JPH0531269A - Production of composite mat - Google Patents

Abstract

PURPOSE:To improve a cushion property and to impart a high grade feel by spraying fine synthetic resin fibers to a mat-like layer entangled with relatively thick synthetic resin filaments like a non-woven fabric and a three-dimensional network structure form so as to entangle these fibers with the above-mentioned filaments. CONSTITUTION:Pellets made of the thermoplastic synthetic resin are charged into a hopper 11 and the mat-like layer Y entangled with the relatively thick synthetic resin filaments like the non-woven fabric and the three-dimensional network structure form is supplied from a supplying section 22 onto a conveyor 21. While the pellets are delivered in a cylinder 12 by a screw 14, the pellets are heated by a heater 15 and the melt flows toward a spinning mouthpiece 16 of a die 13 and is blown out in the form of yarn by the air flow of a high temp. and high velocity from an ambient hot wind ejection port 17. The yarn gathers on the layer Y. The yarn-like synthetic resins infiltrate the layer Y to some extent and adhere to each other to form the bulky composite mat M1 in which the synthetic resins entangle each other. The cushion property is improved in this way and the composite mat which is coated densely with the fibers on the surface and has the high-grade feel is obtd.

Description

Detailed Description of the Invention

[0001]

[Object of the Invention]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a so-called mattress, a sheet, a mat production method as a cushioning material for interior decoration and the like.

[0002]

BACKGROUND OF THE INVENTION The applicant of the present invention has said that fibers of coconut plants such as so-called palm skin and coconut mesocarp fiber are fishing nets, ropes, brooms, scrubbers, rugs, etc. Considering that it has been used near soil, we invented a method for producing a coconut fiber-based composite mat that made advanced use of it, and have already applied for a patent for it, but this method was obtained from a plant after all. It was not suitable for mass production because it tried to process it into what was used. However, this method should not be applied only to palm fiber, and it can be similarly treated if it is essentially the same as palm fiber and can be obtained in a large amount. You should get something similar to.

[0003]

[Technical Items Attempted to Develop] Therefore, the present invention relates to a method for producing a coconut fiber-based composite mat according to the present applicant, in which a wide and relatively thick synthetic resin filament is entangled in a non-woven fabric or a three-dimensional network structure. It is applied to a mat-like layer formed by combining the layers, so that a large amount of a composite mat having improved cushioning properties and imparting a high-grade feeling can be obtained.

[0004]

[Constitution of the invention]

[Means for Achieving the Object] That is, the method for producing a composite mat according to the first invention of the present application is directed to a mat-shaped layer formed by intertwining relatively thick synthetic resin filaments in a non-woven fabric-like or three-dimensional network form. The method further comprises the step of spraying the synthetic resin fine fibers together with the fluid flow and intertwining the mat-shaped layer and the synthetic resin fine fibers.

In the method for producing a composite mat according to the second invention of the present application, a relatively thick synthetic resin filament is entwined in a non-woven fabric-like or three-dimensional network form into a mat-like layer, and Coating each filament,
The method is characterized by including a step of applying a separate stock solution of a viscoelastic substance while leaving pores between the filaments, and a step of subsequently heating to cure the viscoelastic substance coating the filament.

Furthermore, in addition to the above, in the method for producing a composite mat according to the third invention of the present application, in addition to these, the raw material of the synthetic resin filament or the synthetic resin fine fiber includes a deodorant, an aromatic agent, an antibacterial agent, and an insect repellent. It is characterized in that one or a plurality of agents selected from the group consisting of an agent, an insecticide and an insecticide are mixed.

In addition to these, the method for producing a composite mat according to the fourth invention of the present application is, in addition to these, a deodorant, an aromatic, an antibacterial agent,
After one or more fine powder chemicals selected from insect repellents, repellants and insecticides are embedded or adhered to porous synthetic resin fine powder by mechanical impact means, the chemical-loaded particles are used as a raw material. And a synthetic resin filament or a synthetic resin fine fiber is obtained by spinning at a melting temperature of the porous synthetic resin fine powder immediately before reaching the spinneret.

In addition to these, the synthetic resin filament or the synthetic resin fine fiber is the oxide-based fine powder deodorant immediately after spinning out of the spinneret. Is sprayed on. Therefore, the above object is to be achieved.

[0009]

The method for producing a composite mat according to the present invention is basically based on a mat-like layer formed by entwining relatively thick synthetic resin filaments in a non-woven fabric-like or three-dimensional network form and synthesizing the same. Whether to entangle resin fine fibers,
It forms a film of viscoelastic material, improves the cushioning properties of the mat-like layer, and gives the low-grade image of a relatively thick filament a high-class impression. In addition, the raw materials for synthetic resin filaments and synthetic resin fine fibers include deodorants, fragrances, and
By mixing chemicals such as insect repellent, not only the image but also the actual clean and scent. Furthermore, by forming a film of a viscoelastic substance, the cushioning property becomes viscous and gives a heavy feeling. Further, by spraying the fine powder chemicals immediately after spinning, the action of the chemicals becomes direct.

[0010]

EXAMPLES A mat-like layer formed by intertwining relatively thick synthetic resin filaments, which are the constituent elements of the present invention, in a non-woven fabric-like or three-dimensional network form, a viscoelastic substance, a deodorant, an aromatic, and an insect repellent Agents such as agents, oxide-based fine powder deodorant,
The porous synthetic resin fine powder and the like will be sequentially described, and then the illustrated examples will be specifically described.

In the present invention, a mat-like layer formed by intertwining relatively thick synthetic resin filaments in a non-woven fabric-like or three-dimensional network form has a fiber diameter of at least the above-mentioned coconut fiber or more. It is preferable to have a hardness and softness equal to or higher than that,
If the whole is entangled in a relatively coarse non-woven fabric, or entangled in a three-dimensional network structure, and if it has appropriate cushioning properties and can expand, contract, bend, and deform, the material is thermoplastic , Whether it is thermosetting or not. Further, the filament may be an original monofilament fiber obtained as a single filament in the spinning step, or a multifilament as long as it is strong, and further, for example, this may be formed by foam-forming a synthetic resin and then The remaining skeletal structure may be obtained by immersing it in an appropriate solvent or the like to dissolve only the film structure. And this is usually about 5 mm to 50 mm, and 10 mm to 300 by stacking these.
The thickness is about mm. Such a mat-like layer formed by intertwining relatively thick synthetic resin filaments in a non-woven fabric-like or three-dimensional network form is different from an ordinary non-woven fabric made of thin synthetic resin fibers, and can be lifted, for example. It retains a certain shape and deforms only when a load is applied, and exhibits so-called cushioning properties.

In the present invention, the mat-shaped layer formed by intertwining such relatively thick synthetic resin filaments in a non-woven fabric-like or three-dimensional network form is used as the ordinary thin synthetic resin in a non-woven fabric. Entangle the fibers. As the synthetic resin raw material, various synthetic resins such as nylon, vinylon, vinylidene, urethane, polyethylene, polypropylene and acrylic can be applied, and even in the spinning method, melt spinning, other, polymer spinning, Appropriate methods can be applied depending on the material, regardless of whether it is a dry method or a wet method.

In the present invention, a filament in a mat-shaped layer formed by intertwining the relatively thick synthetic resin filament in a non-woven fabric-like or three-dimensional network form is coated with a viscoelastic substance, or the mat-shaped layer is formed. Each viscoelastic substance that can be partially or entirely impregnated will be described.

First, silicone gel is a suitable viscoelastic substance. The silicone gel is, for example, a diorganopolysiloxane (hereinafter referred to as component A) which is a stock solution of the silicone gel represented by the following formula [1]: RR ¹ ₂ SiO— (R ² ₂ SiO) _n SiR ¹ ₂ R ... [1] [ However, R is an alkenyl group, R ¹ is a monovalent hydrocarbon group having no aliphatic unsaturated bond, R ² is a monovalent aliphatic hydrocarbon group (at least 50 mol% of R ²
Is a methyl group, and when it has an alkenyl group, its content is 10 mol% or less), and n is the viscosity of this component at 25 ° C. is 100 to 100,000 cSt.
The viscosity at 25 ° C is 50
00cSt or less and at least 2 S in one molecule
Organohydrogenpolysiloxane (B) which is a stock solution of a silicone gel having a hydrogen atom directly bonded to an i atom.
Component) and the ratio (molar ratio) of the total amount of alkenyl groups contained in the component A to the total amount of hydrogen atoms directly bonded to the Si atoms in the component B is 0.1.
It is an addition reaction type silicone polymer obtained by curing a mixture adjusted to 2.0.

The curing reaction is usually carried out using a catalyst, and the components A, B and the catalyst are mixed and allowed to stand at room temperature or heated to cure them before use in the present invention. A silicone gel forms. When heating and curing, the heating temperature is usually 50 to 160 ° C. The silicone gel obtained in this way is compliant with JIS
(K2207-1980, 50 g load) has a penetration of usually 5 to 250. The hardness of such a silicone gel varies depending on the cross-linking structure formed by the A component and the B component. The viscosity of the silicone gel before curing and the degree of penetration after curing are 5 to 5 times that of silicone oil obtained by using silicone oil having methyl groups at both ends.
It can be adjusted by adding in advance in an amount within the range of 75% by weight. Examples of commercially available products that can be used in the present invention include CF5027, TOUGH-3, TOUGH- manufactured by Toray Dow Corning Silicone Co., Ltd.
4, TOUGH-5, TOUGH-6, TOUGH-7
X32-902 / cat1 manufactured by Shin-Etsu Chemical Co., Ltd.
300, KE1308 / cat1300-L4, F250-121 manufactured by Nippon Unica Co., Ltd., and the like.

In addition to the components A, B and catalysts described above, pigments, curing retardants, flame retardants, conductive fillers, etc. may be added within a range that does not impair the properties of the silicone gel. In order to improve vibration isolation and cushioning properties, a silicone gel mixed with a filler of micro hollow spheres may be used, and such filler material may be Philite (registered trademark) manufactured by Nippon Philite Co., Ltd. Examples include Expancel (registered trademark) and Matsumoto Yushi-Seiyaku Co., Ltd. Matsumoto Microspheres.

In addition to the above silicone gel, polybutadiene gel is suitable as a viscoelastic substance. An example of this is Poly b manufactured and sold by Idemitsu Arco Co., Ltd.
There is dR-45HT. This is a polybutadiene type liquid polymer having a highly reactive hydroxyl group at the molecular end, and is easily cured by an isocyanate to give a good viscoelastic body as in ordinary polyurethane. The polybutadiene gel has excellent water resistance, chemical resistance, and electrical characteristics because the main chain is composed of only hydrocarbons, and also has good low-temperature characteristics because the skeleton has 1,4 bonds. . Further, since it is in a liquid state, it has an advantage that it is easy to process and continuous. After appropriately adding various compounding agents and first mixing, a curing agent is added and secondarily mixed and used.

The compounding agents include carbon black, silica, alumina, and calcium carbonate as fillers for strength, hardness, and heat resistance, and process oil and asphalt as extenders for viscosity adjustment. There is dibutyltin dilaurate as a catalyst for the adjustment of, and heat resistance is improved, and as an antioxidant, Irganox 565 manufactured by Ciba-Geigy Co., Knock Rack NS-6 manufactured by Ouchi Shinko Chemical Co., Ltd. There is TINUVIN 327 manufactured by Ciba-Geigi Co., Ltd. as an ultraviolet absorber, aluminum hydroxide, borax, chlorinated paraffin and antimony oxide as flame retardants, and rylene diisocyanate and methylene diisocyanate as curing agents.

And as a preferred example, the above R-45H is used.
100 parts of T, 0.005 parts of TAS750 manufactured by Shin-Etsu Silicone Co., Ltd. as an antifoaming agent, and 0.005 parts of DBTDL KS-1260 manufactured by Kyodo Chemical Co., Ltd. as a catalyst.
5 parts, 8.3 parts of Millionate MR-200 (NCO content 30.9% by weight) manufactured by Nippon Polyurethane Industry Co., Ltd. as a curing agent, and Microsphere F manufactured by Matsumoto Yushi-Seiyaku Co., Ltd. as micro hollow spheres. -8
Using 1 part of 0ED, first, the components excluding the internal curing agent were sufficiently stirred and mixed at room temperature, and then the curing agent was added to the mixture. Degas and use. The polybutadiene gel thus obtained has a buffering property close to that of the silicone gel and is relatively inexpensive as compared with the silicone gel. Other,
Many of the materials called vibration damping paints, soundproofing paints, and sealing materials exhibit viscoelasticity and are often inferior to the former two in terms of temperature characteristics, but they are very advantageous in terms of price, so they are inexpensive. It is recommended to use this for various products. With something like this, the underside of cars and fenders of railroad cars, fenders,
An inexpensive material that is applied to outer panels and has the effects of soundproofing, rustproofing, heat insulation, and the like is, for example, Knitquaunderseal (trademark) sold by Nippon Special Coating Co., Ltd.

With respect to these viscoelastic substances, the stock solution before curing is sprayed on the mat-shaped layer in a film form, or the whole mat-shaped layer is once impregnated and then covered with a film by an appropriate means. Excessive undiluted solution can be jetted out to coat the filaments, or these viscoelastic substances can be partially or entirely impregnated and used. When the mat-shaped layer is coated with these viscoelastic substances, the elasticity of the original filament is added to the appropriate flexibility and restoration delay of the viscoelastic substance, and the mat-shaped layer is thick and thick. It comes to have cushioning properties. If the hardness of the gel-like substance is about 100 or more, the surface of the substance becomes sticky, and in such a case, a non-sticky skin layer may be formed. In addition, by impregnating the viscoelastic substance, the layers of the viscoelastic substance are synergistically buffered, vibration-proof, sound-proof and sound-absorbing.

Next, deodorant, fragrance, antibacterial agent, insect repellent,
Medications such as anaerobics and insecticides will be described. First, examples of the deodorant include activated carbon, zeolite, cristobalite, amyone, aluminum orisophosphate, a tightly bound body of titanium oxide, zinc oxide and water molecules, and an anico plant extract. Zeolite adsorbs polar molecules such as water and ammonia and sulfur-based gases such as hydrogen sulfide well.
In addition, activated carbon exhibits excellent adsorption ability at low temperatures. Cristobalite is a kind of silicate mineral formed by diatomaceous earth, which is a kind of algae, that became diatomaceous earth for a long time and was further burned by volcanic magma, and has a high adsorption rate of ammonia. Amyeon is a powder composed of natural minerals and has the ability to deodorize by biological action in the soil and the physical and chemical action of rocks and minerals. Aluminum orthophosphate adsorbs ammonia and amines well. Anico is a green-blue liquid that contains ferrous sulfate as a main component and L-ascorbic acid as an oxidation inhibitor. The plant extract includes, for example, flavanols extracted from the Camelliaceae plants represented by tea, flavanols, conifers, and broad-leaved tree extracts. Of these various deodorants, activated carbon, zeolite, cristobalite, amyon, aluminum orthophosphate, etc. are all powders, so they can be mixed as they are with the synthetic resin raw material, or can be mixed with the porous synthetic resin fine powder described below. After that, it can be mixed and spun. Also,
In the case of liquid anico and plant extracts, compatibility with the raw material of the synthetic resin can be considered and applied.

Of the deodorizing agents, the oxide fine powder deodorizing agent represented by the close-bonded body of titanium oxide, zinc oxide and water molecules will be described in more detail. This deodorizing agent is used as a standard for comparative evaluation of deodorizing power. It is particularly excellent in low-temperature and low-concentration adsorption properties of ammonia and hydrogen sulfide. It lowers malodorous molecules by catalytic action, and zinc oxide chemically adsorbs acidic gas, and titanium dioxide physically adsorbs alkaline gas. Then it is considered. And this one is
In addition to its excellent deodorizing ability, it is a fine powder with a particle size on the order of microns or submicrons, and is white,
There are advantages that it gives a feeling of cleanliness and that coloring is effective. And
According to Japanese Patent Laid-Open No. 63-54935, an aqueous solution of a water-soluble titanium compound and a water-soluble zinc compound is mixed with an alkaline aqueous solution, and the resulting precipitate is dried. , Titanium sulphate, titanium chloride, titanium nitrate, zinc sulphate, zinc chloride, zinc nitrate, etc. in a mixed aqueous solution of titanium compound and zinc compound in a molar ratio of 7: 3 to 3: 7, sodium hydroxide and water. A portion or all of an aqueous alkali solution such as potassium oxide, barium hydroxide, or ammonia is added at a reaction temperature of 40 to 60 ° C., and finally a pH of 7 to 9 is reached.
It is preferred that the precipitate is mixed in the range of 1 to 3, and the resulting precipitate is dried at 150 to 220 ° C., and it is available from Titanium Industry Co., Ltd. as a TZ deodorant. Similar oxide-based fine powder deodorants include a combination of zinc oxide, aluminum oxide, and silicon oxide (see JP-A-63-246167), a combination of titanium oxide, zinc oxide, magnesium oxide, and calcium oxide ( JP-A-63-185445 and JP-A-63-183065) are available and can be used in the same manner.

As the fragrance, natural fragrances of animals and plants, synthetic fragrances, prepared fragrances, etc. are used as they are, or those obtained by emulsifying these fragrances and spray-drying to powder. As an antibacterial agent, since a close-bonded body of the titanium oxide, zinc oxide and water molecules can also exhibit antibacterial properties, it can be applied focusing on this effect, in addition to other metal oxides, silver, copper and other metals. Fine particles and the like can be applied. As insecticides, for example, fenitrothion for mites, organic phosphoric acid such as fenthion, and pyrethroids that collectively refer to natural pyrethrins and synthetic pyrethrin compounds,
Others include nicotine and pyrethrum. As the insect repellent, paradichlorobenzene, a combination of allenin and piperonyl ptoxide, a powdered version of Emicon or the like can be used. Further, examples of the repellant include N, N-dimethyl-m-toluamide, which has a strong repellency against tropical mosquitoes.

The mixing of these chemicals means mixing into the synthetic resin filament or the raw material of the synthetic resin fine fiber entangled with the filament. However, when the raw material is a combination of two or more kinds of chemical substances, these are mixed. It also includes chemical substances. That is, taking nylon 6.6 fiber as an example, in addition to nylon 6.6, which is a synthetic resin that has not yet been made into a fiber by polymerization of adipic acid and hexamitylenediamine, and nylon 6.6 itself. It also contains the raw materials adipic acid and hexamethylenediamine. Therefore, in the case of mixing the drug into the synthetic resin raw material, after the polymerization of adipic acid or hexamethylenediamine, the drug may be mixed in a state before spinning,
Further, either or both of adipic acid and hexamethylenediamine may be mixed with a drug, and these may be polymerized. Also, since these drugs do not have to be completely buried in the synthetic resin, mixing the drugs is
For example, it also includes the case where the powder of these chemicals is sprayed onto the fibers in the molten or softened state immediately after leaving the spinneret to partially bury them and adhere.

Next, the porous synthetic resin fine powder on which the above-mentioned drug is once carried will be described. This porous synthetic resin fine powder generally has a particle size of about 0.1 μm to 100 μm, and its surface morphology is formed into various shapes of irregularities, pores, and grooves, such as nylon powder and polyethylene. Powder, acrylic powder, styrene powder,
Various synthetic resins such as ABS powder and polypropylene powder are used, and materials having compatibility and affinity with raw materials of synthetic resin filaments or synthetic resin fine fibers are used.

In using the porous synthetic resin fine powder, first, one or a plurality of the chemicals are embedded or fixed in the porous synthetic resin fine powder by using a mechanical impact means. For this, the conventional mechanical surface modification method can be applied, and the mechanical properties mainly based on impact force are dispersed while the porous synthetic resin fine powder and the fine powder chemical are dispersed in the gas phase in the same processing chamber. Thermal energy is applied to the particles to embed or fix the fine powder drug in the porous synthetic resin fine powder. The particles in such a state are defined as drug-carrying particles. Incidentally, as a treatment method of this kind, a method such as sandblast can be applied, and further, Japanese Patent Laid-Open No. 62-83029,
JP 62-262737 A and JP 62-2984.
The method described in No. 43 etc. can be adopted. As such a processing machine, there is a Nara hybridization system manufactured by Nara Machinery Co., Ltd., or an Angmill manufactured by Hosokawa Micron Co., Ltd. In addition to the mechanical surface modification method, for example, when the diameter of the pores formed in the porous synthetic resin fine powder is large and the diameter of the fine powder drug is relatively small, It is also possible to mix and fill the porous synthetic resin fine powder and the fine powder drug in advance, and give impact force with a piston to embed or fix the fine powder drug in the porous synthetic resin fine powder.

Next, the illustrated embodiment will be described. Figure 1
In FIG. 1, 1 is a melt spinning apparatus by a melt-blowing method, which is a kind of so-called jet spinning method, in which a hopper 11, a cylinder 12 and a die 13 are internally communicated with each other to form a cylinder 12.
A screw 14 is arranged inside, a heater 15 is arranged around the cylinder 12, a die 13 has a double nozzle shape, and a spinneret 16 which is porous and communicates with the cylinder 12 is provided in the center. A hot air jet 17 is provided around the periphery. The hot air outlet 17 continues to a hot air generator (not shown). Reference numeral 2 denotes a mat-shaped layer Y supply device in which relatively thick synthetic resin filaments are entwined in a non-woven fabric-like or three-dimensional network form, and is an endless belt-shaped conveyor 21 and the mat-shaped layer Y. And a supply unit 22 that sequentially supplies the conveyor R while supporting the rolled roll R.

Therefore, thermoplastic resin pellets as a raw material for the synthetic resin are put into the hopper 11, while a relatively thick synthetic resin filament is fed from the supply section 22 onto the conveyor 21 in a non-woven fabric-like or three-dimensional network form. When the mat-shaped layer Y formed by intertwining with each other is supplied, the pellets of the thermoplastic resin are melted by the heating of the heater 15 while being fed through the cylinder 12 by the screw 14, and the spinneret 16 of the die 13 is melted. To a non-woven fabric or third-order filament made of a relatively thick synthetic resin that is moving downward at a low speed. It is accumulated on a mat-shaped layer Y which is intertwined in the original network. At this time, a mat-shaped layer Y itself formed by entwining relatively thick synthetic resin filaments in a non-woven fabric-like or three-dimensional network form, in which fibers are entangled, and relatively coarsely and entangled Therefore, the thread-shaped synthetic resin sprayed from above penetrates between the mat-shaped layers to some extent in the layer, and the bulky mat-shaped layer and synthetic resin fine fibers based on the mat-shaped layer are formed. It becomes a composite mat M1 which is mixed and entangled with. The spinneret 16
Immediately after being discharged from the filamentous synthetic resin, since the cooling is still insufficient, it has adhesiveness and adheres to the filaments of the mat-like layer, and also self-adheres to each other, and the whole uses an adhesive. Be combined without. Here, when the filament-shaped blowing is not performed over the entire width of the mat-like layer Y in which filaments made of a relatively thick synthetic resin are entwined in a non-woven fabric-like or three-dimensional network form, the die 13 is used. Of course, a large number of filaments made of synthetic resin are entwined in a non-woven fabric-like or three-dimensional network structure by oscillating the die 13 or the conveyor 21 as well as arranging them in parallel. The synthetic resin fine fibers are entwined over the entire surface of the layer Y. Further, in this example, a mat-shaped layer Y formed by intertwining relatively thick synthetic resin filaments in a non-woven fabric-like or three-dimensional network form.
Since many synthetic resin fine fibers tend to be present on the upper surface of the above, it is preferable that the synthetic resin fine fibers are entangled with the synthetic resin fine fibers from the back side again after turning upside down. The composite mat M1 thus obtained is a composite product in which a synthetic resin fine fiber and a mat-like layer formed by intertwining relatively thick synthetic resin filaments in a non-woven fabric-like or three-dimensional network form are integrated. As a result, the cushioning property of the original mat-like layer is improved, and the surface is densely covered with fine fibers to give a high-class feeling.

Next, a specific example in which a more effective composite mat is obtained will be described. This is performed by adding one or more of deodorants, aromatics, insect repellents and other chemicals in addition to the synthetic resin raw material. Hereinafter, an example in which an oxide-based fine powder deodorant, titanium oxide, zinc oxide, and a tightly bound body of water molecules are used as a chemical agent will be described. In addition, the fine particles of a tightly bound body of titanium oxide, zinc oxide, and water molecules are simply referred to as TZ.

FIG. 2 shows that, directly below the die 13 in FIG.
The TZ jetting part 31 and the collecting part 32 are sequentially arranged, and the TZ is sprayed onto the synthetic resin fine fibers which are blown out from the spinneret in a filament shape and still have adhesiveness, and the TZ is the surface of the synthetic resin fine fibers. It is an example in which a relatively thick synthetic resin filament is entwined with a mat-shaped layer Y formed by entwining it with a non-woven fabric-like or three-dimensional network form in a fixed manner. Therefore, TZ is placed on the air stream and jetted out. This air stream is adjusted in wind direction, wind speed, air volume, etc. so as not to disturb the stream blown out in a filament form from the spinneret, and at the softening temperature of the synthetic resin. It is better to keep it as hot air. The synthetic resin fine fibers in which TZ is thus impregnated are of course useful as a matter of course, and the mat-like layer-based composite mat M2 in which the TZ is intertwined is also used.
The direct deodorizing action and antibacterial action of TZ prevent the generation of unpleasant odors and mites.

However, according to this example, since TZ is exposed on the synthetic resin fine fibers, there is a drawback that when the fibers are repeatedly deformed and the fibers are rubbed against each other, the powder is relatively easily removed. . However, if TZ is directly mixed with the raw material of the synthetic resin, the TZ aggregates, the spinneret is blocked, and continuous spinning cannot be performed.

Then, next, in order to improve this problem,
After the TZ is once supported on the porous synthetic resin fine powder,
An embodiment in which this is mixed with the raw material of the synthetic resin fine fiber will be described. In this example, as shown in FIG. 3, first, a porous synthetic resin fine powder A, which is the same as the raw material of the synthetic resin fine fibers or has a good compatibility and a good affinity, and TZ are mixed by stirring, and then a cylindrical container 41 is formed. Fill inside. Then, after closing the container 41 with the piston-shaped lid 42, the crank 43 is rotated to impact-impact the porous synthetic resin fine powder A and TZ. By this mechanical impact force, TZ is embedded or fixed in the porous synthetic resin fine powder A. As a result, as shown in FIG. 4, the porous synthetic resin fine powder A becomes the drug-supporting particles B by supporting TZ in its pores H. Therefore,
If the drug-carrying particles B are put into the hopper 11 in FIG. 1 together with the raw material pellets of synthetic resin fine fibers, TZ
Thus, a composite mat in which the synthetic resin fine fibers containing is entangled can be obtained.

FIG. 5 shows, just before the spinneret, a pellet N mixed with a drug mixed with a raw material of a synthetic resin based on the drug-supported particles and a master pellet P which is a raw material of a synthetic resin fine fiber. In this example, the synthetic resin fine fibers spun at the melting temperature of the porous synthetic resin fine powder in the drug-carrying particles are entangled with the mat-shaped layer. In the figure, 11 is a master pellet P,
Further, a hopper serving as an input port for the drug-mixed pellet N, 12 is a cylinder, 13 is a die, 14 is a screw, 15a is a heater for the first half of the cylinder, and 15b is a heater immediately before the spinneret. In the master pellet P and the drug-mixed pellet N, the degree of polymerization and the like of the porous synthetic resin fine powder in the drug-mixed pellet N are adjusted so that the melting temperature is higher than that of the master pellet P, while the melt spinning apparatus is used. In the heater 15a, the master pellet P is melted, but the porous synthetic resin fine powder in the drug-containing pellet N is raised to a temperature at which it is not melted, and the heater 15b is used in the drug-mixing pellet until the spinneret. The fine powder of porous synthetic resin in N is also raised to a temperature at which it can be melted. For this reason, in the first half of the cylinder 12, since the porous synthetic resin fine powder is not heated to the temperature until it melts even if it softens, TZ reaches the latter half of the cylinder 12 as the drug-carrying particles, and is spun. Since the porous synthetic resin fine powder melts only immediately before the spinneret, TZ does not aggregate and does not block the spinneret, and is uniformly dispersed in the filamentous synthetic resin and blown out. In this example, the degree of polymerization of the porous synthetic resin fine powder in the drug-mixed pellet N was adjusted so that its melting temperature was higher than that of the master pellet P, but the present invention is not limited to this. In the pellet N, the base synthetic resin in the drug-mixed pellet N is
The degree of polymerization and the like are adjusted so that the melting temperature is higher than that of the master pellet P, and the heaters 15a and 15b can be similarly applied even if they are set so as to meet this. According to such a spinning method, continuous spinning is possible without blocking the spinneret with the fine powder drug, while a relatively thick synthetic resin obtained by entwining synthetic resin fine fibers spun by this method. The mat-like layer-based composite mat in which filaments made of non-woven fabric or intertwined in a three-dimensional network form are effective in deodorizing and antibacterial effects through the synthetic resin coating without the TZ falling off. . Therefore, it is desired to select and use a synthetic resin raw material having good gas permeability.

In each of the embodiments described above, the synthetic resin fine fibers immediately after spinning are sprayed onto a mat-like layer formed by entwining relatively thick synthetic resin filaments in a nonwoven fabric-like or three-dimensional network form. The present invention is not limited to this, and after spinning, air-cooling and moisturizing, oiling, further low-temperature drawing and heat setting, fuel yarn, wooly, sizing, etc., and then again spraying synthetic resin fibers. Good. Also in this case, a relatively thick synthetic resin filament can be sprayed and entangled with a fluid flow such as an air flow onto a mat-like layer formed by entwining a nonwoven fabric-like or three-dimensional network. When the synthetic resin fine fibers are prepared in advance in this way, the surface of the synthetic resin fine fibers is covered with oil or the like, for example, by oiling or the like, so that the action of the mixed drug may not be direct. In such a case, the synthetic resin fine fibers can be washed with a general detergent, a surfactant or the like to restore the action of the drug reproducibly. Therefore, a composite obtained by spraying a relatively thick synthetic resin filament on a mat-shaped layer entangled in a nonwoven fabric-like or three-dimensional network form while performing rinsing after washing or after washing An enhanced drug effect can be expected in the mat as well. For spraying the synthetic resin fine fibers while washing or rinsing, a rinsing water stream or the like can be used instead of the air stream. Further, in this case, it is necessary to dry after that, and further, an adhesive may be applied to enhance the entanglement between the mat-like layer and the synthetic resin fine fibers.

Still another embodiment will be described. Figure 6
In the above, the mat-shaped layer Y formed by intertwining relatively thick synthetic resin filaments in a non-woven fabric-like or three-dimensional network form is successively fed out from a long roll as in the above-mentioned embodiment. Further, 61 is a dipping tank filled with the undiluted solution G of polybutadiene gel as the viscoelastic substance, 62 is a pair of liquid absorbing rolls mounted on the bottom of the dipping tank 61, and 63 is mounted above the dipping tank 61. The drainage roll, 64 is a large number of fuming nozzles, and 65 is a heating tunnel. In such an apparatus, first, a dipping tank 61 is provided with a mat-like layer Y formed by intertwining relatively thick synthetic resin filaments in a non-woven fabric-like or three-dimensional network form.
And is immersed in a stock solution G of polybutadiene gel filled therein. Here, by passing between the liquid absorbing rolls 62, air in a mat-shaped layer formed by entwining relatively thick synthetic resin filaments in a non-woven fabric-like or three-dimensional network form is temporarily removed, and thereafter, When released from the restraint, it absorbs the undiluted solution G of the surrounding polybutadiene gel. Incidentally, not limited to this method, a conventionally known coating method is also possible, but at least almost the entire surface of a mat-shaped layer Y in which relatively thick synthetic resin filaments are entwined in a nonwoven fabric-like or three-dimensional network form. In the above, absorption or application is performed to the extent that the filament is covered with a film. Subsequently, a mat-shaped layer Y formed by entwining relatively thick synthetic resin filaments sufficiently containing the polybutadiene gel stock solution G in a non-woven fabric-like or three-dimensional network form is passed between the drainage rolls 63. Most of the contained polybutadiene gel undiluted solution G is removed, and thereafter, the undiluted solution of polybutadiene gel G is adhered to the mat-shaped layer only in the form of a film.
After such a state, by passing through the heating tunnel 65, the polyptadiene gel is contained in the mat-like layer formed by entwining relatively thick synthetic resin filaments in a non-woven fabric-like or three-dimensional network form. This will cure the filament into a film. Since it takes a relatively long time for the polybutadiene gel to completely cure, it is better to complete the curing in a separate heating furnace or the like. In the mat-like layer-based composite mat M3 obtained by intertwining the relatively thick synthetic resin filaments thus obtained in a non-woven fabric-like or three-dimensional network form, the filaments are coated with a viscoelastic substance. Therefore, it exhibits a moderate flexibility and restoration delaying property as if the original elasticity was wrapped with the softness of the viscoelastic substance, and it becomes a thick and thick cushioning material. If the hardness of the viscoelastic substance is about 100 or more, the surface of the viscoelastic substance becomes tacky, and in such a case, the surface is covered with an outer skin, or only the portion near the surface is cured,
It is desirable to form a non-tacky skin layer.

In the above embodiments, the synthetic resin fine fibers to be sprayed are mixed with an oxide deodorant, but in the present invention, a relatively thick synthetic resin filament is formed into a non-woven fabric or a three-dimensional network. One or more chemicals selected from deodorant, aromatic, antibacterial, insect repellent, repellant and insecticide should be mixed into the raw material side of the synthetic resin of the mat-like layer formed by entanglement. Although an example in which the synthetic resin filament is coated with polybutadiene gel has been described, this mat-like layer may be formed by impregnating other viscoelastic substances into a part or more of the film or entirely. Good. The composite mat obtained as described above may be used as it is, or in some cases, a mat, a carpet,
Laminated with a foam layer such as urethane, artificial leather, etc., for example,
Interior materials such as rugs inside or in vehicles, chairs and vehicle seats, door linings, ceiling linings, automobile front panels, etc.,
Further, it is provided as a wallpaper with appropriate irregularities or patterns, or provided as a soundproof wall filling material, insole material for shoes, pillow, or the like.

[0037]

As described above, according to the present invention, it is possible to obtain a composite mat having improved cushioning properties, a clean feeling, and a high-grade feeling in which a lower image coming from a conventional relatively thick filament is wiped off, and it is also suitable for mass production. Can be dealt with.

[Brief description of drawings]

FIG. 1 is a schematic side view including a partial cross section of an apparatus for carrying out an embodiment of a method for producing a composite mat of the present invention.

FIG. 2 is a schematic side view including a partial cross section of a main part of an apparatus for performing a method of another embodiment.

FIG. 3 is a side view including a partial cross section of an apparatus for performing a method according to another embodiment.

FIG. 4 is an enlarged plan view of the drug-carrying powder.

FIG. 5 is a side view including a partial cross section of an essential part of an apparatus for performing a method according to another embodiment.

FIG. 6 is a schematic side view including a partial cross section of an apparatus for performing a method according to another embodiment.

[Explanation of symbols]

A Porous synthetic resin fine powder B Drug-supporting particles G Polybutadiene gel stock solution H Porous synthetic resin fine powder pores M1 A mat-shaped composite of relatively thick synthetic resin filaments entwined in a non-woven fabric or three-dimensional network Layer-based composite mat M2 Same as above Mat-shaped layer-based composite mat M3 Same as above Mat-shaped layer-based composite mat N Chemical-mixed pellets P Master pellet R Same as above Mat-shaped layer-rolled roll TZ Titanium oxide, zinc oxide, and Fine particles Y of tightly bound water molecules Y A mat-like layer formed by intertwining relatively thick synthetic resin filaments in a non-woven fabric-like or three-dimensional network structure 1 Melt spinning device 11 Hopper 12 Cylinder 13 Die 14 Screw 15 Heater 15a First half Area heater 15b Heater immediately before spinneret 16 Spinneret 17 Hot air jet 2 Supply device 21 conveyor 22 supply unit 31 TZ ejecting part 32 collecting portion 41 container 42 lid 43 crank 61 dipping bath 62 liquid-absorbent roll 63 drainage roll 64 jet nozzles 65 heating tunnel

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁵ Identification code Office reference number FI technical display location B01D 53/04 A 9042-4D 53/34 116 B 6953-4D D06M 23/00 6953-4D B01D 53 / 34 128 6953-4D 131

Claims (5)

[Claims] 1. A synthetic resin fine fiber is blown together with a fluid flow to a mat-shaped layer formed by entwining relatively thick synthetic resin filaments in a non-woven fabric-like or three-dimensional network form, and synthesized with the mat-shaped layer. A method for producing a composite mat, comprising a step of intertwining with resin fine fibers. 2. A mat-shaped layer formed by intertwining relatively thick synthetic resin filaments in a non-woven fabric-like or three-dimensional network form, each filament is coated, but voids are left between the filaments. A method for producing a composite mat, comprising: a step of applying a separate stock solution of a viscoelastic substance; and a step of subsequently heating to cure the viscoelastic substance that coats the filament. 3. The synthetic resin filament or synthetic resin fine fiber raw material is one or more agents selected from deodorants, fragrances, antibacterial agents, insect repellents, repellants, and insecticides. 3. The method for producing a composite mat according to claim 1, wherein the composite mat is mixed. 4. One or a plurality of fine powder agents selected from deodorants, fragrances, antibacterial agents, insect repellents, insect repellants, and insecticides are applied to a porous synthetic resin fine powder by mechanical impact means. After being embedded or fixed by mixing, the drug-loaded particles are mixed into the raw material,
3. The composite mat according to claim 1 or 2, characterized in that the synthetic resin filament or the synthetic resin fine fiber is obtained by spinning the porous synthetic resin fine powder at a melting temperature immediately before reaching the spinneret. Manufacturing method. 5. The synthetic resin filament or the synthetic resin fine fiber is one in which an oxide-based fine powder deodorant is sprayed immediately after spinning from the spinneret. Method for manufacturing composite mat.