JP5272953B2 - Laminated cushion structure - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a laminated structure excellent in heat resistance, durability and cushion properties, hard to become stuffy and easy to recycle. <P>SOLUTION: The laminated cushion structure is constituted by laminating a cushion material including fiber aggregate on a surface layer and laminating a woven knitted material, which is partially compounded with monofilaments including thermoplastic resin, to a back layer. <P>COPYRIGHT: (C)2011,JPO&amp;INPIT

Description

  INDUSTRIAL APPLICABILITY The present invention is used for various seats such as vehicle seats, bedding, chair upholstery, etc. that have good cushioning properties, are not easily stuffy, have excellent durability, and are easily recycled.

  Conventionally, urethane foam, polyester-cotton-filled cotton, resin-cotton bonded with polyester fiber, or solid cotton are used as cushion materials for furniture such as chairs and beds, and transportation equipment such as automobiles and trains. In order to obtain comfortable performance as a cushion, many are devised such as composites of different cushioning properties or a double structure at the time of cushion molding. All of these cushion materials have a problem that they are bulky or cannot obtain a cushion with a small volume. In addition, the air permeability strongly affects seating comfort, but conventional cushioning materials such as urethane foam, polyester fiber-filled cotton, and resin cotton or solid cotton bonded with polyester fiber can increase the air permeability. There was a limit.

  In addition, foam-crosslinked urethane has good durability as a cushioning material. However, it has poor moisture and water permeability and heat storage, so it is easily stuffy, and it is not thermoplastic. The damage of the gas is large, and the toxic gas removal is expensive. 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. In addition, since the fibers are not fixed in thermoplastic polyester adhesive-filled cotton, the form of use collapses, the fibers move, and there is a problem of reduced sublimation and elasticity due to crimping. become.

  Patent Documents 1 to 3 include examples of resin cotton obtained by bonding polyester fibers with an adhesive, for example, those using a rubber system for the adhesive, and Patent Document 4 includes those using a crosslinkable urethane. These cushion materials are inferior in durability and have problems such as being unable to be recycled because they are not thermoplastic and not having a single composition, and there are problems such as complexity of workability and pollution of chemicals used during production. .

  Polyester hard cotton, for example, Patent Documents 5 to 6 are used. However, since an amorphous polymer in which the fiber component of the thermal bonding fiber used is brittle is used, the bonded portion is brittle, and the bonded portion is easily broken during use. There is a problem inferior in durability, such as a decrease in form and elasticity. As an improved method, Patent Document 7 proposes a method of entanglement, but there is a problem that the brittleness of the bonded portion is not solved and the elasticity is greatly lowered. 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, Patent Document 8 proposes a heat-bonded fiber using a polyester elastomer that softens and recovers even when the bonded portion is deformed, and Patent Document 9 proposes a cushioning material using the fiber. In order to lower the melting point, the polyester elastomer of the adhesive component used in this fiber structure contains 50 to 80 mol% of terephthalic acid in the acid component of the hard segment, and the content of polyalkylene glycol as the soft segment is 30 to 30%. 50% by weight is contained, and the other acid component composition contains isophthalic acid and the like in the same manner as the fiber described in Patent Document 10, the amorphous property is increased, the melting point is 180 ° C. or less, and the heat is low as the melt viscosity. Although the formation of the adhesive part is improved to form an amoeba-like adhesive part, there is a problem that the heat resistance and compression resistance is lowered due to easy plastic deformation.

  Patent Document 11 discloses a thermoplastic olefin network used for civil engineering work. However, unlike a cushion composed of thin fibers, the surface is uneven and the touch is poor, and since the material is olefin, the heat resistance durability is remarkably inferior and cannot be used as a cushion material. In addition, a net-like structure using vinyl chloride has been proposed for entrance mats and the like, but it is unsuitable for cushioning materials because it is easily plastically deformed and toxic hydrogen halide is generated during combustion. .

  There is a laminated structure in which a woven or knitted fabric in which a monofilament made of a thermoplastic resin is arranged in part and a cushion material made of a porous body or a fiber assembly are laminated, for example, Patent Document 12, but a monofilament made of a thermoplastic resin The knitted and knitted fabrics that are partly placed are stretched and fixed, and are highly elastic, and are placed on the surface layer, so most of the human load on the laminated structure is not the cushion material of the back layer. There is a problem that the woven or knitted fabric with the surface layer adjusted and fixed supports, and the cushioning property is inferior to the cushion material of urethane foam used as a conventional cushion material.

JP 60-11352 A JP 61-141388 A Japanese Patent Laid-Open No. 61-141391 JP-A 61-137732 JP 58-136828 A JP-A-3-249213 JP-A-4-245965 JP-A-4-240219 International Publication No. 91/19032 Pamphlet Japanese Patent Publication No. 60-1404 JP 47-44839 A JP 2003-191362 A

  An object of the present invention is to solve the above problems, and to provide a laminated structure that is excellent in heat resistance, durability, and cushioning properties, is not easily stuffy, and can be easily recycled.

Means for solving the above-described problems, that is, the present invention comprises the following constitution.
1. A laminated cushion structure in which a cushion material made of a fiber assembly is laminated on a surface layer, and a woven or knitted fabric made of a monofilament made of a thermoplastic elastic resin is partially laminated on a back layer.
2. 2. The laminated cushion structure according to 1 above, wherein the cushion material made of the fiber assembly is made of a thermoplastic elastic resin.
3. 3. The laminated cushion structure according to 1 or 2 above, wherein the cushion material comprising a fiber assembly has a structure in which at least two layers are laminated.
4). 4. The laminated cushion structure according to 3 above, wherein the hardness of each layer of the cushion material made of a fiber assembly having a structure in which at least two layers are laminated gradually decreases as it goes to the surface layer side.

  The laminated cushion structure of the present invention is a cushion body that is excellent in overall comfort and has both thermal comfort and cushioning properties, without using energy such as electric power, and is used for various seats. be able to.

It is an example of the sinking and rebounding behavior of the bottom of the weight obtained by the weight drop test. The result of evaluation of stuffiness using a sweating mannequin indicates the transition of the absolute humidity in the garment of the sweating mannequin while sitting.

  In the present invention, it is necessary to laminate a woven or knitted fabric in which a monofilament made of a thermoplastic elastic resin is partially arranged on a cushion material made of a fiber assembly. In the conventional cushioning material consisting only of fiber aggregates, and the structure in which the skin material is laminated on them, the seat and back atmosphere becomes hot and humid, especially when sitting for a long time. Gives a feeling of stuffiness. On the other hand, by laminating a woven or knitted fabric in which monofilaments made of a thermoplastic elastic resin are partially arranged, a minute space for releasing heat and moisture is generated, and the unpleasant stuffiness can be remarkably improved.

  The woven or knitted fabric used in the present invention needs to use a monofilament in part. This is because by using a monofilament, a fine space for releasing heat and moisture can be given to the woven or knitted fabric. Further, when a monofilament is used, the frictional resistance is reduced and the durability is excellent. The preferred fineness of the monofilament is 100 to 6000 dtex. If it is less than 100 dtex, there is little resistance to friction, and sufficient durability may not be obtained. If it exceeds 6000 dtex, handling in the production of woven and knitted fabrics becomes difficult. A more preferable range of fineness is 300 dtex to 3000 dtex.

  The structure of the woven or knitted fabric used in the present invention can be selected from various knitted and knitted structures such as warp knitting (single raschel, double russell, tricot), weft knitting, plain weave, twill weave, satin weave, leash weave, etc. It is not limited.

  The woven or knitted fabric used in the present invention need not use only monofilaments, and may be combined with other multifilament yarns such as polyester yarns. For example, as the polyester yarn to be used, an unprocessed one, a loop processed yarn or a false twisted yarn, or a mixture of both may be used. The multifilament yarn may be an original yarn or a pre-dyed yarn. The use of polyester yarn is preferable because all the yarns constituting the woven or knitted fabric are polyester-based and can be easily recycled.

  If it is necessary to impart flame retardancy and light resistance, the woven or knitted fabric used in the present invention uses a yarn containing a flame retardant and a light resistant agent, or imparts a flame retardant and a light resistant agent to the woven or knitted fabric. be able to. As for the elastic yarn, a method of adding melamine cyanurate or imparting a phosphorus compound as a flame retardant to be mixed with a raw material resin is known, but is not particularly limited thereto. In addition, a light fastness formulation by adding carbon black or the like can be used as the light fastener, but it is not particularly limited thereto.

  If it is necessary to impart a color to the monofilament used in the woven or knitted fabric used in the present invention, a dye or a pigment may be contained. As the pigment, a method of adding an inorganic pigment such as a phthalocyanine-based organic pigment, carbon black, titanium oxide, or zinc oxide is known, but is not particularly limited thereto. By using the original yarn containing the pigment, the labor of dyeing can be saved.

  As a raw material of the monofilament used for the woven or knitted fabric used in the present invention, it is necessary to use a thermoplastic elastic resin. This is because the elastic resilience required as a cushion material can be obtained by using the thermoplastic elastic resin.

  The thermoplastic elastic resin in the present invention can be arbitrarily selected from polyester elastomers, polyamide elastomers, polyurethane elastomers, polyolefin elastomers, and the like. By using a thermoplastic elastic resin, since it can be regenerated by remelting, there is an effect that recycling becomes easy. Especially among thermoplastic elastic resins, if it is a thermoplastic polyester block copolymer, even if other polyester yarns are arranged on a part of the woven or knitted fabric, it is a material of the same series, so it is necessary to separate it at the time of disposal. This is preferable.

  Examples of the polyester elastomer used in the present invention include a polyester ether block copolymer having a thermoplastic segment as a hard segment and a polyalkylene diol as a soft segment, or a polyester ether block copolymer having an aliphatic polyester as a soft segment. It can be illustrated. More specific examples of polyester ether block copolymers include aromatic dicarboxylic acids such as terephthalic acid, isophthalic acid, naphthalene 2,6 dicarboxylic acid, naphthalene 2,7 dicarboxylic acid, diphenyl 4,4 'dicarboxylic acid, -At least one dicarboxylic acid selected from alicyclic dicarboxylic acids such as 4-cyclohexanedicarboxylic acid, aliphatic dicarboxylic acids such as oxalic acid, adipic acid, sebacic acid, dimer acid, or ester-forming derivatives thereof Aliphatic diols such as 1,4 butanediol, ethylene glycol, tremethylene glycol, tetremethylene glycol, pentamethylene glycol, hexamethylene glycol and the like, and alicyclics such as 1,1 cyclohexanedimethanol and 1,4 cyclooxane dimethanol Diol or this At least one diol component selected from these ester-forming derivatives and the like, and polyalkylene diols such as polyethylene glycol, polypropylene glycol, polytetramethylene glycol, ethylene oxide-propylene oxide copolymer having an average molecular weight of about 300 to 5,000 Among these, a ternary block copolymer composed of at least one kind. The polyester ester block copolymer is a ternary block copolymer composed of at least one of the dicarboxylic acid, diol, and polyester diol such as polylactone having an average molecular weight of about 300 to 3000. 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, polyalkylenediol Is particularly preferably a polytetramethylene glycol ternary block copolymer or a polyester diol polylactone ternary block copolymer. As a special example, a polysiloxane-based soft segment can be used. Moreover, the said polyester elastomer can be used individually or in mixture of 2 or more types. Furthermore, a polyester elastomer blended with a non-elastomeric component or a copolymerized one can be used in the present invention.

  As the polyamide elastomer used in the present invention, 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 A block copolymer composed of at least one of polyalkylenediols such as polyethylene glycol, polypropylene glycol, polytetramethylene glycol, ethylene oxide-propylene oxide copolymer of 300 to 5000 is used alone or in combination of two or more. May be. Further, blended or copolymerized non-elastomeric components can be used in the present invention.

  The polyurethane elastomer used in the present invention includes (A) a polyether 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) The polyurethane elastomer which extended the chain | strand by the polyamine which has (C) diamine as a main component can be illustrated as a typical example to the prepolymer which the polyisocyanate which has organic diisocyanate as the main component reacted with the both terminal is an isocyanate group. The polyesters and polyethers of (A) include polybutylene adipate copolymer polyester, polyethylene glycol, polypropylene glycol, polytetramethylene glycol, ethylene oxide-propylene oxide copolymer having an average molecular weight of about 1000 to 6000, preferably 1300 to 5000. A polyalkylene diol such as a coalescence is preferable, and as the polyisocyanate of (B), a conventionally known polyisocyanate can be used, but a sosocyanate mainly composed of diphenylmethane / 4'diisocyanate is used, and a conventionally known polyisocyanate is used if necessary. A small amount of triisocyanate or the like may be used. 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.

The polyolefin-based elastomer used in the present invention is preferably a low-density polyethylene resin, particularly preferably an ethylene / α-olefin copolymer resin composed of ethylene and an α-olefin having 3 or more carbon atoms. The ethylene / α-olefin copolymer of the present invention is preferably a copolymer described in JP-A-6-293813, and is obtained by copolymerizing ethylene and an α-olefin having 3 or more carbon atoms. It is. Here, examples of the α-olefin having 3 or more carbon atoms include propylene, butene-1, pentene-1, hexene-1, 4-methyl-1-pentene, heptene-1, octene-1, nonene-1, and decene. -1, undecene-1, dodecene-1, tridecene-1, tetradecene-1, pentadecene-1, hexadecene-1, heptadecene-1, octadecene-1, nonadecene-1, eicosene-1, etc., preferably butene -1, pentene-1, hexene-1, 4-methyl-1-pentene, heptene-1, octene-1, nonene-1, decene-1, undecene-1, dodecene-1, tridecene-1, tetradecene-1 , Pentadecene-1, hexadecene-1, heptadecene-1, octadecene-1, nonadecene-1, and eicosene-1. Two or more of these can also be used, and these α-olefins are usually copolymerized in an amount of 1 to 40% by weight.
This copolymer can be obtained by copolymerizing ethylene and an α-olefin using a catalyst system having a specific metallocene compound and an organometallic compound as basic components.

  As a cushioning material composed of a fiber assembly, if it is made of the above thermoplastic elastic resin that can be used as a raw material for monofilaments used in woven and knitted fabrics, the elastic recovery as a laminated structure is improved and the seating comfort is improved. It is preferable because it is excellent in durability when used for a long time or repeatedly.

  Examples of the cushioning material comprising the fiber assembly in the present invention include a three-dimensional random loop bonded structure, hard cotton, nonwoven fabric, and three-dimensional knitted fabric, but are not particularly limited thereto, This is an original random loop joint structure.

  The three-dimensional random loop joint structure used in the present invention is formed by twisting a continuous linear body of 300 to 10000 dtex made of a thermoplastic elastic resin to form a random loop, and contacting each loop in a melted state. It is a three-dimensional random loop bonded structure formed by fusing most of the part, and preferably has a 25% hardness of 5 to 500 N and a residual strain at 70 ° C. of 35% or less.

  If the fineness of the continuous linear body is less than 300 dtex, the strength is lowered and the repulsive force is lowered, which is not preferable. If it exceeds 10000 dtex, the number of linear members is reduced and the compression characteristics are deteriorated, so that the use portion may be limited. A more preferable fineness of the continuous linear body of the present invention is 400 to 10000 dtex, and more preferably 500 to 50000 dtex, from which a repulsive force can be obtained. The cross-sectional shape is not particularly limited, but when a continuous linear body having a fine fineness is used, a modified cross-section or a hollow cross-section is preferable because the repulsive force is improved.

  The 25% hardness of the three-dimensional random loop bonded structure of the present invention is preferably 5 to 700N. If the 25% hardness is less than 5N, the repulsive force is lost, so it is not suitable for the cushioning material. If the 25% hardness exceeds 700N, the resilience becomes strong and the sitting comfort becomes unsuitable. It will be something. The more preferred hardness of the present invention is a 25% hardness of 20 to 500N, more preferably 20 to 400N.

  In order to obtain sufficient durability as a cushion material made of a fiber structure, it is preferable that the residual strain at 70 ° C. of the above-described three-dimensional random loop joint structure is 35% or less.

It is a preferred embodiment that the cushion material made of the fiber assembly has a structure in which at least two layers are laminated. This is because it is easy to adjust the cushioning property of the cushioning material by changing the cushioning property of each layer of the cushioning material by using a structure in which at least two layers are laminated.
It is a more preferred embodiment that the hardness of each layer of the cushion material made of a fiber assembly having a structure in which at least two layers are laminated is gradually lowered as it goes to the surface layer side. This is because by gradually lowering the hardness as it goes to the surface layer side, the soft layer becomes the upper layer and the initial touch feeling can be improved, and the hard layer becomes the lower layer, and the load applied to the cushion material This is because a cushioning material having more favorable cushioning properties can be obtained.
In addition, as another method of adjusting the cushioning property of the cushion material, the hardness gradually increases in the thickness direction by changing the fineness of the continuous filaments to be formed in the thickness direction during the production of the cushion material made of the fiber assembly. There is also a method of obtaining a cushioning material whose hardness gradually decreases as it goes to the surface layer side of the cushioning material by using a three-dimensional random loop joint structure having a transition structure.

  In the present invention, it is preferable that a woven or knitted fabric formed by partially arranging a monofilament made of a thermoplastic elastic resin is used as a back layer and a cushion material made of a fiber assembly is laminated and the cushion layer is used as a surface layer. The surface layer referred to here means the side that touches the human body when sitting in the laminated structure, and the back layer means the side that does not directly touch the human body.

The laminated structure of the present invention preferably has an air permeability of 30 to 700 cc / cm ² · sec when vented at a pressure of 125 Pa. As a cushioning material, if the air permeability is less than 30 cc / cm ² · sec, it tends to cause stuffiness when seated for a long time, and once it gets wet, it does not dry easily. Arise. On the other hand, if the air permeability exceeds 700 cc / cm ² · sec, air flow tends to occur frequently, which causes a problem in terms of heat retention. A more preferable range of the air permeability is 150 to 400 cc / cm ² · sec.

  The laminated structure according to the present invention can be applied as a seat sheet for railway vehicles, automobiles, ships, general households, offices, etc., but is used for bedding, pillows, etc. used in general households, accommodation facilities, hospitals, railway vehicles, ships, etc. Is also useful. Of course, it can also be used in combination with other materials that should meet the required performance in relation to the application, and can be processed and given a shape within a range that does not degrade the performance of the present invention. Furthermore, functions such as flame retardancy, insecticidal and antibacterial properties, heat resistance, water and oil repellency, coloring, and aromaticity can be imparted by adding chemicals at any stage of commercialization.

  The present invention will be described below based on examples. The present invention is not particularly limited by the examples. In addition, the measuring method used in the Example is as follows.

(Fine diameter of 3D random loop joint)
A sample is cut into a size of 20 cm × 20 cm, and a linear body is collected from 10 places. The specific gravity at 40 ° C. of the linear bodies collected at 10 locations is measured using a density gradient tube. Furthermore, the cross-sectional area of the linear body collected at the 10 locations is determined from a photograph magnified 30 times with a microscope, and the volume of the linear body having a length of 10,000 m is determined from the photograph. The value obtained by multiplying the obtained specific gravity and volume is defined as the fineness (weight of linear body 10,000 m). (Average value of n = 10)

(Thickness and apparent density of 3D random loop joint)
The sample is cut into a size of 15 cm × 15 cm, left unloaded for 24 hours, then measured at four heights, and the average value is taken as the sample thickness. Further, the volume is obtained from the sample thickness, and is represented by a value obtained by dividing the weight of the sample by the volume. (Each average value of n = 4)

(Hardness of 3D random loop joint)
Using Tensilon with a 50 mm diameter pressure plate at a compression speed of 50 mm / min, pre-compressed once to 75% of the initial thickness, left for 3 minutes, and then compressed again to 75% at the same compression speed The load when compressed by 25% with respect to the initial thickness of was measured.

(Restrained strain at 3O 0 C of three-dimensional random loop joint)
The sample was cut into a size of 15 cm × 15 cm, compressed to 50%, left to stand in dry heat at 70 ° C. for 22 hours and then cooled to obtain the thickness (b) after standing for 1 day after removing the compression strain. ) From the following formula, that is, (ab) / a × 100: unit% (average value of n = 3)

(Evaluation of stuffiness by sweating mannequin)
The sweating mannequin was placed on a model chair installed in a constant temperature and humidity chamber controlled at 50 ° C. and 20% RH, and then the temperature and humidity control of the constant temperature and humidity chamber was changed to 18 ° C. and 50% RH, and the sitting was continued. . The absolute humidity in the garment was measured for 30 minutes while sitting.

(Evaluation of stuffiness by monitor test)
The model chair was seated on a monitor of 10 people, and the stuffiness was judged. The feeling of stuffiness after 1 hour in a sitting posture in a room at 28 ° C. and 75% RH was determined as follows, and the average was determined as an overall determination.
[Evaluation] Comfortable without feeling stuffy → ○, Feeling stuffy → ×, Neither → △

(Evaluation of cushioning by weight drop test)
A steel weight with a weight of 4.4 kg and a bottom area of 50 cm ² is dropped on the model chair from a height of 25 cm from the seating surface, and the sinking and rebounding behavior of the bottom of the weight is measured at high speed. Measured at 500 fps with a camera. As an evaluation index of cushioning properties, the damping behavior shown in FIG. 1 has the maximum sinking depth, which is the depth when the bottom surface of the weight sinks, and the seat surface and the bottom surface of the weight when the weight bounces for the second time. The second repulsive energy, which is the area of the part formed by the rebound behavior of, was used. It was determined that the smaller the maximum sinking depth and the second rebound energy, the better the cushioning property.

(Evaluation of cushioning properties by monitor test)
The model chair was seated on 10 monitors and the cushioning property was judged. The feeling of stuffiness after 1 hour in a sitting posture in a room at 28 ° C. and 75% RH was determined as follows, and the average was determined as an overall determination.
[Evaluation] The buttocks do not hurt → ○, the buttocks hurts → ×, neither is → △

[Example 1]
(Creation of woven or knitted fabric)
As wefts, a polyether ester elastomer having a melting point of 222 ° C. as a core component and a polyether ester elastomer having a melting point of 182 ° C. as a sheath component, 20 elastic monofilament yarns of 2080 dtex having a weight ratio of core: sheath = 80: 20 are used. A plain weave fabric was prepared with a weaving density of 28 / inch (2.54 cm) of 830 dtex polyester multifilament yarns / inch (2.54 cm). A dry heat treatment was performed at 200 ° C. for 1 minute in order to find the intersection of the warp and weft of this fabric. It was confirmed that the low-melting-point polyetherester elastomer, which is a monofilament sheath component, was adhered and solidified at the intersection of the warp and weft of the fabric after the heat treatment.
(Creation of first layer 3D random loop joint)
Polyether ester elastomer with a melting point of 200 ° C is melted and discharged at 240 ° C from a nozzle (nozzle hole diameter 1mm, single hole discharge rate 1.4g / min · hole), and cooled so that the water surface is 250mm below the nozzle surface. Distribute water, place a stainless steel endless net with a width of 60 cm in parallel at intervals of 2 cm and place a pair of take-up conveyors on the water surface so that they are partly exposed. However, it was drawn into solid cooling water at room temperature at a rate of 1.2 m per minute, solidified, and cut into a predetermined size to obtain a three-dimensional random loop joined body. Thereafter, the obtained three-dimensional random loop bonded structure was heated at 105 ° C. for 15 minutes to perform pseudo-crystallization treatment. The obtained three-dimensional random loop joined body had a fineness of 2000 dtex, an apparent density of 55 kg / m ³ , a thickness of 20 mm, a 25% hardness of 20 N, and a residual strain at 70 ° C. of 11.3%.
(Creation of second layer 3D random loop joint)
Polyether ester elastomer with a melting point of 200 ° C is melted and discharged at 240 ° C from a nozzle (nozzle hole diameter 1mm, single hole discharge rate 1.4g / min · hole), and cooled so that the water surface is 250mm below the nozzle surface. Distribute water, place a stainless steel endless net with a width of 60 cm in parallel at intervals of 2 cm and place a pair of take-up conveyors on the water surface so that they are partly exposed. Then, it was drawn into solid cooling water at room temperature at a speed of 1.1 m / min, solidified, and cut into a predetermined size to obtain a three-dimensional random loop joined body. Thereafter, the obtained three-dimensional random loop bonded structure was heated at 105 ° C. for 15 minutes to perform pseudo-crystallization treatment. The obtained three-dimensional random loop joined body had a fineness of 2000 dtex, an apparent density of 60 kg / m ³ , a thickness of 20 mm, a 25% hardness of 50 N, and a residual strain at 70 ° C. of 11.9%.
(Create model chairs for laminated structures and evaluation)
The fabric prepared as described above was stretched and fixed to a bench sheet type metal frame having a seating surface of 35 cm × 45 cm. Also, the second layer three-dimensional random loop joined body having a thickness of 20 mm and 25% hardness of 50 N prepared as described above is loaded on the fabric stretched and fixed on the frame, and further, 25% hardness is provided thereon. A 20N first layer three-dimensional random loop joined body was laminated. In this way, a model chair was created in which a laminated cushion structure having a fabric as a back layer and a three-dimensional random loop joined body as a surface layer was incorporated into a seat surface.
The stuffiness and cushioning properties of the model chair made of the laminated cushion structure thus created were evaluated.

[Example 2]
(Creation of woven or knitted fabric)
As wefts, a polyether ester elastomer having a melting point of 222 ° C. as a core component and a polyether ester elastomer having a melting point of 182 ° C. as a sheath component, 20 elastic monofilament yarns of 2080 dtex having a weight ratio of core: sheath = 80: 20 are used. A plain weave fabric was prepared with a weaving density of 28 / inch (2.54 cm) of 830 dtex polyester multifilament yarns / inch (2.54 cm). A dry heat treatment was performed at 200 ° C. for 1 minute in order to find the intersection of the warp and weft of this fabric. It was confirmed that the low-melting-point polyetherester elastomer, which is a monofilament sheath component, was adhered and solidified at the intersection of the warp and weft of the fabric after the heat treatment.
(Creation of first layer 3D random loop joint)
Polyether ester elastomer with a melting point of 200 ° C is melted and discharged at 240 ° C from a nozzle (nozzle hole diameter 1mm, single hole discharge rate 1.4g / min · hole), and cooled so that the water surface is 250mm below the nozzle surface. Distribute water, place a stainless steel endless net with a width of 60 cm in parallel at intervals of 2 cm and place a pair of take-up conveyors on the water surface so that they are partly exposed. Then, it was drawn into solid cooling water at room temperature at a speed of 1.1 m / min, solidified, and cut into a predetermined size to obtain a three-dimensional random loop joined body. Thereafter, the obtained three-dimensional random loop bonded structure was heated at 105 ° C. for 15 minutes to perform pseudo-crystallization treatment. The obtained three-dimensional random loop joined body had a fineness of 2000 dtex, an apparent density of 60 kg / m ³ , a thickness of 20 mm, a 25% hardness of 50 N, and a residual strain at 70 ° C. of 11.9%.
(Creation of second layer 3D random loop joint)
Polyether ester elastomer with a melting point of 200 ° C is melted and discharged at 240 ° C from a nozzle (nozzle hole diameter 1mm, single hole discharge rate 1.4g / min · hole), and cooled so that the water surface is 250mm below the nozzle surface. Distribute water, place a stainless steel endless net with a width of 60 cm in parallel at intervals of 2 cm and place a pair of take-up conveyors on the water surface so that they are partly exposed. However, it was drawn into solid cooling water at room temperature at a rate of 1.2 m per minute, solidified, and cut into a predetermined size to obtain a three-dimensional random loop joined body. Thereafter, the obtained three-dimensional random loop bonded structure was heated at 105 ° C. for 15 minutes to perform pseudo-crystallization treatment. The obtained three-dimensional random loop joined body had a fineness of 2000 dtex, an apparent density of 55 kg / m ³ , a thickness of 20 mm, a 25% hardness of 20 N, and a residual strain at 70 ° C. of 11.3%.
(Create model chairs for laminated structures and evaluation)
The fabric prepared as described above was stretched and fixed to a bench sheet type metal frame having a seating surface of 35 cm × 45 cm. In addition, the second layer three-dimensional random loop joined body having a thickness of 20 mm and a hardness of 25% 20N prepared as described above is loaded on the fabric stretched and fixed to the frame, and further a hardness of 25% is further formed thereon. A 50N first layer three-dimensional random loop joined body was laminated. In this way, a model chair was created in which a laminated cushion structure having a fabric as a back layer and a three-dimensional random loop joined body as a surface layer was incorporated into a seat surface.
The stuffiness and cushioning properties of the model chair made of the laminated cushion structure thus created were evaluated.

[Example 3]
(Creation of woven or knitted fabric)
As wefts, a polyether ester elastomer having a melting point of 222 ° C. as a core component and a polyether ester elastomer having a melting point of 182 ° C. as a sheath component, 20 elastic monofilament yarns of 2080 dtex having a weight ratio of core: sheath = 80: 20 are used. A plain weave fabric was prepared with a weaving density of 28 / inch (2.54 cm) of 830 dtex polyester multifilament yarns / inch (2.54 cm). A dry heat treatment was performed at 200 ° C. for 1 minute in order to find the intersection of the warp and weft of this fabric. It was confirmed that the low-melting-point polyetherester elastomer, which is a monofilament sheath component, was adhered and solidified at the intersection of the warp and weft of the fabric after the heat treatment.
(Creation of three-dimensional random loop assembly)
Polyether ester elastomer with a melting point of 200 ° C is melted and discharged at 240 ° C from a nozzle (nozzle hole diameter 1mm, single hole discharge rate 1.4g / min · hole), and cooled so that the water surface is 250mm below the nozzle surface. Distribute water and place a stainless steel endless net with a width of 60 cm in parallel with a distance of 4 cm between the pair of take-up conveyors so that they partly come out on the water surface. However, it was drawn into solid cooling water at room temperature at a rate of 1.2 m per minute, solidified, and cut into a predetermined size to obtain a three-dimensional random loop joined body. Thereafter, the obtained three-dimensional random loop bonded structure was heated at 105 ° C. for 15 minutes to perform pseudo-crystallization treatment. The obtained three-dimensional random loop joined body had a fineness of 2000 dtex, an apparent density of 55 kg / m ³ , a thickness of 40 mm, a 25% hardness of 20 N, and a residual strain at 70 ° C. of 11.4%.
(Create model chairs for laminated structures and evaluation)
The fabric prepared as described above was stretched and fixed to a bench sheet type metal frame having a seating surface of 35 cm × 45 cm. A three-dimensional random loop joined body having a thickness of 40 mm and a 25% hardness of 20N prepared as described above was loaded on the fabric stretched and fixed to the frame. In this way, a model chair was created in which a laminated cushion structure having a fabric as a back layer and a three-dimensional random loop joined body as a surface layer was incorporated into a seat surface.
The stuffiness and cushioning properties of the model chair made of the laminated cushion structure thus created were evaluated.

[Example 4]
(Creation of woven or knitted fabric)
As wefts, a polyether ester elastomer having a melting point of 222 ° C. as a core component and a polyether ester elastomer having a melting point of 182 ° C. as a sheath component, 20 elastic monofilament yarns of 2080 dtex having a weight ratio of core: sheath = 80: 20 are used. A plain weave fabric was prepared with a weaving density of 28 / inch (2.54 cm) of 830 dtex polyester multifilament yarns / inch (2.54 cm). A dry heat treatment was performed at 200 ° C. for 1 minute in order to find the intersection of the warp and weft of this fabric. It was confirmed that the low-melting-point polyetherester elastomer, which is a monofilament sheath component, was adhered and solidified at the intersection of the warp and weft of the fabric after the heat treatment.
(Creation of first layer 3D random loop joint)
Polyether ester elastomer with a melting point of 200 ° C is melted and discharged at 240 ° C from a nozzle (nozzle hole diameter 3mm, single hole discharge rate 3.0g / min · hole), and cooled so that the water surface is 300mm below the nozzle surface. Distribute water and place a stainless steel endless net with a width of 60 cm in parallel at intervals of 5 cm so that a pair of take-out conveyors are partly exposed on the surface of the water, and sandwich both sides while fusing the contact parts. While being drawn into solid cooling water at room temperature at a rate of 0.9 m / minute, the solid was cut into a predetermined size to obtain a three-dimensional random loop joined body. Thereafter, the obtained three-dimensional random loop bonded structure was heated at 105 ° C. for 15 minutes to perform pseudo-crystallization treatment. The obtained three-dimensional random loop joined body had a fineness of 4900 dtex, an apparent density of 125 kg / m ³ , a thickness of 20 mm, a 25% hardness of 520 N, and a residual strain at 70 ° C. of 13.0%.
(Creation of second layer 3D random loop joint)
Polyether ester elastomer with a melting point of 170 ° C is melted and discharged from a nozzle (nozzle hole diameter 5mm, single hole discharge rate 3.5g / min · hole) at 240 ° C, and cooled so that the water surface is 400mm below the nozzle surface. Distribute water and place a stainless steel endless net with a width of 60 cm in parallel at intervals of 5 cm so that a pair of take-out conveyors are partly exposed on the surface of the water, and sandwich both sides while fusing the contact parts. Then, it was drawn into solid cooling water at room temperature at a speed of 1.1 m / min, solidified, and cut into a predetermined size to obtain a three-dimensional random loop joined body. Thereafter, the obtained three-dimensional random loop bonded structure was heated at 105 ° C. for 15 minutes to perform pseudo-crystallization treatment. The obtained three-dimensional random loop joined body had a fineness of 10,000 dtex, an apparent density of 90 kg / m ³ , a thickness of 20 mm, a 25% hardness of 600 N, and a residual strain at 70 ° C. of 10.5%.
(Create model chairs for laminated structures and evaluation)
The fabric prepared as described above was stretched and fixed to a bench sheet type metal frame having a seating surface of 35 cm × 45 cm. Further, the second layer three-dimensional random loop joined body having a thickness of 20 mm and 25% hardness of 600 N prepared as described above is loaded on the fabric stretched and fixed to the frame, and further, 25% hardness is provided thereon. A 520N first layer three-dimensional random loop joined body was laminated. In this way, a model chair was created in which a laminated cushion structure having a fabric as a back layer and a three-dimensional random loop joined body as a surface layer was incorporated into a seat surface.
The stuffiness and cushioning properties of the model chair made of the laminated cushion structure thus created were evaluated.

[Comparative Example 1]
(Creation of laminated structure and evaluation model chair)
The fabric prepared in Example 1 was stretched and fixed to a bench sheet type metal frame having a seating surface of 35 cm × 45 cm. In addition, the first layer three-dimensional random loop joined body having a thickness of 20 mm and the second layer created in Example 1 are placed on a base placed at a distance of 4 cm from the fabric stretched and fixed to the frame toward the lower layer. Layer 3D random loop joint was loaded. In this way, a model chair was created in which a laminated cushion structure in which a woven fabric was arranged on the surface layer and a three-dimensional random loop joined body was arranged on the back layer was incorporated in the seating surface.
The stuffiness and cushioning properties of the model chair made of the laminated cushion structure thus created were evaluated.

[Comparative Example 2]
The stuffiness and cushioning properties of car seats used in commercial passenger cars were evaluated. The car seat used has a general structure using genuine leather having holes in the skin material by punching, and molded urethane in the cushion material.

[Comparative Example 3]
The feeling of stuffiness and cushioning of car seats used in commercial luxury cars were evaluated. The car seat used is a general structure that uses genuine leather with punched holes in the skin material, and molded urethane in the cushion material. It is an air-conditioning sheet that can blow in seconds.

  As an example of the evaluation result of the stuffiness obtained by the sweating mannequin, the evaluation results of Example 1 and Comparative Examples 1 to 3 are shown in FIG. From FIG. 2, it can be determined that the absolute humidity in the buttock clothing of the sweating mannequin 30 minutes after sitting on the car seat is lower in Example 1 than in Comparative Example 2 and the feeling of stuffiness is small. Further, in Example 1, it can be determined that the absolute humidity in the hip clothes of the sweating mannequin 30 minutes after sitting on the car seat is about the same as in Comparative Example 1 and Comparative Example 3, and the feeling of stuffiness is about the same. From this result, Example 1 has less feeling of stuffiness and superior comfort compared to Comparative Example 1, which is a car seat used in a commercial passenger car, and does not use electric power as in Comparative Example 3. However, it can be said that the feeling of stuffiness can be kept small. In addition, it can be said that Example 1 has the same degree of sensation as that of Comparative Example 1.

  Table 1 shows the humidity in the buttocks garment 30 minutes after sitting on the car seat obtained by the sweating mannequins of Examples 1 to 4 and Comparative Examples 1 to 3. From Table 1, Examples 1 to 3 have lower in-clothes humidity than Comparative Example 2, which is a general car seat, and are similar to those in Comparative Example 3 that is an air-conditioning sheet used for luxury cars. Since it is humidity, it can be said that Comparative Examples 1 to 3 are car seats excellent in thermal comfort, such as the air-conditioning seat of Comparative Example 3, which does not use energy such as electric power and has a low stuffiness. Moreover, it can be said that Examples 1-3 are comparable with the comparative example 1, and the humidity in clothes is comparable and a feeling of stuffiness is comparable.

  Moreover, although Example 4 can be said to have a tendency that the humidity in the buttocks clothes is slightly higher than that of Comparative Examples 1 and 3 and the feeling of stuffiness is large, it is more than Comparative Example 2 which is a car seat used in a commercial passenger car. It can be said that the humidity in the clothes is low and the feeling of stuffiness tends to be small.

  Table 2 shows the evaluation results of the feeling of stuffiness by the monitor test of Examples and Comparative Examples. From the results shown in Table 2, Examples 1 to 3 have a lower humidity in the clothes than Comparative Example 2 which is a general car seat, as well as Comparative Example 3 which is an air-conditioning seat used for luxury cars. Since it is the humidity in the clothes, Examples 1-3 are subjectively evaluated as car seats that have low thermal sensation without using energy such as electric power as in the air-conditioning sheet of Comparative Example 3, and that have excellent thermal comfort. It can be said from the result. Moreover, Examples 1-3 can also be said from subjective evaluation that the feeling of stuffiness is comparable to Comparative Example 1.

  Moreover, although it can be said that Example 4 has a tendency to be more stuffy than Comparative Examples 1 and 3, it tends to be less stuffy than Comparative Example 2, which is a car seat used in commercial passenger cars. It can also be said from the subjective evaluation.

  Table 3 shows the evaluation results of the cushioning properties by the weight drop test of Examples and Comparative Examples. From the results in Table 3, Example 1 has the same maximum subsidence depth and second repulsion energy as compared to Comparative Example 2 and Comparative Example 3 which are car seats used in commercial mass-produced cars and luxury cars. And, it can be said that the cushioning property of Example 1 is as excellent as a car seat used in a commercial automobile. Further, since Example 1 has a deeper maximum sinking depth and a smaller second repulsion energy than Comparative Example 1, Example 1 is softer than Comparative Example 1 and less cushioning so that it has a cushioning property. It can be said that it is excellent.

  Example 2 is carried out because the maximum sinking depth is slightly shallower and the second repulsion energy is slightly larger than those of Comparative Example 2 and Comparative Example 3 which are car seats used in commercial passenger cars and luxury cars. It can be said that Example 2 is slightly inferior in cushioning properties because it is slightly harder than a car seat used in a commercially available car and has a slightly larger feeling of elasticity. In addition, since Example 2 has a deeper maximum sinking depth and a smaller second repulsion energy than Comparative Example 1, Example 2 is softer than Comparative Example 1 and less cushioning so that it has a cushioning property. It can be said that it is excellent.

  Example 3 is deeper in the maximum subsidence depth and smaller in the second repulsion energy than Comparative Example 1 and Comparative Examples 2 and 3 which are car seats used in commercially available popular cars and luxury cars. Therefore, since Example 3 is too soft with respect to the comparative example 1 and the car seat currently used for the commercially available motor vehicle, it can be said that it is somewhat inferior to cushioning property.

  In Example 4, the maximum subsidence depth is shallower and the second repulsion energy is larger than those of Comparative Example 1 and Comparative Examples 2 and 3 which are car seats used in commercial mass-produced cars and luxury cars. Therefore, since Example 4 is too hard with respect to the comparative example 1 and the car seat currently used for the commercially available motor vehicle, it can be said that it is inferior to cushioning property.

  Table 4 shows the evaluation results of the cushioning properties by the monitor test of Examples and Comparative Examples. From the results in Table 4, it can be said that Example 1 has the same degree of cushioning as Comparative Example 2 and Comparative Example 3, which are car seats used in commercial mass-produced cars and luxury cars. Moreover, it can be said that Example 1 is superior to Comparative Example 1 in cushioning properties.

  It can be said that Example 2 is slightly inferior in cushioning property to Comparative Example 2 and Comparative Example 3, which are car seats used in commercial mass-produced cars and luxury cars. Moreover, it can be said that Example 2 is superior to Comparative Example 1 in cushioning properties.

  It can be said that Example 3 is slightly inferior in cushioning property to Comparative Example 1 and Comparative Examples 2 and 3 which are car seats used in commercially available popular cars and luxury cars. Moreover, it can be said that Example 3 is superior to Comparative Example 1 in cushioning properties.

  It can be said that Example 4 is inferior to the comparative example 1 and the comparative example 2 and the comparative example 3 which are the car seats used for a commercial passenger car and a luxury car. Moreover, it can be said that Example 4 is inferior to the comparative example 1 in cushioning property with the same degree of cushioning property.

  Table 5 shows the evaluation results of the stuffiness and cushioning properties. Example 1 is superior in cushioning properties to the comparative example 1 in which the surface layer is a woven fabric and the back layer is arranged in a three-dimensional random loop joined body, and the stuffiness is comparable. Moreover, Example 1 has a low feeling of stuffiness and excellent thermal comfort as compared with Comparative Example 2 which is a general car seat, and the cushioning property is excellent to the same extent. Example 1 is superior in thermal comfort with the same degree of stuffiness without using electric power, as compared with Comparative Example 3 which is an air-conditioning seat used in a car seat of a luxury car, and the cushioning property is also excellent in the same degree. . That is, Example 1 is a cushioning body that is excellent in overall comfort and has both thermal comfort and cushioning properties without using energy such as electric power due to the material and its laminated structure.

  Example 2 is slightly superior in cushioning properties and has a similar low stuffiness to Comparative Example 1 in which the surface layer is a woven fabric and the back layer is a three-dimensional random loop joined body. Moreover, although Example 2 has a low feeling of stuffiness and excellent thermal comfort compared to Comparative Example 2 which is a general car seat, it is slightly inferior in cushioning properties. Example 2 is superior in thermal comfort to the comparative example 3 which is an air-conditioning seat used for a car seat of a luxury car without using electric power, and has the same degree of stuffiness, but is slightly inferior in cushioning properties.

  In Example 3, the cushioning property is slightly superior to the comparative example 1 in which the surface layer is a woven fabric and the back layer is arranged in a three-dimensional random loop joined body, and the feeling of stuffiness is comparable. Moreover, although Example 3 has a low feeling of stuffiness and excellent thermal comfort compared to Comparative Example 2 which is a general car seat, it is slightly inferior in cushioning properties. Example 3 is superior in thermal comfort to the comparative example 3 which is an air-conditioning seat used for a car seat of a luxury car without using electric power, and has the same degree of stuffiness, but is slightly inferior in cushioning properties.

  Example 4 is slightly inferior in stuffiness, although the cushioning property is inferior to that of Comparative Example 1 in which the surface layer is woven and the back layer is arranged in a three-dimensional random loop joined body. Moreover, although Example 4 has a low feeling of stuffiness and is somewhat excellent in thermal comfort as compared with Comparative Example 2 which is a general car seat, it is inferior in cushioning properties. Example 4 is slightly inferior in thermal comfort and inferior in cushioning properties to Comparative Example 3 which is an air-conditioning seat used for a car seat of a luxury car.

  The laminated cushion structure of the present invention is a cushion body that is excellent in overall comfort and has both thermal comfort and cushioning properties, without using energy such as electric power, and is used for various seats. be able to.

Claims (2)

Cushioning material made of fiber aggregate in the surface layer, a laminated cushion structure knitted woven formed by arranging a part of the monofilament made of a thermoplastic elastic resin on the back layer are the product layer made of a fiber aggregate A laminated cushion structure, which is a cushion material in which the cushion material has a structure in which at least two layers are laminated, and the hardness of each layer gradually decreases as it goes to the surface layer side .   The laminated cushion structure according to claim 1, wherein the cushion material made of the fiber assembly is made of a thermoplastic elastic resin.