JPH07238462A - Nonwoven fabric laminated structure, its production and product using the same - Google Patents

Abstract

PURPOSE:To obtain a nonwoven fabric laminated elastic structure capable of blocking vibration, excellent in heat durability, shape-retaining property and cushioning property, hardly causing stuffiness and constituted of a network material obtained by laminating and joining a short fiber hard stock whose heat bonding component consists of a thermoplastic elastic resin and most suitable as a cushioning material and to provide a method for producing the nonwoven fabric laminated elastic structure and to obtain a product such as quilt or cushion for furniture, beds and vehicles using the nonwoven fabric laminated elastic structure. CONSTITUTION:In this laminated elastic structure, a nonwoven fabric, obtained by mixing a heat-bondable short fiber consisting of a thermoplastic elastic resin with a short fiber consisting of a thermoplastic nonelastic resin, opening the mixed short fiber and forming the opened short fiber in three-dimensional structure, in which most of the contact part of the yarns is fused by heat bonding and the face is flatted is joined and integrated on the one side of a network material obtained by meandering continuous yarn consisting of a thermoplastic elastic resin having <=100000 denier fineness and mutually contacting the yarn to form a three-dimensional structure and substantially flatting both faces of the structure. The laminated elastic structure has 0.01-0.2g/cm<2> density. Furthermore, this method for producing the laminated elastic structure and this product, using the laminated elastic structure are provided.

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION The present invention relates to a reticulated body made of a thermoplastic elastic resin having excellent cushioning properties, heat resistance durability and vibration absorption properties, and a recyclable short fiber hard cotton layer laminated and joined. Non-woven fabric laminated structure and manufacturing method, and products such as futons, furniture, beds, and cushioning materials for vehicles using the non-woven fabric laminated structure.

[0002]

2. Description of the Related Art At present, as a cushion material for furniture, beds, trains, automobiles, etc., urethane foam, non-elastic crimped fiber wadding,
In addition, resin cotton or hard cotton to which non-elastic crimped fibers are adhered is used.

However, although the foamed-crosslinked urethane has very good durability as a cushioning material, it is inferior in moisture permeability and water permeability and has a heat storage property, so that it easily steams, and since it is not thermoplastic, it is difficult to recycle and incinerated. If
The incinerator is heavily damaged and the cost of removing toxic gas is high. For this reason, landfilling has become more frequent, but it is difficult to stabilize the ground, and there is a problem that landfilling sites are limited and costs increase. Further, although it has excellent processability, it also has a problem of pollution of chemicals used during manufacturing. In addition, since the fibers are not fixed in the thermoplastic polyester fiber wadding, the form may collapse during use, the fibers may move, and the crimp may cause a decrease in bulkiness and elasticity. become.

As a resin cotton in which polyester fibers are adhered with an adhesive, for example, a rubber-based adhesive is used, Japanese Patent Application Laid-Open No.
0-11352, JP-A 61-141388, JP-A 61-141391 and the like. Further, as a method using a cross-linkable urethane, JP-A-61-1377
No. 32 publication and the like. These cushion materials have inferior durability, and also have problems such as not being recyclable because they are neither thermoplastic nor single composition, and there are problems such as complexity of processability and pollution of chemicals used during manufacturing. .

Polyester hard cotton, for example, JP-A-58-3
1150, JP-A-2-154050, JP-A-3-220354, etc., but since an amorphous polymer having a brittle adhesive component of the heat-bonding fiber used is used (for example, JP-A-58). -136828, Japanese Patent Application Laid-Open No. 3-
However, there is a problem in that durability is poor such that the bonded portion is brittle and the bonded portion is easily broken during use and the form and elasticity are reduced. As an improved method, a method of entanglement treatment has been proposed in Japanese Patent Laid-Open No. 4-245965, but there is a problem that the brittleness of the bonded portion is not solved and the elasticity is largely reduced. In addition, there is complexity during processing. Further, there is a problem that the bonded portion is hard to be deformed and soft cushioning is hard to be imparted. For this reason, the polyester elastomer that is soft even at the bonded portion and recovers even if it is deformed to some extent
A heat-bonding fiber using a non-elastic polyester as a core component is disclosed in JP-A-4-240219, and a cushion material using the fiber is disclosed in WO-91 / 19032, JP-A-5-155651. It is proposed in Japanese Patent Laid-Open No. 5-163654. The adhesive component used in this fiber structure has a polyalkylene glycol content of 30 to 50 as a soft segment of polyester elastomer.
Wt%, 5% terephthalic acid as the acid component of the hard segment
It contains 0 to 80 mol% and is used as another acid component composition
As in the fiber described in Japanese Patent Publication No. 0-1404, isophthalic acid is contained to increase the amorphous property, and the melting point is 180.
The temperature is below ℃, and the heat-bonded part is well formed with a low melt viscosity to form an ameber-shaped bonded part, but it is easy to plastically deform, and because the core component is an inelastic polyester, plastic deformation especially under heating Becomes remarkable, and there is a problem that the heat resistance and compression resistance are lowered. As an improved method for these, Japanese Patent Laid-Open No.
No. 163654 proposes a structure consisting only of a polyester elastomer containing isophthalic acid as a sheath component and a heat-bonding composite fiber using an inelastic polyester as a core component. Plastic deformation becomes remarkable, the heat resistance and compression resistance deteriorate, and there is a problem in using it as a cushion material. On the other hand, there is a method in which a silicone oil is added to a base material of hard cotton to lower the friction coefficient of fibers to improve durability and improve the texture.
It has been proposed in the publication. However, there is a problem with the adhesiveness of the heat-adhesive fiber and the durability is poor, so it is not preferable for use as a cushioning material.

A thermoplastic olefin network used for civil engineering work is disclosed in JP-A-47-44839. However, unlike a cushion made of fine fibers, the surface is uneven and the touch is poor, and since the material is olefin, the heat resistance durability is extremely poor and it cannot be used as a wadding layer or cushion material. In addition, Japanese Patent Publication No. 3-1766
No. 6 discloses a method in which ejection filaments having different fineness are fused to each other to form a mold, but the mesh structure is not suitable as a cushion material. Japanese Examined Patent Publication No. 3-55583 discloses that
A method of thinning only a very surface with a thinning device such as a rotating body before cooling is described. With this method, the surface cannot be flattened and a thick thin linear layer cannot be formed. Therefore, it does not provide a comfortable cushioning material. JP-A-1-207462 discloses a floor mat made of vinyl chloride, but it is not preferable as a cushioning material because it has poor compression recovery at room temperature and remarkably poor heat resistance. Note that no consideration is given to vibration damping in the above-mentioned structure.

[0007]

To solve the above problems,
Vibration-isolated, heat-resistant durability, shape-retaining property, and cushioning properties that prevent stuffiness and are composed of a reticulated body made of thermoplastic elastic resin in which short fiber hard cotton whose thermo-adhesive component is made of thermoplastic elastic resin is laminated and joined. Non-woven laminated structure optimal for cushioning material and manufacturing method, futon, furniture using the non-woven laminated structure,
It aims to provide products such as beds and vehicle cushions and manufacturing methods.

[0008]

Means for Solving the Problems The means for solving the above problems, that is, the present invention, is to make continuous filaments made of a thermoplastic elastic resin having a fineness of 100 to 100,000 denier meander and contact each other. A thermo-adhesive short fiber made of a thermoplastic elastic resin and a thermoplastic non-elastic resin are formed on one surface of a net-like body in which most of the contact portions are fused to form a three-dimensional three-dimensional structure, and both surfaces are substantially flattened. The non-woven fabric is made by mixing and opening three-dimensionally structured short fibers consisting of, and the surface of which most of the contact portion is fused and integrated by the heat-adhesive component is substantially flattened, resulting in a joined and integrated density of 0. 0.01 g / cm ³ to 0.2 g / cm ³ non-woven fabric laminated structure, thermoplastic elastic resin is melted at a melting temperature 20 to 80 ° C. higher than its melting point and directed downward from the nozzle To discharge and melt 3 fused in contact with each other in state
After forming a three-dimensional structure, it was sandwiched by a take-up device and cooled in a cooling tank, and then one side was mixed and opened with short fibers made of thermoplastic elastic resin and short fibers made of inelastic resin, and then three-dimensionally structured. A method of manufacturing a nonwoven fabric laminated structure in which a plurality of opened webs are laminated and compression heat molding is used to fuse and integrate most of the contact portion with a thermal adhesive component, and a product using the nonwoven fabric laminated structure.

The thermoplastic elastic resin in the present invention means, as the soft segment, an ether type glycol, a polyester type glycol, a polycarbonate type glycol or a long chain hydrocarbon having a molecular weight of 300 to 5,000. Polyester elastomer obtained by block-copolymerizing an olefinic compound having a carboxylic acid or a hydroxyl group at the terminal, a polyamide elastomer, a polyurethane elastomer,
Examples include polyolefin elastomers. By using a thermoplastic elastic resin, it becomes possible to regenerate by remelting, and thus recycling becomes easy. For example, as the polyester elastomer, a polyester ether block copolymer having a thermoplastic polyester as a hard segment and a polyalkylenediol as a soft segment, or a polyester ester having an aliphatic polyester as a soft segment A block copolymer can be illustrated. More specific examples of the polyester ether block copolymer include aromatic dicarboxylic acids such as terephthalic acid, isophthalic acid, naphthalene 2.6 dicarboxylic acid, naphthalene 2.7 dicarboxylic acid, and diphenyl 4.4'dicarboxylic acid. At least one of alicyclic dicarboxylic acids such as 1,4-cyclohexanedicarboxylic acid, aliphatic dicarboxylic acids such as succinic acid, adipic acid, sebacic acid dimer acid, and dicarboxylic acids selected from ester-forming derivatives thereof Seeds and aliphatic diols such as 1.4 butanediol, ethylene glycol, trimethylene glycol, tetremethylene glycol, pentamethylene glycol and hexamethylene glycol, 1.1 cyclohexane Alicyclic diols such as dimethanol and 1,4-cyclohexane dimethanol, or these Of at least one diole component selected from the ester-forming derivatives thereof and polyethylene glycol having an average molecular weight of about 300 to 5,000.
Is a ternary block copolymer composed of at least one kind of polyalkylenediol such as glycol, polypropylene glycol, polytetramethylene glycol, and glycol made of ethylene oxide-propylene oxide copolymer. . The polyester ester block copolymer is a ternary block copolymer composed of at least one of the above dicarboxylic acids, diol, and polyester diol such as polylactone having an average molecular weight of about 300 to 5,000. . Thermal adhesion, hydrolysis resistance, stretchability,
Considering heat resistance and the like, terephthalic acid is used as the dicarboxylic acid, or naphthalene 2.6 dicarboxylic acid, 1.4 butanediol is used as the diole component, and polytetramethylene glycol is used as the polyalkylenediol. The terpolymer block copolymer or the terpolymer block copolymer of polylactone as the polyester diol is particularly preferable. In a special case, it is possible to use the one in which a polysiloxane-based soft segment is introduced. In addition, the above elastomer is blended with a non-elastomer component,
Those obtained by copolymerization and those obtained by softening the polyolefin component are also included in the thermoplastic elastic resin of the present invention. As a polyamide elastomer, the hard segment is nylon 6, nylon 66, nylon 610,
Polyethylene glycol, polypropylene glycol, polytetramethylene glycol, ethylene oxide having an average molecular weight of about 300 to 5000 is used as the soft segment in the skeleton of nylon 612, nylon 11, nylon 12, etc. and their copolymerized nylon. -A block copolymer composed of at least one kind of polyalkylenediol such as glycol composed of propylene oxide copolymer may be used alone or in combination of two or more kinds. Furthermore, blends of non-elastomer components and copolymers thereof can be used in the present invention. Examples of the polyurethane elastomer include (A) a polyester and / or a polyester having a hydroxyl group at the terminal and having a number average molecular weight of 1,000 to 6000 in the presence or absence of a usual solvent (dimethylformamide, dimethylacetamide, etc.). ) A typical example is a polyurethane elastomer obtained by reacting a polyisocyanate containing an organic diisocyanate as a main component with a prepolymer having isocyanate groups at both ends and (C) extending the chain with a polyamine containing a diamine as a main component. Can be illustrated as (A) Polyester, Polyester
The tellers have an average molecular weight of about 1000 to 6000,
Preferably from 1300 to 5000 polybutylene adipates
Copolyester, polyethylene glycol, polypropylene glycol, polytetramethylene glycol
Polyalkylenediol such as glycol and ethylene oxide-propylene oxide copolymer glycol is preferable, and as the polyisocyanate of (B), a conventionally known polyisocyanate can be used. An isocyanate mainly composed of 4'diisocyanate may be used, and if necessary, a trace amount of conventionally known triisocyanate may be added and used. As the polyamine (C), known diamines such as ethylenediamine and 1.2-propylenediamine are mainly used, and if necessary, trace amounts of triamine and tetraamine may be used in combination. These polyurethane elastomers may be used alone or in combination of two or more. The melting point of the thermoplastic elastic resin of the present invention is preferably 140 ° C. or higher at which heat resistance and durability can be maintained,
It is more preferable to use a material having a temperature of 160 ° C. or higher because the heat resistance and durability are improved. If necessary, an antioxidant, a light-proofing agent or the like may be added to improve durability. The soft segment content of the thermoplastic elastic resin constituting the component having the function of absorbing vibration and stress, which is the object of the present invention, is preferably 15% by weight or more, more preferably 30% by weight or more, and heat resistance and sag resistance Therefore, it is preferably 80% by weight or less, and more preferably 70% by weight or less. That is, the soft segment content of the component having the vibration and stress absorbing function of the nonwoven fabric laminated structure of the present invention is preferably 15% by weight or more and 80% by weight or less, more preferably 30% by weight or more and 70% by weight or less. is there.

The component comprising the thermoplastic elastic resin constituting the nonwoven fabric laminated structure of the present invention preferably has an endothermic peak below the melting point in the melting curve measured by a differential scanning calorimeter. Those having an endothermic peak below the melting point have significantly improved heat resistance and sag resistance than those having no endothermic peak. For example, a preferable polyester-based thermoplastic resin of the present invention contains 90 mol% or more of terephthalic acid or naphthalene 2.6 dicarboxylic acid having rigidity in the acid component of the hard segment, more preferably terephthalic acid or The content of naphthalene 2.6 dicarboxylic acid is 95 mol% or more, particularly preferably 100 mol%, and after transesterification of the glycol component, polymerization is carried out to a required degree of polymerization, and then, as a polyalkylene diol, preferably When the average molecular weight of polytetramethylene glycol having an average molecular weight of 500 or more and 5000 or less, particularly preferably 1000 or more and 3000 or less, is copolymerized in an amount of 15% by weight or more and 70% by weight or less, more preferably 30% by weight or more and 60% by weight or less,
If the content of terephthalic acid or naphthalene 2.6 dicarboxylic acid, which has rigidity in the acid component of the hard segment, is high,
The crystallinity of the de-segment is improved, plastic deformation is less likely to occur, and the heat resistance and fatigue resistance are improved, but if heat treatment is performed at a temperature lower than the melting point by at least 10 ° C or more after annealing by heat, the heat resistance and fatigue resistance will be further improved. The property is improved. If annealing is performed after applying compressive strain, heat resistance and sag resistance are further improved. The endothermic peak is more clearly expressed in the melting curve measured by a differential scanning calorimeter of the nonwoven fabric laminated structure thus treated at a temperature of room temperature or higher and melting point or lower. If annealing is not performed, no endothermic peak appears in the melting curve above room temperature and below the melting point. By analogy with this, it is considered that the annealing causes rearrangement of the hard segments and formation of pseudo-crystallization-like cross-linking points to improve the heat resistance and sag resistance. (This treatment is defined as pseudo crystallization treatment.) This pseudo crystallization treatment effect is also effective for polyamide elastic resin and polyurethane elastic resin.

The thermoplastic non-elastic resin in the present invention means
Examples thereof include polyester, polyamide and polyolefin. In the present invention, it is preferable to use one having a glass transition temperature of 40 ° C. or higher. For example, for polyester, polyethylene terephthalate (PE
T), polyethylene naphthalate (PEN), polycyclohexylene dimethylene terephthalate (PCHD
T), polycyclohexylene dimethylene naphthalate (PCHDN), polybutylene terephthalate (PB)
Examples thereof include T), polybutylene naphthalate (PBN), polyarylate, and copolymerized polyesters thereof. For polyamide, polycaprolactam (NY
6), polyhexamethylene adipamide (NY66), polyhexamethylene sebacamide (NY6-10) and the like. As polyolefin, polypropylene (P
P), polybutene-1 (PB-1) and the like can be exemplified. As the thermoplastic non-elastic resin used in the present invention, polyester is often used for the side material of the cushion material, and therefore PET and PEN having good heat resistance can be used as a cushion material that can be recycled without being separated when discarded. , PBN, P
Polyesters such as CHDT are particularly preferred. Furthermore, P
A flame-retardant polyester (hereinafter abbreviated as flame-retardant polyester) formed by polycondensation with ET, PEN, PBN, PCHDT or the like to copolymerize a phosphorus-containing ester-forming compound or containing a phosphorus-containing flame retardant is preferable. JP-A-51-823
92, JP-A-55-7888, JP-B-55
-41610 and the like are exemplified.
Although vinyl chloride has a self-extinguishing property, it produces a large amount of toxic gas when it is burned, so that it is not preferable to use it in the present invention.

The present invention provides a three-dimensional three-dimensional structure in which continuous filaments made of a thermoplastic elastic resin having a fineness of 100 to 100,000 denier are bent and brought into contact with each other, and most of the contact portions are fused. Formed, and on one surface of the net-like body whose both sides are substantially flattened, the short fibers whose thermo-adhesive component is a thermoplastic elastic resin are mixed and opened with the short fibers made of a thermoplastic non-elastic resin to form a three-dimensional structure. The density of the bonded and integrated non-woven fabric, in which the surface where most of the contact part is fused and integrated by the thermal adhesive component is substantially flattened, is 0.01 g / cm
³ to 0.2 g / cm ³ of nonwoven fabric laminated structure. The function of the cushioning material is that the cushioning layer is composed of a layer that thickens the basic fineness and makes it a little harder to support the body shape, and a layer that slightly increases the density with a component with good vibration damping and absorbs vibrations and blocks vibrations. However, the surface layer is a soft layer with a fineness and a large number of constituent fibers, which gives a comfortable touch to the buttocks due to a proper subsidence to evenly disperse the buttocks pressure distribution and vibration that could not be absorbed by the cushion layer. By integrating the layer that absorbs and absorbs the vibration of the resonance part of the human body, the stress and the vibration can be integrally deformed and absorbed to improve the sitting comfort. In the present invention, the function of the cushion layer is given to the net-like body formed by the fused three-dimensional structure made of the thermoplastic elastic resin, and the function of the surface layer is the short fiber whose thermo-adhesive component is made of the thermoplastic elastic resin. Three-dimensionally structured by mixing and opening with short fibers made of thermoplastic non-elastic resin,
A non-woven fabric laminated structure which can be provided by bonding to a non-woven fabric (short-fiber non-woven fabric) whose surface where most of the contact portions are fused and integrated by a heat-adhesive component and which is substantially flattened to give a preferable cushioning material function. Is. The short fiber non-woven fabric having a surface layer function constituting the non-woven fabric laminated structure of the present invention provides a comfortable buttocks touch due to an appropriate depression as a soft layer, and therefore the heat-adhesive component is made of a thermoplastic elastic resin (preferably If the vibration absorption function and the deformation stress absorption function are satisfied by 40% by weight or more, and if it exceeds 70% by weight, the shape retention of the short fibers deteriorates and the subsidence increases, so 70% by weight or less) Fineness is 20 denier The following short fibers (heat-bonding fibers) and thermoplastic non-elastic resin having a fineness of 20 denier or less are mixed and opened to form a three-dimensional structure, and most of the contact portion is formed. It is composed of a non-woven fabric whose surface fused and integrated by a heat-adhesive component is substantially flattened.
The fineness of the thermal bonding fibers and the matrix fibers is 20 denier - To below 0.01 g / cm ³ or more 0.05 g / cm ³ can be imparted over the the preferred surface layer features apparent density of the short fiber nonwoven fabric Le, structure It is not preferable because the number of lines is reduced and the features as a dense structure do not appear and the comfortable touch is impaired.
In addition, when the heat-bonding fiber contains an inelastic resin, the thicker the fineness, the greater the mechanical deformation of the inelastic resin against the compressive deformation, resulting in large damage and reduced sag resistance, which is not preferable. On the other hand, if the fineness is too small, the bulkiness is lowered, the deformation response is deteriorated, and the function of the surface layer is lowered, which is not preferable. The preferred fineness of the heat-bonded fiber is 1 denier.
10 to 10 denier, more preferably 3 to 6 denier. The matrix fiber is preferably 3 denier to 15 denier, and more preferably 5 denier to 13 denier because it is necessary to maintain elasticity to give a proper subduction. The heat-bonded fibers and the base material fibers are mixed and opened to form a three-dimensional structure, and most of the contact portions are substantially fused and integrated by heat bonding (preferably all contact points are fused and integrated). By making the non-woven fabric flat, the local pressure of the buttocks is received on the surface, the pressure distribution is uniformly dispersed, and the three-dimensional three-dimensional structure of the short fiber non-woven fabric is made of the thermoplastic elastic resin of the heat adhesive component. Since the fusion bonding is integrated, the entire structure deforms while the thermal bonding point undergoes large deformation, and the deformation stress is absorbed by energy conversion. When the deformation stress is released, the rubber elasticity of the thermoplastic elastic resin makes it easy. Since it has a function to restore the original form, it has good sag resistance. Further, the damage to the cushion layer can be gradually reduced, and the sag resistance of the entire structure is improved. If they are not fused and integrated, the shape cannot be maintained, the local pressure is received by the surface, the pressure distribution cannot be evenly distributed, and the entire structure is deformed and energy conversion is not possible. Inferior and not preferable. Since the heat-adhesive component is composed of fibers containing a thermoplastic elastic resin with good vibration absorption, it also functions as a layer that cuts off the vibration of the resonance part of the human body by absorbing the vibration that could not be absorbed by the cushion layer. I will also help. When the heat-adhesive component is composed of a thermoplastic non-elastic resin, it cannot follow local deformation stress and the structure is destroyed due to stress concentration, resulting in poor recoverability. Further, since the thermoplastic non-elastic resin has a poor vibration absorbing property, it is not preferable because it has a poor function as a layer for blocking vibration. The thickness of the short fiber non-woven fabric layer is not particularly limited, but is preferably 3 mm to 30 mm and particularly preferably 5 mm to 20 mm so that the surface layer function can be exhibited. On the other hand, the mesh body having a cushion layer function is a three-dimensional three-dimensional structure in which continuous filaments made of a thermoplastic elastic resin are fused at most of the contact portions, and are fused and integrated, and both sides are substantially flat. Since the vibration absorption function of the thermoplastic elastic resin absorbs and attenuates most of the vibrations given from the outside, the surface of the reticulate body is substantially absorbed even when a large deformation stress is locally applied. Since most of the contact portion is flattened and fused, and the surface is joined with the short fiber non-woven fabric at the surface, it receives the deformation stress at the surface of the mesh body and disperses the deformation stress and develops the body shape holding function. Since the filaments made of thermoplastic elastic resin form a three-dimensional structure and are fused and integrated,
The entire structure is deformed and absorbs the deformation stress by energy conversion, and when the deformation stress is released, the rubber elasticity of the thermoplastic elastic resin easily restores the original shape, so it has good sag resistance. Is. A known net-like body composed of filaments made only of non-elastic resin does not have rubber elasticity when subjected to a large deformation that cannot be absorbed by the surface layer, and therefore plastic deformation due to compressive deformation does not occur and recovery is inferior. When the surface of the reticulate body is not substantially flattened, the local external force transmitted from the short fiber non-woven fabric is selectively transmitted to the filaments and bonding points of the surface, resulting in stress concentration. There is a possibility that fatigue due to stress concentration may occur due to such external force and the sag resistance may deteriorate. When the filaments are made of thermoplastic elastic resin, the entire structure is deformed in the three-dimensional structure portion, so stress concentration is relieved. However, in the non-elastic resin, stress is concentrated at the bonding point and structural damage is caused. It will not occur and will not recover. Furthermore, if the surface is not substantially flattened and has irregularities, the buttocks feel a foreign substance when sitting, which is unfavorable for sitting. When the linear shape is not continuous, the adhesive point becomes a stress transmission point in a net having a large fineness, so that remarkable stress concentration occurs at the adhesive point, resulting in structural destruction and poor heat resistance and durability. If they are not fused, the shape cannot be maintained and the structure does not deform integrally, resulting in a fatigue phenomenon due to stress concentration and poor durability, and at the same time deforming the shape and making it impossible to maintain the body shape, which is not preferable. . The more preferable degree of fusion in the present invention is that most of the portions where the filaments are in contact are fused, and most preferably all the contact portions are in fusion. Thus, continuous filaments made of a thermoplastic elastic resin having good vibration absorption and elastic recovery form a three-dimensional three-dimensional structure in which most of the contact portions are fused, and the fusion is integrated so that the surface is substantially flat. The reticulated body with the integrated cushioning layer function receives the deformation stress transmitted from the surface layer composed of the short-fiber non-woven fabric made of thermoplastic elastic resin on the surface to improve the dispersion of the stress and improve the stress applied to each linear shape. The entire structure is deformed to absorb the deformation stress by improving the cushioning property to support the buttocks and recovers when the stress is released, and the vibration transmitted from the frame also has the vibration absorption and elastic recovery properties. The cushion layer made of a good thermoplastic elastic resin absorbs and blocks vibrations of the resonance part of the human body, so that the sitting comfort and durability can be improved. From this purpose,
The fineness of the filament made of thermoplastic elastic resin having good vibration absorption and elastic recovery forming the reticulated body of the present invention is 100 to 10.
It is 0000 denier. Apparent density 0.2g / cm ³
In the case of the following, if the number exceeds 100,000 denier, the number of constituents decreases, density unevenness is generated, a structure with poor durability is partially formed, fatigue due to stress concentration increases, and durability deteriorates, which is not preferable. Regarding the fineness of the filament made of the thermoplastic elastic resin of the present invention, if the fineness is too thin, the anti-compression property becomes too low and the stress absorbability due to deformation is lowered.
It is not less than 00 denier and not more than 50,000 denier which does not impair the denseness of the structural surface due to the decrease in the number of constituents.
More preferably 500 denier or more, 10,000 denier
It is less than or equal to le. The apparent density of the reticulate body of the present invention is 0.0
05G / cm ³ in repulsive force is lost, there is a case where vibration absorption capacity and deformation stress absorption capacity is less likely to express insufficient and becomes cushioning function, comfort too high repulsive force at 0.25 g / cm ³ or more Since it may deteriorate, the vibration absorbing ability and the deformation stress absorbing function can be fully utilized to easily develop the function as a cushioning body 0.01 g / cm ³ or more.
20 g / cm ³ or less is preferable, more preferably 0.03
It is g / cm ³ or more and 0.08 g / cm ³ or less. As a preferred embodiment, a method in which the reticulate body in the present invention has a different fineness laminated structure in which a linear shape having a different fineness is combined with an apparent density to have an optimum configuration can be selected. The thickness of the reticulate body of the present invention is not particularly limited, however, if the thickness is less than 5 mm, the stress absorbing function and the stress dispersing function are deteriorated, so that the preferable thickness is capable of exhibiting a surface function for dispersing force and a vibration or deformation stress absorbing function. The thickness is 10 mm or more, more preferably 20 mm or more. The apparent density as a laminated structure in which the net body of the present invention and the short fiber non-woven fabric are integrally bonded is 0.01 g / cm.
³ to 0.2 g / cm ³ . If it is less than 0.01 g / cm ³ , the cushioning function such as body shape retention and vibration absorption is deteriorated, which is not preferable. If it exceeds 0.2 g / cm ³ , the impact resilience becomes large and the sitting comfort becomes poor, which is not preferable. Preferred apparent density is 0.02 g / cm ^{3 to} 0.1 g / cm ³
And more preferably 0.03 g / cm ^{3 to} 0.06 g
/ Cm ³ .

The cross-sectional shape of the filaments of the reticulate body of the present invention is not particularly limited, but a hollow cross-section or a deformed cross-section is particularly preferable because it can impart preferable anti-compression property (repulsive force) and touch. The anti-compression property can be adjusted by the fineness and the modulus of the material used to make the fineness fine, or in the soft material the hollowness and the irregularity can be increased to adjust the gradient of the initial compression stress, and the fineness can be made slightly thicker or slightly. A material with a high modulus lowers the hollow ratio and the degree of irregularity to provide anti-compression property with a comfortable sitting feeling. As another effect of the hollow cross section and the irregular cross section, by increasing the hollow ratio and the degree of irregularity, if the same anti-compression property is given, the weight can be further reduced, and the energy saving can be achieved when it is used for the seat of an automobile or the like. If it is a futon or the like, it will be easier to handle when raising and lowering. As another preferable method for imparting preferable anti-compression property (repulsive force) and touch, there is a method of forming the filament of the reticulated body of the present invention into a composite structure. Examples of the composite structure include a score core structure, a side-by-side structure, and a combination structure thereof. However, especially when the cushion layer is largely deformed, the energy and
In order to obtain a three-dimensional three-dimensional structure that can be converted and restored, a sheath-core structure or a side-by-side structure in which 50% or more of the linear surface is occupied by a soft thermoplastic elastic resin, and a combination thereof are mentioned. That is, in the sheath core structure, the sheath component is a thermoplastic elastic resin having a large content of soft segments that can easily convert energy into vibration and deformation stress, and the core component is a thermoelastic resin having a small content of soft segments exhibiting anti-compression properties. Composed of a plastic elastic resin, it can give a comfortable touch to the buttocks due to an appropriate depression. With the side-by-side structure, the melt viscosity of a thermoplastic elastic resin with a high soft segment content that facilitates energy conversion of vibration and deformation stress is lower than the melt viscosity of a thermoplastic elastic resin with a low soft segment content that exhibits anti-compression properties. A structure with a large proportion of thermoplastic elastic resin occupying a linear surface and having a high soft segment content (metamorphically, eccentric sheath
It is particularly preferable that the ratio of the thermoplastic elastic resin having a large soft segment content occupying the linear surface is 80% or more as a structure in which the thermoplastic elastic resin is arranged in the sheath / core structure). Most preferably, it is a sheath core in which the proportion of the thermoplastic elastic resin having a large soft segment content occupying the linear surface is 100%. When the proportion of the thermoplastic elastic resin with a large soft segment content that occupies the linear surface is large, the flowability when melting and fusing is high, so there is the effect of strengthening the adhesion, and the structure deforms as a unit. In this case, the fatigue resistance against stress concentration at the bonding point is improved,
Heat resistance and durability are further improved.

Since a non-woven fabric laminated structure in which a net-like body made of a thermoplastic elastic resin and a short-fiber non-woven fabric are joined and integrated to substantially flatten both sides, other net-like bodies, non-woven fabrics, knitted fabrics, hard fabrics, Other heat-adhesive components (heat-bonded non-woven fabric, heat-bonded fiber, heat-bonded film, heat-bonded resin, etc.) and adhesives are used to bond cotton, film, foam, metal, etc. In order to obtain a product such as a vehicle seat, a ship seat, a vehicle seat, a ship seat, a commercial bed for home use, a home use bed, a furniture chair, an office chair, a futon, etc. Since the contact area with the adhesive body surface can be widened,
It is possible to obtain a product having a wide adhesion area and strong adhesion and good adhesion durability. In addition, by performing the above-mentioned pseudo-crystallization treatment at any stage from the stage of forming the net body and the laminated structure into a product, the component made of the thermoplastic elastic resin in the structure was measured by a differential scanning calorimeter. It is more preferable that the melting curve has an endothermic peak at a temperature of room temperature or higher and melting point or lower because the heat resistance and durability of the product is remarkably improved. When the filaments of the reticulate body forming the nonwoven fabric laminated structure of the present invention have a composite structure, the back surface of the laminated structure can also be provided with a heat-adhesive function, and a reinforcing material or the like can be integrated into a heat-adhesive structure. For example, in the sheath core structure, a thermoplastic elastic resin containing a large amount of soft segment that facilitates energy conversion of vibration and deformation stress of the sheath component is used as a heat-adhesive component, and a soft segment containing the compressive property of the core component is contained. A thermoplastic adhesive resin having a small amount is used as a high melting point component to have a function of holding a net-like shape, and the melting point of the thermal bonding component is lower than the melting point of the high melting point resin by 10 ° C. or more. The function of can be added. Further, the short fiber non-woven fabric of the surface layer of the non-woven fabric laminated structure of the present invention is adhered by a heat-adhesive fiber, and can be used as the heat-adhesive layer, but it is preferable that the heat-adhesive component has a soft segment content and a low melting point. By using the thermoplastic elastic resin of (1), it is possible to improve the energy conversion of vibration and deformation stress, and also to impart a good thermal adhesive function. The melting point of the heat-bonding component forming the filaments or fibers in the laminated structure, which is preferable for exhibiting the heat-bonding function, is 15 ° C to 80 ° C lower than the melting point of the high-melting component, more preferably 20 ° C to 60 ° C. It has a low melting point. The laminated structure of the present invention having a heat-bonding function has a substantially flat surface, and most of the contact portions are fused, thereby forming a mesh, nonwoven fabric, knitted fabric, hard cotton, film, foam. Since the contact area with the body to be heat-bonded, such as metal or metal, can be widened, the heat-bonded area becomes wider, and a new heat-bonded molded body and vehicle seat, ship seat, vehicle, ship, hospital. You can obtain products such as commercial and household beds, furniture chairs, office chairs, and futons. In addition, by performing pseudo crystallization at any stage until new molded products and products are commercialized, the filaments made of the thermoplastic elastic resin in the structure are melted by a differential scanning calorimeter. It is more preferable to make the curve have an endothermic peak at a temperature of room temperature or higher and melting point or lower because a product with significantly improved heat resistance and durability can be provided. When the adherend is adhered in a stretched state at the time of heat-bonding, the adhered body does not relax the stretched state due to the rubber elasticity of the adhesive layer, so that the adherend can be a molded body having tension and less likely to wrinkle.

Next, the manufacturing method of the present invention will be described. A thermoplastic elastic resin is discharged downward from the nozzle at a melting temperature higher than its melting point by 20 ° C. or more and less than 80 ° C. from a multi-row nozzle having a plurality of orifices, and they are brought into contact with each other in a molten state to be fused. While forming a three-dimensional structure, it is sandwiched by a take-up device and cooled in a cooling tank, and then one side is mixed and opened with short fibers made of a thermoplastic elastic resin and short fibers made of an inelastic resin, and three-dimensionally opened. This is a method for producing a nonwoven fabric laminated structure in which structured structured webs are laminated and compression thermoforming is used to fuse and integrate most of the contact portions with a thermal adhesive component. The reticulate body is obtained by melting a thermoplastic elastic resin by using a general melt extruder, supplying the multi-row nozzle having a plurality of orifices, and discharging the resin downward from the orifices. The melting temperature at this time is 20 ° C to 80 ° C from the melting point of the thermoplastic elastic resin.
It is a high temperature. If the melting temperature is higher than 80 ° C. higher than the melting point of the thermoplastic elastic resin, thermal decomposition becomes remarkable and the rubber elastic properties of the thermoplastic elastic resin deteriorate, which is not preferable. On the other hand, unless the temperature is higher than the melting point of the thermoplastic elastic resin by 10 ° C. or more, melt fracture occurs and normal filament formation cannot be performed. Further, when the filament is formed by looping after discharge and is brought into contact and fused. The temperature may be lowered and the filaments may not be fused to each other, resulting in a network having insufficient adhesion, which is not preferable. The preferred melting temperature is 20 ° C to 60 ° C above the melting point
Higher temperatures, more preferably 25 ° C to 40 ° C above the melting point. The shape of the orifice is not particularly limited, but may be a hollow cross section (for example, a triangular hollow, a round hollow, a shape with a projection, etc.) and / or an irregular cross section (for example, a triangular, Y-shaped, star-shaped cross-section secondary mode). In addition to the above effects, it is difficult for the three-dimensional structure formed by the discharge filaments in the molten state to relax the flow, and on the contrary, the flow time at the contact point is maintained for a long time to strengthen the adhesion point. It is particularly preferable because it can be When heating for adhesion as described in Japanese Patent Application Laid-Open No. 1-2075, the three-dimensional structure is easily relaxed, a planar structure is formed, and a three-dimensional three-dimensional structure becomes difficult, which is not preferable. As an effect of improving the properties of the reticulate body, the apparent bulk can be increased, the weight can be reduced, the anti-compression property can be improved, and the elasticity can be improved, which is difficult to obtain. The hollow section has a hollow ratio of 8
If it exceeds 0%, the cross section tends to be crushed, so that it is preferably 10% or more and 70% or less, more preferably 20% or more and 60% or less so that the effect of weight reduction can be exhibited. The pitch between the holes of the orifice needs to be a pitch with which the loop formed by the line can sufficiently contact. The pitch between holes is shortened for a dense structure, and the pitch between holes is lengthened for a coarse structure. The pitch between the holes of the present invention is preferably 3 mm to 20 mm, more preferably 5 mm to 10 mm. In the present invention, different densities and different fineness can be obtained as desired. The different density layer can be formed by a configuration in which the pitch between rows or the pitch between holes is also changed, or a method in which the pitch between both rows and holes is also changed. Also, if the pressure loss difference at the time of discharge is given by changing the cross-sectional area of the orifice, the principle that the discharged amount of molten thermoplastic elastic resin extruded from the same nozzle at a constant pressure becomes smaller for the orifice with larger pressure loss, is used. It is possible to manufacture a reticulated structure composed of filaments of different fineness by using a nozzle having at least a plurality of rows having different cross-sectional areas of orifices in a section in the longitudinal direction. Then, discharge downward from the nozzle,
While forming a loop, they are brought into contact with each other in a molten state to be fused to form a three-dimensional structure, sandwiched by a take-up net, and bent in the molten state on the surface of the mesh body by bending it by 45 ° or more. After deforming to flatten the surface and at the same time form a structure by adhering the contact points with the discharge line that is not bent, a cooling medium (usually using room temperature water can increase the cooling rate, It is preferable because it is cheap in terms of cost), and is rapidly cooled to obtain the three-dimensional three-dimensional net-structured net-like body of the present invention. The distance between the nozzle surface and the take-off point is preferably at least 40 cm or less to prevent the discharge filament from being cooled and the contact portion not being fused. If the discharge amount of the discharge line is 5g / hole or more, 10cm-40
cm is preferable, and 5 cm to 20 cm is preferable when the discharge amount of the discharge filament is less than 5 g / hole. The thickness of the net-like body is determined by the opening width (interval between the take-up nets) of the take-up net sandwiching both surfaces of the three-dimensional structure in the molten state. In the present invention, the opening width of the take-up net is set to 5 mm or more for the above reason. Next, it is drained and dried, but if a surfactant or the like is added to the cooling medium, draining and drying may be difficult, or the thermoplastic elastic resin may swell, which is not preferable. still,
The desired loop diameter and wire diameter can be determined by the distance between the nozzle surface and the take-up conveyor installed on the cooling medium that solidifies the resin, the melt viscosity of the resin, the hole diameter of the orifice and the discharge amount, and the like. A pair of take-up conveyors with adjustable spacing installed on the cooling medium sandwiches and holds the melted discharge filaments to fuse the portions that are in contact with each other and continuously draw in the cooling medium to solidify. By adjusting the distance between the conveyors when forming the body, the thickness can be adjusted while the fused net-like body is in a molten state, and a desired thickness can be obtained. If the conveyor speed is too high, the formation of contact points may be insufficient, or the contact point may be cooled until the fusion point is sufficiently formed, resulting in insufficient fusion of the contact portion.
Further, if the speed is too slow, the melt will stay too much and the density will increase, so it is necessary to set the conveyor speed suitable for the desired apparent density. Next, in the present invention, it is joined and integrated with a short fiber non-woven fabric having a surface layer function. The thermoadhesive fiber having a fineness of 20 denier or less, in which the thermoadhesive component is a thermoplastic elastic resin, is obtained by individually melting a low-melting thermoplastic elastic resin and a high-melting thermoplastic non-elastic resin to form a known composite spinning fiber. Thus, a spun yarn can be obtained by spinning and stretching. However, in this method, since the heat-adhesive component has a low melting point, heat setting at a high temperature cannot be performed at the time of stretching, so that only a high shrinkage rate of 30% to 80% can be obtained. Dimensional defects occur. In the present invention, in order to solve this problem, it is preferable to obtain the finished yarn at a stretch by reducing the shrinkage rate to 10% or less by high-speed spinning at 3000 m / min or more. Next, crimping is applied and cut into a desired cut length to obtain a heat-bonded fiber. The composite form of the heat-bonding fibers used in the present invention is not particularly limited,
Since it needs to function as a heat-bonding fiber, it is side-by-side or sheath-core, and the low melting point component is 50% of the fiber surface.
The low melting point component preferably occupies 100% or more of the surface of the fiber. The matrix fiber is a known method in which a non-elastic resin is given a latent crimping ability by an asymmetric cooling method or a composite spinning method, and after the stretching, heat treatment is performed to develop a three-dimensional crimp, and then cut, or after the cutting, a heat treatment is performed and the three-dimensional winding is performed. A matrix fiber is obtained by expressing shrinkage. Since the matrix fiber is required to have sag resistance and heat resistance, the initial tensile resistance is at least 35 g / denier and the initial tensile resistance at 70 ° C is at least 10 g / denier. Is preferred. The crimp degree of three-dimensional crimp is 15% due to its bulkiness and anti-compression property.
As described above, the number of crimps is preferably 10 to 25 crimps / inch. The heat-bonded fibers and the matrix fibers thus obtained are mixed and opened. When the amount of heat-bonding fibers is small, the vibration absorbing function is deteriorated, which is not preferable. If the amount of the heat-bonding fibers is too large, the bulkiness may decrease. Therefore, the preferable mixing ratio of the heat-bonding fibers and the base material fibers is 20 /.
A weight ratio of 80 to 60/40 is obtained by pre-opening and mixing with an opener or the like, and then opening with a card or the like to open and open a web having a three-dimensional structure on the surface of the reticulate body. To form a short fiber non-woven fabric by thermocompression and thermoforming to form a short fiber non-woven fabric, and then to integrally join the net and short fiber non-woven fabric. You can also In this case, a thermal adhesive layer or an adhesive may be separately used between the reticulate body and the short fiber non-woven fabric for bonding and integration, or the thermal rebonding function of the reticulate body or the short fiber non-woven fabric may be used for bonding and integration. Good. As a preferred method of the present invention, a temperature of at least 10 ° C. or lower than the melting point of the thermoplastic elastic resin is used in any step leading to commercialization of the nonwoven fabric laminated structure obtained by once cooling the reticulated body or integrally molding it. It is a more preferable production method to obtain a nonwoven fabric laminated structure or product by carrying out pseudo-crystallization treatment by annealing. The pseudo-crystallization treatment temperature is at least 10 ° C. lower than the melting point (Tm), and is higher than the α dispersion rising temperature (Tαcr) of Tan δ. This process has an endothermic peak below the melting point,
The heat and sag resistance is remarkably improved as compared with the case where the pseudo crystallization treatment is not carried out (the case where there is no endothermic peak). The preferred pseudo-crystallization treatment temperature of the present invention is (Tαcr + 10 ° C) to (Tm-20 ° C). If it is pseudo-crystallized by simple heat treatment, heat resistance and sag resistance are improved. But 10
It is more preferable to impart compressive deformation of not less than 100% and anneal to significantly improve heat resistance and sag resistance. Further, when the reticulate body is once cooled and then subjected to a drying step, the pseudo crystallization treatment can be simultaneously performed by setting the drying temperature to the annealing temperature. Also, a pseudo crystallization treatment can be separately performed in the process of commercialization. Then, it is cut into a desired length or shape and used as a cushion material.

When the nonwoven fabric laminated structure of the present invention is used as a cushion, it is necessary to select a resin to be used, a fineness, a loop diameter and a bulk density depending on the purpose of use and the site of use. For example, in order to give a soft touch, moderate depression and bulging with tension, a dense structure with a slightly high density and fine fineness is preferable, and in order to exert the cushion function of the middle layer, the resonance frequency is low. However, in order to improve the body shape retention by linearly changing the appropriate hardness and hysteresis at the time of compression, in order to maintain durability, medium density, thick fineness, a layer with a slightly larger loop diameter and low density It is preferable to have a structure in which layers having a fine fineness and a fine loop diameter are laminated and integrated. Since the nonwoven fabric laminated structure of the present invention has the functions of the surface layer and the cushion layer at the same time, it can be formed into a shape suitable for the purpose of use by using a molding die or the like to the extent that the three-dimensional structure is not impaired, and only the side cloth is covered. It can be used for vehicle seats, boat seats, beds, chairs, furniture and the like. Of course, it is also possible to use it in combination with another material that should meet the required performance in relation to the application, for example, a different mesh body, a hard cotton cushion material composed of a short fiber aggregate, a non-woven fabric, or the like. In addition, other than the resin manufacturing process, it is processed into a molded product from the manufacturing process within a range that does not deteriorate the performance,
Flame retardant, insect repellent antibacterial, heat resistant, at any stage of commercialization
Water and oil repellency, coloring, aroma and other functions can be processed by adding chemicals.

[0017]

EXAMPLES The present invention will be described in detail below with reference to examples.

The evaluations in the examples were carried out by the following methods. Endothermic peak (melting peak) from melting point (Tm) and endothermic peak below melting point TA50, DSC50 type differential thermal analyzer manufactured by Shimadzu ) The temperature was determined. Tαcr polymer is heated to the melting point + 10 ° C and the thickness is about 300 μm.
Film was prepared and measured using a Vibron DDVII type manufactured by Orientec Co., Ltd. at a rate of 110 Hz and a temperature rising rate of 1 ° C./min. Tan δ (ratio M ″ / imaginary elastic modulus M ″ to real part M ′ of elastic modulus) The rising temperature of α dispersion corresponding to the transition temperature from the rubber elastic region to the melting region of M ′). Apparent Density The sample is cut into a size of 15 cm × 15 cm, the heights at four locations are measured, the volume is determined, and the weight of the sample is divided by the volume. (Average value of n = 4) Fineness of filaments Each filament portion is cut out from 10 points of the sample, embedded in acrylic resin, the cross section is cut out, and a section is prepared to obtain a cross section photograph. The cross-sectional area (Si) of each part is obtained from the cross-sectional photograph of each part. In addition, a piece obtained in the same manner was dissolved in acrylic resin with acetone, degassed in vacuum, and a density gradient tube was used to 40 ° C.
Determine the specific gravity (SGi) measured in. Then, a linear weight of 9000 m is obtained from the following equation. (Unit: cgs) Fineness = [(1 / n) ΣSi × SGi] × 900000 Fusing Whether or not the sample is fused by visual judgment depends on whether or not the fibers adhering to each other cannot be pulled apart by hand It is determined that something that does not come off is fused. Heat resistance and durability (residual strain at 70 ° C) Cut a sample into a size of 15 cm x 15 cm, compress it by 50%, leave it in dry heat at 70 ° C for 22 hours, then cool to remove compression strain and leave it for 1 day (b) Is calculated, and is calculated from the thickness (a) before processing by the following equation, that is, (ab) / a × 100. Unit% (average value of n = 3) Cyclic compressive strain A sample was cut into a size of 15 cm x 15 cm, and a Shimazu Seisakusho pulsarcer was used at 25 ° C and 65% in an RH room at 50%.
The compression recovery was repeated at a cycle of 1 Hz up to the thickness of 20,000 times, and the thickness of the sample after 20,000 times was left for one day and the thickness before the treatment (b) were obtained, and from the thickness before the treatment (a), the following formula, that is, (a- b) /
Calculated from a × 100. Unit% (average value of n = 3) Sit comfort Covering the side of the nonwoven fabric laminated elastic structure cut into the shape of a bucket sheet with the side of polyester moquette made of Toyobo Co., Ltd. Heim, seat frame The seats with four side seats and six back parts with side landscaps were set, and a paneler was seated on the seats created at 30 ° C RH75% room for the following evaluations. . (N = 5) (1) Feeling on the floor: The degree of "dosun" when sitting and the feeling of hitting the floor were qualitatively and qualitatively evaluated. Not felt; ◎, hardly felt; ○, slightly felt; △, felt; × (2) Feeling of stuffiness: Feeling stuffy when sitting for 2 hours and the buttocks and the part of the crotch that contacts the seat inside the crotch Qualitatively evaluated. Almost no feeling: ◎, slightly stuffy; ○, slightly stuffy; △, significantly stuffy; × (3) How long you can sit in the seat within 8 hours: within 1 hour; × within 2 hours; △ within 4 hours;
○ 4 hours or more; ◎ (4) A qualitative qualitative evaluation was performed on the degree of waist fatigue when the user sat in the seat for 4 hours. None; ◎, hardly tired; ○, slightly tired; △, very tired; × (5) Overall evaluation: 4 points from ◎ of the evaluations from (1) to (4), ○
3 points, △ is 2 points, × is 1 point and does not include Δ with 12 points or more; very good (⊚), that with 12 points or more; Good (○), 10 points or more is x It was evaluated as those which did not contain; those which were somewhat bad (Δ) and those which contained x; bad (x).

Example 1 As a polyester elastomer, dimethyl terephthalate (DMT) or dimethyl naphthalate (DM) was used.
N) and 1.4 butanediol (1.4 BD) were charged with a small amount of a catalyst, and after transesterification by a conventional method, polytetramethylene glycol (PTMG) was added and polycondensation was performed while heating and depressurizing. -Formation of terester block copolymer elastomer, then addition and mixing of 2% of antioxidant, kneading, pelletizing, and vacuum drying at 50 ° C for 48 hours are shown in Table 1. .

[0020]

[Table 1]

Orifice shapes having a staggered arrangement with a hole-to-hole pitch of 5 mm in the width direction and a hole-to-hole pitch of 10 mm in the length direction on an effective surface of a nozzle having a width of 50 cm and a length of 5 cm have an outer diameter of 2 mm and an inner diameter of 1.6 mm.
With a nozzle with a triple bridge hollow forming cross section,
The obtained thermoplastic elastic resin raw materials are melted by separate extruders, A-1 is distributed as a sheath component and A-2 is distributed as a core component immediately before the orifice, and the melt temperature is 245 ° C. Discharge rate per single hole 2.0 g / min (A-1: 1 g / min, A
-2: 1 g / min) is discharged below the nozzle, cooling water is placed 12 cm below the nozzle surface, and stainless steel endless nets with a width of 60 cm are arranged in parallel at 5 cm intervals with a pair of take-up conveyors partially above the water surface. The melted discharge line is bent to form a loop to fuse the contact portions to form a three-dimensional net structure, and both sides of the melted net are drawn. While being sandwiched by a take-up conveyor, it was drawn into cooling water at 25 ° C. at a speed of 1 m / min to be solidified and flattened on both sides, and then the net-like body obtained by cutting to a predetermined size had a triangular cross section. It had a hollow cross section of a rice ball shape and had a hollowness of 40% and a fineness of 9000 denier, and the average apparent density was 0.046 g / cm ³ .
Separately, the thermoplastic elastic resin A-3 is individually melted so as to become a sheath component and PBT having a relative viscosity of 1.0 as a core component by a conventional composite spinning machine by a conventional method, and distributed immediately before the orifice. Then, each discharge amount was 50/50 weight ratio, 1.6 g / min per hole (0.8 g / min: 0.8 g / min) was discharged from the C-type orifice at the spinning temperature of 285 ° C., and spun. A yarn having a fineness of 4.1 denier at a speed of 3500 m / min and a shrinkage of 4% at a dry heat of 160 ° C is converged, and a tow-like crimp is applied to give mechanical crimp and cut into 64 mm. Then, a heat-bonding fiber made of a thermoplastic elastic resin having a sheath core cross section was obtained. The matrix fiber has an intrinsic viscosity of 0.63 and 0.
56 PET was distributed in a weight ratio of 50/50 to make a composite spinning at 3.0 g / min per hole (1 g / min: 1 g / min) at a spinning temperature of 265 ° C. and a spinning speed of 1300 m / min, and then The drawn yarn obtained by two-stage drawing at 70 ° C. and 180 ° C. was cut into 64 mm and subjected to free heat treatment at 170 ° C. to develop a three-dimensional crimp, and a hollow core having a hollow core with a hollow ratio of 32% Fineness 6 denier, initial tensile resistance 38 g / denier
A base material fiber having a crimp degree of 20% and a crimp number of 18 / inch was obtained. The heat-bonded fibers thus obtained and the base material fibers were mixed at a weight ratio of 40/60, pre-opened with an opener and then opened with a card, and the web obtained was laminated to have a basis weight of 1000 g / m ² . and, laminated net-like body, an apparent density of 0.05 g / cm ³
It was compressed so that it was heated to 180 ° C. for 5 minutes and then cooled to obtain a nonwoven fabric laminated structure having flat both sides.
Then, compress it by 10% of its thickness, and heat it with hot air at 100 ° C
Table 2 shows the characteristics of the nonwoven fabric laminated structure of the present invention obtained by the pseudo-crystallization treatment. As is apparent from Table 2, Example 1 was a cushion material excellent in heat resistance and durability at room temperature because it was a non-woven fabric laminated structure in which the characteristics of the soft elastic resin were utilized. It can be seen that the seat created for evaluation also has excellent performance.

[0022]

[Table 2]

Example 2 20 mol% of dimethyl isophthalate (DMI) and DMT
Table 1 shows the formulation of the polyester-based thermoplastic elastic resin obtained in the same manner as in Example 1 by charging 80 mol% and 1.4-butanediol (1.4-BD) with a small amount of a catalyst.
A reticulate body obtained in the same manner as in Example 1 except that the orifice had a round cross section with a diameter of 1 mm and only A-3 was used as a single component had a solid round cross section and a fineness of 9000 deniers.
The average apparent density is 0.
It was 046 g / cm ³ . Next, Table 2 shows the characteristics of the nonwoven fabric laminated structure obtained in the same manner as in Example 1. As is clear from Table 2, Example 2 is a cushioning material that is practically usable in terms of heat resistance and durability at room temperature, and has excellent sitting comfort.
It can be seen that the seat created for evaluation is also excellent.

Example 3 As a polyurethane elastomer, 4,4'-diphenylmethane diisocyanate (MDI), PTMG and 1.4BD as a chain extender were added and polymerized, and then 2% of an antioxidant was added and mixed. Table 3 shows the formulation of the polyether urethane polymer after kneading, pelletizing and vacuum drying.

[0025]

[Table 3]

The thermoplastic elastic resin thus obtained (seed component:
B-1 and core component: B-2) except that the melting temperature was 220 ° C., and the cross-sectional shape of the cis-core structure of the filaments of the reticulate body obtained in the same manner as in Example 1 was hollow with a triangular diaper-shaped hollow cross section. The rate was 40%, the fineness was 9800 denier, and the average apparent density was 0.047 g / cm ³ . On the other hand, the properties of the heat-bonded fiber obtained in the same manner as in Example 1 except that B-1 was used as the sheath component, PBT used in Example 2 as the core component, and the spinning temperature was 260 ° C. The shrinkage ratio at 4.5 denier and 150 ° C. was 3%. This heat-bonded fiber and the base material obtained in Example 1 were made into a laminated web of 1000 g / m ^{2 in} the same manner as in Example 1, laminated with the mesh, heat treated with hot air at 160 ° C. for 5 minutes, and then cooled. As a result, a non-woven fabric laminated structure having flat surfaces on both sides was obtained. Then compress 10% of the thickness to 100
Table 2 shows the characteristics of the nonwoven fabric laminated structure of the present invention obtained by the pseudo crystallization treatment for 20 minutes with hot air at ℃. Example 3 is a non-woven fabric laminated structure that takes advantage of the characteristics of soft urethane, and was a cushioning material excellent in heat resistance, durability at room temperature, and sitting comfort. It can be seen that the seat created for evaluation is also excellent.

Comparative Examples 1-2 Polyethylene terephthalate (PE) having an intrinsic viscosity of 0.63
T) Only the single component and only the polypropylene (PP) having a melt index of 12 are melted at a melting temperature of 280 ° C. and 2
Comparative Example 1 obtained in the same manner as in Example 2 except that the temperature was 50 ° C.
The fineness of the reticulate body used in Example 2 was 8800 denier and the apparent density was 0.047 g / cm ³ , and the fineness of the reticulate body used in Comparative Example 2 was 23,000 denier and the apparent density was 0.047 g.
It was / cm ³ . Next, Table 2 shows the characteristics of the nonwoven fabric laminated structure obtained in the same manner as in Example 2 except that the pseudo crystallization treatment was not performed. Comparative Example 1 has a poor heat resistance and durability because it is a reticulated body made of non-elastic polyester, and despite the fact that a short fiber non-woven fabric using a heat-bonding fiber whose thermo-bonding component is a thermoplastic elastic resin is used for the surface layer. , A cushion material that is hard and uncomfortable to sit on. In Comparative Example 2, the surface layer and the reticulate body are heat-resistant because the fine fiber is a reticulate body made of non-elastic olefin, and the heat-bonding component is a short fiber non-woven fabric made of a thermoplastic adhesive resin and made of polyester. Since it did not adhere, it was adhered with a urethane adhesive, but it was a cushioning material that had poor heat resistance and durability and was uncomfortable to sit on.

Comparative Example 3 Example 2 was repeated except that a take-up conveyor net was placed 60 cm below the nozzle surface and no pseudo crystallization treatment was performed after the take-up conveyor net was taken out.
Table 2 shows a part of the properties of the reticulate body obtained by the same method as described above.
Since the non-woven fabric laminated structure could not be formed due to poor adhesion and poor shape retention, repulsive force at 50% compression,
Apparent density, reinforcement effect, residual strain at 70 ℃, repeated compression strain,
Also, the sitting comfort is not evaluated. Comparative Example 3 is an example that is not suitable for a cushioning material because its shape is not fixed.

Comparative Example 4 A filament obtained in the same manner as in Example 2 except that the pseudo crystallization treatment was not performed had a fineness of 9100 denier and an average apparent density of 0.
4-45-EE manufactured by Toyobo Co., Ltd., which uses 045 g / cm ³ of reticulate body and thermoplastic non-elastic resin as a thermal bonding component in thermal bonding fiber
Table 2 shows the characteristics of the nonwoven fabric laminated structure in which the short fiber nonwoven fabric prepared in the same manner as in Example 1 was laminated on the surface layer and was joined and integrated, except that no pseudo crystallization treatment was performed using No. 7. In Comparative Example 4, since the cushion layer was made of the thermoplastic elastic resin, the cushioning material was comfortable to sit on, but was slightly poor in heat resistance and durability.

Comparative Example 5 A nozzle having a width of 50 cm and a length of 5 cm and having a staggered arrangement of holes with a pitch of 10 mm in the width direction and a pitch of 20 mm between the holes in the length direction was used as a nozzle having a diameter of 2 mm to form a single hole. Discharge at a rate of 25 g / min per nozzle, nozzle surface 30 cm
The fineness of the filament obtained in the same manner as in Example 2 was 11 except that a take-up conveyor net was arranged below and the take-up was carried out at 1 m / min.
At 3000 denier, the average apparent density is 0.154 g.
Table 2 shows the characteristics of the non-woven fabric laminated structure produced in the same manner as in Example 2 except that the net-like body of 1 cm ³ / cm ³ was used and the pseudo-crystallization treatment was not performed. Comparative Example 5 was a cushioning material having a remarkably fineness and a non-woven fabric laminated structure with uneven density, and thus the heat resistance and durability were poor and the sitting comfort was slightly poor.

Comparative Example 6 The filament fineness obtained in the same manner as in Example 2 was 9000 denier, and the average apparent density of the reticulate body was 0. 0, except that the spacing (opening width) of the take-up conveyor net was 5 cm. 043 g / cm ³
Table 2 shows the characteristics of the non-woven fabric laminated structure prepared in the same manner as in Example 2 except that the net-like body whose surface was not substantially flattened was used and the pseudo-crystallization treatment was not performed. Comparative Example 6
Since the surface of the net-like body was uneven, the apparent density was low, but the durability was poor, the thermal adhesion was insufficient, and the cushioning material was a little inferior in sitting comfort with a feeling of foreign matter.

Comparative Example 7 Obtained in the same manner as in Example 2 except that the amount of discharge per single hole was 3 g / min, the speed of the take-up conveyor net was 0.3 m / min, and no pseudo-crystallization treatment was performed. Streak fineness of 13
000 denier, the average apparent density of the reticulate body is 0.21.
Table 2 shows the characteristics of the non-woven fabric laminated structure prepared in the same manner as in Example 2 except that the grit / cm ³ mesh was used and no pseudo-crystallization treatment was performed. Since Comparative Example 7 had a high apparent density, it was a cushioning material having a good touch but a little inferior sitting comfort, and insufficient heat resistance and durability.

COMPARATIVE EXAMPLE 8 A nozzle having a width of 50 cm and a length of 5 cm and having a staggered arrangement of 4 mm pitch between holes in the width direction and 3 mm pitch between holes in the length direction and having an orifice diameter of 1 mm was used for each single hole. Of a filament obtained in the same manner as in Example 2 except that the discharge rate was 0.012 g / min, a take-up conveyor net was placed 5 cm below the nozzle surface, and the rate was 1.5 m / min. Fineness is 4
The net density of the non-woven fabric laminated structure is 0.009 by using the mesh body having 0 denier and the apparent density of 0.008 g / cm ^3.
Table 2 shows the characteristics of the non-woven fabric laminated structure produced in the same manner as in Comparative Example 7 except that the nonwoven fabric laminated structure was compressed to have g / cm ³ . Comparative Example 8 is a cushion material having a fine mesh with a fine linear fineness as a cushion layer, and the apparent density is too low to cause a large sinking, a large floor feeling, and a slightly inferior sitting comfort. .

Example 5 The nonwoven fabric laminated elastic structure obtained in Example 1 was cut into a length of 120 cm and put into a side cloth having a width of 120 cm and a length of 200 cm which was quilted every 5 cm in thickness, 120 cm in width and 50 cm in length. Created a mattress. This mattress was placed on a bed, and a paneler-4 person used it for 7 hours in a room at 25 ° C. RH 65% to sensory-evaluate the sleeping comfort. In addition, the bet is
The quilt is hung and the comforter is 1.8kg down / feather: 9
0/10 batting was used, and the pillow was worn by the paneler every day. As a result of the evaluation, the bed was a bed which had no feeling of flooring, had a moderate depression, and did not feel stuffy and had a comfortable sleeping comfort. For comparison, a similar mattress was prepared from a urethane foam plate with a density of 0.04 g / cm ³ and a thickness of 10 cm, and the mattress was placed on a bed and the sleeping comfort was evaluated. It was a bed that made me feel stuffy and didn't feel comfortable to sleep.

Example 6 The nonwoven fabric laminated structure obtained in Example 1 was used, with a width of 38 cm and a length of 40.
The corner was cut into a shape with 10 cm of the corner, and the polyester moquette used for sitting comfort evaluation was set on the side of the office chair frame, and the commercially available polyurethane was used for the cushion. Compared to a chair, it provides a comfortable sitting 4
As a result of evaluation by sitting for a while, the one using the nonwoven fabric laminated structure of the present invention was remarkably excellent in the feeling of dampness, the feeling of flooring, and the time to be able to stand while sitting.

[0036]

EFFECTS OF THE INVENTION Striations made of thermoplastic elastic resin having good vibration and stress absorption form a three-dimensional structure and are fused and integrated to form a net-like body having a substantially flat surface as a cushion layer. The nonwoven fabric laminated structure of the present invention in which a short-fiber nonwoven fabric, which is integrally bonded by heat-bonding with a heat-bonding fiber made of a thermoplastic elastic resin whose adhesive component has good vibration and stress absorption properties, is bonded and integrated as a surface layer has a vibration isolation property and a heat resistance It is a cushioning material that has improved durability, bulkiness, and sitting comfort, and does not damp easily.
A vehicle seat, a marine seat, which is provided with the above-mentioned preferable characteristics by covering the side surface as it is or in combination with another material,
Products such as vehicles, ships, commercial beds for hospitals and hotels, furniture cushions, bedding products, etc. can be provided. Furthermore, it is also useful as an interior material and a heat insulating material for vehicles and building materials.

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Claims (6)

[Claims] 1. A three-dimensional three-dimensional structure in which continuous filaments made of a thermoplastic elastic resin having a fineness of 100 to 100,000 denier are bent and brought into contact with each other so that most of the contact portions are fused. , A thermo-adhesive short fiber made of a thermoplastic elastic resin and a short fiber made of a thermoplastic non-elastic resin are mixed and spread on one side of a net-like body whose both sides are substantially flattened to form a three-dimensional structure. Of the non-woven fabric, the surface of which is fused and integrated by a heat-adhesive component, and whose surface is substantially flattened, has a density of 0.01 g / cm ³ to 0.2.
Nonwoven fabric laminated structure of g / cm ³ . 2. The nonwoven fabric laminated structure according to claim 1, wherein the cross-sectional shape of the continuous filaments is a hollow cross section or an irregular cross section. 3. The nonwoven fabric laminated structure according to claim 1, wherein the thermoplastic elastic resin forming the continuous filament has an endothermic peak at a temperature of room temperature or higher and melting point or lower in a melting curve measured by a differential scanning calorimeter. 4. A thermoplastic elastic resin is discharged downward from the nozzle at a melting temperature higher by 20 to 80 ° C. than the melting point of the multi-row nozzle having a plurality of orifices, and the thermoplastic elastic resin is brought into contact with each other in a molten state to be fused. While forming a three-dimensional structure,
After being sandwiched by a take-up device and cooled in a cooling tank, a single-sided mixed fiber of short fibers made of thermoplastic elastic resin and short fibers made of inelastic resin is mixed and opened to form a three-dimensional structured web. A method for producing a non-woven fabric laminated structure in which a large part of the contact portion is melt-bonded and integrated with a thermo-adhesive component by laminating and compression thermoforming. 5. The method for producing a nonwoven fabric laminated structure and a product according to claim 4, wherein after cooling once, annealing is performed at a temperature of at least 10 ° C. or lower than the melting point of the thermoplastic elastic resin. 6. A vehicular seat, a vehicular seat, a vehicular, a marine, a hospital, etc. commercial and household bed, furniture chair, office chair, and the like, which use the nonwoven fabric laminated structure according to claim 1. The product described on one of the futons.