressive stress. However, a known olefin-based or vinyl chloride-based material is used. The case is different from the present invention in that the heat resistance is inferior and the plastic deformation is caused by heating during sterilization to reduce the bulk. In addition, by applying the above-described pseudo-crystallization treatment at an arbitrary stage from the network formation stage to the product production, the melting curve obtained by measuring the components made of the thermoplastic elastic resin in the network with a differential scanning calorimeter at room temperature. It is more preferable to have an endothermic peak at a temperature not higher than the melting point because the elasticity and heat resistance of the thermoplastic elastic resin are remarkably improved and the heat resistance and durability of the product is remarkably improved.
[0015]
The cross-sectional shape of the filaments constituting the cushion layer of the present invention is not particularly limited, but it is particularly preferable because it can provide a preferable anti-compressibility (repulsive force) and touch by making it a hollow cross-section or an irregular cross-section. preferable. The anti-compressibility can be adjusted by adjusting the fiber diameter and the modulus of the material used to make the wire diameter thinner, and for soft materials the hollowness and deformity can be increased to adjust the initial compressive stress gradient, and the wire diameter is made slightly thicker. If the material has a slightly high modulus, the hollowness and the degree of deformity are lowered to provide an anti-compression property with good sleeping comfort. As another effect of hollow cross section and deformed cross section, by increasing the hollow ratio and deformity, the same anti-compression property can be given, and it becomes possible to reduce the weight, and in the case of bed mat replacement, futon, cushion, etc. Improves handling when lifting and lowering. As another preferable method capable of imparting preferable anti-compressibility (repulsive force) and touch, there is a method in which the filaments of the present invention have a composite structure. Examples of the composite structure include a scissor structure, a side-by-side structure, and a combination structure thereof. However, in order to obtain a three-dimensional three-dimensional structure that can recover vibrations and deformation stresses that cannot be energy-converted even if the cushion layer is largely deformed, it is possible to soften 50% or more of the linear surface with a soft thermoplastic elastic resin. And a scissor structure or a side-by-side structure and a combination structure thereof. In the sheath structure, the sheath component is a thermoplastic elastic resin with a high soft segment content that allows easy energy conversion of vibration and deformation stress, and the core component is a thermoplastic elastic resin with a low soft segment content that exhibits anti-compression properties. A comfortable touch can be given to the contact portion such as the back portion and the buttocks portion by being made of resin and being appropriately submerged. In the side-by-side structure, vibration and deformation stresses are easily converted into energy, and the melt viscosity of a thermoplastic elastic resin with a high soft segment content is set lower than the melt viscosity of a thermoplastic elastic resin with a low soft segment content and exhibiting anti-compressibility. Structure with a large proportion of thermoplastic elastic resin with a large soft segment content occupying a linear surface (metaphorically a structure in which a thermoplastic elastic resin is arranged in an eccentric sheath / core sheath) The ratio of the thermoplastic elastic resin having a high soft segment content occupying a linear surface is particularly preferably 80% or more, and most preferably the thermoplastic elastic resin having a high soft segment content occupying a linear surface. This is a score of 100%. If the proportion of the thermoplastic elastic resin with a large soft segment content occupies the linear surface increases, the fluidity when melted and fused becomes high, which has the effect of strengthening the adhesion, and the structure deforms integrally. In this case, fatigue resistance against stress concentration at the adhesion point is improved, and heat resistance and durability are further improved. In the mat of the present invention, a web made of polyester fiber mainly composed of a hydrophilic polyester fiber is laminated on one side of the cushion layer, and hard cotton, natural fiber web, non-woven fabric, knitted fabric, fabrics, etc. are installed on the other side. It is also possible to cover and integrate with a side fabric made of knitted fabric. The mat of the present invention is particularly useful for marine seats, vehicles, ships, hospitals and other commercial and household beds, futons, cushions, furniture mats, etc., but vehicle seats, furniture chairs, It is also useful as a cushion for office chairs.
[0016]
Next, the production method of the present invention will be described. A three-dimensional structure in which a thermoplastic elastic resin is discharged from a multi-row nozzle having a plurality of orifices at a melting temperature that is 20 ° C. to 80 ° C. higher than its melting point, and is ejected downward from the nozzle and brought into contact with each other in a molten state. Is a mat manufacturing method in which polyester fiber webs are laminated on both sides or one side, and the entire surface is covered with side lands after being sandwiched by a take-up device and cooled in a cooling tank. A mat manufacturing method in which pseudo-crystallization treatment is performed by annealing at a temperature of at least 10 ° C. or less than the melting point of the thermoplastic elastic resin constituting the network, and the polyethylene glycol is mixed in an amount of 1% by weight to 10% by weight. This is a mat manufacturing method using a web whose main matrix is fiberized polyester fiber. In the network of the present invention, a thermoplastic elastic resin is melted using a general melt extruder, supplied to a multi-row nozzle having a plurality of orifices, and discharged downward from the orifices. The melting temperature at this time is 20 to 80 ° C. higher than the melting point of the thermoplastic elastic resin. If the melting temperature is higher than the melting point of the thermoplastic elastic resin by more than 80 ° C., the thermal decomposition becomes remarkable and the rubber elastic property of the thermoplastic elastic resin is deteriorated. On the other hand, if it is not higher than the melting point of the thermoplastic elastic resin by 10 ° C. or more, melt fracture occurs and normal filaments cannot be formed. It is not preferable because the temperature is lowered and the filaments are not fused to each other, resulting in a network having insufficient adhesion. The preferred melting temperature is 20 to 60 ° C. above the melting point, more preferably 25 to 40 ° C. above the melting point. The shape of the orifice is not particularly limited, but a hollow cross section (for example, a triangular hollow, a round hollow, a hollow with a protrusion, etc.) and a deformed cross section (for example, a triangular, Y, star, etc.) In addition to the above effects, the three-dimensional structure formed by the melted discharge filaments makes it difficult for the flow to relax, and conversely maintains a long flow time at the contact point to strengthen the adhesion point. This is particularly preferable. In the case of heating for adhesion described in JP-A-1-2075, the three-dimensional structure is easy to relax, and a planar structure is formed, making it difficult to form a three-dimensional structure. As an effect of improving the properties of the net-like 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. 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, in which the effect of weight reduction can be exhibited. The pitch between the holes of the orifices needs to be a pitch at which the loop formed by the linear shape can sufficiently come into contact. To obtain a dense structure, the pitch between holes is shortened, and to obtain a dense structure, the pitch between holes is increased. The pitch between holes of the present invention is preferably 3 mm to 20 mm, more preferably 5 mm to 10 mm. In the present invention, different density and different fineness can be achieved as desired. The different density layer can be formed by a configuration in which the pitch between rows or the pitch between holes is changed, and a method in which both the pitch between rows and between holes are also changed. Also, if the cross-sectional area of the orifice is changed to give a pressure loss difference at the time of discharge, the discharge amount of the molten thermoplastic elastic resin pushed out from the same nozzle at a constant pressure is reduced as the orifice with a larger pressure loss is used. A network structure composed of different fineness filaments can be manufactured using a nozzle having at least a plurality of rows having different sectional areas of orifices in the longitudinal section. Next, it is ejected downward from the nozzle, and while forming a loop, it is brought into contact with each other in a molten state and fused to form a three-dimensional structure. The twisted discharge wire is bent and deformed by 45 ° or more to flatten the surface, and at the same time, the contact point with the unbent discharge wire is bonded to form a structure, and then the cooling medium (usually room temperature) It is preferable to use this water because the cooling rate can be increased and the cost can be reduced, and the water is rapidly cooled to obtain the network having the three-dimensional solid network structure 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 from being fused. When the discharge rate is 5 g / min or more, it is preferably 10 cm to 40 cm. When the discharge rate is less than 5 g / min, 5 cm to 20 cm is preferable. The thickness of the network is determined by the opening width of the take-up net (interval between take-up nets) that sandwiches both surfaces of the three-dimensional structure in the molten state. In the present invention, the opening width of the take-up net is set to 5 mm or more for the reasons described above. Next, draining and drying are not preferred, but adding a surfactant or the like to the cooling medium is not preferable because draining or drying becomes difficult or the thermoplastic elastic resin swells. It should be noted that 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 melt viscosity at the time of forming the network is preferably 500 poise to 10,000 poise, and exceeds 20000 poise This is not preferable because the loop forming speed becomes slow and it becomes difficult to form a dense network structure.) The desired loop diameter and wire diameter can be determined by the hole diameter and discharge amount of the orifice. A pair of take-up conveyors with adjustable spacing installed on the cooling medium sandwiches and stops the melted discharge filaments, and fuses the parts in contact with each other while continuously drawing into the cooling medium and solidifying it. When the body is formed, by adjusting the interval of the conveyor, the thickness can be adjusted while the fused network is in a molten state, and a desired thickness can be obtained. If the conveyor speed is too high, the formation of contact points may be insufficient, or cooling may occur before the fusion points are sufficiently formed, resulting in insufficient fusion of the contact portions. Further, if the speed is too slow, the melt stays too much and the density becomes high, so it is necessary to set a conveyor speed suitable for the desired apparent density. Next, in the present invention, the network is once cooled, then continuously or discontinuously subjected to pseudo-crystallization treatment and cut into a predetermined size, or after cutting, pseudo-crystallization treatment. On the other hand, the polyester fiber of the wadding layer may be a staple obtained by a known method. However, in the present invention, it is preferable to use a polyester fiber having a polyester or the like added to the fiber surface as a hydrophilic agent, and a polyester as a hydrophilic agent. -A fiber using polyester kneaded with tellurium or the like is particularly preferable. As a method of kneading the hydrophilizing agent which is a particularly preferred embodiment of the present invention, a method of mixing at the time of polymerization, a method of preparing and using a resin kneaded using an extruder having a kneading function to a polyester resin, and There is a method of mixing and kneading directly at the time of melt spinning. In the present invention, for example, in the method of direct mixing and kneading at the time of spinning, a twin-screw extruder having a kneading function such as a dull mage or a cross saw in a compression part or a tip metering part of a screw of an extruder or A method of melt-kneading the polyester resin at a temperature of 10 ° C. or higher and lower than 30 ° C. from the melting point of the polyester while supplying a predetermined amount together with the polyester using a single screw extruder, or a polyester resin having a melting point of 20 ° C. or higher and lower than 50 ° C. A method of melting at a temperature, and then melting at a melting temperature of the polyester between a compression portion and a tip metering portion of an extruder, and supplying a polyethylene glycol as a hydrophilizing agent quantitatively (direct melt blending) The latter is more preferable in the present invention. For example, polyethylene glycol preferably has a number average molecular weight of 5000 or more and less than 50000, and more preferably 8000 or more and less than 20000. The kneaded state is incompatible mixing with polyester as the main matrix. Thus, the molten polyester resin kneaded with the hydrophilizing agent is spun at a temperature not lower than 10 ° C. and lower than 50 ° C. from the melting point of the polyester with a metering pump to obtain polyester fibers. In the present invention, the nozzle orifice shape is selected so that the fiber cross section is preferably an irregular cross section or a hollow cross section. More preferably, an orifice shape of a nozzle having an irregular hollow cross section is selected. The polyester fiber is preferably obtained by imparting latent crimping ability by a non-target cooling method or a composite spinning method, and by producing a three-dimensional crimp by heat treatment after stretching or by cutting or by heat treatment after cutting. . Since the polyester fiber is required to have sag resistance and heat resistance, the initial tensile resistance is at least 35 g / denier and the initial tensile resistance at 70 ° C. is at least 10 g / denier. Is preferred. The degree of crimp of the three-dimensional crimp from the bulkiness and the anti-compression property is preferably 15% or more, and the number of crimps is preferably 10-25 pieces / inch. The hydrophilic polyester fiber thus obtained is mixed and opened with a desired blending amount with other polyester fibers as a main matrix of the wadding layer. The mixing ratio of the hydrophilic polyester fiber and the other polyester fiber is 100/0 to 50/50 by weight, pre-opened and mixed with an opener, etc., and then opened with a card or the like to obtain a three-dimensional structure. When the opened web is formed and the thickness is 3 mm to 10 mm, the apparent density is 0.1 g / cm. Three Hereinafter, preferably, the apparent density is 0.01 g / cm. Three To 0.06g / cm Three As a wadding layer, the web laminated in such a manner is preferably an apparent density of 0.01 g / cm when the thickness is changed from 3 mm to 10 mm by a conventional method. Three To 0.06g / cm Three The punch density on the web is 5 / cm 2 More than 30 / cm 2 In the following, as a wadding layer whose shape has been stabilized by needle punching, it is laminated on the surface and / or the back surface of the mesh body, and then the entire surface is covered with a knitted fabric as a side fabric, with an apparent density of 0.1 g / cm. Three Hereinafter, preferably, the apparent density is 0.01 g / cm. Three To 0.06g / cm Three The mat of the present invention is obtained by being inserted and sewn while being compressed. The mat of the present invention is preferable because only the knitted fabric is installed on the side surface of the mat because the air permeability of the side surface is enhanced and the pump function of the cushion layer for replacing fresh outside air can be further enhanced. The side ground may be sewn into a predetermined shape of the mat, put on a cushion body in which a cushion layer and a wadding layer are laminated, bind the insertion port, and then perform button fastening as desired. 2 to 8 button stops per mat area 2 Is preferable. It is preferable to perform the button stop while pressing the button so that 80% or more of the thickness can be maintained. In the processing of the side surface of the side surface, piping may be sewn by covering the corner portion with another fabric. Note that the crystallization treatment in the present invention is performed at an arbitrary step leading to commercialization at a temperature lower than at least the melting point (Tm) of the thermoplastic elastic resin by 10 ° C. or more and above the α dispersion rising temperature (Tαcr) of Tanδ. By this treatment, the heat sag resistance is remarkably improved from those having an endothermic peak below the melting point and not having a pseudo crystallization treatment (no endothermic peak). The preferred pseudocrystallization temperature of the present invention is from (Tαcr + 10 ° C.) to (Tm−20 ° C.). When pseudo-crystallization is performed by simple heat treatment, heat sag resistance is improved. However, it is more preferable to anneal by applying a compressive deformation of 10% or more because the heat sag resistance is remarkably improved.
In addition, when the network is once cooled and then subjected to a drying step, pseudo-crystallization treatment can be simultaneously performed by setting the drying temperature to the annealing temperature. Moreover, a pseudo crystallization process can be separately performed in the process of commercialization.
[0017]
The mat of the present invention can use only a cushion body by utilizing its function in addition to a bed, a mattress, a cushion, a furniture mat, and the like. For example, the cushion layer is molded into a shape suitable for the purpose of use using a molding die or the like to the extent that the three-dimensional structure is not damaged, and then the padding layer is laminated and sewn on the side ground to sew the vehicle seat and ship It can be used for seats, chairs, furniture, etc. Of course, it can also be used in combination with other materials that should meet the required performance in relation to the application, for example, a different mesh, a hard cotton cushion made of short fiber aggregates, a nonwoven fabric, and the like. In addition, it can be processed into a molded product from the manufacturing process as long as the performance is not deteriorated even outside the resin manufacturing process, and flame retardant, antibacterial, heat resistance, water and oil repellency, coloring, fragrance, etc. It is possible to perform processing such as adding a drug to impart the function.
[0018]
【Example】
The present invention is described in detail below with reference to examples.
[0019]
In addition, evaluation in an Example was performed with the following method.
1. melting point (Tm) and endothermic peak below melting point
The endothermic peak (melting peak) temperature was determined from the endothermic curve measured at 20 ° C./min using a TA50, DSC50 type differential thermal analyzer manufactured by Shimadzu Corporation.
2. Tαcr
The polymer was heated to the melting point + 10 ° C. to prepare a film having a thickness of about 300 μm, and Tanδ (imaginary modulus M ”measured at 110 Hz with a heating rate of 1 ° C./min using an orientec Vibron DDVII type. The rising temperature of α dispersion corresponding to the transition temperature from the rubber elastic region to the melting region of the ratio M ″ / M ′) of the elastic part and the real part M ′ of the elastic modulus.
3. Room temperature elongation recovery rate
The polymer is heated to the melting point + 10 ° C. to prepare a film having a thickness of about 300 μm. Using Tensilon UTM type 4 manufactured by Orientec Co., Ltd., the strain is returned to 0% after stretching by 300% at a stretching speed of 100%, and for 2 minutes. A value obtained by dividing by 300% the elongation rate obtained by subtracting from 300% the elongation rate at which stress develops again at the time of elongation when it is further stretched to break after standing is shown in%. (N = 3)
4. 70 ° C elongation recovery rate
The polymer is heated to a melting point of + 10 ° C. to form a film having a thickness of about 300 μm. Tensilon UTM4 type manufactured by Orientec Co., Ltd. is used, and the elongation strain is 10% at a stretching rate of 100% in a heating oven at 70 ° C. After holding for 24 hours, the strain is returned to 0%, left to stand for 5 minutes, and then stretched again until breaking. The value divided by is shown in%. (N = 3)
5. Apparent density
The sample is cut into a size of 15 cm × 15 cm, the heights at four locations are measured, the volume is obtained, and the weight of the sample is shown as a value that is gradually reduced by the volume. (Average value of n = 4)
6. Wire diameter
Samples are cut out from 10 locations, embedded in acrylic resin, cut into cross sections, cut into sections, and cross-sectional photographs are obtained. The wire diameter is obtained from the enlarged cross-sectional photograph, and the value calculated by the enlargement magnification (average value of n = 10)
7. Fusion
Whether the sample is fused by visual judgment or not is determined by pulling the bonded fibers by hand or not by whether or not the sample is fused.
8. Heat resistance (70 ° C residual strain)
The sample was cut into a size of 15 cm × 15 cm, compressed 50%, left to stand in dry heat at 70 ° C. for 22 hours and then cooled to remove the compressive strain, and the difference between the thickness after standing for 1 day and the thickness before processing, and the thickness before processing. The ratio is expressed in% (average value of n = 3)
9. Cyclic compression strain
The sample is cut into a size of 15 cm × 15 cm, and compression recovery is repeated at a cycle of 1 Hz up to a thickness of 50% in a 25 ° C. 65% RH chamber with a Shimadzu servo pulsar, and the sample after 20,000 times is obtained. The ratio between the thickness after standing for 1 day, the difference in thickness before treatment and the thickness before treatment is shown in%. (Average value of n = 3)
10.Air permeability
The side land is a direct side land manufactured by Techno World Co., Ltd. (Cosmo Instrument design product) air flow rate measuring device, measured using a high pressure type (cc / cm 2 Seconds) as the air permeability. The amount of air that can be discharged from the side through the wadding layer to the net is high enough to correspond to a sample thickness that can punch a sample with one side of the wadding layer covered with a knitted fabric into a cylinder with a diameter of 10 cm and seal the side. The sample was placed in a metal cylinder with an inner diameter of 10 cm in a compressed state of 5%, and the upper and lower parts were sealed with packing having a compression thickness of 5% to prevent side leakage, and manufactured by Techno World Corporation ( Cosmo instrument design product) Ventilation rate (cc / cm) measured using an air flow meter and high pressure type 2 Seconds) as the air permeability.
11.Bendability
The prepared mat is pushed out from a horizontal plane with one end held down, and the length until the mat is brought into contact with the inclined surface cut out at 45 ° is shown by the following criteria. Less than 100 cm: ◎, less than 130 cm: ○, less than 150 cm: Δ, 150 cm or more: ×
12.Drainage
After measuring the weight of the mat, immerse it in a water bath and take it out after 10 minutes. Drain it as much as possible, and lean it against a wall in a room of 30 ° C RH 65% and measure the weight after standing for 24 hours to determine the amount of residual moisture. The evaluation was based on the following criteria. Residual moisture 5% or less: ◎, Residual moisture 7% or less: ○, Residual moisture 10% or less: △, Residual moisture 10% or more: ×
13. Comfortable
The prepared mat was set on a bed frame, and the following evaluation was performed by putting the panel in a room at 28 ° C. and 75% RH. (N = 5) A sheet was laid on the bed mat, a down / feather: 90/10 mixed feathers (1.8 kg) were included in the comforter, and a pillow used at home was used.
(1) Discomfort: The degree of “discomfort felt on the back” when sleeping was qualitatively evaluated. Do not feel; ◎, feel almost; ○, feel a little; △, feel; ×
(2) Sinking: Sensory qualitative evaluation was performed on the degree of body retention when sleeping. Very comfortable with moderate subsidence; ◎, slightly subdued or slightly large and comfortable; ○, slightly submerged or large and slightly lacking in comfort; △; No; x
(3) Sensation of stuffiness: The sensation of stuffiness felt on the part that touched the bed mat such as the buttocks and back was qualitatively evaluated. Almost feelless: ◎, feel slightly stuffy; ○, feel slightly stuffy; △, noticeably stuffy; ×
(4) Feeling of body pressure: how long you can stand without moving after sleeping: within 30 minutes; x within 1 hour; △ within 2 hours; ○ over 2 hours;
[0020]
Example 1
As a polyester elastomer, dimethyl terephthalate (DMT) or dimethyl naphthalate (DMN) and 1.4 butanediol (1 / 4BD) are charged with a small amount of catalyst, and after ester exchange by a conventional method, Polytetramethylene glycol (PTMG) was added and polycondensed while raising the temperature and pressure to form a polyester ester block copolymer elastomer, and then 1% antioxidant and 10% flame retardant (phosphorus content 5000) Table 1 shows the formulation of the thermoplastic elastic resin raw material obtained by pelletizing after adding and mixing, and vacuum drying at 50 ° C. for 48 hours.
[0021]
[Table 1]
Orifice shape with a staggered arrangement of 120mm wide and 10cm long nozzle effective surface width width hole pitch 5mm and length direction hole pitch 10mm is 2mm outer diameter, 1.6mm inner diameter and triple bridge hollow formability In a nozzle having a cross-section, the obtained thermoplastic elastic resin raw material is melted by a separate extruder, and A-1 is distributed to the sheath component and A-2 is distributed immediately before the orifice so as to be the core component. At a melting temperature of 245 ° C., the discharge amount per single hole is 2.0 g / min (A-1: 1 g / min, A-2: 1 g / min) and discharged below the nozzle. A stainless steel endless net with a width of 140 cm is arranged in parallel at intervals of 10 cm so that a part of the pair of take-up conveyors comes out on the water surface, and the molten discharge line is twisted to form a loop. To form a three-dimensional network structure while fusing the contact parts , While sandwiching both sides of the molten network with a take-up conveyor, it is drawn into a 25 ° C. cooling water at a rate of 1 m / min and solidified by flattening both sides, taken out, drained, and continuously at 120 ° C. The network obtained by passing through a setter in which heated air is circulated for 15 minutes, cooling, and cutting to a predetermined size is a triangular cornice-shaped hollow section with a cross-sectional shape of a scissor structure and a hollow ratio of 40%. In addition to the melting point having a wire diameter of 1.2 mm, the filaments having endothermic peeping at 126 ° C. are joined together by the fusion at the contact points of the loops to be formed, and both surfaces are substantially flattened. Apparent density of 0.046 g / cm 2 The thickness was 9.5 cm, the cyclic compression strain was 2.8%, and the heat durability was 11.2%. Separately, the polyester fiber is 10 [2 · 3 · di (2) as an acid component having an intrinsic viscosity of 0.63 and 0.56 in two extruders having a dull shape at the compression portion and the meta-ring portion.・ Hydroxyethoxy) -carbonylpropyl] 9,10, dihydro, 9, oxa, 10 phosphaphenalene, 10.Poxy copolymerized with oxylo to have a phosphorus content of 1200 ppm was supplied to each at 280 ° C. The PEG melted at 270 ° C. from the compression portion was supplied by a plunger pump so that the addition amount was 5% by weight, and each polyester melt-kneaded directly at 280 ° C. by the melt blending method in a weight ratio of 50 The orifice shape is hollow at a spinning temperature of 280 ° C. as 3.0 g / min per single hole (1.5 g / min: 1.5 g / min). The composite yarn was spun at a spinning speed of 1300 m / min from a nozzle that forms a fiber with two protrusions, and then drawn in two stages at 70 ° C and 180 ° C. The drawn yarn was cut to 64 mm and freed at 170 ° C. -Heat treatment to develop a three-dimensional crimp, and a side-by-side fineness of 6 denier with an irregular hollow section with three protrusions and a degree of irregularity (circumferential circle area / cross-sectional area) of 2.0 and a hollowness of 16%, initial A polyester fiber having a tensile resistance of 35 g / denier, a crimping degree of 23%, and a number of crimps of 16 pieces / inch was obtained. Next, the apparent density when the thickness of the web obtained by pre-opening the polyester fiber with an opener and then opening with a card becomes 8 mm is 0.05 g / cm. 2 Punch density 10 / cm so that 2 A cushion body in which a wading layer cut into a predetermined size by needle punching at the front and back is laminated on the front and back of the mesh body, has an air permeability of 30 cc / cm made of Toyobo Haim polyester fiber. 2 Insert a second wide into a side ground sewn to a specified size, close the insertion slot, and compress slightly, 8 pieces / m 2 The bet mat of the present invention was obtained by applying a button stop at a density of 5%. Table 2 shows the evaluation results of the obtained betting mat. As clearly shown in Table 2, the bed mat is excellent in heat resistance, durability, bendability, drainage, air permeability and comfortable sleeping. This bed mat exhibited flame retardancy and the combustion gas toxicity index was 5.0. From this, it can be seen that this is a mat for betting with high safety in the event of a fire.
[0023]
[Table 2]
Example 2
A nozzle with a 120 cm wide and 5 cm long nozzle effective surface with a staggered array of 5 mm pitch between holes in the width direction and 10 mm pitch between holes in the length direction is a nozzle with a round cross section of 1 mm outer diameter. The elastic resin raw material A-5 is melted with an extruder, discharged at a melting temperature of 245 ° C. at a discharge rate of 2.0 g / min per single hole, below the nozzle, and cooling water is disposed below the nozzle surface 15 cm, A stainless steel endless net with a width of 140 cm is arranged in parallel and at intervals of 4.5 cm so that a part of the pair of take-up conveyors comes out on the surface of the water, and the molten discharge line is twisted and looped. A three-dimensional network structure is formed while fusing the contact portions, and both sides of the molten network are sandwiched by a take-up conveyor and drawn into 25 ° C. cooling water at a rate of 1 m / min. After flattening, after draining, draining, A network obtained by passing through a setter in which heated air is continuously circulated at 120 ° C. for 15 minutes and cooling and then cutting to a predetermined size has a round cross section and a wire diameter of 0.9 mm. Lines having an endothermic peak at 126 ° C. in addition to the melting point of the loop are formed by joining the contact points of the loops formed by fusion, the surfaces are substantially flattened, and the average apparent density is 0.048 g. /cm 2 The thickness was 4.5 cm, the cyclic compression strain was 7.5%, and the heat durability was 18.4%. Next, PET having an intrinsic viscosity of 0.63 was spun at a single-hole discharge rate of 3.0 g / min at 285 ° C. from a nozzle having a C-shaped hollow cross section by a conventional method. It has a three-dimensional crimp obtained in the same manner as in Example 1 except that the latent crimping capability was imparted by an asymmetric cooling method, and has a hollow section of 36% hollowness, a fineness of 6 denier, and an initial tensile resistance of 38 g / denier. -Polyester fiber having a crimp of 25% and a number of crimps of 14 / inch was obtained. Using this polyester fiber, an apparent density of 0.05 g / cm was obtained by pre-opening with an opener and then opening with a card. 2 Punch density 10 / cm so that 2 A cushion body in which a wadding layer cut into a predetermined size by needle punching at the front and back is laminated on the front and back of the mesh body, has an air permeability of 30 cc / cm made of Toyobo's Heim polyester fiber. 2 Table 2 shows the evaluation results of the bed mats obtained by inserting into the side ground sewn in a predetermined shape using the second broad. As clearly shown in Table 2, the bed mat is excellent in heat resistance, durability, bendability, drainage, air permeability and sleeping comfort. This mat had a combustion gas toxicity index of 5.0. From this, it can be seen that the mat is safe in the event of a fire.
[0025]
Example 3
Orifice shape with a staggered arrangement of 120 mm wide and 5 cm long nozzle surface with a width-to-hole pitch of 5 mm and a length-to-hole pitch of 10 mm has an outer diameter of 2 mm and an inner diameter of 1.6 mm. The obtained thermoplastic elastic resin A-3 was melted in a cross-section nozzle by an extruder, and discharged below the nozzle at a discharge rate of 2.0 g / min per single hole at a melting temperature of 235 ° C. Cooling water is arranged 12 cm below the surface, and a stainless steel endless net having a width of 140 cm is arranged in parallel at intervals of 4.5 cm so that a part of the pair of take-up conveyors comes out on the water surface. A three-dimensional network structure is formed by forming a loop to form a loop and fusing the contact portions, and after drawing into solids at 25 ° C. in cooling water at a rate of 1 m / min. And set with circulating heated air at 120 ° C. -A net-like body obtained by passing the inside for 15 minutes, cooling, and cutting to a predetermined size and having both surfaces substantially flattened has a cross-sectional shape of a hollow rice ball-shaped cross section, and a melting point with a wire diameter of 1.2 mm. In addition, the filaments having an endothermic peak at 126 ° C. are joined together by fusion at the contact points of the loops to be formed, and the average apparent density is 0.048 g / cm. 2 The thickness was 4.5 cm, the cyclic compression strain was 5.8%, and the heat resistance was 10.8%. Next, the polyester fiber obtained in Example 1 and the polyester fiber obtained in Example 2 were mixed at a weight ratio of 70/30, and the web serving as the wadding layer obtained in the same manner as in Example 1 was used as the cushion layer. Air permeability of 30cc / cm made of Toyobo's polyester fiber 2 Table 2 shows the evaluation results of the bed mats obtained by inserting into the side ground sewn in a predetermined shape using the second broad. As clearly shown in Table 2, the bed mat is excellent in heat resistance, durability, bendability, drainage, air permeability and sleeping comfort. The bed mat had a combustion gas toxicity index of 5.1. From this, it can be seen that this is a betting mat with good safety in the event of a fire.
[0026]
Example 4
Polyurethane elastomer, 4.4 'diphenylmethane diisocyanate (MDI), PTMG and 1.4BD as chain extender are added and polymerized, then 2% antioxidant is added, mixed, kneaded, pelletized, and vacuumed Table 3 shows the formulation of the polyether-based urethane polymer after drying.
[0027]
[Table 3]
A striated score of a reticulate filament obtained in the same manner as in Example 1 except that the obtained thermoplastic elastic resin (case component: B-1, core component: B-2) was melted at 220 ° C. The cross-section of the structure is a triangular rice ball-shaped hollow cross section with a 40% hollowness and a wire diameter of 1.1 mm. In addition to the melting point with an endothermic peak at 126 ° C, the contact points of the loops to be formed are almost Bonded by fusion, both sides are substantially flattened, and the average apparent density is 0.047 g / cm 2 The thickness was 9.5 cm, the cyclic compression strain was 3.6%, and the heat durability was 7.5%. Next, a cushion body obtained by laminating the needle-punched wadding layer used in Example 2 on the cushion layer was used, and the air permeability of 30 cc / cm made of polyester fiber of Heim manufactured by Toyobo Co., Ltd. 2 Table 2 shows the evaluation results of the bed mats obtained by inserting into the side ground sewn in a predetermined shape using the second broad. As is apparent from Table 2, the bed mat is excellent in heat resistance, durability, bendability, drainage, breathability and sleeping comfort.
[0029]
Comparative Example 1
A network obtained in the same manner as in Example 2 except that only a single component of polypropylene (PP) having a melt index of 12 was melted at 220 ° C. had a solid round cross section and a wire diameter of 1.8 mm, other than the melting point. Lines that do not have an endothermic peak at the contact points of the loops to be formed are almost joined by fusion, both surfaces are substantially flattened, and the average apparent density is 0.047 g / cm. 2 The thickness was 4.5 cm, the cyclic compression strain was 39.6%, and the heat resistance was 49.8%. Subsequently, the apparent density when the thickness of the web obtained by pre-opening the polyester fiber obtained in Example 1 with an opener and then opening with a card is 6 mm is 0.05 g / cm. 2 Punch density 10 / cm so that 2 A cushion body obtained by laminating a padding layer that has been needle punched and cut to a predetermined size on the front and back surfaces of the cushion layer is a breathability of 30 cc / cm made of Toyobo's Heim polyester fiber. 2 Table 2 shows the evaluation results of the bed mats obtained by inserting into the side ground sewn in a predetermined shape using the second broad. As is apparent from Table 2, because of the network made of inelastic olefin, it is a bed mat that has excellent drainage, but has good heat resistance, durability, bendability, and breathability, but is extremely inferior in sleeping comfort other than stuffiness. This is a bed mat that fails to fire and causes problems in the event of a fire.
[0030]
Comparative Example 2
A nozzle having a round cross section with an outer diameter of 1 mm and an orifice shape with a staggered arrangement of 120 mm wide and 10 cm long nozzles with a pitch between holes of 5 mm in the width direction and a pitch of 10 mm between the holes in the length direction. The elastic resin raw material A-5 is melted with an extruder, discharged at a melting temperature of 235 ° C. at a discharge amount of 3.0 g / min per single hole, and discharged below the nozzle, and cooling water is disposed 5 cm below the nozzle surface. A stainless steel endless net with a width of 140 cm is arranged in parallel and at intervals of 9.5 cm so that a part of the pair of take-up conveyors comes out on the water surface, and the molten discharge line is twisted and looped. A three-dimensional network structure is formed while fusing the contact parts, and both sides of the molten network are sandwiched by a take-up conveyor and drawn into 25 ° C. cooling water at a rate of 1 m / min. After flattening, after draining, draining, The net-like body obtained by cutting into a predetermined size has a round cross-section, and the filaments having no endothermic peak other than the melting point having a wire diameter of 5.9 mm are in contact with each other of the loops formed. The points are mostly joined by fusion, both sides are substantially flattened, and the average apparent density is 0.074 g / cm. 2 The thickness was 9.5 cm, the cyclic compression strain was 18.3%, and the heat durability was 28.4%. Next, Table 2 shows the evaluation results of the bed mats obtained in the same manner using the wadding layer obtained in Example 2. As clearly shown in Table 2, the bed mat is superior in terms of drainage and dampness, but is inferior in heat comfort, durability, bendability and sleepiness other than dampness. This bed mat had a combustion gas toxicity index of 5.1.
[0031]
Comparative Example 3
A net obtained by the same method as in Comparative Example 2 except that a take-up conveyor net was placed 30 cm below the nozzle surface at a melting temperature of 245 ° C. and the take-up speed was 0.3 m / min. In the cross section, the filaments having no endothermic peak other than the melting point with a wire diameter of 1.9 mm, the contact points of the loops to be formed are almost joined by fusion, and both surfaces are substantially flattened, Average apparent density is 0.24 g / cm 2 The thickness was 9.5 cm, the cyclic compression strain was 19.8%, and the heat durability was 29.4%. Next, Table 2 shows the evaluation results of the betting mat obtained in the same manner as in Comparative Example 2. As clearly shown in Table 2, the bed mat is superior in terms of drainage and dampness, but is inferior in heat comfort, durability, bendability and sleepiness other than dampness. The bed mat had a combustion gas toxicity index of 5.1.
[0032]
Comparative Example 4
A net obtained in the same manner as in Comparative Example 3 except that the discharge amount per single hole was 0.3 g / min, a take-up conveyor net was placed 5 cm below the nozzle surface, and the take-up speed was 1.9 m / min. The cross-sectional shape is a round cross-section, and the filaments having no endothermic peak other than the melting point with a wire diameter of 0.4 mm are joined to each other at the contact points of the loops to be formed. Flattened with an average apparent density of 0.004 g / cm 2 The thickness was 9.5 cm, the cyclic compression strain was 13.6%, and the heat durability was 22.4%. Next, Table 2 shows the evaluation results of the betting mat obtained in the same manner as in Comparative Example 2. As is apparent from Table 2, the bed mat is excellent in breathability, bendability and drainage, but inferior in heat resistance, durability and sleeping comfort.
[0033]
Comparative Example 5
The same method as in Comparative Example 2 except that the melting rate is 230 ° C., the discharge rate per single hole is 1.5 g / min, the take-up conveyor net is arranged 60 cm below the nozzle surface, and the take-up speed is 1 m / min. The net-like body obtained in (2) has a round cross-section and a filament having no endothermic peak other than the melting point having a wire diameter of 1.9 mm. However, the filament does not form a loop and has almost no contact point. It was not possible to form a network. This line has an apparent density of 0.05 g / cm 2 Table 2 shows the evaluation results of the bet mat obtained in the same manner as in Comparative Example 2 in the form of a web having a thickness of 9.5 cm. As apparent from Table 2, when the contact points are not joined, the bed mat is inferior in sleeping comfort. In addition, since this bed mat is inferior in sleeping comfort, other evaluation is not carried out.
[0034]
Comparative Example 6
At a melting temperature of 245 ° C., the discharge rate per single hole is 1.5 g / min, a take-up conveyor net is placed 20 cm below the nozzle surface, and the surface of the conveyor net on one side is given 5 mm unevenness. Except for the speed of 1 m / min, the network obtained by the same method as in Comparative Example 2 has a round cross section and a filament having no endothermic peak other than the melting point with a wire diameter of 0.9 mm. The contact points of the loops to be formed are joined by fusion, one side is substantially flattened, but the other side has irregularities, and the average apparent density is 0.035 g / cm. 2 The thickness of the thickest portion was 9.5 cm, the compressive strain was 19.5%, and the heat resistance was 29.2%. Next, Table 2 shows the evaluation results of the betting mat obtained in the same manner as in Comparative Example 2. This mat became a poor-looking mat due to the uneven surface of the side ground. As shown in Table 2, it excels in bending, draining, stuffiness, and less pressure, but it is slightly inferior in heat resistance and durability. Matt. This bed mat had a combustion gas toxicity index of 5.1.
[0035]
Comparative Example 7
A nozzle with a 120 mm width and 1 cm long nozzle surface with a 5 mm pitch between holes in the width direction and a 5 mm pitch between holes in the length direction and a staggered arrangement of nozzles with a 1 mm outer diameter round cross section is used. With a discharge rate of 0.3 g / min, a take-up conveyor net is arranged 5 cm below the nozzle surface, and a pair of take-up conveyors are arranged so as to partially come out on the water surface at intervals of 0.4 cm. Except for 0 m / min, the network obtained by the same method as in Comparative Example 3 is formed with a filament having a round cross section and having no endothermic peak other than the melting point with a wire diameter of 0.4 mm. The points of contact between the loops are mostly joined by fusion, both sides are substantially flattened, and the average apparent density is 0.064 g / cm. 2 The thickness was 0.4 cm, the cyclic compression strain was 18.6%, and the heat durability was 29.8%. Next, Table 2 shows the evaluation results of the betting mat obtained in the same manner as in Comparative Example 2. As clearly shown in Table 2, the bed mat is excellent in bendability and drainage, but is inferior in heat resistance and durability, and has a cushion layer that is too thin so that sleeping comfort is remarkably inferior.
[0036]
Comparative Example 8
The properties of the network obtained in the same manner as in Example 2 except that the pseudo-crystallization treatment was not performed were as follows. However, the contact points of the loops to be formed are almost joined by fusion, both surfaces are substantially flattened, and the average apparent density is 0.048 g / cm. 2 The thickness was 4.5 cm, the cyclic compression strain was 16.5%, and the heat durability was 26.4%. Separately, the apparent density of the web obtained by pre-opening the polyester fiber used in Example 2 with an opener and then opening with a card is 0.12 g / cm. 2 Punch density 10 / cm so that 2 The evaluation results of the bed mat obtained by laminating the padding layers that were needle punched and cut into a predetermined size on the front and back of the cushion layer and inserting the padding layers in the same manner as in Comparative Example 2 It shows in Table 2. As is apparent from Table 2, since the density of the wadding layer was too high, the bed mat was poor in breathability and bendability and inferior in comfort.
[0037]
Comparative Example 9
The scoured Indian cotton and the polyester fiber used in Example 2 were mixed at a weight ratio of 70/30, pre-opened with an opener, then opened with a card, and the apparent density was 0. .05g / cm 2 Punch density 10 / cm so that 2 A bed obtained by laminating a padding layer cut into a predetermined size by needle punching on the front and back of the cushion layer obtained in Comparative Example 8, and inserting it into the side land obtained in the same manner as in Comparative Example 8. Table 2 shows the evaluation results of the mats for use. As is clear from Table 2, the bed comfort was good, but because the wadding layer contained other than polyester fibers, it was a mat for betting with poor drainage. The mat of Example 1 and the mat of Comparative Example 9 were coarsely crushed, dried and tried to re-fibre, but the mat of Example 1 was able to form fibers, but the mat of Comparative Example 9 was used for spinning. The yarn breakage was not able to be made into fibers. This indicates that mats containing materials other than polyester are difficult to directly recycle products.
[0038]
Comparative Example 10
The network used in Comparative Example 8 was made of Toyobo's Haimu polyester fiber with a permeability of 30cc / cm. 2 Table 2 shows the evaluation results of the bed mats obtained by inserting into the side ground sewn in a predetermined shape using the second broad. As is apparent from Table 2, the bed mat was good in bendability and sleeping comfort but poor in heat resistance and durability.
[0039]
Comparative Example 11
Apparent density 0.05g / cm Three For a bet obtained in the same manner as in Comparative Example 8 by slicing a commercially available polyester hard cotton to a thickness of 5 mm, cutting it into a predetermined size, forming a wadding layer, and laminating it on the mesh obtained in Comparative Example 8 The evaluation results of the mat are shown in Table 2. As is apparent from Table 2, the bed mat is slightly good in sleeping comfort but is inferior in heat resistance, durability, bendability and drainage.
[0040]
Comparative Example 12
Laminated cotton as card web, apparent density 0.05g / cm Three Table 2 shows the evaluation results of the bed mat obtained by inserting the cotton wool having a thickness of 10 cm into the side fabric made of polyester fibers sewn to a predetermined size. As is apparent from Table 2, the bed mat is slightly good in sleeping comfort but is inferior in heat resistance, durability, bendability and drainage.
[0041]
Comparative Example 13
Thickness 10cm, apparent density 0.05g / cm Three Table 2 shows the evaluation results of bet mats obtained by inserting into a side fabric made of polyester fibers sewn to a predetermined size using a commercially available polyester hard cotton as a cushioning material. As clearly shown in Table 2, the bed mat is slightly comfortable but has little sinking, and is inferior in heat resistance, durability, bendability and drainage.
[0042]
Comparative Example 14
Thickness 10cm, apparent density 0.05g / cm Three Table 2 shows the evaluation results of bet mats obtained in the same manner as in Comparative Example 2 using commercially available polyurethane foam as a cushioning material. As is apparent from Table 2, the bed mat is excellent in heat resistance and durability, but has good bendability, drainage and air permeability, but is inferior in sleeping comfort.
[0043]
Example 5
In the evaluation results of the mattress obtained in the same manner as in Example 1 except that the thickness of the net obtained in Example 2 was changed, the mattress was excellent in all of heat resistance, durability, bendability, drainage, and sleeping comfort. .
[0044]
Example 6
According to the evaluation result of the buckle obtained in the same manner as in Example 1 except that the thickness of the net-like body obtained in Example 2 was changed, the cushion was superior in heat resistance, durability, drainage and sitting comfort.
[0045]
【The invention's effect】
The mat is made by laminating a wadding layer made of a polyester fiber web on a cushion layer made of a net-like body in which filaments made of a thermoplastic elastic resin having a good stretch recovery property are fused and integrated and flattened. It is difficult and comfortable to sleep, has excellent heat resistance, shape retention and cushioning properties, has good folding properties, generates little toxic gas in the event of a fire, can be washed to remove germs such as MRSA, and is recycled. It is possible to provide an easy mat and a manufacturing method which are easy to use for beds, mattresses, cushions and furniture for households, hospitals and hotels.
Claims (8)
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP15447995A JP3637929B2 (en) | 1995-06-21 | 1995-06-21 | Mat and its manufacturing method |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP15447995A JP3637929B2 (en) | 1995-06-21 | 1995-06-21 | Mat and its manufacturing method |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH09757A JPH09757A (en) | 1997-01-07 |
| JP3637929B2 true JP3637929B2 (en) | 2005-04-13 |
Family
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP15447995A Expired - Lifetime JP3637929B2 (en) | 1995-06-21 | 1995-06-21 | Mat and its manufacturing method |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3637929B2 (en) |
Family Cites Families (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH05329281A (en) * | 1992-06-02 | 1993-12-14 | Toyobo Co Ltd | Flame-retardant seat for vehicle |
| JP2921638B2 (en) * | 1993-02-26 | 1999-07-19 | 東洋紡績株式会社 | Cushion net structure and manufacturing method |
-
1995
- 1995-06-21 JP JP15447995A patent/JP3637929B2/en not_active Expired - Lifetime
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| Publication number | Publication date |
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| JPH09757A (en) | 1997-01-07 |
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