JP6566900B2 - 3D crosspiece structure - Google Patents

Description

  The present invention relates to a three-dimensional crosspiece structure having a three-dimensional crosspiece structure used for mattresses, cushions and the like.

  Various methods have been proposed for conventional three-dimensional network structures in which the filaments formed by extrusion are partially entangled and provided with loops, or two- or four-surface molding methods for three-dimensional network structures. For example, as shown in Patent Document 1, a die having a plurality of holes is formed at the tip of a melted filament made of a thermoplastic synthetic resin as a raw material or a main raw material for the purpose of forming a three-dimensional network structure. When producing a three-dimensional network structure by pushing down downward from a die in the part, submerging partly, naturally descending between the take-up machines, and drawing the filaments slower than the descent speed, the take-up machines face each other Then, a predetermined shape (for example, a quadrilateral shape) is formed in a direction perpendicular to the extrusion direction by this take-up machine, and the interval between the take-up machines facing each other is set narrower than the width of the extruded line aggregate, This is a method of forming a three-dimensional network structure formed by bringing two or four surfaces of the outer periphery of the filament aggregate into contact with the take-up machine before and after the take-up machine is submerged.

JP 2001-328153 A

  A conventional three-dimensional network structure with good air permeability has a property that loops are formed randomly and shrink when heated. For this reason, for example, when used for mattresses, if the disinfection at high temperature is repeated, the three-dimensional network structure contracts, so the cover tends to wrinkle, the user feels uncomfortable, and pressure ulcers may occur due to long-term use. It was. In particular, in the longitudinal direction with a long length, when the three-dimensional network structure contracts, the influence is large, and wrinkles tend to be a problem.

  Further, the conventional three-dimensional network structure may not be able to exhibit a function that matches the characteristics of the human body. For example, when used in a mattress, the human body controls posture while sleeping, stretches the body, changes position, loosens muscles and body, and evenly balances the burden on the body, resetting the body distortion Although there is a natural adjustment function, the structural characteristics of the corresponding three-dimensional network structure were insufficient. The demands for products that use a three-dimensional network structure are diversified, and the quality requirements for the products are high, but there is a problem that it is difficult to ensure product quality for such diverse requirements that match the characteristics of the human body. Was.

Accordingly, the present invention is to realize a structure of properties in the longitudinal direction elongated by heat, to allow cleaning at high temperatures, it is an object to ensure diverse quality requirements.

The present invention comprises a polyethylene-based thermoplastic resin having a longitudinal direction corresponding to the extrusion direction, a transverse direction perpendicular to the extrusion direction, and a thickness direction, by forming continuous loops by randomly welding the continuous filaments, A three-dimensional crosspiece structure comprising a polyester-based thermoplastic elastomer or a mixture of a polyethylene-based thermoplastic resin and a polyethylene-based thermoplastic elastomer, wherein the three-dimensional crosspiece structure has a bulk density and a dense portion in the extrusion direction. Is a three-dimensional network structure having cross-shaped sparse and dense structures that alternately appear, in the case of a polyethylene thermoplastic resin at a temperature of 90 ° C. for 30 minutes, in the case of a polyester thermoplastic elastomer at 130 ° C. for 30 minutes, In the case of a mixture of a polyethylene-based thermoplastic resin and a polyethylene-based thermoplastic elastomer, after a dry hot air test at 90 ° C. for 30 minutes, before Thermal elongation degree before drying hot air test is a three-dimensional bar structure 0-8% in the longitudinal direction.

  30 minutes at a temperature of 90 ° C. in the case of a polyethylene-based thermoplastic resin, 30 minutes at 130 ° C. in the case of a polyester-based thermoplastic elastomer, or 30 minutes at 90 ° C. in the case of a mixture of a polyethylene-based thermoplastic resin and a polyethylene-based thermoplastic elastomer After the drying hot air test, the thermal elongation before and after the drying hot air test is preferably 0 to 8% in the transverse direction.

  It is preferable that the three-dimensional crosspiece structure has anisotropic thermal expansion characteristics in which the thermal expansion rates in the vertical direction and the horizontal direction are different.

  The three-dimensional crosspiece structure preferably has a rebound resilience change rate of 20% or less after a constant load repeated test.

The apparent density of the three-dimensional bar structure is ^{0.025g / cm 3 ~0.2g / cm 3} , the thickness was 5mm~500mm in monolayer and multilayer, wire diameter diameter 0.1Mm～1. 5 mm is preferable.

  The polyethylene-based thermoplastic resin is preferably polyethylene or an ethylene / α-olefin copolymer resin mainly composed of ethylene and an α-olefin having 3 or more carbon atoms.

  The mixture of the polyethylene-based thermoplastic resin and the polyethylene-based thermoplastic elastomer is a mixture of an ethylene / α-olefin copolymer resin mainly composed of ethylene and an α-olefin having 3 or more carbon atoms and a polyethylene-based thermoplastic elastomer, and the mixture The content of the polyethylene-based thermoplastic elastomer is preferably 45% or less by weight.

  The three-dimensional crosspiece structure is preferably used for a cushion, a cushion sheet, a cushion, a pillow, a care product, a bed cushion, or a mattress.

  The three-dimensional crosspiece structure includes a plurality of surfaces, of which two, three, or four surfaces are preferably formed, and are preferably formed into an irregular shape as necessary.

  The three-dimensional crosspiece structure according to the present invention is an excellent three-dimensional crosspiece structure that has a low hysteresis loss and a soft high resilience characteristic, and can provide an elastic characteristic that matches the characteristics of the human body. Because of this superior property, it can adapt to the characteristics of the human body, and can respond to diversification of demands for elastic properties of products, and sophistication of quality requirements for products, medical care products, bedding, furniture, or vehicles. It has become possible to provide a three-dimensional crosspiece structure suitable for cushion materials or skin materials used for seats and the like. For example, an application example of a mattress for medical / nursing care can realize an appropriate elastic characteristic of a three-dimensional crosspiece structure, and can respond to natural adjustment functions of the human body during sleep, etc. Easy to get up. In addition, caregivers can achieve their objectives with little force using the repulsive force of the mattress when changing the patient's position.

  Furthermore, since it has a thermal expansion / contraction property that thermally expands in the vertical and horizontal directions, for example, when used in a mattress, even when disinfected at a high temperature, the mattress will not shrink and the cover will not wrinkle. Caused pressure ulcers are also less likely to occur. Therefore, since heat disinfection is easy and drying is easy, it can cope with hospital infections, and a three-dimensional crosspiece structure suitable for a cushion material required for medical use or nursing care can be provided. In addition, since it has anisotropic thermal expansion characteristics with different thermal expansion rates in the vertical and horizontal directions, it can be adapted to the application of the three-dimensional crosspiece structure and the characteristics of the human body in that application. Since the form can be formed into two, three, four or irregular shapes depending on the method of use, various uses can be considered as a medical auxiliary instrument.

  The three-dimensional crosspiece structure of this embodiment will be described. This three-dimensional cross structure is constituted by a plurality of filaments entangled randomly in a loop shape and heat-welded. The three-dimensional cross structure is a three-dimensional network structure having a cross-like dense and dense structure in which a rough portion and a dense portion alternately appear in the extrusion direction during production.

  The three-dimensional crosspiece structure can have various forms, such as one with a hard end, one with a different surface layer thickness on the front and back, one with different softness on the front and back, and one with a hole inside. It is. Also, the hardness can be changed depending on the site depending on the purpose of use.

  The three-dimensional crosspiece structure of the present invention preferably has a hysteresis loss of 34% or less. A small hysteresis loss means that the return force after release is fast and large. A hysteresis loss of 34% or less is preferable because the resilience is large and the object of the present invention is soft and highly repulsive. If it exceeds 34%, the elastic repulsion force becomes slow and weak, which is not preferable. More preferably, it is 15 to 34%, and further preferably 20 to 34%.

The apparent density (bulk density) of the three-dimensional crosspiece structure of the present invention is an important factor that determines soft and high resilience, and is designed as necessary, but is preferably 0.025 g / cm ^3. ~0.2g / cm ^3, more preferably from ^{0.04g / cm 3 ~0.09g / cm 3} . If the apparent density is less than 0.025 g / cm ³ , the shape cannot be maintained, and if it exceeds 0.20 g / cm ³ , it is not suitable as a mattress.

  The three-dimensional crosspiece structure of the present invention is a continuous filament comprising a thermoplastic resin or a thermoplastic elastomer or a mixture of a thermoplastic resin and a thermoplastic elastomer having a filament diameter (diameter) of 0.3 mm to 1.5 mm. This is a three-dimensional spring structure in which random loops are welded together in a molten state. The wire diameter may be irregular or hollow, but it is an important factor for obtaining a soft touch. If the wire diameter is small, the hardness required for cushioning cannot be maintained, and conversely, if the wire diameter is too large, it becomes hard. Therefore, it is necessary to set an appropriate range.

  The loop length of the loop is preferably 5 to 50 mm, particularly 8 to 15 mm. Depending on the purpose, the surface loop may be laid to form a high-density surface layer, or a high-density surface layer may not be formed.

  Since the thickness of the three-dimensional crosspiece structure of the present invention is greatly related to softness and high resilience, it is more preferably 5 mm to 500 mm, more preferably 10 to 150 mm, and even more preferably 30 to 110 mm. If it is less than 5 mm, the high resilience is low, which is not preferable. If it exceeds 500 mm, the resilience becomes too high, which is not preferable.

  The vertical and horizontal dimensions of the three-dimensional crosspiece structure are, for example, a width of 600 to 2000 mm, a length of 1300 to 2500 mm, a height of 30 to 120 mm, and a pillow of 250 to 500 mm and a length of 300 to 300 for mattresses and cushions. An example is 800 mm and a height of 40 to 120 mm. Further, it can be used as a single material, a composite material or a multilayer material for the skin material. Although the dimension illustrated the typical dimension, it is not necessarily restricted to the dimension.

  The material of the three-dimensional cross structure is preferably a polyethylene resin, a polyester thermoplastic elastomer, or a mixture of a polyethylene resin and a polyethylene thermoplastic elastomer.

  When the three-dimensional crosspiece structure of the present invention is composed of a polyethylene-based thermoplastic resin, the longitudinal and lateral thermal elongation rates before and after the 90 ° C. dry hot air test are preferably 0% or more and 8% or less. % Or less is more preferable. If the thermal elongation rate before and after the 90 ° C. dry hot air test exceeds 8%, it is difficult to enter the cover. If the thermal elongation rate before and after the 90 ° C. dry hot air test is less than 0%, it is not preferable because the length of the product is shortened and the cover is wrinkled when disinfected at a high temperature.

 When the three-dimensional crosspiece structure of the present invention is composed of a polyester-based thermoplastic elastomer, the longitudinal and lateral thermal elongation rates before and after the 130 ° C. dry hot air test are preferably 0% or more and 8% or less. % Or less is more preferable. If the thermal elongation rate before and after the 130 ° C. dry hot air test exceeds 8%, it is difficult to enter the cover. If the thermal elongation rate before and after the 130 ° C. dry hot air test is less than 0%, the length of the product is shortened and the cover is wrinkled when disinfected at a high temperature, which is not preferable.

  When the three-dimensional crosspiece structure of the present invention is composed of a mixture of a polyethylene-based thermoplastic resin and a polyethylene-based thermoplastic elastomer, the longitudinal and lateral thermal elongation rates before and after the 90 ° C. dry hot air test are 0% or more. Is preferably 8% or less, more preferably 3% or less. If the thermal elongation rate before and after the 90 ° C. dry hot air test exceeds 8%, it is difficult to enter the cover, which is not preferable. If the thermal elongation rate before and after the 90 ° C. dry hot air test is less than 0%, it is not preferable because the length of the product is shortened and the cover is wrinkled when disinfected at a high temperature.

  When the three-dimensional crosspiece structure of the present invention is used as a cushioning material, it is necessary to appropriately select a resin, a wire diameter, a loop diameter, a surface layer, a bulk density, and a shape to be used depending on the purpose of use and the use site. For example, the raw materials are selected in a timely manner according to the hardness preference in the country of use. When used as a layer, an appropriate bulk density is selected depending on whether it is a surface layer or an intermediate layer. Further, it can be molded into a shape suitable for the purpose of use using a molding die or the like to such an extent that the three-dimensional structure is not impaired, and can be used for a vehicle seat, an aircraft seat, a ship seat, a chair, furniture, and the like. Of course, in order to meet the required performance, it is also possible to use a combination of multiple layers of the same structure and the same material, multiple layers of the same structure and different materials, hard cushion material, urethane, latex, and non-woven fabric. The material can be processed and processed so as to have functions of making it flame-retardant, non-flammable, antibacterial, and colored. A removable cover with one or two layers may be designed in a timely manner with materials suitable for air permeability and waterproof performance.

The polyethylene-based thermoplastic resin used in the three-dimensional crosspiece structure of the present invention is preferably a low-density polyethylene resin having a bulk density of 0.94 g / cm ³ or less, particularly ethylene and an α-olefin having 3 or more carbon atoms. It is preferable to consist of an ethylene / α-olefin copolymer resin. Use of a raw material exceeding 0.94 g / cm ³ is not preferable because the cushion material tends to be hard. More preferably 0.935 g / cm ³ or less, still more 0.91 g / cm ³ or less is more preferred. A floor of 0.8 g / cm ³ or more in view of the strength retention is more preferably 0.85 g / cm ³ or more.

  The ethylene / α-olefin copolymer 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. 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.

  The polyester-based thermoplastic elastomer used in the three-dimensional crosspiece structure of the present invention is mainly composed of a high-melting-point crystalline polymer segment (a) composed of a crystalline aromatic thermoplastic polyester / elastomer unit, and an aliphatic polyether unit. A thermoplastic polyester / elastomer block copolymer (A) mainly composed of a low-melting polymer segment (b) composed of an aliphatic thermoplastic polyester / elastomer unit is preferred.

  Among thermoplastic elastomers, a polyester block copolymer having a crystalline aromatic polyester unit as a hard segment and an aliphatic polyether unit such as poly (alkylene oxide) glycol and / or an aliphatic polyester unit such as polylactone as a soft segment. A polymer (polyester elastomer) has characteristics that are excellent in low-temperature and high-temperature characteristics, and is characterized by relatively low temperature dependency of rigidity.

Preferably the bulk density of the thermoplastic polyester elastomer is 1.01~1.60g / cm ^3, more preferably 1.05~1.20g / cm ^3.

  The polyester-based thermoplastic elastomer is preferably used in that the temperature dependency can be reduced in a wide temperature range. The polyester-based thermoplastic elastomer includes a high-melting-point crystalline polymer segment (a1) composed of a crystalline aromatic polyester unit, a low-melting-point polymer segment (a2) composed of an aliphatic polyether unit and / or an aliphatic polyester unit. The high-melting crystalline polymer segment (a1) is mainly composed of an aromatic dicarboxylic acid or an ester-forming derivative thereof and a diol or an ester-forming derivative thereof. Specific examples of aromatic dicarboxylic acids that are polyesters include terephthalic acid, isophthalic acid, phthalic acid, naphthalene-2,6-dicarboxylic acid, naphthalene-2,7-dicarboxylic acid, anthracene dicarboxylic acid, diphenyl-4,4. '; -Dicarboxylic acid, diphenoxyethane Carboxylic acid, 4,4'; - diphenyl ether dicarboxylic acid, 5-sulfoisophthalic acid, and 3-like sodium sulfoisophthalate and the like. Although aromatic dicarboxylic acid is mainly used, if necessary, a part of the aromatic dicarboxylic acid may be converted to alicyclic dicarboxylic acid such as 1,4-cyclohexanedicarboxylic acid, cyclopentanedicarboxylic acid, 4,4 ′;-dicyclohexyldicarboxylic acid. It may be substituted with an acid or an aliphatic dicarboxylic acid such as adipic acid, succinic acid, oxalic acid, sebacic acid, dodecanedioic acid, and dimer acid. Of course, ester-forming derivatives of dicarboxylic acids such as lower alkyl esters, aryl esters, carbonates, and acid halides can be used equally. Specific examples of the diol include diols having a molecular weight of 400 or less, for example, aliphatic diols such as 1,4-butanediol, ethylene glycol, trimethylene glycol, pentamethylene glycol, hexamethylene glycol, neopentyl glycol, decamethylene glycol, , 1-cyclohexanedimethanol, 1,4-dicyclohexanedimethanol, alicyclic diols such as tricyclodecane dimethanol, and xylylene glycol, bis (p-hydroxy) diphenyl, bis (p-hydroxy) diphenylpropane, 2,2 ′;-bis [4- (2-hydroxyethoxy) phenyl] propane, bis [4- (2-hydroxyethoxy) phenyl] sulfone, 1,1-bis [4- (2-hydroxyethoxy) phenyl] Cyclohexane Aromatic diols such as 4,4 ′;-dihydroxy-p-terphenyl and 4,4 ′;-dihydroxy-p-quarterphenyl are preferred, and such diols are ester-forming derivatives such as acetylated, alkali metal salts. It can also be used in the form of Two or more of these dicarboxylic acids, derivatives thereof, diol components and derivatives thereof may be used in combination. An example of a preferable high-melting crystalline polymer segment (a1) is a polybutylene terephthalate unit derived from terephthalic acid and / or dimethyl terephthalate and 1,4-butanediol. Also preferred are those composed of polybutylene terephthalate units derived from terephthalic acid and / or dimethyl terephthalate, and polybutylene isophthalate units derived from isophthalic acid and / or dimethyl isophthalate and 1,4-butanediol. .

  The low melting point polymer segment (a2) of the polyester thermoplastic elastomer used in the present invention is an aliphatic polyether and / or an aliphatic polyester. Aliphatic polyethers include poly (ethylene oxide) glycol, poly (propylene oxide) glycol, poly (tetramethylene oxide) glycol, poly (hexamethylene oxide) glycol, copolymers of ethylene oxide and propylene oxide, poly (propylene oxide) Examples thereof include ethylene oxide addition polymers of glycol and copolymer glycols of ethylene oxide and tetrahydrofuran. Examples of the aliphatic polyester include poly (ε-caprolactone), polyenanthlactone, polycaprylolactone, polybutylene adipate, and polyethylene adipate. From the elastic properties of the polyester block copolymers obtained from these aliphatic polyethers and / or aliphatic polyesters, poly (tetramethylene oxide) glycol, poly (propylene oxide) glycol ethylene oxide adducts, ethylene oxide and tetrahydrofuran Are preferably used such as copolymer glycol, poly (ε-caprolactone), polybutylene adipate, and polyethylene adipate, among which poly (tetramethylene oxide) glycol, poly (propylene oxide) glycol ethylene oxide adduct, and The use of a copolymer glycol of ethylene oxide and tetrahydrofuran is preferred. The number average molecular weight of these low-melting polymer segments is preferably about 300 to 6000 in the copolymerized state. The amount of copolymerization of the low melting point polymer segment (a2) in the polyester thermoplastic elastomer used in the present invention is not particularly limited, but is preferably about 10 to 90% by weight, more preferably about 30 to 85% by weight, About 50 to 80% by weight is particularly preferable. When the copolymerization amount of the low melting point polymer segment (a2) is less than 10% by weight, the flexibility and the bending fatigue property are deteriorated. On the other hand, when the copolymerization amount of the low melting point polymer segment (a2) exceeds 90% by weight, mechanical properties, high temperature characteristics, oil resistance, and chemical resistance are not sufficiently exhibited.

  The polyester-based thermoplastic elastomer used in the present invention can be produced by a known method. Specific examples thereof include, for example, a method of transesterifying a lower alcohol diester of a dicarboxylic acid, an excessive amount of a low molecular weight glycol and a low melting point polymer segment component in the presence of a catalyst, and polycondensing the resulting reaction product, and Any method such as a method in which a dicarboxylic acid, an excess amount of glycol and a low melting point polymer segment component are esterified in the presence of a catalyst and the resulting reaction product is polycondensed may be used.

  You may use said block copolymer individually or in mixture of 2 or more types.

  Furthermore, blends of non-elastomeric components, copolymers, and the like can be used in the present invention.

  The mixture of the polyethylene-based thermoplastic resin and the polyethylene-based thermoplastic elastomer used in the three-dimensional crosspiece structure of the present invention is composed mainly of an ethylene / α-olefin copolymer resin composed of ethylene and an α-olefin having 3 or more carbon atoms and a polyethylene-based mixture. A mixture of thermoplastic elastomers is preferred, and the content of the polyethylene-based thermoplastic elastomer in the mixture is preferably 45% or less by weight. If the content of the polyethylene-based thermoplastic elastomer in the mixture exceeds 45% by weight, the hysteresis loss increases and it becomes difficult to turn over, which is not preferable.

The polyethylene-based thermoplastic elastomer used in the three-dimensional crosspiece structure of the present invention is composed of a thermoplastic elastomer in which ethylene-propylene rubber (EPDM, EPM) is finely dispersed and two types of polyolefin composed of two types of catalysts. It is preferable that these are alternately formed in blocks in the molecule.

Preferably the bulk density of the polyethylene-based thermoplastic elastomer is 0.92~0.85g / cm ^3, more preferably 0.95~0.81g / cm ^3.

  The melting point of polyethylene is preferably 60 ° C to 120 ° C. In the case of a polyester elastomer, the melting point of the thermoplastic elastomer is preferably 140 ° C. or higher because heat resistance can be maintained, and when the temperature is 160 ° C. or higher, the heat durability is improved. In addition, if necessary, an antioxidant, a light-resistant agent and the like can be added to improve durability. It is also effective to increase the molecular weight of the thermoplastic resin in order to improve heat resistance and sag resistance.

  The melt flow rate (hereinafter abbreviated as MFR) of the polyethylene resin used in the three-dimensional crosspiece structure of the present invention is 3.0 to 35 g / 10 min, and the MFR of the polyester thermoplastic elastomer is 3.0 to 45 g / min. 10 minutes, and the MFR of the mixture of the polyethylene resin and the polyethylene thermoplastic elastomer is 6 to 35 g / 10 min.

The measuring method and measuring device of the wire diameter reduction rate of the polyethylene resin will be described. Capillograph 1D (manufactured by Toyo Seiki Co., Ltd.) was used as the measuring device for the wire diameter reduction rate. Temperature 190 ° C., the tube inner diameter _{D 1} is 1.0 mm, applying a pressure from the top of the capillary length 10 mm, extruding the raw material resin at an extrusion amount 3 g / 10min. The filament of the extruded material resin was cooled with an alcohol, the diameter of the filament was cut in cross-section and D _2. Wire diameter reduction rate = D ₂ / D ₁ The wire diameter reduction rate was measured according to the shear rate of the raw material resin.

  The measuring method and measuring device for the wire diameter reduction rate of the polyester-based thermoplastic elastomer are the same as described above except that the temperature becomes 210 ° C.

 The measuring method and measuring device of the linear reduction rate of the mixed resin of polyethylene resin and polyethylene thermoplastic elastomer are the same as the above except that the temperature becomes 190 ° C.

Wire diameter reduction rate of the polyethylene resin used in the present invention, the wire diameter decrease rate for shear rate 24.3Sec ^-1 is 0.93 to 1.16, the wire diameter decrease rate for shear rate 60.8Sec ^-1 There is 1.00 to 1.20, a diameter reduction rate is from 1.06 to 1.23 with respect to shear rate 121.6Sec ^-1, shear rate is the wire diameter decrease rate for 243.2sec ^-1 1. is from 11 to 1.30, wire diameter decrease rate for shear rate 608.0Sec ^-1 is 1.15 to 1.34, the shear rate is the wire diameter decrease rate for 1216 sec ^-1 1.16-1.38 It is preferable that

Wire diameter reduction rate of the polyester-based thermoplastic elastomer resin used in the present invention, the wire diameter decrease rate for shear rate 60.8Sec ^-1 is 1.10 to 1.38, the diameter decrease rate for shear rate 121.6Sec ^-1 is 1.12 to 1.39, the wire diameter decrease rate for shear rate 243.2Sec ^-1 is 1.15 to 1.42, the wire diameter decrease rate for shear rate 608sec ^-1 is 1.17 to 1.43, the wire diameter for the shear rate 1216 sec ^-1 The reduction rate is preferably 1.19 to 1.47.

The wire diameter reduction rate of the mixture of the polyethylene thermoplastic resin and the polyethylene thermoplastic elastomer resin used in the present invention is 1.02 to 1.25 with respect to a shear rate of 60.8 sec ⁻¹ , and a shear rate of 121.6 sec. wire diameter decrease rate for ^-1 is 1.11 to 1.30, the wire diameter decrease rate for shear rate 243.2Sec ^-1 is 1.15 to 1.35, the wire diameter decrease rate for shear rate 608Sec ^-1 it is 1.20 to 1.40, It is preferable that the wire diameter reduction rate with respect to a shear rate of 1216 sec ⁻¹ is 1.23 to 1.45.

  The continuous filaments made of the thermoplastic resin forming the three-dimensional crosspiece structure of the present invention may be combined with other thermoplastic resins as long as the object of the present invention is not impaired. As a composite form, the filaments themselves may be combined.

  As a composite of three-dimensional crosspiece structure layer, sandwich structure of elastomer layer / non-elastomeric layer / elastomeric layer, two-layer structure of elastomer layer / non-elastomeric layer, partially in the center of the matrix elastomer layer A composite structure in which a non-elastomeric layer is arranged is exemplified.

  The three-dimensional crosspiece structure of the present invention has different three-dimensional crosspiece structures such as those having different loop sizes, different wire diameters, different compositions, different densities, etc. in relation to required performance. Appropriate selection can be made to form a multilayer. Whether the cushion is bonded or not is designed according to the application and the cover. In the case of multiple layers, if a three-dimensional crosspiece structure made of a resin containing an elastomer component is placed on the surface layer, the heat resistance performance of the surface layer will be high, and heat will not easily be transmitted to the inner three-dimensional crosspiece structure. As a result, the heat resistance performance of the multilayer body as a whole is high, which is preferable. The composite and multi-layered three-dimensional crosspiece structure can be manufactured using several extruders.

  The three-dimensional crosspiece structure of the present invention may be multilayered and may be bonded and integrated with a wadding layer made of side fabric, cotton, urethane, or nonwoven fabric by heat or ultrasonic waves. What was integrated by bonding is used as a cushion for a seat, for example. Here, cotton and non-woven fabric are preferable since they have high durability, and the non-woven fabric is preferably one in which fibers and fibers are fused with a binder fiber or one having a straight structure with a support structure.

  Although an example of the manufacturing method of the three-dimensional crosspiece structure of this embodiment is described, it is not necessarily limited to this manufacturing method. As described in JP-A-2001-328153, etc., raw materials mainly composed of polyethylene, polyester-based thermoplastic elastomer, or a mixture of polyethylene resin and polyethylene-based thermoplastic elastomer are 10 ° C. to 20 ° C. from their melting points. The raw material melted and melted at a high melting temperature is sent to the inside of the die, pressure is applied, and each filament discharged from the extrusion port of the lower die is made up of a plurality of arrays of extrusion holes. It becomes a line aggregate consisting of a plurality of lines and falls naturally.

  The temperature range inside the die can be set to 100 to 400 ° C., and the extrusion amount can be set to 20 to 200 Kg / HR. As for the pressure inside the die, for example, the pressure due to the discharge pressure of a 75 mm screw can be mentioned, and the pressure range is about 0.2 to 25 MPa.

  The diameter of the die inside the die corresponds to the wire diameter of the wire having the three-dimensional cross structure, is preferably 0.2 to 4.0 mm, and more preferably 0.4 to 1.8 mm.

  Next, it is received by at least a pair of left and right shooters supplied with water or hot water (see the publication of International Publication No. WO2012 / 157289), and the filaments are brought into contact with each other in a molten state to form a three-dimensional structure. While landing on the surface of the water. At this time, depending on the angle of the shooter, the amount of water to be supplied, the diameter of the extrusion port, the distance between the die surface and the shooter and the take-up conveyor, the melt viscosity of the resin, the hole diameter and the discharge amount of the extrusion port, etc. The wire diameter is determined. The wire diameter (diameter) is 0.1 to 1.8 mm, and the average diameter (length) of the random loop is 5 mm to 50 mm.

  Next, among the filament aggregates, the filaments located on the longitudinal side surfaces of the outer circumference contact the inclined surfaces where the water of the pair of longitudinal shooters flows, thereby disturbing the vertical descent trajectory and adjacent to each other. While entangled with the filaments in a loop shape, it slides down the inclined surface while being washed with water supplied from the supply pipe or heated water. At this time, the filament is directly affected by gravity, and is entangled along the inclined surface to form a loop. A pair of short shooters may be provided. Also, an integral shooter may be provided.

  The water supply port is provided with a supply pipe in the longitudinal direction above each of the longitudinal shooters, and each of the inclined surfaces is heated within a range of water or 10 to 90 ° C, preferably 40 to 60 ° C. Water is supplied. The supply pipe is connected upstream to a water supply source. The heated water may be supplied to the short shooter by adjusting the water flow from the supply pipe, or a similar supply pipe may be provided above the short shooter.

  Of the filament aggregates, filaments that have descended without contacting any of the inclined surfaces of the shooter pass through the forming opening. At this time, among the filaments that pass through the molding opening, those that pass near the lower side of the inclined surface come into contact with the filaments that slide down the inclined surface, and are entangled in a loop shape. The disturbance is propagated to some extent in the adjacent central line and descends. Of the filaments that pass through the molding opening, those that pass near the center of the molding opening land on the water surface, and the take-up speed by the take-up machine is slower than the descending speed of the filament assembly, so it has landed. Each filament is bent and entangled in a substantially loop shape near the water surface. The speed of the take-up machine is preferably 5 to 40 m / hour. The take-up machine uses a caterpillar-structured endless belt to take up the filament aggregate. However, the present invention is not limited to this, and a roller or the like can be used. A loop may be formed.

  Next, the three-dimensional crosspiece structure is cooled in the water tank, and is taken down by the pair of take-up machines at a speed slower than the descent of the assembly, and is smaller than the gap in the short direction of the molding opening. It is pinched and receives an auxiliary compression action. At the time when it is lowered to the position of the endless belt, the cooling and solidification of the filament aggregate due to submergence has not been completed yet, so that a compression molding effect is obtained by clamping with a take-up machine. When the filament aggregate is taken out and sent out by the take-up machine, the filament aggregate in the molten state is cooled and solidified with water, finally the shape is fixed, and it is pulled out from the cooling tank by being sandwiched between rollers.

  It is desirable that the water level of the water tank be equal to or higher than the height of the lower end portion of the inclined surface of the shooter. Regardless of the height of the shooter, the lower end of the inclined surface is set as a reference, and it is not a problem that a part of the take-up machine is exposed on the water. As for the water level, the height from the lower end of the inclined surface is preferably set to 0 to 45 mm, more preferably set to a height of 1 to 30 mm, and further set to a height of 3 mm to 22 mm. preferable. The water level includes the same height as that of the lower end of the inclined surface, and the present invention can be implemented as long as the water level is higher than that. It is preferable to set the water level height in consideration of variations in the water level during production, machine levelness, and the like. Although affected by manufacturing conditions, if the water level is set to a height of 3 mm or more, it is possible to prevent the water level from becoming lower than the lower end of the inclined surface due to the influence of water pressure or the like. On the other hand, if the water level exceeds 30 mm from the lower end of the inclined surface, depending on the conditions, the resin starts to solidify, and the fusion between the fibers deteriorates, and the surface roughness increases, which is inappropriate.

  Next, the three-dimensional crosspiece structure having the same shape as the molding opening in the cross section is drained, sent to a drying heat treatment tank by a roller, and annealed by a drying heat treatment with hot air. At this time, it is preferable to set the take-up speeds of the rollers before and after the drying heat treatment tank to be different. For example, the take-up speed of the roller near the exit of the dry heat treatment tank is set lower than the take-up speed of the roller near the entrance of the dry heat-treatment tank. After the drying heat treatment, it is cut into a desired length to obtain a three-dimensional crosspiece structure. You may cut | disconnect to desired length before drying heat processing.

  The annealing by the drying heat treatment is performed for a predetermined time at a drying temperature on the three-dimensional crosspiece structure taken out from the water tank and drained. In the case of low-density polyethylene, the drying temperature is preferably not higher than the melting point, and preferably 10 to 70 ° C. lower than the melting point. In the case of a polyester thermoplastic elastomer, it is preferably not higher than the melting point of the polyester thermoplastic elastomer, and preferably 10 to 70 ° C. lower than the melting point. Moreover, in the case of a mixture of a polyethylene-based thermoplastic resin and a polyethylene-based thermoplastic elastomer, the temperature is preferably equal to or lower than the melting point of the mixture, and preferably 10 ° C. to 30 ° C. lower than the melting point.

  The annealing may be performed by removing the mold from the water tank, draining the water, storing the three-dimensional bar structure in a compressed state in a frame, heat treating with hot air, and removing the mold. In this case, in the case of low-density polyethylene, the drying temperature is preferably not higher than the melting point, and preferably 10 to 70 ° C. lower than the melting point. Moreover, in the case of a thermoplastic elastomer, it is preferable that it is below melting | fusing point of a thermoplastic elastomer, and it is preferable that it is 10-70 degreeC lower than melting | fusing point. Moreover, in the case of a mixture of a polyethylene-based thermoplastic resin and a polyethylene-based thermoplastic elastomer, the temperature is preferably equal to or lower than the melting point of the mixture, and preferably 10 ° C. to 70 ° C. lower than the melting point.

  After forming the three-dimensional crosspiece structure in the water tank as described above, it may be annealed in a later process (hereinafter referred to as additional annealing), or by adding heated water to the water tank, May be annealed (hereinafter referred to as “annealing during production”).

  The annealing during production is preferably performed at a temperature that is at least 10 ° C. to 70 ° C. lower than the melting point of the polyethylene-based thermoplastic resin or the polyester-based thermoplastic elastomer. In the case of a mixture of a polyethylene resin and a polyethylene thermoplastic elastomer, it is preferably 10 to 70 ° C. lower than the melting point.

  In the case of annealing during production, instead of supplying room temperature water to at least a pair of shooters, warm water supplied to the shooters is in the range of 20 to 90 ° C (preferably 20 to 80 ° C or more, more preferably 25 to 50 ° C. ) And annealing may be performed while forming a random loop by randomly welding the filaments. In the case of warm water, 25-50 ° C. in the case of low density polyethylene, 25-70 ° C. in the case of thermoplastic elastomer, 25-60 ° C. in the case of a mixture of polyethylene resin and polyethylene thermoplastic elastomer. Is preferred. Examples of the warming water include (A) heating the water flowing through the shooter, (B) heating the water tank itself, and (C) increasing the internal temperature by forming the shooter like a tank. Moreover, it is good also as those composites. If the temperature of the heated water supplied to the shooter is raised too much, the resin may stick to the shooter. Therefore, the temperature is preferably an appropriate temperature, for example, 10 to 60 ° C. The additional annealing is performed by lifting the three-dimensional beam structure from the water tank and then immersing it in hot water or hot air.

  Annealing may be performed either once by additional heat treatment by dry heat treatment or the like, or production annealing by warm water in a water tank or the like, or may be performed after production annealing and annealing in two stages. Further, additional annealing may be performed in two stages. In this case, the second additional annealing temperature is set higher than the first additional annealing temperature.

  The three-dimensional crosspiece structure of the present invention realizes soft and highly repulsive characteristics and longitudinal and lateral thermal elongation characteristics by the above-described manufacturing method. Also, different thermal elongation characteristics are realized in the vertical and horizontal directions. According to the inventor's analysis, the elastic and thermal elongation characteristics, and the mechanism that leads to the anisotropic thermal elongation rate are complex and not all are clear, but the appropriate range of raw materials Wire diameter reduction rate, melt viscosity, MFR, extrusion process from hole diameter of die, wire loop formation process, wire cooling process, additional annealing by annealing and annealing during production As a result, when the wire naturally descends, entangles, and cools, basically, the tangling in the vertical and horizontal directions is caused by the characteristic fluctuation / oscillation of the thickness of the wire. We think that form is different.

  The reason for the thermal expansion in the horizontal direction and the vertical direction is that the wire diameter reduction rate of the raw material, the diameter of the base, the take-up speed of the conveyor, annealing, and the like are factors.

  The three-dimensional crosspiece structure of the present invention is processed from a resin production process to a molded body within a range that does not deteriorate the performance, and at any stage of commercialization, deodorant antibacterial, deodorant, antifouling, coloring, aroma, flame retardant In addition, functions such as incombustibility and moisture absorption / release can be imparted by processing such as addition of chemicals.

  Hereinafter, the present invention will be specifically described with reference to examples, but the present invention is not limited thereto. In addition, the measurement and evaluation of the characteristic value in an Example were performed as follows.

(1) Wire diameter (mm)
The resin yarn was cut out from the central portion of the sample, and the thickness of the resin yarn was measured 5 times with a caliper. The average value of the five measurements was taken as the wire diameter. Measured against S1 and S2. The wire diameter of the elastomer sample was estimated from the polyester measurement results. The temperature with annealing was 60 ° C., and the temperature without annealing was 23 ° C.

(2) Sample thickness and bulk density (g / cm ³ )
The sample was cut into a size of 30 cm × 30 cm and allowed to stand for 24 hours with no load, and then the height at four locations was measured to obtain the average value as the sample thickness. The volume was determined from the sample thickness, and the value obtained by dividing the weight of the sample by the volume was taken as the bulk density of the sample.

(3) Average diameter of random loop (mm)
The sample is cut into a size of 20 cm × 20 cm, the random circle of irregular shape formed on the surface in the extrusion direction is measured at 10 locations where the diameter of the loop circle is larger, and the average value is cut off to the millimeter or less. The average diameter of the random loop was used.

(4) Hardness (N)
The sample was cut into a size of 30 cm (length) × 30 cm (width), and this test piece was measured by applying the JIS K 6400-2: 2012 A method. The test temperature is 20 ° C. and the humidity is 65%.

(5) Rebound resilience (cm)
The sample was cut into a size of 30 cm (length) × 30 cm (width), and this test piece was measured by applying JIS K 6400-3: 2011. A steel ball having a diameter of 41.5 mm and a weight of 290 g was used. The drop height was 500 mm. The test temperature is 23 ° C. and the humidity is 50%.

(6) Rate of change in rebound resilience after constant load test (%)
A sample is cut into a size of 30 cm (longitudinal) × 30 cm (horizontal), and the impact resilience (a) before the constant gravity repeat test is measured by the method described in (5). A constant gravity repeated compression test is performed on the sample whose impact resilience was measured. The constant gravity repeated compression test is performed in accordance with the JISK6400-4 repeated compression residual strain test method A (constant load method). The repeated compression test is performed at a temperature of 23 ± 2 ° C and a relative humidity of 50 ± 5%. Method A (constant load method) uses a pressure plate with a diameter of 25 cm to compress the sample 80,000,000 times repeatedly at a speed of 70 ± 5 times per minute with a force of 750N ± 20N. The time during which the maximum force 750 ± 20N is applied is 25% or less of the time required for repeated compression. After the test, leave the sample for 100 ± 0.5 minutes without applying any force. The impact resilience (b) after the constant gravity test is measured by the method described in (5). The rebound resilience change rate (%) after the constant gravity test is calculated by the following equation, which is obtained by dividing the resilience after the constant gravity test by the rebound elasticity before the constant gravity test.
(Rebound resilience change rate after constant gravity test (%)) = (1- (b) / (a)) x 100

(7) Compression deflection coefficient (%)
The sample was cut into a size of 30 cm (length) × 30 cm (width), and the test piece was measured by applying JIS K 6400-2: 2012 E method. The test temperature is 23 ° C. and the humidity is 50%.

(8) Hysteresis loss (%)
The sample was cut into a size of 30 cm (length) × 30 cm (width), and the test piece was measured by applying JIS K 6400-2: 2012 E method.

(9) Thermal elongation before and after dry hot air test (%)
The sample was cut into a size of 30 cm (longitudinal) × 30 cm (horizontal), and marking was performed so as to be 25 cm in each of two places in the vertical and horizontal directions of the test piece. Marking was performed with a pen that can be easily identified even after the dry hot air test. The marked test piece was placed in a hot air drying furnace for 30 minutes. Then, the sample was taken out from the hot air circulation drying furnace and cooled at room temperature of 22 ° C. for 30 minutes. After cooling, the vertical and horizontal marking distances were measured at two locations, and the average value at each of the two locations was taken as the vertical length after the test and the horizontal length after the test. All lengths were measured using a measuring instrument capable of reading up to 0.01 cm. The thermal elongation rate before and after the dry hot air test was calculated by ( obtained length−25 ) / 25 × 100. The dry hot air test temperature of the polyethylene resin was 90 ° C., the dry hot air test temperature of the polyester thermoplastic elastomer was 130 ° C., and the dry hot air test temperature of the polyethylene resin and the polyethylene thermoplastic elastomer was 90 ° C.

(10) Tensile strength (N)
The sample was cut into a size of 20 cm (vertical) × 5 cm (horizontal), and this test piece was fixed to a jig so that the distance between the fixtures was 10 cm. The tensile speed was 10 cm / min. The room temperature at the time of measurement is 20 ° C., and the humidity is 65%. Since the thermoplastic elastomer has a thickness, a jig for fixing was used. The same sample was measured twice vertically and horizontally, and the maximum point load was taken as the measured value.

[Example 1]
Screw diameter of the extruder is 65mm, die temperature is 205 ° C, die width direction is 890mm, thickness direction is 75mm, hole pitch is 10mm, nozzle hole diameter is 1.6mm, air gap (distance from nozzle bottom surface to water surface) 67mm, main The raw material was polymerized hexane, hexene and ethylene by a known method using a metallocene compound as a catalyst, and the obtained ethylene / α-olefin copolymer had a linear diameter reduction rate of 1.05 and a shear rate of 60 with respect to a shear rate of 24.3 sec ⁻¹ . The wire diameter reduction rate for .8 sec ⁻¹ is 1.12, the wire diameter reduction rate for shear rate 121.6 sec ⁻¹ is 1.15, the wire diameter reduction rate for shear rate 243.2 sec ⁻¹ is 1.18, and the wire diameter for shear rate 608 sec ⁻¹ . Reduction rate is 1.23, wire diameter reduction rate for shear rate of 1216 sec ⁻¹ is 1.26, MFR is 12 g / 10 min, dense A wire having a degree of 0.90 g / cm ³ at a melting temperature of 180 ° C. and an extrusion rate of 86 kg / h is discharged below the nozzle, the lower end of the shooter is disposed 36 mm below the nozzle surface, and the lower end is submerged. A pair of take-up conveyors are arranged in parallel so that the stainless steel conveyors are parallel to each other with an opening width of 71 mm on the water surface, and the molten discharge line is supplied on the shooter with 36 ° C warm water on the shooter. The solidification process is performed, and the three-dimensional crosspiece structure is formed while the contact portions are intertwined to form a loop to fuse the contact portion, and both sides of the melted three-dimensional crosspiece structure are taken up. While being sandwiched in, the take-in speed is 6.7 mm / sec and drawn into 36 ° C. warm water, flattened on both sides, cut into a predetermined size, and annealed by 60 ° C. hot air for 5 minutes by dry heat treatment The three-dimensional crosspiece structure was obtained. The obtained three-dimensional crosspiece structure is formed of a strip having a quadrangular cross section and a line diameter of 0.6 to 1.1 mm, the surface is flattened, and the bulk specific gravity is 53 kg / m ³ , Thickness 75 mm, width 890 mm, 90 ° C., 30 minutes before and after drying hot air test, elongation ratio is 2.31% in the vertical direction, 1.52% in the horizontal direction, hysteris loss is 28.7%, rebound resilience is 31 cm, constant gravity repetition The impact resilience change rate after the test was 0%. The temperature was 19 ° C. and the humidity was 42%.

[Example 2]
The screw diameter of the extruder is 40 mm, the die temperature is 190 ° C., the die width direction is 500 mm, the thickness direction is 25 mm, the hole pitch is 10 mm, the nozzle hole diameter is 1.6 mm, the air gap (distance from the nozzle bottom surface to the water surface) is 38 mm, ethylene -A α-olefin copolymer (raw material is the same as in Example 1) polyethylene is melted at a temperature of 160 ° C., and a filament is discharged at an extrusion rate of 13 kg / h below the nozzle. The bottom end is submerged, and a stainless steel conveyor with a width of 55 cm is arranged in parallel so that a pair of take-up conveyors are partly exposed on the surface of the water at intervals of an opening width of 23 mm. The solidification process is performed by supplying warm water of 36 ° C onto the shooter at the same time, and the contact portions are intertwined to form a loop to fuse the contact portion. The three-dimensional crosspiece structure is formed while the both sides of the molten three-dimensional crosspiece structure are sandwiched by a take-up conveyor, and the take-up speed is 4.1 mm / sec. It cut | disconnected to the predetermined | prescribed magnitude | size and annealed by 60 degreeC hot air for 5 minutes by drying heat processing, and obtained the three-dimensional crosspiece structure. The obtained three-dimensional crosspiece structure is formed of a strip having a quadrangular cross section and a line diameter of 0.6 to 1.1 mm, the surface is flattened, and the bulk specific gravity is 70 kg / m ³ , Thickness 25mm, width 500mm, 90 ° C, thermal elongation rate before and after drying hot air test for 30 minutes is 1.87% in the longitudinal direction, 1.39% in the transverse direction, 28.6% in hysteresis loss, rebound resilience is 33cm, constant The rebound resilience change rate after the multiple repetition test was 6.1%. The temperature was 21 ° C. and the humidity was 48%.

[Example 3]
The screw diameter of the extruder is 65 mm, the die temperature is 217 ° C., the die width direction is 900 mm, the thickness direction is 30 mm, the hole pitch is 10 mm, the nozzle hole diameter is 1 mm, the air gap (distance from the nozzle bottom surface to the water surface) is 69 mm, the main raw material thermoplastic elastomer (trademark "Hytrel") wire diameter decrease rate for shear rate 60.8Sec ^-1 is 1.26, the diameter decrease rate for shear rate 121.6sec ^-1 1.28, for a shear rate 243.2Sec ^-1 as linear diameter reduction small ratio 1.30, diameter reduction rate is 1.30 for a shear rate of 608sec ^-1, wire diameter reduction rate is 1.33 for a shear rate of 1216 sec ^-1, MFR is 14 g / 10min, density 1.08 g / cm ^3, a melting temperature At 195 ° C., the filament is discharged at the extrusion rate of 27.5 kg / h below the nozzle, and the nozzle surface is 69 mm below the nozzle surface. The lower end of the rotor is placed and the lower end is submerged. A stainless steel conveyor with a width of 105 cm is arranged in parallel so that a pair of take-up conveyors are partly exposed on the water surface at intervals of an opening width of 70 mm. The solidification process is performed by supplying hot water of 63 ° C onto the shooter, and the three-dimensional crosspiece structure is formed by melting the contact part by fusing the contact line to form a loop. The both sides of the three-dimensional crosspiece structure in the state are sandwiched by a take-up conveyor, drawn and solidified at a take-up speed of 3.9 mm / sec, flattened on both sides, annealed with hot water at 80 ° C, and then cut into a predetermined size. Then, annealing was performed by dry heat treatment with hot air at 130 ° C. for 5 minutes to obtain a three-dimensional crosspiece structure. The obtained three-dimensional crosspiece structure is formed of a strip having a square cross section and a line diameter of 0.5 to 1.0 mm, the surface is flattened, the bulk specific gravity is 71 kg / m3, and the thickness is 30 mm, width 900 mm, 130 ° C., 30 minutes before and after the drying hot air test, the thermal elongation rate is 0.78% in the vertical direction, 1.70% in the horizontal direction, 17.1% in the hysteresis loss, 33 cm of rebound resilience, constant gravity repetition The impact resilience change rate after the test was 0%. The temperature was 33 ° C. and the humidity was 48%.

[Example 4]
The screw diameter of the extruder is 65 mm, the die temperature is 225 ° C., the die width direction is 900 mm, the thickness direction is 73 mm, the hole pitch is 10 mm, the nozzle hole diameter is 1.6 mm, the air gap is 69 mm (distance from the nozzle bottom surface to the water surface), heat A filament is discharged from a plastic elastomer (registered trademark “Hytrel”) (same raw material as in Example 3) at a melting temperature of 202 ° C., with an extrusion rate of 40 kg / h below the nozzle, and the lower end of the shooter is 69 mm below the nozzle surface The bottom end is submerged, and a 105cm wide stainless steel conveyor is placed in parallel with an opening width of 72mm so that a part of the pair of take-up conveyors comes out on the water surface. It is solidified by supplying warm water of 63 ° C onto the shooter, and the wire is intertwined to form a loop to fuse the contact portion and to form a three-dimensional beam. After forming the structure and sandwiching both sides of the molten three-dimensional crosspiece structure with a take-up conveyor, the take-up speed is 2.7 mm / sec, and the both sides are solidified by flattening both sides, and then annealed with hot water at 80 ° C. After cutting to a size of 1 mm and annealing with a hot air of 130 ° C. for 5 minutes, a three-dimensional crosspiece structure was obtained. The obtained three-dimensional crosspiece structure is formed of a strip having a quadrangular cross section and a line diameter of 0.5 to 1.2 mm, the surface is flattened, the bulk specific gravity is 63 kg / m ³ , the thickness is 73 mm, and it is dried. The thermal elongation rate before and after the hot air test is 1.22% in the vertical direction, 3.08% in the horizontal direction, 16.7% in the hysteresis loss, 34 cm in the rebound resilience, and 5.9% in the rebound resilience change rate after the constant gravity test there were. The temperature was 30 ° C. and the humidity was 44%.

[Example 5]
The screw diameter of the extruder is 40 mm, the die temperature is 195 ° C., the die width direction is 500 mm, the thickness direction is 51 mm, the hole pitch is 10 mm, the nozzle hole diameter is 1 mm, the air gap (distance from the nozzle bottom surface to the water surface) is 38 mm, ethylene An α-olefin copolymer (same material as in Example 1) mixed with a main component and a non-combustible material was discharged at a melting temperature of 160 ° C., and a line was discharged below the nozzle at an extrusion rate of 23 kg / h. The bottom of the shooter is placed 38mm below, the bottom is submerged, and a stainless steel conveyor with a width of 55cm is arranged in parallel so that a pair of take-up conveyors are partly exposed on the water surface at intervals of an opening width of 40mm. The strip is solidified by supplying 36 ° C warm water onto the shooter, and at the same time, the strip is contacted and intertwined to form a loop. A three-dimensional crosspiece structure is formed by fusing the parts, and the both sides of the molten three-dimensional crosspiece structure are sandwiched by a take-up conveyor and drawn into a hot water of 36 ° C. at a take-up speed of 6.8 mm / sec. Then, it was cut into a predetermined size and dried and heat-treated with hot air at 60 ° C. for 5 minutes to obtain a three-dimensional cross structure having a bulk density of 45 kg / m ³ . The obtained three-dimensional crosspiece structure is formed of a strip having a quadrangular cross section and a line diameter of 0.7 to 1.3 mm, the surface is flattened, the bulk specific gravity is 50 kg / m ³ , and the thickness is 51 mm. , Width 400 mm, 90 ° C., 30 minutes before and after the dry hot air test, the elongation rate is 2.68% in the longitudinal direction, 1.28% in the transverse direction, 27.0% in the hysteresis loss, the impact resilience is 24 cm, after the constant repetition test The rebound resilience change rate was 16.7%. The temperature was 15 ° C. and the humidity was 52%.

[Example 6]
Extruder screw diameter 40mm, die temperature 195 ° C, die width direction 500mm, thickness direction 25mm, hole pitch 10mm, nozzle hole diameter 1mm, air gap (distance from nozzle bottom surface to water surface) 38mm, metallocene compound Hexane, hexene and ethylene are polymerized by a known method using a catalyst as a catalyst, and the resulting ethylene / α-olefin copolymer (same material as in Example 1) as a main component is mixed with a nonflammable material at a melting temperature of 160 ° C. Then, the line is discharged below the nozzle at an extrusion rate of 17 Kg / h, the lower end of the shooter is placed 36 mm below the nozzle surface, the lower end is submerged, and a pair of stainless steel conveyors with a width of 55 cm are parallel with an opening width of 40 mm. Arrange the take-out conveyor so that it partially comes out on the surface of the water. -A solidification process is performed by supplying the material to the top, and a three-dimensional beam structure is formed by contact-entanglement of the filaments to form a loop and fuse the contact part to form a three-dimensional beam structure. While both sides are sandwiched by a take-up conveyor, the take-up speed is 4.5 mm / sec and solidified by drawing into hot water of 36 ° C., flattening both sides, cutting to a predetermined size, and drying heat treatment with hot air at 60 ° C. for 5 minutes Thus, a three-dimensional cross structure having a bulk density of 65 kg / m ³ was obtained. The obtained three-dimensional crosspiece structure is formed of a strip having a quadrangular cross section and a line diameter of 0.7 to 1.3 mm, the surface is flattened, the bulk specific gravity is 50 kg / m ³ , and the thickness is 43 mm. , 400 mm wide, 90 ° C., 30 minutes before and after drying hot air test, the thermal elongation rate is 2.06% in the vertical direction, 1.22% in the horizontal direction, 30.0% in hysteresis loss, rebound resilience of 32 cm, constant gravity repeated test The subsequent impact resilience change rate was 12.5%. The temperature was 21 ° C. and the humidity was 48%.

[Example 7]
Extruder screw diameter is 40mm, die temperature is 205 ° C, die width direction is 500mm, thickness direction is 60mm, hole pitch is 10mm, nozzle hole diameter is 1mm, air gap (distance from nozzle bottom surface to water surface) 38mm, metallocene Hexane, hexene, and ethylene are polymerized by a known method using the compound as a catalyst, and the resulting ethylene / α-olefin copolymer (same material as in Example 1) and olefin block copolymer (polyethylene thermoplastic elastomer) are in a weight ratio. At 20 ° C mixing and melting temperature of 200 ° C, the wire is discharged under the nozzle at an extrusion rate of 22Kg / h, the lower end of the chute is placed 39mm below the nozzle surface, and a stainless steel conveyor with a width of 55cm is opened in parallel. A pair of take-up conveyors are arranged so as to partially come out on the water surface at intervals of 40 mm, and the solidified treatment is performed by supplying the molten discharge line on the chute and supplying warm water of 29 ° C on the chute. With , The line is contact entangled to form a loop to fuse the contact part to form a three-dimensional crosspiece structure, and the take-up speed is 4.5 while sandwiching both sides of the molten three-dimensional crosspiece structure with a take-up conveyor. After solidifying by drawing into warm water of 29 ° C at mm / sec and flattening both sides, it is cut to a predetermined size and dried and heat-treated for 5 minutes with hot air of 60 ° C, a tertiary with a bulk density of 65 kg / m ³ A former crosspiece structure was obtained. The obtained three-dimensional crosspiece structure is formed by a strip having a quadrangular cross section and a line diameter of 0.8 to 1.5 mm, the surface is flattened, the bulk specific gravity is 65 kg / m ³ , and the thickness is 50 mm. , Width 405mm, 90 ° C, 30 minutes before and after drying hot air test, the thermal elongation rate is 3.04% in the vertical direction, 2.72% in the horizontal direction, 29.1% in the hysteresis loss, the resilience is 16cm, the change in the resilience after the constant gravity test The rate was 5.5%. The temperature was 12 ° C and the humidity was 45%.

[Comparative Example 1]
As a result of performing each test on a network structure (thickness: 45 mm, width: 400 mm) made of a polyester-based thermoplastic elastomer of a mattress made by another company, heat before and after a dry hot air test with a bulk specific gravity of 40 kg / m ³ and 130 ° C. for 30 minutes Elongation rate is -0.32 (shrinkage) in the vertical direction, -0.12% (shrinkage) in the horizontal direction, hysteris loss is 70.4%, rebound resilience is 22 cm, rebound resilience change rate after constant-gravity test 68.2 %Met.

[Comparative Example 2]
As a result of performing each test on a polyester thermoplastic elastomer network structure (thickness: 25 mm, width: 400 mm) made of another company's mattress different from Comparative Example 1, the bulk specific gravity was 50 kg / m ³ , 130 ° C, 30 minutes. The thermal elongation rate before and after the dry hot air test was −0.28 (shrinkage) in the longitudinal direction, −0.20% (shrinkage) in the transverse direction, 81.0% of hysteresis loss, 21 cm of impact resilience, The rebound resilience change rate was 4.8%.

  As described above, according to the present invention, since it has a thermal expansion property that thermally expands in the vertical direction and the horizontal direction, for example, when used in a mattress, even when disinfected at a high temperature, the mattress shrinks and the cover becomes wrinkled. The pressure ulcer caused by wrinkles is less likely to occur and is suitable. In addition, since it has anisotropic thermal expansion characteristics with different thermal expansion rates in the vertical and horizontal directions, it can be adapted to the application of the three-dimensional crosspiece structure and the characteristics of the human body in that application.

  Furthermore, since the hysteresis loss is small and it has a soft high resilience characteristic, it is possible to provide an elastic characteristic that matches the characteristics of the human body, and to meet the diversification of the demand for the elastic characteristic of the product and the sophistication of the quality requirement for the product.

  Applications include not only mattress materials and mattresses, but also cushions, cushions, and cushions for the disabled. Sometimes polyethylene and thermoplastic polyester elastomer are laminated.

  The present invention is not limited to the above-described embodiment, and various modifications, substitutions, deletions, etc. can be made without departing from the technical idea of the present invention. Loss and the like are also included in the technical scope of the present invention.

  The present invention has a small hysteresis loss, has a soft high resilience characteristic, has a thermal elongation characteristic that is thermally elongated by a dry hot air test in the longitudinal direction and the transverse direction, and has different thermal elongation characteristics in the longitudinal direction and the transverse direction. We can provide vehicle seats, cushions, mattresses, covers, etc. with elastic properties that fit the health consciousness. In particular, soft and easy-to-extend cushions such as pressure ulcers and nursing care can be provided. It can also be used for cushions used for vehicle seats, beds, mats, etc., and seats used for covers.

Claims (9)

Polyethylene-based thermoplastic resin, polyester-based thermoplastic, which has a longitudinal direction corresponding to the extrusion direction, a transverse direction orthogonal to the extrusion direction, and a thickness direction, by forming continuous loops by partially welding the continuous filaments at random. It is a three-dimensional crosspiece structure comprising an elastomer or a mixture of a polyethylene-based thermoplastic resin and a polyethylene-based thermoplastic elastomer,
The three-dimensional cross structure is a three-dimensional network structure having a cross-like dense and dense structure in which the bulk density and the dense portion are alternately expressed in the extrusion direction,
30 minutes at a temperature of 90 ° C. in the case of a polyethylene-based thermoplastic resin, 30 minutes at 130 ° C. in the case of a polyester-based thermoplastic elastomer, or 30 ° C. at a temperature of 90 ° C. in the case of a mixture of a polyethylene-based thermoplastic resin and a polyethylene-based thermoplastic elastomer. A three-dimensional crosspiece structure having a thermal elongation rate of 0 to 8% in the longitudinal direction before and after the dry hot air test after a minute hot air test.   30 minutes at a temperature of 90 ° C. in the case of a polyethylene-based thermoplastic resin, 30 minutes at 130 ° C. in the case of a polyester-based thermoplastic elastomer, or 30 ° C. at a temperature of 90 ° C. in the case of a mixture of a polyethylene-based thermoplastic resin and a polyethylene-based thermoplastic elastomer. The three-dimensional crosspiece structure according to claim 1, wherein the thermal elongation rate before and after the dry hot air test is 0 to 8% in the lateral direction after the dry hot air test for minutes.   The three-dimensional crosspiece structure according to claim 1 or 2, wherein the three-dimensional crosspiece structure has anisotropic thermal expansion characteristics in which the thermal expansion rates in the vertical direction and the horizontal direction are different.   The three-dimensional crosspiece structure according to any one of claims 1 to 3, wherein a rate of change in impact resilience after a constant load repeated test is 20% or less. The apparent density of the three-dimensional bar structure is ^{0.025g / cm 3 ~0.2g / cm 3} , the thickness was 5mm~500mm in monolayer and multilayer, wire diameter diameter 0.1Mm～1. The three-dimensional crosspiece structure according to any one of claims 1 to 4, which is 5 mm.   6. The three-dimensional beam according to claim 1, wherein the polyethylene-based thermoplastic resin is polyethylene or an ethylene / α-olefin copolymer resin mainly composed of ethylene and an α-olefin having 3 or more carbon atoms. Structure.   The mixture of the polyethylene-based thermoplastic resin and the polyethylene-based thermoplastic elastomer is a mixture of an ethylene / α-olefin copolymer resin mainly composed of ethylene and an α-olefin having 3 or more carbon atoms and a polyethylene-based thermoplastic elastomer, and the mixture The three-dimensional crosspiece structure according to any one of claims 1 to 5, wherein a content of the polyethylene-based thermoplastic elastomer is 45% or less by weight.   The three-dimensional crosspiece structure according to any one of claims 1 to 7, wherein the three-dimensional crosspiece structure is used for a cushion, a cushion sheet, a cushion, a pillow, a care product, a bed cushion, or a mattress.   The three-dimensional crosspiece structure according to any one of claims 1 to 8, comprising a plurality of surfaces, and two, three, or four of them are formed.