JPH07268757A - Laminated nonwoven fabric mesh, its production and product produced by using the fabric - Google Patents

Abstract

PURPOSE:To produce a laminated nonwoven fabric structure having excellent thermal aging resistance, shape-retainability and cushioning property and most suitable as a non-stuffing cushioning material, a process for producing the structure and a product such as vehicle sheet produced by using the laminated nonwoven fabric structure. CONSTITUTION:This laminated nonwoven fabric structure is produced by forming a three-dimensional steric structure with a continuous conjugate filament composed of a thermoplastic elastomer resin and a thermoplastic non-elastomer resin and having a fineness of 100-100,000de, integrating the filaments with each other by melting to obtain a mesh material essentially flat at both faces and bonding and integrating a surface of the mesh material with a nonwoven fabric produced by three-dimensionally agglomerating heat-bondable conjugate short fibers composed of two kinds of thermoplastic elastomer resins. The contacting parts of the fibers are melted and integrated with the heat-bondable component, thus the fabric has an essentially flat surface. This invention also relates to its production process and an article produced by using the structure.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a reticulated thermoplastic elastomer resin and a thermoplastic non-elastic resin, which have excellent cushioning properties, heat resistance durability and vibration absorption properties, and short fiber hard fibers. TECHNICAL FIELD The present invention relates to a non-woven laminate network formed by laminating and bonding cotton layers, a manufacturing method thereof, and a product such as a futon, furniture, bed, or cushion material for a vehicle using the non-woven laminate network.

[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-blocking, excellent heat resistance and durability, shape retention, and cushioning properties that prevent stuffiness. A reticulated composite of thermoplastic elastic resin and thermoplastic non-elastic resin laminated and joined with short fiber hard cotton made of thermoplastic elastic resin. An object of the present invention is to provide a non-woven laminate network and a manufacturing method which are most suitable for a cushion material composed of a body, and a product and a manufacturing method using the non-woven laminate network such as a futon, furniture, bed, and cushion for vehicles.

[0008]

[Means for Solving the Problems] Means for solving the above problems, that is, the present invention provides a continuous composite filament having a fineness of 100 to 100,000 denier, which is a composite of a thermoplastic elastic resin and a thermoplastic non-elastic resin. The three-dimensional three-dimensional structure is formed by bending and making contact with each other and most of the contact portions are fused, and both surfaces of the structure are substantially flattened, and one surface has two types of thermoplasticity. The heat-adhesive composite short fibers made of elastic resin are three-dimensionally structured, most of the contact parts are fused and integrated by the heat-adhesive component, and the non-woven fabric whose surface is substantially flat is joined and integrated, resulting in a high density. 0.01 g
/ Cm ³ to 0.2 g / cm ³ non-woven laminate network, multi-row nozzle with multiple orifices so that thermoplastic elastic resin and thermoplastic inelastic resin can be combined Distributing immediately before, discharging at a melting temperature 10 to 120 ° C. higher than the melting point of the thermoplastic resin, downward from the nozzle, contacting each other in a molten state and fusing to form a three-dimensional structure, After sandwiching with a take-up device and cooling in a cooling tank, heat-adhesive composite short fibers consisting of two types of thermoplastic elastic resins are opened on one side, and webs having a three-dimensional structure are laminated, and by compression thermoforming, It is a method for producing a non-woven laminate network, which is characterized in that most of the contact portions are fused and integrated by a heat-adhesive component, and a product using the non-woven laminate network.

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 with a number average molecular weight of 1000 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 function of absorbing vibrations and stress of the nonwoven fabric laminated network 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 network 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. An endothermic peak is more clearly expressed at a temperature of room temperature or higher and melting point or lower in the melting curve of the nonwoven fabric laminated network treated as described above measured by a differential scanning calorimeter. 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) obtained 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 has a fineness of 100,000 denier or less.
Below is a series of thermoplastic elastic resin and thermoplastic inelastic resin.
The continuous filaments are bent and brought into contact with each other so that the contact portion
Form a three-dimensional solid structure in which most of the
Thermoplastic elasticity on one side of a substantially flat mesh
Short fibers made of resin are three-dimensionally structured, and most of the contact area
The surface where the components are fused and integrated by the heat-adhesive component is substantially flat.
The density of bonded and integrated non-woven fabrics is 0.01
g / cm³To 0.2 g / cm³The non-woven laminated net of
It The function of the cushion material is that the cushion layer has a basic fineness.
Thicken and make it a little harder to reduce body vibration and vibration
Vibrates by absorbing the vibration by increasing the density a little with a debilitating component
It consists of a layer that blocks the
As a soft layer with a large number of pieces
Gives comfortable buttocks touch and evenly distributes buttocks pressure distribution
Vibration that could not be absorbed by the cushion layer
The layer that absorbs and blocks the vibration of the resonance part of the human body is integrated.
By absorbing the stress and vibration,
The ground can be improved. In the present invention, the cushion
The function of the layer is a fusion-bonded three-dimensional structure made of thermoplastic elastic resin.
The body structure has a net-like structure, and the surface layer functions as heat.
Short fibers made of plastic elastic resin are three-dimensionally structured and
The majority of the touch area is the surface that is fused and integrated by the thermal adhesive component.
Having in qualitatively flattened non-woven fabric (short fiber non-woven fabric)
And join together to give a desirable cushioning function
It is a non-woven laminate laminate that can be formed. Nonwoven Laminated Net of the Present Invention
The short fiber non-woven fabric that has the function of the surface layer that constitutes the strip is soft
As a layer, it gives a comfortable touch to the buttocks by sinking,
Fineness that can satisfy vibration absorption function and deformation stress absorption function is 2
3 short fibers made of thermoplastic elastic resin of 0 denier or less
Dimensionally structured, and most of the contact area is melted by the thermal adhesive component.
Constructed with a non-woven fabric that has a substantially flat surface
To achieve. Short fibers when the fineness of short fibers exceeds 20 denier
The apparent density of the non-woven fabric can be added to the desired surface layer function.
0.01 g / cm³0.05g / cm or more³Place to
In this case, the number of components is reduced, which is a characteristic of a dense structure.
Is not desirable because it does not produce a comfortable touch. Also,
The number of thermal bonding points decreases and the dispersion of deformation stress deteriorates.
Since the stress concentration at
Not preferable. On the other hand, if the fineness is too small, the anti-compression property will be remarkable.
Shock absorbers on the side and cushion layers.
-It is not preferable because it may lose its function. Preferred short
The fineness of the fiber is 1 denier to 10 denier, more preferably
Is 3 to 6 denier. Short fibers have a three-dimensional structure
And most of the contact parts were fused and integrated by thermal bonding.
Substantial surface (preferably all contact points are fused together)
The non-woven fabric is flattened locally to keep the buttocks locally
If you receive various pressures on the surface and evenly distribute the pressure distribution,
In both cases, the three-dimensional three-dimensional structure of short fiber non-woven fabric was used as a heat-adhesive component.
Since the thermoplastic elastic resin is fused and integrated,
While the short fibers made of elastic resin are deforming, the entire structure
Deforms and absorbs the deformation stress by energy conversion and deforms
Easy to release due to rubber elasticity of thermoplastic elastic resin when stress is released
Has a function to restore the original form, so it has good sag resistance
Is. Furthermore, the damage to the cushion layer can be gradually reduced.
Therefore, the sag resistance of the entire structure is improved. Integrated fusion
If not, the shape cannot be maintained and the local pressure is not applied.
The pressure distribution cannot be uniformly distributed, and the structure
The whole is deformed and energy cannot be converted, so durability is poor.
Less preferred. Thermoplastic with good absorption of short fibers
As it is made of elastic resin, it is absorbed by the cushion layer
It also absorbs vibrations that were not possible and blocks the vibrations of the resonant parts of the human body.
It also functions as a layer to cut off. Short fibers are thermoplastic non-elastic
If it is made of flexible resin, it cannot follow the local deformation stress.
Therefore, stress concentration causes the structure to be destroyed and
It is inferior and not preferable. In addition, the thermoplastic non-elastic resin is
Since the dynamic absorption is poor, the function as a layer that blocks vibration is poor.
Less preferred. The thickness of the short fiber non-woven fabric layer is not particularly limited.
However, it is preferable that the surface layer function is 3 mm to 30 mm.
In particular, 5 mm to 20 mm is particularly preferable. On the other hand, the cushion
The reticulate body having the layer function is made of thermoplastic elastic resin and thermoplastic non-elastic
Continuous filaments compounded with a hydrophilic resin form a three-dimensional structure
Most of the contact area is fused and integrated, and both sides are
It has been ratified, and thermoplastic vibrations given from the outside
Most of the vibration is absorbed and damped by the vibration absorption function of the elastic resin
However, even when a large deformation stress is locally applied,
The body surface is substantially flattened and most of the contact area is melted.
Wearing and the surface is face-bonded with the short fiber non-woven fabric
Therefore, it receives the deformation stress on the surface of the mesh and disperses the deformation stress.
And composite with thermoplastic elastic resin and thermoplastic inelastic resin
The formed linear shapes form a three-dimensional structure and are fused and integrated.
Since the thermoplastic non-elastic resin is
The thermoplastic elastic resin is transformed into a heat
Partially difficult before the plastic inelastic resin exceeds the elastic limit
The entire structure, which has a shape and is fused and integrated, is deformed and
The deformation stress is absorbed by the gear conversion, and the deformation stress is released.
Then, the thermoplastic inelastic resin recovers elastically,
Since oil also develops rubber elasticity and easily recovers its original form,
Good sag and deformation due to stress during compression
The strain changes linearly, and when sitting, the hips with low repulsive force
It gives a feeling of flooring as it supports the
It expresses the body shape retention function. From thermoplastic elastic resin only
The net is too soft and the depression is slightly larger.
The present invention has solved the drawbacks and improved the body shape retention function. Public knowledge
In the reticulated body composed of filaments consisting only of non-elastic resin,
When subjected to a large deformation that cannot be absorbed by the surface layer, rubber elasticity
Since it does not have, it does not recover due to plastic deformation due to compressive deformation.
And the durability is poor. The surface of the mesh is substantially flat
Localized from short fiber non-woven fabric if not localized
External force is selectively transmitted to the surface stripes and adhesion points.
Can be reached and stress concentration can occur.
Fatigue resistance against stress due to fatigue due to stress concentration
May decrease. The filament is a thermoplastic elastic tree.
When made of fat and thermoplastic elastic resin and thermoplastic inelastic
If it is combined with resin, it is structured with a three-dimensional structure part.
Since the whole is deformed, stress concentration is relieved, but inelastic trees
If it consists of only fat, stress concentrates at the bonding point as it is.
Then, structural destruction occurs and it cannot be recovered. Furthermore, the surface is real
When sitting without qualitative flatness and unevenness, buttocks
To give a feeling of foreign matter to the user
Yes. If the line is not continuous, the net with a large fineness
In the case of a strip, the bonding point is the stress transfer point, so
Stress concentration causes structural damage and heat resistance and durability are poor.
Not good. If not fused, shape retention is possible
In addition, the structure is not deformed as a unit, which causes fatigue due to stress concentration.
A labor phenomenon occurs and durability is deteriorated, and at the same time, the shape is deformed.
It is not preferable because the body shape cannot be maintained. The invention
The more preferable degree of fusion is the large area where the filaments are in contact.
Half is fused, most preferably the contact area
Are all fused together. Thus, vibration absorption and bullet
Continuous wire composited with thermoplastic elastic resin with good property recovery
Forming a three-dimensional three-dimensional structure in which the contact portions of the stripes are mostly fused.
Cushion with integrated fusion and substantially flat surface
The reticulate body having the function of the elastic layer is made of thermoplastic elastic resin.
Deformation stress transmitted from surface layer composed of short fiber non-woven fabric
The surface to improve the dispersion of stress and
The stress is reduced and the entire structure is deformed to absorb the deformation stress.
In addition, the cushioning property that supports the buttocks is also improved, and stress is
When released, it recovers and the vibration transmitted from the frame is also absorbed.
The thermoplastic elastic resin part with good absorbency and elastic recovery absorbs
Sitting comfort and durability by blocking the vibration of the resonance part of the human body
It is possible to improve the sex. To this end, the invention
The fineness of the filaments forming the mesh is 100,000 denier or less.
Below. Apparent density 0.2g / cm³If you
If the number exceeds 100,000 denier, the number of components will be small.
Structure, resulting in uneven density and partial poor durability.
Fatigue due to stress concentration, resulting in reduced durability.
It is not preferable. Fibers of filaments that form the mesh body of the present invention
As for the degree, if the fineness is too fine, the compression resistance becomes too low and the deformation
As the stress absorbability due to
Yes, there is no loss of structural precision due to a decrease in the number of components.
It is less than 50,000 denier. More preferably 50
It is 0 denier or more and 10,000 denier or less. Starting
The apparent density of the bright mesh is 0.005 g / cm³Then anti
Loss of power, and vibration absorption capacity and deformation stress absorption capacity are insufficient.
It may become difficult to develop the cushion function because
0.25g / cm³Above, the repulsive force is too high and the sitting heart
Since the ground may be deteriorated, vibration absorption capacity and deformation stress
The function as a cushion body is developed by utilizing the absorption function.
Easy to get 0.01g / cm³0.20 g / cm or more³The following is
Preferably, more preferably 0.03 g / cm³0.0 or more
8 g / cm³It is the following. The reticulate body in the present invention has a fineness
Optimal configuration by combining different linear shapes with apparent density
A method with a different fineness laminated structure is also selected as a preferred embodiment.
You can choose. 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 absorption function and the stress dispersion function will be
Therefore, the preferable thickness is the surface function that distributes the force.
10mm as thickness that can absorb vibration and deformation stress absorption function
It is above, more preferably 20 mm or more. The present invention
Layered structure in which the net body and the short fiber nonwoven fabric are integrally bonded
Apparent density is 0.01 g / cm³To 0.2 g /
cm³Is. 0.01 g / cm³Less than body retention and vibration
The cushioning function such as absorption is reduced, which is not desirable.
Yes. 0.2 g / cm ³If it exceeds, the impact resilience will increase and the seat
It is not preferable because it does not feel comfortable. Good looking
The degree is 0.02g / cm³~ 0.1g / cm³And better
More preferably 0.03 g / cm³~ 0.06g / cm³Is.
When the mesh and short fiber non-woven fabric are not joined and integrated
When the structure undergoes shear deformation, the structure is not integrated and joined.
Since it cannot be deformed as a whole, short-fiber non-woven fabric is not very useful.
The structure may be destroyed due to
Even if there is no body shape retention layer support
Is not good and is not preferable.

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 composed of a thermoplastic inelastic resin exhibiting anti-compression properties. It can give a comfortable touch to the buttocks due to moderate depression. With the side-by-side structure, it is possible to easily convert the vibration and deformation stress into energy, and the melt viscosity of the thermoplastic elastic resin with many soft segment contents is made lower than the melt viscosity of the thermoplastic non-elastic resin showing anti-compressive property to form a linear surface. A structure in which the proportion of the thermoplastic elastic resin that occupies a large amount of the soft segment is increased (metaphorically, a structure in which the thermoplastic elastic resin is arranged in the eccentric sheath-core structure)
It is particularly preferable that the proportion of the thermoplastic elastic resin occupying the linear surface in the large amount of the soft segment is 80% or more, and most preferably the thermoplastic elastic resin occupying the linear surface in the large amount of the soft segment content. Ratio 10
It is the score of 0%. 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 points is improved, and the heat resistance and durability are further improved.

Since a linear net-like body in which a thermoplastic elastic resin and a thermoplastic non-elastic resin are composited and a short fiber non-woven fabric are joined and integrated, a non-woven fabric laminated net body in which both surfaces are substantially flattened is provided. Other heat-adhesive components (heat-bonded non-woven fabric, heat-bonded fiber, heat-bonded non-woven fabric, knitted fabric, hard cotton, film, foam, metal, etc.
Heat-adhesive film, heat-adhesive resin, etc.) and adhesives are used to make a monolithic laminated structure, and seats for vehicles, seats for ships, vehicles, ships, hospital beds, etc. When obtaining products such as office chairs and duvets, the contact area with the surface to be adhered can be widened, so that the adhesive area can be widened and a product with strong adhesion and good adhesion durability can be obtained. In addition, by performing the above-mentioned pseudo crystallization treatment at any stage of commercialization from the mesh and the laminated mesh formation step, the component composed of the thermoplastic elastic resin in the nonwoven laminated mesh is analyzed by a differential scanning calorimeter. It is more preferable that the measured 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 reticulated body forming the non-woven fabric laminated network of the present invention have a composite structure, the back surface of the non-woven fabric reticulated body can also be provided with a heat-bonding function, and the reinforcing material and the like can be integrated into the heat-bonding structure. For example, in the sheath core structure, a thermoplastic elastic resin containing a large amount of soft segments, which facilitates energy conversion of vibration and deformation stress of the sheath component, is used as a heat-adhesive component, and a thermoplastic non-compressive material having a compressive property of the core component is used. The function of the heat-bonding layer can also be imparted by using a structure in which the elastic resin has a high melting point component for providing the function of holding the net shape, and the melting point of the heat-bonding component is lower than the melting point of the high-melting resin by 10 ° C. or more. . Also,
The short-fiber non-woven fabric of the surface layer of the non-woven fabric laminated network of the present invention is heat-bonded, and can be used as the heat-bonding layer.
Preferably, the thermal adhesive component is a low melting point thermoplastic elastic resin having a high soft segment content, and the non-thermal adhesive component is a high melting point thermoplastic elastic resin having a low soft segment content. -The conversion can be made good, and the three-dimensional structure can be retained to provide a good heat adhesion function. The melting point of the heat-adhesive component forming the filaments or fibers in the non-woven laminate network preferable for exhibiting the heat-adhesive function is 15 ° C to 80 ° C lower than the melting point of the high-melting component, and more preferably 20 ° C to 60 ° C. ℃ lower melting point. The non-woven laminate network of the present invention having a heat-bonding function has a substantially flat surface, and most of the contact portions are fused to form a network, a non-woven fabric, a knitted fabric, a hard cotton, a film, Since it is possible to increase the contact area with the surface of the foam, metal, etc. to be heat-bonded, the heat-bonding area becomes wider, and a new heat-bonded new molded body and vehicle seat, ship seat, vehicle, ship, You can get products such as beds for business and home use such as hospitals, 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. The thermoplastic elastic resin and the thermoplastic inelastic resin are distributed in front of each orifice so that the thermoplastic elastic resin and the thermoplastic inelastic resin can be compounded from a multi-row nozzle having a plurality of orifices, and the melting point of the thermoplastic resin is higher than the melting point of the thermoplastic resin by 120 ° C or more.
It is discharged downward from the nozzle at a melting temperature higher than less than, and in a molten state, they are brought into contact with each other and fused to form a three-dimensional structure, sandwiched by a take-up device and cooled in a cooling tank, and then heated on one side. Thermobonding fibers made of plastic elastic resin and short fibers made of non-elastic resin are mixed and spread to form a three-dimensional structured web, which is laminated, and compression thermoforming is used to bond most of the contact area to the heat bonding component. This is a method for producing a non-woven fabric laminated network body that is fused and integrated by. The reticulated body is prepared by separately melting the thermoplastic elastic resin and the thermoplastic non-elastic resin by using a general melt extruder, and mixing and mixing so as to form a composite just before the orifice as in a general composite spinning method. Discharge downward from the orifice. In the sheath core, the core component is supplied from the center, and the sheath component is merged and discharged from around the core component.
On the side-by-side, the components are merged and discharged from the left and right or the front and back. The melting temperature at this time is 10 ° C. to 120 ° C. higher than the melting point of the thermoplastic resin. When the melting temperature is higher than the melting point of the low-melting point component and exceeds 120 ° C., thermal decomposition is remarkable and the characteristics of the thermoplastic resin are deteriorated, which is not preferable. On the other hand, unless the temperature is higher than the melting point of the high-melting point component by 10 ° C. or more, melt fracture occurs and normal filament formation becomes impossible, and the temperature of the filament when contacting and fusing while forming loop after discharge. May decrease, and the filaments may not be fused to each other, resulting in a network having insufficient adhesion. In the case of side-by-side, the linear adhesion may be poor, which is not preferable. The preferred melting temperature is 20 ° C. to 100 ° C. higher than the melting point of the low melting point component, more preferably 30 ° C. to 80 ° C. higher than the melting point, and 15 ° C. to 40 ° C. higher than the melting point of the high melting point component, more preferably The materials are combined and discharged at the same melting temperature, which is 20 ° C. to 30 ° C. higher than the melting point. Unless the melting temperature difference immediately before joining is 10 ° C. or less, abnormal flow may occur and the formation of the composite morphology may be impaired. The shape of the orifice is not particularly limited, but a hollow cross section (for example, a hollow shape having a triangular shape, a round shape, a hollow shape with a protrusion, etc.) and / or an irregular cross section (for example, a triangular shape,
In addition to the above effects, the three-dimensional structure formed by the discharge filaments in the molten state is less likely to flow relaxation, and conversely at the contact point Is particularly preferable because the adhesion point can be strengthened by keeping the fluidizing time of (1) long. 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. In the hollow cross section, if the hollow ratio exceeds 80%, the cross section tends to be crushed. Therefore, it is preferably 10% or more and 70% or less, more preferably 20% or more and 60% or less, which can exhibit the effect of weight reduction. 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. In addition, if the cross-sectional area of the orifice is changed to give a pressure loss difference at the time of discharge, the melted thermoplastic resin is extruded from the same nozzle with a constant pressure, and the discharge amount decreases as the orifice loses more pressure. It is possible to manufacture a net-like 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 direction. Then, the liquid is discharged downward from the nozzle, and 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, and are sandwiched by a take-up net to melt the surface of the net-like body. Bending the twisted discharge line of 45 degrees or more to deform it to flatten the surface and at the same time bond the contact points with the unbent discharge line to form a structure, and then continuously cool the medium (usually at room temperature). It is preferable to use the water of (1) because the cooling rate can be increased and the cost can be reduced). The distance between the nozzle surface and the collection point is at least 4
It is preferable to set the thickness to 0 cm or less to prevent the discharge line from being cooled and the contact portion not being fused. 10 cm to 40 cm is preferable when the discharge amount of the discharge line is 5 g / min or more, and 5 when the discharge amount of the discharge line is less than 5 g / min.
cm to 20 cm is preferred. 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. 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 for solidifying the resin, the melt viscosity of the resin, the orifice hole diameter 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 thermo-adhesive fiber having a fineness of 20 denier or less, which is made of a thermoplastic elastic resin, individually melts a low-melting thermoplastic elastic resin and a high-melting thermoplastic elastic resin, spins them by a well-known composite spinning, and draws them. And you can get the finished thread. However, in this method, since the melting point of the heat-adhesive component is low, heat setting at a high temperature at the time of stretching cannot be performed, so that only a high shrinkage rate of 30% to 80% can be obtained.
When the web is thermoformed, shrinkage of the web causes defective molding. In the present invention, in order to solve this problem,
It is preferable to obtain it by a method in which the shrinkage rate is reduced to 10% or less by high-speed spinning at a speed of 00 m / min or more and the finished yarn is obtained all at once. Next, crimping is applied and cut into a desired cut length to obtain a heat-bonded fiber. The composite form of the heat-bonding fiber used in the present invention is not particularly limited, but it is preferable that the low-melting point component occupies 50% or more of the surface of the fiber in side-by-side or sheath-core because it is required to function as a heat-bonding fiber. More preferably, the low melting point component occupies 100% or more of the surface of the fiber. The heat-bonded fiber thus obtained is pre-opened with an opener or the like and then opened with a card or the like, and a spread web having a three-dimensional structure is laminated and compressed on the surface of the reticulated body to heat it. It is also possible to form a short fiber nonwoven fabric by joining and integrating by molding, or by singly laminating and compressing only the opening web and forming a structure by thermoforming to form a short fiber nonwoven fabric, and then joining and integrating the mesh body and the short fiber nonwoven fabric. . 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 network obtained by once cooling the network or integrally molding. It is a more preferable production method to obtain a non-woven fabric laminated network or product by performing 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. By this treatment, the heat-resistant sag resistance is remarkably improved as compared with the one having no endothermic peak (having no endothermic peak) having an endothermic peak below the melting point. 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.
However, it is more preferable to impart compressive deformation of 10% or more and anneal to significantly improve the 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 non-woven fabric laminated network of the present invention is used as a cushion, it is necessary to select the resin to be used, the fineness, the loop diameter and the 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 network of the present invention has the functions of both the surface layer and the cushion layer at the same time, it can be formed into a shape suitable for the purpose of use using a molding die or the like so as not to impair the three-dimensional structure, and 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 thickness (b) after leaving the sample for 20,000 times after repeating compression recovery at a cycle of 1 Hz up to the thickness of 1 is calculated from the thickness (a) before the treatment, that is, (ab) / ax Calculated from 100. Unit% (average value of n = 3) Sit comfort Seating frame covered with a polyester moquette hem made of Toyobo Co., Ltd. on the surface layer side of the non-woven laminate mesh body cut and molded into the shape of a bucket sheet. Set the seat to 4 seats and 6 seats on the back to create seats with side lands, and use the seats created at 30 ° C RH75% room with a panel
The following evaluations were performed. (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 different extruders, A-1 is distributed as a sheath component, and PBT having a relative viscosity of 1.0 is distributed just before the orifice so as to become a core component, and the melting temperature is changed. Discharge rate per single hole at 260 ° C: 2.0 g / min (A-
(1: 1 g / min, PBT: 1 g / min), and the 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 with a pair of take-up conveyors at intervals of 5 cm. It is arranged so that it partially appears on the surface of the water, and the discharge line in the molten state is bent to form a loop, and the contact portion is fused to form a three-dimensional network structure. While sandwiching both sides of the body with a take-up conveyor, the body 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 cut into a predetermined size. -It has a triangular cross section with a score structure and a hollow cross section with a hollowness of 40% and a fineness of 9000 denier, and an average apparent density of 0.046 g.
It was / cm ³ . Separately, the thermoplastic elastic resin A-1 is individually melted by a conventional method so that the thermoplastic elastic resin A-1 becomes the sheath component and A-2 becomes the core component, and is dispensed immediately before the orifice, and each discharge is performed. The amount was 50/50 weight ratio, 1.6 g / min per single hole (0.8 g / min: 0.8 g / min) was discharged at a spinning temperature of 245 ° C., and was obtained at a spinning speed of 3500 m / min. A yarn having a fineness of 4.1 denier and a shrinkage rate of 8% at a dry heat of 160 ° C is converged and mechanically crimped with a crimper in a tow shape, cut into 64 mm and heat of a cross section A heat-bonded short fiber made of a plastic elastic resin was obtained. The resulting heat-bonded fiber was pre-opened with an opener and then opened with a card to obtain a web, which was laminated to a basis weight of 1000 g / m ² and laminated on the reticulated body to give an apparent density of 0. It was compressed to 0.05 g / cm ³ , heat-treated for 5 minutes with hot air at 180 ° C., and then cooled to obtain a nonwoven fabric laminated mesh body having flat both sides. Next, Table 2 shows the characteristics of the nonwoven fabric-laminated network of the present invention obtained by compressing 10% of the thickness and performing pseudo-crystallization treatment with hot air at 100 ° C. for 20 minutes. As is clear from Table 2, Example 1 was a cushioning material having excellent heat resistance and durability at room temperature and excellent sitting comfort because it was a nonwoven fabric laminated reticulate body which made the best use of the characteristics of the soft elastic resin. 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 a nozzle having a circular cross section with a hole diameter of 1 mm was used as the orifice component and A-3 was used as the sheath component had a solid round cross section and a fineness of 9,000 denier.
The average apparent density is 0.
It was 046 g / cm ³ . Next, Table 2 shows the characteristics of the nonwoven fabric laminated network 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:
In the same manner as in Example 1 except that B-1) was used, the cross-sectional shape of the linear filaments of the linear filaments was a triangular rice ball type hollow cross section with a hollow ratio of 40% and a fineness of 9800 denier. The average apparent density was 0.047 g / cm ³ . On the other hand,
The heat-bonded fiber obtained in the same manner as in Example 1 except that B-1 was the sheath component, B-2 was the core component, and the spinning temperature was 200 ° C was that the fineness was 4.5 denier. The shrinkage percentage at 150 ° C. was 9%. 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 reticulate body having flat both sides was obtained. Then compress 10% of the thickness to 100 ° C
Table 2 shows the characteristics of the non-woven fabric laminated network of the present invention obtained by performing the pseudo crystallization treatment for 20 minutes with hot air. Example 3 is a non-woven laminate reticulate body that takes advantage of the characteristics of soft urethane, and has heat resistance.
It was a cushioning material with excellent durability and comfort at room temperature. It can be seen that the seat created for evaluation is also excellent.

Comparative Examples 1 and 2 The PBT used in Example 1 was used as a sheath component and an intrinsic viscosity of 0.
PET of 63 is the core component and polyethylene of melt index 5 is the sheath component, and P of melt index 12 is used.
With P as the core component, the melting temperature is 280 ° C and 240 ° C.
Except that, the reticulate body used in Comparative Example 1 obtained in the same manner as in Example 2 has a fineness of 8700 denier and an apparent density of 0.047 g / cm ³ , and the reticulate body used in Comparative Example 2 has a fineness of 24000. Denier with an apparent density of 0.047 g / cm
^{Was 3} . Then, except that the pseudo crystallization treatment was not performed
Table 2 shows the characteristics of the nonwoven fabric-laminated network obtained in the same manner as in Example 2. 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.
In addition, since the non-woven fabric laminated network 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 network in which the short fiber nonwoven fabric prepared in the same manner as in Example 1 was laminated on the surface layer except that no pseudo crystallization treatment was performed using 7. Comparative Example 4 was a cushioning material which was comfortable to sit on but had slightly poor 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 2000 denier, the average apparent density is 0.154 g.
Table 2 shows the properties of the non-woven fabric laminated network prepared in the same manner as in Example 2 except that the net-like network of 1 cm ³ / cm ³ was used and no pseudo-crystallization treatment was performed. Comparative Example 5 was a cushioning material having a remarkably fineness and a non-woven fabric laminated network having unevenness in density, resulting in poor heat resistance and a little uncomfortable sitting comfort.

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 network produced in the same manner as in Example 2 except that the network 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 network prepared in the same manner as in Example 2 except that the network of g / cm ³ was used and the pseudo-crystallization treatment was not 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 net is 0.009 by using the net of 0 denier and the apparent density of 0.008 g / cm ^3.
Table 2 shows the characteristics of the non-woven fabric-laminated network produced in the same manner as in Comparative Example 7 except that the composition 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 laminated elastic mesh obtained in Example 1 was cut into a length of 120 cm and put in 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 non-woven fabric laminated net body obtained in Example 1 has 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 stuffy feeling, the feeling of flooring, and the time to be able to stand while sitting were significantly excellent in those using the nonwoven fabric laminated reticulate body of the present invention.

[0036]

EFFECTS OF THE INVENTION The surface formed by fusion-bonding the filament formed by combining the thermoplastic elastic resin having good vibration and stress absorption property and the thermoplastic non-elastic resin improving the body-holding property forms a three-dimensional structure. The non-woven fabric laminated reticulate body of the present invention in which a substantially flat reticulated body is used as a cushion layer and a short fiber non-woven fabric composed of a thermoplastic elastic resin having good vibration and stress absorption is joined and integrated as a surface layer has a vibration isolation property. It is a cushioning material that has improved heat resistance and durability, bulkiness, and sitting comfort, and is resistant to stuffiness, and is provided with the above-mentioned preferable characteristics by covering the side material as it is or in combination with other materials. It is possible to provide products such as seats for ships, seats for vehicles, ships, beds for business use in hospitals and hotels, cushions for furniture, bedding and the like. Furthermore, it is also useful as an interior material and a heat insulating material for vehicles and building materials.

Claims (6)

[Claims] 1. A continuous composite filament having a fineness of 100 to 100,000 denier, which is a composite of a thermoplastic elastic resin and a thermoplastic non-elastic resin, is made to meander and contact each other, and most of the contact portion is fused. The three-dimensional three-dimensional structure is formed, and both sides of the structure are substantially flattened, and one surface thereof is three-dimensionally structured with thermoadhesive composite staple fibers composed of two types of thermoplastic elastic resins. The majority of the contact parts are fused and integrated by the heat-adhesive component, and the non-woven fabric whose surface is substantially flat is joined and integrated, and the density is 0.01 g / cm ³ to 0.2 g / cm ^3. A non-woven laminated reticulate body characterized by: 2. The nonwoven fabric laminated reticulate body according to claim 1, wherein the cross-sectional shape of the continuous composite filaments is a hollow cross section and / or a modified cross section. 3. The non-woven fabric laminated reticulated body according to claim 1, wherein the thermoplastic elastic resin forming the continuous composite 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 and a thermoplastic inelastic resin are distributed in front of each orifice so that they can be compounded from a multi-row nozzle having a plurality of orifices, and the melting point is 10 to 120 ° C. higher than the melting point of the thermoplastic resin. At a temperature, it is discharged downward from the nozzle, and in a molten state, they are brought into contact with each other and fused to form a three-dimensional structure, sandwiched by a take-up device and cooled in a cooling tank, and then two types of heat are applied to one side. Characterized by laminating webs that are three-dimensionally structured by opening thermo-adhesive composite short fibers made of a plastic elastic resin, and by compression thermoforming, most of the contact parts are fused and integrated with a thermo-adhesive component. And a method for producing a non-woven laminate network. 5. The method for producing a non-woven fabric reticulated body according to claim 4, wherein annealing is performed at a temperature of at least 10 ° C. or lower than the melting point of the thermoplastic elastic resin in the step of integrally molding after cooling and commercialization. 6. A vehicle seat, a ship seat, a vehicle, a ship, a hospital bed, etc. for business and home use, a furniture chair, and an office chair using the nonwoven fabric laminated reticulated body according to claim 1. And the product described in any of the futons.