JP3745449B2 - Bedding material and manufacturing method thereof - Google Patents

Description

【００５４】
次に本発明寝具素材の製造方法について説明する。
【００５５】
本発明寝具素材は、下記方法で作製することができる。即ち、繊維全体に対し５０重量％以上の炭素繊維を含み、繊維全体の５０〜１００重量％が卷縮繊維で組成された繊維集合体として綿状繊維シートの両面に熱硬化性樹脂溶液を噴霧しつつ、シートを長手方向に折り畳み重ね合わせた後に、熱硬化性樹脂を加熱硬化させることにより、繊維相互の接触点が結着され炭素繊維の３次元網目構造が形成される。なお、前記繊維集合体には、熱融着性繊維を配合するのもよく、熱融着性繊維を配合した場合には、繊維集合体の積層物を熱融着性繊維の融点以上に加熱することにより、熱融着性繊維とこれに絡み合った炭素繊維等とを結着でき、熱硬化性樹脂と熱融着性繊維とを併用した場合には、一層強固な３次元的ネットワークが形成できる。
【００５６】
上記において、繊維集合体としての綿状繊維シートは、卷縮された炭素質繊維などで組成された繊維を開繊機などの開繊手段により開繊し、カード機などのカーディング手段によりシート状ウェブを形成することにより作製できる。このシート状ウェブの繊維の方向性は特に制限されるものではなく、例えば前記カード機に代え、繊維を空気流で飛ばし回転する有孔円筒上に堆積させる方法により調製したウェブは、繊維の方向性がないランダムなものとなるが、このようなランダムウェブであってもよい。
【００５７】
綿状繊維シートの折り畳み回数（積層数）は、構造体の使用用途を考慮し２層以上において適当に選択すればよい。例えば、構造体の嵩密度を大きくし、圧縮反発性、保温性などを高めようとする場合には、積層数を多くするのがよい。また、繊維集合体としての綿状繊維シートの厚みは、特に限定されるものではなく、所望の物性値を持つ３次元構造体を得るのに都合のよい厚みを製造作業性を勘案して適当に設定すればよい。
【００５８】
なお、シート厚みは、一般にはシートの折り畳み回数や成形後の構成体の厚みや製造作業性などを考慮して決められるが、嵩密度が大きく、圧縮反発力や保温性の良い構造体を得ようとする場合には、薄いシートを用いて折り畳み回数を多くするのがよい。折り畳み回数を多くするほど、熱硬化性樹脂液を繊維全体に均一に行き渡らせ易いので、繊維接触点の結着が堅固且つムラなく行えるからである。
【００５９】
但し、繊維相互間の接触点が全て強固に結着された構造体が好ましいとは必ずしもいえない。なぜなら、構造体の使用用途によって、要求される圧縮弾性特性等が異なり、使用用途によっては非結着接触点の存在する構造体が好ましい場合があるからである。即ち、結着剤の量を少なくし、または結着剤の噴霧にムラを生じしめるなどにより、非結着接触点を多くすることが可能であるが、このような構造体では、外部から負荷が掛かったとき、先ず非結着接触点部分の繊維が滑動する結果、負荷の一部が吸収されるので初期の圧縮反発特性がより柔らかな構造体となる。このような圧縮弾性特性が望まれる用途も存在する。なお、非結着接触点が多すぎると、使用時に繊維が移動し易く、繊維の偏在化が生じるので繰り返し使用性が悪い。よって、結着接触点と非結着接触点のバランスを図るのが好ましい。
【００６０】
前記繊維集合体は、卷縮された炭素質繊維単独で構成してもよいが、他の繊維（卷縮された非炭素質繊維、非卷縮の炭素質繊維又は非卷縮の非炭素質繊維）と組み合わせて構成することもできる。他の繊維としては、不燃性又難燃性の種々の繊維、例えば無機繊維（ガラス繊維；アルミニウムシリケート質繊維、アルミナ質繊維、炭化ケイ素繊維などのセラミック繊維；アスベスト、ロックウールなどの鉱物系繊維；ステンレスなどの金属繊維；前記炭素繊維と同様な材料を原料とした非卷縮炭素質繊維など）、有機繊維（ビスコースレーヨン、キュプラなどのレーヨン繊維、アセテート繊維、熱硬化性樹脂の繊維（ノボロイド繊維などのフェノール樹脂繊維）、ナイロン繊維、難燃性ポリエステル繊維、芳香族ポリアミド繊維（アラミド繊維など）などの高分子繊維など）が挙げられる。これらの繊維は２種以上を併用して構成することもできる。
【００６１】
更に図３〜図６に基づいて本発明寝具素材の製造方法を具体的に説明する。
【００６２】
図５、６は、本発明にかかる寝具素材を作製するための製造装置の例であり、このうち図５は繊維シートの折り畳み機構を説明するための概略斜視図（側面図）であり、図６は結合剤の噴霧機構を説明するための概略斜視図（正面図）である。
カード機などのカーディング手段により紡出された繊維シート１がコンベア２及び一対のベルト３により連続的に搬送され、ベルト３ａの上部から垂直型クロスラッパー４内に導入される。クロスラッパー４では、一対のベルト３により挟持されながら繊維シート１が上部から下方へ搬送される。また、繊維シート１の厚み方向に揺動可能なスイング機構により前記繊維シートは横方向に揺動しながら、クロスラッパ４の下部から、昇降可能な載置台又は前進可能なコンベア６上に供給される。繊維シート１は、コンベア６上で複数層に折り畳まれ、積層体７が形成される。
【００６３】
スイング機構は、前記繊維シート１の厚み方向に伸びて配設されたレール５ａと、このレール上を左右に走行するローラ５ｂを備えている。なお、ローラ５ｂの走行に伴って、上部のベルト３ａとレール５ａとの間の距離が変動し、繊維シート１に外力が作用する恐れがある。したがって、上記装置では、ローラ５ｂの走行に伴って上部のベルト３ａの傾斜角度を変化させることにより、前記距離を一定に保ち、繊維シート１に外力が作用するのを抑制している。
【００６４】
前記スイング機構の下部には、繊維シート１の両側においてそれぞれ繊維シート１の横方向に往復動可能な噴霧機構が取り付けてあり、繊維シート１に結合剤を噴霧しながら、シートを長手方向と直交する方向に折り畳むことができるようになっている。
【００６５】
図５、６に示されるように、噴霧機構は、スイング機構の下部のうち、繊維シート１の幅よりも外方側の両側部に取り付けられていた保持板１１と、この保持板１１間に略平行に取り付けられた一対のレール１２と、各レール１２に沿って移動可能な滑車１３と、これらの滑車１３が取り付けられた取付け板１４と、この取付け板１４に取付けられた中空アーム１５ａと、このアーム１５ａの先端部に取り付けられたノズル１５とを備えている。なお、前記アーム１５ａからの滑車１３の脱落を防止するとともに、取付け板１４を円滑に移動させるため、各レール１２にはそれぞれ２つの滑車１３が配置されているとともに、各滑車１３にはレール１２の幅に対応して形成された環状凹部が形成されている。また、前記アーム１５ａには、熱硬化性樹脂などの結着剤の溶液を供給するための、伸縮自在なチューブまたはホース１６が接続されている。前記アーム１５ａの先端部は折曲または湾曲し、ノズル１５は、繊維シート１の面の方向に向いている。また、ノズル１５は、回動可能なヒンジ機構により、噴射角度が可変できるようになっている。
【００６６】
保持板１１のプレート１７の両側部には一対の歯車１８が回転可能に取り付けられているとともに、これらの歯車１８間にはチェーン１９が掛渡されている。一方の歯車１８は、プーリ間に掛渡されたベルトを介して、モータにより回転駆動されるようになっている。
【００６７】
そして、前記ノズル１５を往復運動させるため、取付け板１４はチェーン１９に連結されており、プレート１７又は保持板１１のうち前記繊維シート１の幅に対応する部位には、前記滑車１３の移動を規制するとともに、滑車の到達を検出するためのストッパが取り付けてある。このストッパによる検出信号は、前記モータの回転方向を反転させるための反転信号として利用される。
【００６８】
上述のように動作する機構を備えた装置により、本発明にかかる炭素繊維の積層体が生産性よく製造される。この装置で製造された積層体（長手方向と直交する方向に折り畳み結着したもの）を、図３に示す。この積層体の端部を切断し、本発明にかかる寝具素材が作製される。図４に、本発明にかかる寝具素材の繊維配向状態を模式的に示した。上記装置で製造した本発明寝具素材は、炭素繊維相互が接触点で互いに結着され３次元網目構造が堅固に形成されたものとなる。
【００６９】
ところで、上記装置を用いた製造方法においては、卷縮繊維の種類や卷縮率、卷縮数を変化させ、また綿状シートの組成や、積層体の厚み（積層枚数）、結着剤の添加量などを調整し、或いは積層体を押圧しながら加熱結着するなどの手法により、嵩密度が２０〜４０Ｋｇ／ｍ³ 、最大荷重を１００ｇｆ／ｃｍ² としたときの圧縮硬さＬＣが０．７〜０．８の範囲の特性値を有し、かつ制電性、通気性にも優れた寝具素材を容易に得ることができる。つまり、本発明で規定する範囲内で条件を変化させることにより、容易に所望の物性値を有する寝具素材となすことができる。
【００７０】
例えば綿状繊維シートの繊維の全てを炭素繊維からなる卷縮繊維とし、その平均卷縮率を２０％、平均卷縮数を２回／ｃｍ、繊維長を７５ｍｍとし、綿状繊維シートに対するフェーノル樹脂量を１０〜１７重量％とした場合、嵩密度が２０〜３０Ｋｇ／ｍ³ 、最大荷重を１００ｇｆ／ｃｍ² としたときの圧縮硬さＬＣが０．７〜０．７６、圧縮回復率ＲＣが６５％以上、６５％圧縮時応力に対する２５％圧縮時応力の比が１０〜１３．６、圧縮残留歪み率が１０％以下、表面抵抗が１×１０⁸ Ω以下、体積固有抵抗が１×１０⁵ ＫΩ・ｃｍ以下、通気性が５０ｃｃ／ｃｍ² ・ｓｅｃ以上のものとすることができる。
【００７１】
この寝具素材は、ソフトな圧縮特性（弾性反発力）を与えるので、比較的柔らかい寝心地を与える敷布団、例えば子供やお年寄り用の敷布団などの素材として好適である。
【００７２】
また、上記において、例えば綿状繊維シートに対するフェノール樹脂量を１８〜２５重量％とすることにより、嵩密度が３０〜４０Ｋｇ／ｍ³ 、最大荷重を１００ｇｆ／ｃｍ² としたときの圧縮硬さＬＣが０．７６以上、圧縮回復率ＲＣが６５％以上、６５％圧縮時応力に対する２５％圧縮時応力の比が１３．６以上、圧縮残留歪み率が１０％以上、表面抵抗が１×１０⁸ Ω以下、体積固有抵抗が１×１０⁵ ＫΩ・ｃｍ以下、通気性が３０ｃｃ／ｃｍ² ・ｓｅｃ以上のものとすることができる。
【００７３】
このものは、上記素材に比べ圧縮弾性が大きいので、硬めの敷布団、例えば成人男子用の敷布団などに適する。
【００７４】
【発明の実施の形態】
実施例により具体的に本発明の実施の形態を説明する。
（実施例１）
渦流法により紡糸された嵩高の卷縮されたピッチ系汎用炭素繊維（（株）ドナック製、ドナカーボ、平均繊維径１３μｍ、平均繊維長７５ｍｍ）を開繊機およびメタリックカード機（池上機械（株）製、６０−ＭＤＫ）に順次供給し、平均７ｍｍ厚の綿状繊維シートを得た。この繊維シートの嵩密度は５．７Ｋｇ／ｍ³ であった。噴霧形成機（（株）岩本製作所製、垂直型クロスラッパー）を用い、この繊維シートの両側に少量のフェノール樹脂液を均一に噴霧しながら、繊維シートを幅１．２ｍで折り畳み、３０層の積層体を形成した。なお、前記フェノール樹脂液としては、水溶性のフェノール樹脂（住友デュレズ（株）製、スミライトレジン）４０重量部を水６０重量部に薄めて用いた。
【００７５】
次いで、前記積層体を熱風循環式硬化炉に入れ、厚調整板の間隔を４０ｍｍ、加熱温度を２３０℃として約３０分間加熱硬化した後、端部を切り離して本発明にかかる寝具素材（厚み４０ｍｍ、縦２．１ｍ、横１．０ｍ）を作製した。なお、綿状繊維シート中のフェノール樹脂の含有量は、１７重量％であった。
【００７６】
この寝具素材（本発明Ａ）の諸物性を測定したところ、嵩密度が３０Ｋｇ／ｍ³ 、最大荷重を１００ｇｆ／ｃｍ² としたときの圧縮硬さＬＣが０．７６、圧縮回復率ＲＣが６７％、２５％圧縮時応力に対する６５％圧縮時応力の比が１３．６、圧縮残留歪率が１．７％、表面抵抗が２．７×１０⁶ Ω、体積固有抵抗が４．９×１０⁴ ＫΩ・ｃｍ、通気性が７３ｃｃ／ｃｍ² ・ｓｅｃであった。なお、通気性の測定はＪＩＳ Ｌ１０７９に基づいて行った。
【００７７】
この寝具素材Ａは、ポリエステルの３次元網目構造体およびポリウレタン素材（従来素材）との対比において前記表１に一覧表示すると共に、前記図１に圧縮荷重−圧縮変形量曲線を示したものである。なお、表２にこの寝具素材の他の特性を示す。
【００７８】
この素材Ａを厚み方向に２枚重ね合わせて敷布団を作製し、実際に寝て寝心地を確認したところ、快適な寝心地感が得られた。また、繰り返し使用性を１か月間使用後の残留歪率および人間による寝心地感で評価した。その結果、１か月間使用後の残留歪率（平均値）は５％以下であり、また敷布団の寝心地感も当初のものと同様であった。
【００７９】
【表２】

【００８０】
（実施例２）
平均繊維径１３μｍ、平均繊維長７５ｍｍの卷縮されたピッチ系汎用炭素繊維を７０重量部と、熱融着性のポリエステル繊維（ユニチカ（株）製メルティ、デニール数４、平均繊維長 ３８ｍｍ）を用い平均厚み６ｍｍ、密度６．７Ｋｇ／ｃｍ³ の綿状繊維シートとしたこと、この綿状繊維シートを１５層に折り畳んだこと、調整板の間隔を３０ｍｍとしたこと、及び綿状繊維シートに対するフェーノール樹脂の含有量を１０重量％としたこと以外は、上記実施例１と同様にして本発明にかかる寝具素材Ｂ（厚み３０ｍｍ、縦２．１ｍ、横１．０ｍ）を作製した。
【００８１】
この素材Ｂは、諸物性を測定したところ、嵩密度が２０Ｋｇ／ｍ³ 、最大荷重を１００ｇｆ／ｃｍ² としたときの圧縮硬さＬＣが０．７０、圧縮回復率ＲＣが６７％、２５％圧縮時応力に対する６５％圧縮時応力の比が１０．７、圧縮残留歪率が２．８％、表面抵抗が９．８×１０⁶ Ω、体積固有抵抗が５．６×１０⁴ ＫΩ・ｃｍ、通気性が９４ｃｃ／ｃｍ² ・ｓｅｃであった。なお、この寝具素材は、前記表１及び図２（本発明Ｂ）に示したものである。
【００８２】
この素材Ｂを厚み方向に３枚重ね合わせた敷布団を作製して、上記と同様な方法により寝心地や繰り返し使用性を確認したところ、良好な寝心地感と繰り返し使用性（１か月間使用後の残留歪率の平均値が５％以下）が得られた。なお、実施例２の敷布団は、実施例１の敷布団に比べよりソフトな弾力感ある寝心地であった。
【００８３】
（実施例３）
平均繊維径１８μｍ、平均繊維長７５ｍｍの卷縮率されたピッチ系汎用炭素繊維を用いたこと、綿状繊維シートの厚みを平均９ｍｍとしたこと、フェノール樹脂液の含有量を多くしたこと（綿状繊維シートに対し、２５重量％）、及び厚み調製板の間隔を２０ｍｍとして加熱硬化した以外は、実施例１と同様にして本発明にかかる寝具素材Ｃ（厚み３０ｍｍ、縦２．１ｍ、横１．０ｍ）を作製した。
【００８４】
この素材Ｃの諸物性を測定したところ、厚み２０ｍｍ、嵩密度が４０Ｋｇ／ｍ³ 、最大荷重を１００ｇｆ／ｃｍ² としたときの圧縮硬さＬＣが０．８、圧縮回復率ＲＣが６７％、２５％圧縮時応力に対する６５％圧縮時応力の比が１６．７、圧縮残留歪率が１．３％、表面抵抗が４．７×１０⁵ Ω、体積固有抵抗が１．９×１０³ Ω・ｃｍ、通気性が５２ｃｃ／ｃｍ² ・ｓｅｃであった。
【００８５】
この素材Ｃを厚み方向に４枚重ね合わせて敷布団となし、上記と同様に寝心地感や繰り返し使用性を確認した。その結果、硬めの弾力性（腰が強い）を与える寝心地感であったが、十分に快適な寝心地が得られた。
【００８６】
【発明の効果】
以上から明らかなように、本発明寝具素材は、炭素繊維が本来的に有している強靱性、耐熱性、化学的安定性、不燃性、無毒性などの優れた特質を有し、かつ炭素繊維の単純集合物では決して得られない特性、即ち人に優しい適度な弾力性、圧縮反発性、圧縮耐久性、通気性を有する。したがって、本発明寝具素材を用いて敷布団等の寝具を作製した場合、寝心地や繰り返し使用性、保温性に優れ、かつ防災性を兼ね備えた寝具が提供できる。
【図面の簡単な説明】
【図１】本発明にかかる寝具素材Ａ及びウレタン構造体における負荷荷重と圧縮変形量との関係を示すグラフである。
【図２】本発明にかかる寝具素材Ｂ、及ポリエステル繊維からなる３次元構造体における負荷荷重と圧縮変形量との関係を示すグラフである。
【図３】本発明製造方法で作製された積層体の概略斜視図である。
【図４】本発明にかかる寝具素材の繊維配列状態を模式的に示す説明図である。
【図５】折り畳み機構を説明するための装置概略図（側面図）である。
【図６】噴霧機構を説明するための装置概略図（正面図）である。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a bedding material mainly composed of carbon fiber, and more particularly to a bedding material having an elastic structure mainly composed of carbon fiber as an essential component.
[0002]
[Prior art]
Carbon fiber is used in a wide range of fields in recent years because it has excellent properties of being light, tough, excellent in heat resistance and chemically stable. For example, it is used as a structural material for fishing rods and rackets in place of natural materials such as bamboo and wood. Moreover, it replaces with metal materials, such as iron, and is used as structural materials, such as a motor vehicle and an aircraft. Furthermore, they are used as reinforcing materials such as plastics and concrete materials.
[0003]
However, carbon fibers having such excellent characteristics have been used only a little as materials for living-related textile products. In particular, it has been rarely used as a material for bedding. The reason for this is that carbon fibers have a strong bending elastic force and rigidity properties compared to fibers conventionally used as bedding materials such as cotton, wool or polyester fibers. If the bedding is made up of carbon fiber instead, it will be tingling and uncomfortable to use, and a mere swell of carbon fiber will not provide adequate swelling and soft compression resilience, making it comfortable. This is because there is a problem that it cannot be made to have a feeling of sleep, and further, it is inferior in repeated usability.
[0004]
However, conventional bedding materials also have some drawbacks. For example, natural materials such as cotton, wool, and feathers lose their elasticity and become uncomfortable due to their repeated use. . In addition, natural materials are finite and flammable, so there is a problem with safety against fire. There is also a problem that resistance to insects and fungi is weak.
[0005]
In recent years, synthetic fiber cotton such as polyurethane and polyester cotton has been used as a bedding material in place of such natural fibers. However, these synthetic materials have the following drawbacks. That is, polyurethane is elastic and does not get lost even after long-term use, but it is thermally denatured when exposed to high temperatures (200 to 230 ° C.), and generates toxic decomposition gas when exposed to higher temperatures. In addition, it is difficult to say that the ventilation characteristics give a comfortable sleeping feeling that matches human sensitivity. Polyester cotton, on the other hand, has the feature of not producing flame-retardant and toxic combustion gases, but when it is repeatedly used because it is not sufficiently compressive durable when exposed to high temperatures (around 250 ° C), There is a drawback in that the elastic characteristics gradually change and the sleeping comfort becomes worse.
[0006]
On the other hand, recently, materials with flame retardant treatment applied to natural fibers have been developed, but this is not very resistant to fire, and the problem of poor repeated use is completely solved. It has not been.
[0007]
[Problems to be solved by the invention]
The present invention aims to provide a novel bedding material that can solve the above-mentioned problems in conventional bedding materials, and toughness and heat resistance of carbon fibers by using carbon fibers as the main material. In addition, it aims to provide a new bedding material that has the characteristics of excellent chemical stability and that has moderate elasticity, compression resilience, compression durability, etc. that can never be obtained with a simple aggregate of carbon fibers. Is.
[0008]
[Means for Solving the Problems]
  As a result of intensive studies in order to achieve the above object, the present inventors, as a result of appropriately binding a cotton-like aggregate of carbon fibers formed by blending crimped fibers with a specific binder, It is found that the contact points between the fibers can be suitably combined, and the rigidity (bending elasticity) of the carbon fibers is advantageously applied, and a repulsive force having soft and repeated compression resistance can be obtained.A series ofCompleted the invention.
[0009]
  That is,First 1According to the present invention, a fiber assembly including 50% by weight or more of carbon fiber with respect to the whole fiber, and 50 to 100% by weight of the whole fiber is composed of crimped fibers, and a thermosetting resin and / or heat-fusible. The bedding material is composed of a binding agent composed of fibers, and a contact point between the fibers is bound by the binding agent to form a three-dimensional network structure..
[0010]
  SecondThe invention ofAccording to the first inventionIn bedding materials, bulk density is 20-40Kg / m^Three The maximum load is 100 gf / cm² The compression hardness LC is 0.7 to 0.8, the compression recovery rate RC is 65% or more, and the compression residual strain rate is 10% or less.
[0011]
  ThirdThe invention ofThe invention according to the first or second aspect described aboveIn bedding material, surface resistance is 1 × 10⁸Ω or less and volume resistivity is 1 × 10^FiveIt is characterized by being KΩ · cm or less.
[0012]
  4thThe invention ofAccording to the first, second or third inventionIn bedding material, breathability is 30cc / cm²-It is more than sec.
[0013]
  First FiveThe invention ofAccording to the first, second, third or fourth inventionThe bedding material is characterized in that a binder containing 50% by weight or more of a thermosetting resin is contained in an amount of 10 to 40% by weight based on the entire fiber.
[0014]
  6thThe invention ofAccording to the first, second, third, fourth or fifth inventionIn the bedding material, the crimped fiber has a fiber length of 0.1 to 10 cm.
[0015]
  7thThe invention ofAccording to the first, second, third, fourth, fifth or sixth inventionIn the bedding material, the crimped fibers are made of carbon fibers.
[0016]
  8thThe invention ofAccording to the first, second, third, fourth, fifth, sixth or seventh inventionIn the bedding material, the carbon fiber is a pitch-based carbon fiber.
[0017]
  Ninth inventionIs a method for producing a bedding material comprising carbon fiber as a main constituent material, comprising 50% by weight or more of carbon fiber with respect to the whole fiber, and 50 to 100% by weight of the whole fiber is composed of crimped fibers. While spraying the thermosetting resin liquid on both sides of the fibrous fiber sheet, it is folded in a zigzag in the longitudinal direction and stacked in multiple layers, and then the thermosetting resin is heat-cured, or the cotton-like fiber sheet is heat-fusible In the case of including fibers, the bulk density is 20 to 40 kg / m by thermally fusing the heat-fusible fibers and heat-curing the thermosetting resin to bind the carbon fibers and the sheets.^Three The maximum load is 100 gf / cm² The compression hardness LC is 0.7 to 0.8, the compression recovery rate RC is 65% or more, the ratio of the 65% compression stress to the 25% compression stress is 10 or more, and the compression residual strain ratio is 10%. It is characterized by comprising a step of producing the following carbon fiber structure.
[0018]
  A tenth aspect of the invention relates to the ninth aspect of the invention.In the bedding material manufacturing method, the carbon fiber structure has a surface resistance of 1 × 10⁸Ω or less and the volume resistivity is 1 × 10^FiveIt is characterized by being KΩ · cm or less.
[0019]
  An eleventh invention according to the ninth or tenth invention described above.In the method of manufacturing a bedding material,Bedding materialBreathability is 30cc / cm²-It is more than sec.
[0020]
  A twelfth invention according to the ninth, tenth, or eleventh invention.In the bedding material manufacturing method, the binding between the carbon fibers and between the sheets is made to contain 10 to 40% by weight of a binder containing 50% by weight or more of a thermosetting resin with respect to the whole fiber. It has been made.
[0021]
  A thirteenth invention relates to the ninth, tenth, eleventh or twelfth invention.In the bedding material manufacturing method, crimped fibers having a fiber length of 0.1 to 10 cm are used.
[0022]
  A fourteenth invention is according to the ninth, tenth, eleventh, twelfth or thirteenth invention.In the method for manufacturing a bedding material, a crimped fiber made of carbon fiber is used as the crimped fiber.
[0023]
  A fifteenth aspect of the invention relates to the ninth, tenth, eleventh, twelfth, thirteenth or fourteenth aspect of the invention.In the bedding material manufacturing method, pitch-based carbon fibers are used as the carbon fibers.
[0024]
Here, each physical property value of the bedding material is defined as follows. That is, the compression hardness LC has an initial thickness of no load and a maximum load of 100 gf / cm.² The value obtained by dividing the energy required for compression to the work energy required when the load-strain curve changes linearly (in a straight line).
[0025]
The compression recovery rate RC is a maximum load of 100 gf / cm.² This is the value obtained by dividing the energy amount in the recovery process from the compressed state to returning to the no-load state by the amount of energy required for compression to 100, and multiplying this by 100.
[0026]
The compressive stress ratio is a value obtained by dividing the stress when compressed by 65% by the stress when compressed by 25%.
[0027]
Compression residual strain rate is the original thickness M₀After compressing to 50% of this and holding this state for 40 hours, unloading and 30 minutes after the thickness M₁Is measured and (1-M₁/ M₀) A value calculated from x100.
[0028]
Of the above physical property values, LC and RC are 10 cm.²A circular sample, and a compressive stress ratio was measured at 25 ° C. using a square sample of 50 mm × 50 mm.
[0029]
On the other hand, the surface resistance is the horizontal electrical resistance between the two electrodes when two electrode plates are placed in contact with the surface of a sufficiently dried sample so that the distance between the facing electrodes is 10 cm. Specifically, two electrode plates having a width of 1 cm and a length of 10 cm are formed on the vertical side of a sample of 10 cm long × 12 cm wide so that the distance between the electrodes is 10 cm.RespectivelyThe value measured at 25 ° C. when placed in contact.
[0030]
Further, the volume resistivity means an electrical resistance index given by (area of front and back surfaces orthogonal to thickness direction × electric resistance value in thickness direction) / (thickness × 2), specifically, a sample of 10 cm × 10 cm. The value calculated using the electrical resistance value of the thickness direction measured on the conditions that the electrode plate of 10 cm x 10 cm is contacted and arranged on the front and back surfaces and the electrical resistance between both electrode plates is measured at 25 ° C.
[0031]
The size of the surface resistance and the volume resistivity has a meaning as a macro index reflecting the kind of fiber composing the material, the bulk density, and the degree of contact between the fibers.
[0032]
By the way, the bedding material of the present invention having the above-described structure is formed by forming a three-dimensional network of carbon fibers in which carbon fibers (including other fibers may be included) are firmly bonded to each other with a binder. In the bedding material of the present invention having such a feature, when a person's weight is added, load pressure is diffused and absorbed throughout the bedding material through a three-dimensional network. The stress derived from the bending elastic force (elastic repulsive force) of each carbon fiber is gathered through a three-dimensional network, and one compression repulsive characteristic is formed as a whole.
[0033]
Thus, such compression repulsion characteristics have a bulk density of 20 to 40 kg / m.^Three The maximum load is 100 gf / cm² The compression hardness LC is 0.7 to 0.8, the compression recovery rate RC is 65% or more, the ratio of the 65% compression stress to the 25% compression stress is 10 or more, and the compression residual strain ratio is 10%. When it is characterized by the following, it becomes a soft and comfortable compressive elasticity (→ LC and compressive stress ratio) for humans, and it is excellent in lightness (→ bulk density) and repeated use (→ compression residual strain rate). It will be.
[0034]
Furthermore, in addition to the above-mentioned compression repulsion characteristics, the surface resistance is 1 × 10⁸Ω or less, volume resistivity is 1 × 10^FiveKΩ · cm or less, and air permeability is 30cc / cm²・ If it is longer than sec, the generation of static electricity due to friction between the person's clothing and bedding can be prevented, and moisture (sweat) emitted from the human body during sleep will not be trapped inside the bedding. Made with a divergent material.
[0035]
If the compressive stress ratio is 8 or more, there is usually no so-called feeling of flooring. However, when the weight of the person using the bedding is very large, the compressive stress ratio should be 10 or more. More preferred. Also, the surface resistance is 1 × 10⁸Ω or less, and the volume resistivity is 1 × 10^FiveIf KΩ · cm or less, electrostatic disturbance (charging, suction of dust, etc.) can be sufficiently prevented, but more preferably the surface resistance is 1 × 10.⁷Ω or less, and the volume resistivity is 1 × 10^FourIt is good to set it as Kohm * cm or less. This is because if it is less than this value, electrostatic failure can be completely prevented.
[0036]
The air permeability is 30cc / cm²・ If it is sec or more, moisture can be sufficiently released without sacrificing the heat retention of the bedding, but when taking into account the season when there is a lot of sweating, the air permeability is 50 cc / cm.²-More preferably, it is set to sec or more.
[0037]
Further, other components of the present invention will be described sequentially.
[0038]
The crimped fiber may be made of carbon fiber, or may be made of a fiber other than carbon fiber, but preferably the crimped fiber made of carbon fiber is used in combination with other fibers, More preferably, it is a crimped fiber made of only carbon fibers. This is because heat resistance other than carbon fiber is inferior to carbon fiber, and chemical stability may be inferior.
Further, if the amount of the crimped fiber relative to the whole fiber is 50% by weight or more, a three-dimensional network structure can be formed sufficiently. However, it is necessary to produce a structure having a higher bulk density and a higher compression repulsion. It is better to increase the amount of fiber. If the amount of crimped fibers is less than 50% by weight, a good three-dimensional network structure cannot be formed, resulting in insufficient compression resilience.
[0039]
Furthermore, the fiber length of the crimped fiber is preferably 0.1 to 10 cm. If the fiber length of the crimped fiber is less than 0.1 cm, the foot of the network is too short, and the bulk density becomes too low to obtain good compression resilience. On the other hand, if the fiber length exceeds 10 cm, the legs are too long, so the number of contact points between the fibers decreases, and a three-dimensional network structure that gives good compression resilience cannot be formed. The crimp rate and the number of crimps of the crimped fiber are not particularly limited, but the average crimp rate is preferably 10% or more and the average crimp number is preferably 1 / cm or more.
[0040]
The amount of carbon fiber relative to the entire fiber may be at least 50% by weight. If it is 50% by weight or more, the bending elastic properties of the carbon fibers generally dominate the compression properties of the three-dimensional network structure, and the preferred properties of the carbon fibers such as heat resistance and chemical stability become dominant. Because. However, as the proportion of the carbon fibers increases, a three-dimensional network structure having suitable characteristics of the carbon fibers can be obtained. Therefore, it is preferable to increase the amount of the carbon fibers.
[0041]
In the present invention, various carbon fibers can be used, and the type is not limited. For example, carbon fibers that are carbonized or graphitized using polyacrylonitrile, polymers such as phenol resin, rayon, etc., pitches such as petroleum pitch, coal pitch, etc. can be used. Of these, general-purpose pitch-based carbon fibers are used. It is preferable in terms of the toxicity, processability, cost, etc. of the generated gas under forced heating.
[0042]
As the binder, a thermosetting resin or a heat-fusible fiber can be used, and each may be used alone, or both may be used in combination. Specifically, the ratio of the thermosetting resin fiber in the binder is preferably 50% by weight or more, and this binder is preferably added in an amount of 10 to 40% by weight based on the whole fiber. And in order to form a stronger network, it is preferable to use 5-20% of thermosetting resin with respect to the whole fiber. If the ratio of the thermosetting resin to the whole fiber is less than 5% by weight, the number of fiber contact points that are not bound increases, and a coarse network with weak compression repulsion force can be formed. Therefore, depending on the physical properties to be applied to the bedding This range can also be selected.
[0043]
Examples of the thermosetting resin that can be used in the present invention include phenol resin, epoxy resin, vinyl ester resin, unsaturated polyester resin, thermosetting acrylic resin, polyurethane resin, and polyimide resin. Of these, phenol resin, vinyl ester resin, and polyurethane resin are preferably used from the viewpoint of heat resistance and flame retardancy, and more preferably phenol resin is used because the toxicity of generated gas under forced heating is low. It is good.
[0044]
Further, as the heat-fusible fiber, polyester fiber, nylon fiber, or the like can be used, and polyester fiber is preferably used from the viewpoint of cost.
[0045]
Further, the heat-fusible fiber as a binder is usually blended into a fiber assembly together with other fibers such as carbon fiber, but when blended, it should be mixed with other fibers sufficiently uniformly. It is good. This is because as the number of contact points (entanglement) with other fibers increases, a better three-dimensional fiber network can be formed by heat fusion.
[0046]
On the other hand, the thermosetting resin is preferably added by a method of spraying the fiber aggregate in a state dissolved in a solvent such as water or alcohol. When spraying in solution, the thermosetting resin is evenly distributed throughout the cotton-like fiber sheet.If you go aroundIn both cases, the spread thermosetting resin solution gathers in the vicinity of the contact point between the fibers due to the action of surface tension, and the contact points between the fibers tend to be efficiently and firmly bound. Therefore, a strong three-dimensional network structure can be formed. In such a three-dimensional network structure of carbon fibers, as described above, when pressure is applied from the outside, the pressure is diffused and absorbed throughout the structure through the three-dimensional network, while individual carbon The bending elastic force (elastic repulsive force) of the fibers is gathered through a three-dimensional network and generates a soft compression repulsive force as a whole. Therefore, it is possible to obtain a bedding material having a three-dimensional network structure that has compression characteristics that are comfortable to humans, that is never obtained with a simple aggregate of carbon fibers, that is excellent in sleeping comfort and reusability, and that is further breathable.
[0047]
Here, based on FIGS. 1 and 2 and Table 1, it will be described in detail that the bedding material of the present invention has soft compression characteristics that are comfortable for human beings.
[0048]
1 and 2 are graphs showing the relationship (hysteresis characteristics) between the compressive load and the amount of compressive deformation of a bedding material according to the present invention and a conventional bedding material. “Invention A” of FIG. 1 has a thickness of 40 mm and a bulk density of 30 kg / m.^Three The “urethane” is a bedding material according to the present invention having a thickness of 20 mm and a bulk density of 40 kg / m.^Three This is a urethane foam structure (conventional product). Further, “Invention B” of FIG. 2 has a thickness of 30 mm and a bulk density of 20 kg / m.^Three The “polyester” is a material having a thickness of 35 mm and a bulk density of 46 kg / m, which is obtained by mixing a polyester fiber having a low melting point into a main polyester fiber and heat-sealing it.^Three This is a polyester three-dimensional network structure (conventional product). 1 and 2 indicate a case where the compression load is gradually increased, and a left downward arrow indicates a case where the compression load is gradually decreased. In addition, the measurement is a pressure area of 10 cm.² Maximum load 100gf / cm² FIG. 1 shows three measurement results.
[0049]
In FIGS. 1 and 2, the present inventions A and B are drawn with a gentle curve in the relationship between the compression load and the amount of compressive deformation, which means that the subsidence (compression) and repulsion stress with respect to the changing load are continuous. It means to be intelligent and soft. Therefore, in the mattress using the bedding material of the present invention, a soft and stable rebound stress can be obtained, and a comfortable sleeping comfort can be obtained. On the other hand, in the urethane foam structure, the relationship between the compression load and the amount of compressive deformation is linear and abrupt, and it has strong resistance to initial compression and final compression (when the load is small). The amount of compressive deformation is extremely small. On the other hand, it changes suddenly (discontinuously) from the middle (when the load increases). Therefore, in the mattress composed of the structure having such characteristics, the feel is rugged and the sleeping comfort is not stable.
[0050]
The above is also apparent from a comparison of the compression hardness LC and the 65% / 25% compression stress ratio between the present inventions A and B and the foamed urethane structure in Table 1. That is, the compression hardness LC of the present inventions A and B (0.76 and 0.70, respectively) is significantly smaller than that of the urethane foam (> 1), and the 65% / 25% compression stress ratio (13.6, respectively). 10.7) is significantly larger than the urethane foam structure (2.5). From this comparison, it can be seen that the present inventions A and B have soft and stable rebound resilience.
[0051]
On the other hand, the comparison between the present inventions A and B and the polyester fiber three-dimensional network structure shows that the present inventions A and B have a smaller bulk density than the polyester three-dimensional structure, and can achieve an equivalent compression recovery rate RC. Small compression hardness LC (0.82 for 0.76 and 0.70) and better 65% / 25% compressive stress ratio (8.4 for the latter versus 13.6 and 10.7) Can be realized. Furthermore, the compression residual strain ratios of the present inventions A and B are 1.7 and 2.8, respectively, whereas the polyester three-dimensionalStructureIt is 15, and the present inventions A and B are remarkably superior. From this, it can be seen that the three-dimensional network structure of the present inventions A and B is tougher than the polyester three-dimensional structure. In addition, it is thought that such excellent rebound resilience characteristics of the present invention A and B reflect the bending elasticity of the carbon fiber and the firmness of the three-dimensional network structure.
[0052]
As is apparent from the above, the bedding material of the present invention is composed mainly of carbon fiber, and thus has the advantageous properties of carbon fiber such as thermal stability (disaster prevention) and weather resistance, and is also human. It has the characteristics of being excellent in soft compression repulsion, repetitive use, antistatic properties, and air permeability that are comfortable for the user. Therefore, the bedding material of the present invention is optimal as a material for bedding, in particular, a mattress or a mat.
[0053]
[Table 1]

[0054]
Next, the manufacturing method of this invention bedding material is demonstrated.
[0055]
The bedding material of the present invention can be produced by the following method. That is, the thermosetting resin solution is sprayed on both sides of the cotton-like fiber sheet as a fiber assembly containing 50% by weight or more of carbon fiber with respect to the whole fiber and 50 to 100% by weight of the whole fiber is composed of crimped fibers. However, after the sheets are folded and overlapped in the longitudinal direction, the thermosetting resin is heated and cured, whereby the contact points between the fibers are bound to form a three-dimensional network structure of carbon fibers. The fiber assembly may be blended with a heat-fusible fiber. When a heat-fusible fiber is blended, the fiber aggregate laminate is heated to a temperature higher than the melting point of the heat-fusible fiber. This makes it possible to bind heat-fusible fibers and entangled carbon fibers, etc., and when a thermosetting resin and heat-fusible fibers are used in combination, a stronger three-dimensional network is formed. it can.
[0056]
In the above, the cotton-like fiber sheet as the fiber assembly is formed by opening fibers composed of crimped carbonaceous fibers or the like by a fiber opening means such as a fiber opening machine, and by carding means such as a card machine. It can be produced by forming a web. The directionality of the fibers of the sheet-like web is not particularly limited. For example, instead of the card machine, a web prepared by a method in which fibers are deposited on a perforated cylinder that is blown by an air flow and rotated is used as the fiber direction. Such a random web may be used although it is a random one having no sex.
[0057]
The number of times the cotton fiber sheet is folded (number of layers) may be appropriately selected in two or more layers in consideration of the intended use of the structure. For example, when the bulk density of the structure is increased to increase the compression resilience, the heat retention, etc., the number of stacked layers should be increased. In addition, the thickness of the cotton-like fiber sheet as the fiber assembly is not particularly limited, and a thickness convenient for obtaining a three-dimensional structure having desired physical properties is appropriate in consideration of manufacturing workability. Should be set.
[0058]
In general, the sheet thickness is determined in consideration of the number of times the sheet is folded, the thickness of the structure after forming, the manufacturing workability, and the like. However, a structure having a large bulk density and good compression resilience and heat retention is obtained. When trying to do so, it is better to increase the number of folding using a thin sheet. This is because as the number of times of folding is increased, the thermosetting resin liquid is more easily spread over the entire fiber, so that the fiber contact points can be firmly and uniformly bonded.
[0059]
However, it cannot necessarily be said that a structure in which all the contact points between fibers are firmly bound is preferable. This is because the required compression elastic characteristics and the like differ depending on the use of the structure, and a structure having a non-binding contact point may be preferable depending on the use. In other words, it is possible to increase the number of non-binding contact points by reducing the amount of the binding agent or causing unevenness in the spraying of the binding agent. First, as a result of the sliding of the fiber at the non-binding contact point portion, a part of the load is absorbed, so that a structure having a softer initial compression repulsion characteristic is obtained. There are also applications where such compression elastic properties are desired. If there are too many non-binding contact points, the fibers are likely to move during use, and the fibers are unevenly distributed, so that repeated usability is poor. Therefore, it is preferable to balance the binding contact point and the non-binding contact point.
[0060]
The fiber assembly may be composed of crimped carbonaceous fibers alone, but other fibers (crimped non-carbonaceous fibers, non-crimped carbonaceous fibers, or non-crimped non-carbonaceous materials). Fiber). Other fibers include various non-flammable or flame retardant fibers, such as inorganic fibers (glass fibers; aluminum silicate fibers, alumina fibers, silicon carbide fibers, etc .; mineral fibers such as asbestos, rock wool, etc. Metal fibers such as stainless steel; non-crimped carbonaceous fibers made from the same material as the carbon fiber, organic fibers (vison rayon, rayon fibers such as cupra, acetate fibers, thermosetting resin fibers ( Phenolic resin fibers such as novoloid fibers), nylon fibers, flame retardant polyester fibers, polymer fibers such as aromatic polyamide fibers (such as aramid fibers), and the like. These fibers can also be used in combination of two or more.
[0061]
Furthermore, the manufacturing method of this invention bedding material is demonstrated concretely based on FIGS.
[0062]
5 and 6 are examples of a manufacturing apparatus for producing a bedding material according to the present invention, and FIG. 5 is a schematic perspective view (side view) for explaining a fiber sheet folding mechanism. 6 is a schematic perspective view (front view) for explaining a binder spraying mechanism.
The fiber sheet 1 spun by carding means such as a card machine is continuously conveyed by a conveyor 2 and a pair of belts 3 and introduced into the vertical cross wrapper 4 from the upper part of the belt 3a. In the cross wrapper 4, the fiber sheet 1 is conveyed downward from above while being sandwiched between the pair of belts 3. Further, the fiber sheet is fed from a lower part of the cross wrapper 4 onto a placing table that can be raised or lowered or a conveyor 6 that can be moved forward while swinging in the lateral direction by a swing mechanism that can swing in the thickness direction of the fiber sheet 1. The The fiber sheet 1 is folded into a plurality of layers on the conveyor 6 to form a laminated body 7.
[0063]
The swing mechanism includes a rail 5a disposed extending in the thickness direction of the fiber sheet 1, and a roller 5b that travels left and right on the rail. As the roller 5b travels, the distance between the upper belt 3a and the rail 5a varies, and an external force may act on the fiber sheet 1. Therefore, in the said apparatus, the distance is kept constant by changing the inclination-angle of the upper belt 3a with the driving | running | working of the roller 5b, and it suppresses that an external force acts on the fiber sheet 1. FIG.
[0064]
At the lower part of the swing mechanism, a spray mechanism that can reciprocate in the lateral direction of the fiber sheet 1 is attached on both sides of the fiber sheet 1, and the sheet is orthogonal to the longitudinal direction while spraying the binder on the fiber sheet 1. It can be folded in the direction you want.
[0065]
As shown in FIGS. 5 and 6, the spray mechanism includes a holding plate 11 attached to both sides on the outer side of the width of the fiber sheet 1 in the lower part of the swing mechanism, and the holding plate 11. A pair of rails 12 mounted substantially in parallel, a pulley 13 movable along each rail 12, a mounting plate 14 to which these pulleys 13 are mounted, and a hollow arm 15a mounted to the mounting plate 14 And a nozzle 15 attached to the tip of the arm 15a. In order to prevent the pulley 13 from falling off the arm 15a and to move the mounting plate 14 smoothly, two pulleys 13 are arranged on each rail 12 respectively.BeenIn addition, each pulley 13 is formed with an annular recess formed corresponding to the width of the rail 12. In addition, an elastic tube or hose 16 for supplying a solution of a binder such as a thermosetting resin is connected to the arm 15a. The tip of the arm 15a is bent or curved, and the nozzle 15 is directed in the direction of the surface of the fiber sheet 1. The nozzle 15 is a hinge that can be rotated.mechanismThus, the injection angle can be varied.
[0066]
A pair of gears 18 are rotatably attached to both sides of the plate 17 of the holding plate 11, and a chain 19 is suspended between these gears 18. One gear 18 is stretched between pulleys.beltThroughmotorDriven by rotationIt looks like.
[0067]
In order to reciprocate the nozzle 15, the mounting plate 14 is moved to the chain 19.Are connected,In the part corresponding to the width of the fiber sheet 1 in the plate 17 or the holding plate 11,pulley13 for restricting movement and detecting the arrival of pulleysStopperIs attached.This stopperThe detection signal byMotorUsed as an inversion signal to reverse the direction of rotationBe done.
[0068]
The carbon fiber laminate according to the present invention is manufactured with high productivity by the apparatus including the mechanism that operates as described above. FIG. 3 shows a laminate (folded and bound in a direction perpendicular to the longitudinal direction) manufactured by this apparatus. The edge part of this laminated body is cut | disconnected, and the bedding material concerning this invention is produced. In FIG. 4, the fiber orientation state of the bedding material concerning this invention was shown typically. The bedding material of the present invention manufactured by the above apparatus is such that the carbon fibers are bonded to each other at the contact point and the three-dimensional network structure is firmly formed.
[0069]
By the way, in the manufacturing method using the above apparatus, the type of crimp fiber, the crimp rate, the number of crimps are changed, the composition of the cotton-like sheet, the thickness of the laminate (number of laminates), the binder The bulk density is 20 to 40 kg / m by adjusting the amount added or by heating and binding the laminated body.^Three The maximum load is 100 gf / cm² A bedding material having a characteristic value of a compression hardness LC in the range of 0.7 to 0.8 and excellent in antistatic properties and air permeability can be easily obtained. That is, by changing the conditions within the range defined in the present invention, it is possible to easily make a bedding material having desired physical property values.
[0070]
For example, all the fibers of the cotton-like fiber sheet are crimped fibers made of carbon fiber, the average crimp rate is 20%, the average number of crimps is 2 times / cm, the fiber length is 75 mm, When the resin amount is 10 to 17% by weight, the bulk density is 20 to 30 kg / m.^Three The maximum load is 100 gf / cm² Compression hardness LC is 0.7 to 0.76, compression recovery rate RC is 65% or more, ratio of 25% compression stress to 65% compression stress is 10 to 13.6, compression residual strain rate Is 10% or less, and the surface resistance is 1 × 10⁸Ω or less, volume resistivity is 1 × 10^FiveKΩ · cm or less, breathability of 50cc / cm²・ It can be longer than sec.
[0071]
Since this bedding material gives soft compression characteristics (elastic repulsive force), it is suitable as a material for a mattress that gives a relatively soft sleeping comfort, for example, a mattress for children or the elderly.
[0072]
Moreover, in the above, for example, the bulk density is 30 to 40 kg / m by adjusting the amount of phenol resin to the cotton fiber sheet to 18 to 25% by weight.^Three The maximum load is 100 gf / cm² The compression hardness LC is 0.76 or more, the compression recovery rate RC is 65% or more, the ratio of 25% compression stress to 65% compression stress is 13.6 or more, and the compression residual strain ratio is 10% or more. , Surface resistance is 1 × 10⁸Ω or less, volume resistivity is 1 × 10^FiveKΩ · cm or less, breathability of 30cc / cm²・ It can be longer than sec.
[0073]
Since this material has a higher compression elasticity than the above materials, it is suitable for a hard mattress, such as a mattress for an adult boy.
[0074]
DETAILED DESCRIPTION OF THE INVENTION
The embodiment of the present invention will be specifically described by way of examples.
(Example 1)
Bulky crimped general-purpose carbon fibers spun by the vortex method (Donac Co., Ltd., Dona Carbo, average fiber diameter 13 μm, average fiber length 75 mm) are opened and metallic card machine (Ikegami Machinery Co., Ltd.) , 60-MDK) to obtain a cotton-like fiber sheet having an average thickness of 7 mm. The fiber sheet has a bulk density of 5.7 kg / m.^Three Met. Using a spray forming machine (vertical cross wrapper manufactured by Iwamoto Seisakusho Co., Ltd.), while uniformly spraying a small amount of phenolic resin solution on both sides of the fiber sheet, the fiber sheet was folded at a width of 1.2 m to obtain 30 layers. A laminate was formed. In addition, as said phenol resin liquid, 40 weight part of water-soluble phenol resins (Sumitomo Durez Co., Ltd. product, Sumilite resin) were used by diluting to 60 weight part of water.
[0075]
Next, the laminate is placed in a hot-air circulation type curing furnace, the thickness adjusting plate interval is 40 mm, and the heating temperature is 230 ° C. for about 30 minutes.Heat curingThen, the edge part was cut off and the bedding material (thickness 40mm, length 2.1m, width 1.0m) concerning this invention was produced. In addition, content of the phenol resin in a cotton-like fiber sheet was 17 weight%.
[0076]
When various physical properties of this bedding material (present invention A) were measured, the bulk density was 30 kg / m.^Three The maximum load is 100 gf / cm² The compression hardness LC is 0.76, the compression recovery ratio RC is 67%, the ratio of the 65% compression stress to the 25% compression stress is 13.6, the compression residual strain ratio is 1.7%, the surface Resistance is 2.7 × 10⁶Ω, volume resistivity is 4.9 × 10^FourKΩ · cm, breathability of 73cc / cm²・ It was sec. In addition, the measurement of air permeability was performed based on JIS L1079.
[0077]
The bedding material A is listed in Table 1 in comparison with a polyester three-dimensional network structure and a polyurethane material (conventional material), and the compression load-compression deformation curve is shown in FIG. . Table 2 shows other characteristics of this bedding material.
[0078]
When two sheets of the material A were stacked in the thickness direction to create a mattress, and the sleeping comfort was confirmed by actually sleeping, a comfortable feeling of sleeping was obtained. In addition, repeated usability was evaluated based on the residual strain after use for one month and the feeling of sleep by humans. As a result, the residual distortion rate (average value) after use for 1 month was 5% or less, and the sleeping comfort of the mattress was the same as the initial one.
[0079]
[Table 2]

[0080]
(Example 2)
70 parts by weight of crimped pitch-based general-purpose carbon fiber having an average fiber diameter of 13 μm and an average fiber length of 75 mm, and heat-fusible polyester fiber (Melty manufactured by Unitika Ltd., denier number 4, average fiber length of 38 mm) Used average thickness 6mm, density 6.7Kg / cm^ThreeThe cotton-like fiber sheet was folded, the cotton-like fiber sheet was folded into 15 layers, the spacing between the adjusting plates was 30 mm, and the phenol resin content relative to the cotton-like fiber sheet was 10% by weight. Except for the above, a bedding material B (thickness 30 mm, length 2.1 m, width 1.0 m) according to the present invention was produced in the same manner as in Example 1 above.
[0081]
This material B has a bulk density of 20 kg / m when various physical properties are measured.^Three The maximum load is 100 gf / cm² The compression hardness LC is 0.70, the compression recovery rate RC is 67%, the ratio of the 65% compression stress to the 25% compression stress is 10.7, the compression residual strain ratio is 2.8%, the surface Resistance 9.8 × 10⁶Ω, volume resistivity is 5.6 × 10^FourKΩ · cm, breathability of 94cc / cm²・ It was sec. This bedding material is shown in Table 1 and FIG. 2 (present invention B).
[0082]
A mattress with three sheets of this material B stacked in the thickness direction was prepared, and the sleeping comfort and repeated usability were confirmed by the same method as described above. As a result, good sleeping comfort and repeated usability (residual after use for one month) An average value of distortion was 5% or less). In addition, the mattress of Example 2 was more comfortable and comfortable than the mattress of Example 1.
[0083]
(Example 3)
Use of crimped pitch-based general-purpose carbon fibers with an average fiber diameter of 18 μm and an average fiber length of 75 mm, an average thickness of the cotton-like fiber sheet of 9 mm, and an increased content of the phenol resin solution (cotton Bedding material C (thickness of 30 mm, length of 2.1 m, width of the present invention) in the same manner as in Example 1, except that the weight of the fiber sheet was 25% by weight, and the thickness adjusting plate was heat-cured at 20 mm. 1.0 m).
[0084]
When various physical properties of the material C were measured, the thickness was 20 mm, and the bulk density was 40 kg / m.^Three The maximum load is 100 gf / cm² Compression hardness LC is 0.8, compression recovery ratio RC is 67%, ratio of 65% compression stress to 25% compression stress is 16.7, compression residual strain ratio is 1.3%, surface Resistance is 4.7 × 10^FiveΩ, volume resistivity is 1.9 × 10^ThreeΩ · cm, breathability is 52cc / cm²・ It was sec.
[0085]
Four sheets of this material C were overlapped in the thickness direction to form a mattress, and a feeling of sleep and repeated usability were confirmed in the same manner as described above. As a result, although it was a feeling of sleep giving stiff elasticity (strong waist), a sufficiently comfortable sleep feeling was obtained.
[0086]
【The invention's effect】
As is apparent from the above, the bedding material of the present invention has excellent characteristics such as toughness, heat resistance, chemical stability, nonflammability, and nontoxicity inherent to carbon fibers, and carbon. It has properties that can never be obtained with a simple assembly of fibers, that is, moderate elasticity, compression resilience, compression durability, and breathability that are gentle to humans. Therefore, when a bedding such as a mattress is produced using the bedding material of the present invention, it is possible to provide a bedding that is excellent in sleeping comfort, repetitive usability, and heat retaining properties and has disaster prevention properties.
[Brief description of the drawings]
FIG. 1 is a graph showing the relationship between the load applied and the amount of compressive deformation in a bedding material A and a urethane structure according to the present invention.
FIG. 2 is a graph showing the relationship between the load applied and the amount of compressive deformation in a three-dimensional structure made of bedding material B and polyester fibers according to the present invention.
FIG. 3 is a schematic perspective view of a laminate produced by the production method of the present invention.
FIG. 4 is an explanatory view schematically showing a fiber arrangement state of a bedding material according to the present invention.
FIG. 5 is an apparatus schematic diagram (side view) for explaining a folding mechanism;
FIG. 6 is a schematic view (front view) of an apparatus for explaining a spray mechanism.

Claims (8)

With respect to the total fiber comprises 50 wt% or more of carbon fibers, 50 to 100 wt% of the total fibers are composed of a fiber aggregate, which is a composition in crimped fibers, and thermosetting resins or Ranaru binder , The contact point between the fibers is bound by the binder ,
Bulk density is 20-40Kg / m ³ The maximum load is 100 gf / cm ² The compression hardness LC is 0.7 to 0.8, the compression recovery rate RC is 65% or more, and the compression residual strain rate is 10% or less,
A bedding material comprising a three-dimensional network structure having a surface resistance of 1 × 10 ⁸ Ω or less and a volume resistivity of 1 × 10 ⁵ KΩ · cm or less . The crimped fibers, fiber length of 0.1 to 10, an average crimped of 10% or more, average crimped number is carbon fiber is one / cm or more, bedding material of claim 1, wherein. The bedding material according to claim 2, wherein the crimped fibers are pitch-based carbon fibers . The bedding material according to claim ² , wherein the air permeability of the bedding material is 30 cc / cm ² · sec or more. A method for producing a bedding material comprising carbon fiber as a main constituent material, comprising 50% by weight or more of carbon fiber with respect to the whole fiber, and 50 to 100% by weight of the whole fiber composed of crimped fibers While spraying the thermosetting resin liquid on both sides of the sheet, it is folded in a zigzag in the longitudinal direction and superimposed on multiple layers, and then the laminate is sandwiched between thickness adjusting plates and compressed to a preset compression ratio. A bulk density of 20 to 40 kg / m ³ is obtained by heating and curing the curable resin to bind and connect the intersections of the fibers. The maximum load is 100 gf / cm ² When the compression hardness LC is 0.7 to 0.8, the compression recovery rate RC is 65% or more, the compression residual strain rate is 10% or less, and the surface resistance is 1 × 10 ⁸ Ω or less, A method for manufacturing a bedding material, which manufactures a bedding material comprising a three-dimensional network structure whose volume resistivity is regulated to 1 × 10 ⁵ KΩ · cm or less. The bedding material according to claim 5 , wherein carbon fibers having a fiber length of 0.1 to 10 cm, an average crimp rate of 10% or more, and an average number of crimps of 1 / cm or more are used as the crimped fibers. Way . The method for manufacturing a bedding material according to claim 6 , wherein pitch-based carbon fibers are used as the crimped fibers. The method for manufacturing a bedding material according to claim 6 , wherein the air permeability of the bedding material is regulated to 30 cc / cm ² · sec or more.

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