JPH08336446A - Mattresses and manufacturing method - Google Patents

Abstract

PURPOSE: To provide a mattresses and manufacturing method thereof most suitable for bed mattress, a Japanese style mattress, a floor cushion, and a furniture cushion of general home, hospital and hotel applications that are to be kept always clean, to be washable, not to become mushy, having superior heat-retaining, shape keeping, and bending characteristics and moderate durability. CONSTITUTION: Mattresses are formed from three-dimensional structures of a continuous wire of a diameter of less than 5mm of thermoplastic elastomer. The structure is formed through fusion bonding of the wires at most of contacting points of bending and twisting wires. Both sides of surfaces are layers of cushion of network structures of practically flat and of apparent density of 0.005-0.10g/cm<3> , and thickness of more than 5mm. On either surface or on both surfaces, cushion layers stacked with wadding layers are to be covered with a side cloth. The wadding layer consists of hard cotton fabric with apparent density of less than 0.1g/cm<3> , and being bonded with fibers of matrix of natural fibers and thermoplastic elastic resin as thermo-bonding component.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION The present invention is suitable for general household use, which is difficult to get stuffy, has excellent heat retention and body shape retention, is comfortable to sleep, has excellent durability and bendability, can be washed, and can always maintain cleanliness. The present invention relates to a bed mat that is most suitable for beds for hospitals and hotels, and mats that are also suitable for cushioning materials such as bedding and furniture.

[0002]

2. Description of the Related Art At present, bed mats for beds use a hard steel wire spring or a foamed material such as styrofoam for a cushion layer, and a wadding layer laminated with resin cotton or hard cotton with adhered urethane foam or inelastic crimped fiber. Integrated,
Also, a cushion body made of only a foamed material such as urethane having the same composition or a resin cotton or a hard cotton to which an inelastic crimped fiber is adhered is used.

However, the one using a hard steel wire spring for the cushion layer is remarkably excellent in supportability, but is inferior in bending property, and the hard steel wire spring is separated and treated at the time of disposal. Complexity is a big problem. The cushion layer or wadding layer or the one using foam-crosslinking type urethane for the cushion body has very good durability as a cushion body, but it has poor moisture permeability and heat storage property, so it easily gets damp and slightly bendable. In addition, since it is not thermoplastic and it is difficult to recycle it and it is incinerated, the incinerator is greatly 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, recently, bed mats need to be washed due to the problem that hospital beds become hot beds such as MRSA, but urethane, which has poor water permeability, cannot be washed, which has become a social problem.

A resin cotton, in which a cushion layer or a wadding layer or a cushion body is formed by adhering polyester fibers with an adhesive,
For example, as an adhesive using a rubber system, Japanese Patent Laid-Open No. 60-
11352, JP-A-61-141388,
There is JP-A-61-141391. In addition, as one using a crosslinkable urethane, Japanese Patent Laid-Open No. 61-137732
There is a bulletin, etc. Those using these as a cushion layer or a wadding layer can improve breathability and reduce stuffiness, but are inferior in durability and bendability, and are not thermoplastic or single composition and therefore cannot be recycled. There are also problems such as complexity of processability and pollution of chemicals used during manufacturing. Also, although it can be washed, it has a problem of poor drainage.

Polyester hard cotton for the cushion layer or the wadding layer or the cushion body, for example, JP-A-58-311.
50, JP-A-2-154050, JP-A-3
However, since an amorphous polymer in which the adhesive component of the heat-adhesive fiber used is brittle is used (for example, JP-A-58-136828 and JP-A-3-24).
(Patent No. 9213, etc.) There is a problem that durability is inferior such that the bonded portion is brittle and the bonded portion is easily broken during use, and the form and elasticity are lowered. Furthermore, it is inferior in bendability. Also, although it can be washed, it has a problem of poor drainage. As a method for improving durability, a method of entanglement treatment has been proposed in Japanese Patent Laid-Open No. 4-245965 and the like, but brittleness of an adhesive portion is not solved and elasticity is largely reduced, and there is a problem that bending property is poor. . 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. Therefore, a heat-bonded fiber using a polyester elastomer which is soft and recovers even if it is deformed to some extent and uses an inelastic polyester as a core component is disclosed in JP-A-4-240219, and a cushion using the fiber is disclosed. The body is WO-91 / 19032, JP-A-5-155651, JP-A-5-163.
No. 654, etc. The adhesive component used in this fiber structure contains 30 to 50% by weight of polyalkylene glycol as the soft segment of polyester elastomer, and 50 to 80 mol% of terephthalic acid as the acid component of the hard segment. However, similar to the fiber described in JP-B-60-1404 as another acid component composition, isophthalic acid is added to increase the amorphous property, and the melting point becomes 180 ° C. or lower, resulting in low melt viscosity and thermal bonding. The amoebar-shaped adhesive part is formed by improving the part formation, but it is easy to plastically deform, and because the core component is an inelastic polyester, the plastic deformation becomes remarkable especially under heating, and the heat resistance and compression resistance are high. There is a problem that it deteriorates, and it is inferior in bendability and can be washed, but it has a problem that drainability is poor. As a method of further improving the durability, a structure comprising only a polyester polyester elastomer containing isophthalic acid as a sheath component and a heat-bonding conjugate fiber using an inelastic polyester as a core component is disclosed in JP-A-5-163654. Although proposed, the plastic deformation under heating becomes remarkable due to the above-mentioned reason, the heat resistance and compression resistance are lowered, and there is a problem in using it for the cushion body.
Further, Japanese Patent Laid-Open No. 63-158094 proposes a method in which a silicone oil is added to a hard cotton base material to lower the coefficient of friction of fibers to improve durability and improve the texture.
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 in a cushion body. On the other hand, as a method of improving the bendability, a method of forming a folding structure is disclosed in JP-A-55-36373 and JP-A-2-142513.
As disclosed in Japanese Patent Laid-Open No. 5-3894 and Japanese Patent Laid-Open No. 5-3894, the bending property is improved, but the durability and the problem at the time of washing are not improved, and there are many problems when used as a cushion body. is there. In addition, a cavity is formed in the bent portion to improve the bendability, for example, Japanese Patent Laid-Open No. 5-28.
Although there is a publication such as Japanese Patent No. 5031, the problem of foam such as urethane or the problem of hard cotton cannot be solved at all.

A thermoplastic olefin network used for civil engineering work is disclosed in JP-A-47-44839. As a cushion body using them, Shokai 58
No. 93270 discloses a laminated structure of a hard structure and a soft structure. No. 58-95760 discloses a structure having an air conditioning unit inside a net having a hard structure.
Although Japanese Patent Laid-Open No. 05714 describes that a net-like body that is assumed to have a hard structure is used, no consideration is given to heat resistance and durability, comfortableness to sleep, handleability such as weight reduction and washability.
Japanese Unexamined Patent Publication (Kokai) No. 58-109670 proposes a mesh body having irregularities on one side, but unlike a cushion made of thin fibers, the surface is uneven and the touch is bad, and heat resistance durability, sleeping comfort and weight reduction are achieved. No consideration was given to handling such as washing and washing. Japanese Unexamined Patent Publication No. 6-327723 discloses a reticulated body having a hole portion into which a cleaning pipe, a ventilation pipe, etc. can be mounted. However, since the material is olefin, the heat resistance and durability are remarkably inferior, and the weight reduction and the washability are achieved. It is not possible to use it as a wadding layer or cushioning material because it is not considered in handling. In addition, Japanese Patent Publication No. 3-1766
Japanese Patent Laid-Open No. 6-61 also discloses a method in which ejection filaments having different fineness are fused to each other to form a mole, but a net-like structure which is not suitable as a cushion material. Japanese Examined Patent Publication No. 3-55583 describes a method of thinning only a very surface with a thinning device such as a rotating body before cooling. 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. Japanese Unexamined Patent Publication No. 1-207462 discloses a vinyl chloride floor mat, 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 the bed mat in the above structure.

[0007]

To solve the above problems,
It is hard to get stuffy, has good heat retention, shape retention, etc., has good heat resistance and durability, and is easy to use.
The purpose is to provide the most suitable mats for beds, mattresses, seats, and cushions for furniture that can be sorted and recycled.

[0008]

[Means for Solving the Problems] To solve the above problems
Means of the invention, i.e. at least the upper surface of the cushion layer
A wadding layer is laminated on the
Mats, and the cushion layer is made of thermoplastic elastic resin.
Bends a continuous filament made of fat with a diameter of 5 mm or less
A random loop is formed, and each loop is connected.
It is a three-dimensional three-dimensional net structure in which most of the touch is fused.
The three-dimensional three-dimensional network is formed on both upper and lower surfaces.
Is flattened and the apparent density is 0.005
0.10 g / cm³, Thickness of 5 mm or more, waddin
The matrix layer is made of natural fibers as a main matrix and
In the box, the thermoplastic adhesive is used as the thermal adhesive component.
Fibers are dispersed and mixed in, and partially fixed at intersections of fibers
And the apparent density of the wadding layer is 0.1.
g / cm³The mats are characterized by the following.
Furthermore, the thermoplastic elastic resin forming the cushion layer is
The recovery rate after 300% elongation at room temperature (room temperature elongation recovery rate) is
20% or more, 10% elongation at 70 ° C was maintained for 24 hours
The recovery rate afterwards (extension recovery rate at 70 ° C) is 30% or more.
The wire diameter of the net-like body that constitutes the cushion layer is
0.01mm or more, apparent density is 0.01g / cm³From
0.08g / cm³, Mats with a thickness of 10 mm or more
Yes, the wire diameter of the net-like body that constitutes the cushion layer is 0.1 mm
2mm or less, apparent density 0.02g / cm³From
0.06g / cm³, The thickness is 20 mm or more and 500 mm or less
Mats with a porosity of 90% or more in the wadding layer
Mats having a thickness of 2 mm or more and 10 mm or less
The cushion layer and the wadding layer are laminated through the fabric.
Mats that have been embodied and are made of thermoplastic elastic resin.
The melting curve measured by a differential scanning calorimeter
A mat using a net having an endothermic peak at a temperature below the point
And the disconnection of the filaments of the net-like body that constitutes the cushion layer.
Mats whose surface shape is a hollow cross section or an irregular cross section
The cushion body has an air permeability of 50cc / cm ²Is more than a second
Mats and thermoplastic elasticity that make up the cushion
Mats whose resin is polyester and natural fiber
Mats made of silk with natural fibers made of wool.
Mats made of hemp natural fiber,
Thermoplastic elastic tree from multi-row nozzle with multiple orifices
The fat is melted at a melting temperature 20 to 80 ° C. higher than its melting point.
It is discharged downward from the ridge and the continuous line
Loops, and loops are brought into contact with each other to melt
It is sandwiched with a take-up device while wearing it and forming a three-dimensional structure
After cooling in a cooling tank, on the three-dimensional structure obtained,
Thermoplastic with natural fiber matrix on both bottom or one side
Of hard cotton joined with fibers made of heat-elastic adhesive resin
It is a manufacturing method of mats that are laminated and covered with side material, and commercialized
Of the thermoplastic elastic resin that constitutes the reticulate body in any process
Annealing at a temperature of at least 10 ° C below the melting point
This is a method for producing mats that perform pseudo-crystallization treatment.

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.
It is a ternary block copolymer composed of at least one of polyalkylenediol such as glycol, polypropylene glycol, polytetramethylene glycol, glycol made of ethylene oxide-propylene oxide copolymer and the like. . 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 as dicarboxylic acid, or naphthalene 2.6 dicarboxylic acid, 1.4 butanediol as diole component, and polytetramethylene glycol as 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 a 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. In addition, since the reticulate body constituting the bed mat of the present invention contains a phosphorus compound for imparting flame retardancy as a preferred embodiment, the thermal stability is slightly inferior to that not containing a flame retardant. It is particularly preferable to add an antioxidant or the like to improve heat resistance and durability. The antioxidant is preferably a hindered phenol-based antioxidant and a hindered amine-based antioxidant, and a nitrogen-free hindered phenol-based antioxidant is 1% to 5%. It is particularly preferable to suppress the thermal decomposition by adding it, because the generation of toxic gas with a small lethal amount at the time of combustion can be suppressed. The elongation recovery measured by the method described later of the thermoplastic elastic resin forming the cushion layer, which is a mat that can have both favorable durability and cushioning property, which is the object of the present invention, is the recovery rate after 300% elongation at room temperature. (Room temperature elongation recovery rate) is 20% or more, and the recovery rate after holding 10% elongation at 70 ° C. for 24 hours (70 ° C. elongation recovery rate) is 30% or more, more preferably room temperature elongation recovery rate. 30% or more,
The 70 ° C extension recovery rate is 40% or more, and most preferably, the room temperature extension recovery rate is 40% or more, and the 70 ° C extension recovery rate is 50% or more. The soft segment content of the thermoplastic elastic resin constituting the component imparting such elongation recovery is preferably 15% by weight or more, more preferably 30% by weight or more, and 80% by weight from the viewpoint of heat and fatigue resistance. The following is preferable, and 70% by weight or less is more preferable. That is, the soft segment content of the component having the function of absorbing vibrations and stress of the elastic 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. .

Since it is necessary to impart flame retardancy as a preferred embodiment of the mats of the present invention, the phosphorus content (Bppm) in the thermoplastic elastic resin is 60A + 200≤B≤ with respect to the soft segment content (A% by weight). It is good to satisfy the relationship of 100,000. If not satisfied, flame retardancy may be inferior. If it exceeds 100,000 ppm, the plastic deformation due to the plasticizing effect becomes large and the heat resistance of the thermoplastic elastic resin becomes poor, which is not preferable. Preferable phosphorus content (Bppm)
Is 30 with respect to the soft segment content (A% by weight)
A + 1800 ≦ B ≦ 100,000, and more preferable phosphorus content (Bppm) is 16A + 2600 ≦ B ≦ 50000 with respect to the soft segment content (A weight%). For flame retardancy, there is a method to add a high level of flame retardancy by adding a large amount of halides and inorganic substances, but when burning, a large amount of toxic halogen gas with a small lethal amount is generated, and there is a problem of poisoning during fire. Therefore, in the incineration, the damage of the incinerator becomes large, so that in the present invention, the preferable halide content is 10% by weight or less, the more preferable halide content is 5% by weight or less, and the most preferable halide content is It does not. Examples of the phosphorus-based flame retardant of the present invention include:
In the case of a polyester-based thermoplastic elastic resin, as a flame retardant in the hard segment portion at the time of resin polymerization, for example, as described in JP-A-51-82392, 10 [2.3]
・ Di (2-hydroxyethoxy) -carbonylpropyl] 9,10 ・ dihydro ・ 9 ・ oxa ・ 10 phosphaphenalene ・ 10 Polyester obtained by copolymerizing a carboxylic acid such as oxylo as a part of the acid component of the hard segment A flame-retardant property is imparted by adding a phosphorus-based compound such as tris (2.4-di-t-butylphenyl) fusphite to the thermoplastic elastic resin in a later step or a method of forming the thermoplastic elastic resin. be able to. Other flame retardants capable of imparting flame retardancy include various phosphoric acid esters, phosphorous acid esters, phosphonic acid esters (the above phosphoric acid esters containing a halogen element as necessary), or polymers derived from these phosphorus compounds. It can be illustrated. In the present invention, various modifiers, additives, colorants and the like can be added to the thermoplastic elastic resin as needed. Phosphorus is added to the flame-retardant adhesive component of the cushion layer netting or wadding layer constituting the bed mat of the present invention in order to provide flame retardancy. The reason is, as described above, from the viewpoint of safety. The goal is to minimize the use of toxic gases, such as cyanogen gas and halogen gas, which are produced in the event of fire and have a low lethal dose. Therefore, the toxicity index of the combustion gas of the reticulate body constituting the mats of the present invention is preferably 6 or less, more preferably 5.5 or less. The combustion gas toxicity index of the wadding layer is preferably 12 or less, more preferably 10 or less, and most preferably 7 or less. Cellulose is most preferable as a natural fiber that can reduce the toxicity index, and when using protein fiber silk, wool, feathers, etc., a polyester fiber with a low toxicity index is used for the heat-bonding fiber or the fiber mixed in the matrix. It is desirable to make the fiber mixing ratio as high as possible. Further, it is preferable to use a material having a high polyester fiber mixing ratio also for the side surface. It is preferable that the thermoplastic elastic resins forming the mesh body of the cushion layer are of the same type. For example, when the polyester-based thermoplastic elastic resin is used, the cushion layer can be recycled and recycled without separately separating it.

The component comprising the thermoplastic elastic resin constituting the mats 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, as a preferable polyester-based thermoplastic resin of the present invention, terephthalic acid or naphthalene 2.6 dicarboxylic acid having rigidity in the acid component of the hard segment is used.
The content of 0 mol% or more, more preferably the content of terephthalic acid or naphthalene 2.6 dicarboxylic acid is 95 mol% or more, and particularly preferably 100 mol% to the required degree of polymerization after transesterification of the glycol component. Polymerize, then
As the polyalkylene diol, 15 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 preferably used.
% To 70% by weight, more preferably 30% by weight
When the amount of copolymerization is 60% by weight or more, the crystallinity of the hard segment is improved if the content of terephthalic acid or naphthalene 2.6 dicarboxylic acid having rigidity in the acid component of the hard segment is large. Although it is less likely to undergo plastic deformation and the heat resistance and sag resistance are improved, the heat resistance and sag resistance is further improved by performing an annealing treatment at a temperature lower than the melting point by at least 10 ° C. or more after melt heat bonding. If annealing is performed after applying compressive strain, heat resistance and sag resistance are further improved. The reticulated body treated in this way has a melting curve measured by a differential scanning calorimeter, and more clearly shows an endothermic peak 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 natural fibers in the present invention include cotton, hemp, palm shell fibers, cellulosic fibers such as jute, wool, silk,
It refers to naturally occurring organic fibers such as protein fibers such as feathers. In the present invention, the term "matrix composed mainly of natural fibers" means a system in which at least 50% by weight or more of the matrix fibers are composed of natural fibers. In the present invention, the mixing ratio of the natural fiber in the matrix fiber is 50% or more, preferably 6 in order to sufficiently exhibit the hygroscopicity and water absorption of the natural fiber.
It is 5% or more, and more preferably 100%. Then
In the present invention, in consideration of enabling washing, it is necessary to increase the drying rate by mixing synthetic fibers having a low equilibrium moisture content to increase the drying rate in consideration of the drainage property after washing and the drying rate. The mixing ratio of the low synthetic fibers is preferably at least 15% by weight or more, more preferably 30% by weight or more.
It is less than 0% by weight. On the other hand, there is toxicity of combustion gas in safety at the time of fire, and in order to reduce toxicity of combustion gas, cellulosic fiber is preferable, and when protein fiber is used, as described above, synthesis with low toxicity index is performed. It is desirable to mix the resin fibers to reduce the toxicity index. In the present invention,
The toxicity index of the wadding layer is at least 15 or less, preferably 10 or less, more preferably 7 or less. Since the protein fiber also has flame retardancy, the present invention
At least 50% or more of the natural fiber is contained in the wadding layer.

The synthetic resin in the present invention means a thermoplastic resin. Thermoplastic resins include polyester, polyamide,
Examples include polyolefins. 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 (PET), polyethylene naphthalate
(PEN), polycyclohexylene dimethylene terephthalate (PCHDT), polycyclohexylene dimethylene naphthalate (PCHDN), polybutylene terephthalate (PBT), polybutylene naphthalate (PB)
N), polyarylate, etc., and copolyesters thereof can be exemplified. For polyamide, polycaprolactam (NY6), polyhexamethylene adipamide (NY)
66), polyhexamethylene sebacamide (NY6-1)
0) etc. can be illustrated. Examples of the polyolefin include polypropylene (PP) and polybutene-1 (PB-1). As the thermoplastic resin used in the present invention, when polyester is used for the cushion layer and the side material, polyester such as PET, PEN, PBN and PCHDT which can be recycled without separation when discarded and has good heat resistance is used. Is particularly preferable. Furthermore, PET, PEN, PB
A flame-retardant polyester (hereinafter abbreviated as flame-retardant polyester) obtained by polycondensation with N, PCHDT or the like to copolymerize a phosphorus-containing ester-forming compound or containing a phosphorus-containing flame retardant is preferable. -82392, JP-A-55-7888, JP-B-55-41610 and the like are exemplified. Although vinyl chloride has self-extinguishing properties, it produces a large amount of toxic gas when burned, and its heat resistance and durability are poor, so it is not preferable to use it in the present invention.

The basic cushion layer of the mats of the present invention is
A continuous filament made of a thermoplastic elastic resin having a fiber diameter of 5 mm or less is bent and brought into contact with each other to form a three-dimensional solid structure in which most of the contact portions are fused and integrated, and both sides are substantially Due to the flattened reticulated body, even if externally applied deformation through the wadding layer, especially when a large deformation stress is locally applied, the flattened reticulated body surface receives the deformation stress Since the deformation stress is dispersed and the filaments made of thermoplastic elastic resin form a three-dimensional structure and are fused and integrated, the entire structure is deformed and the deformation stress is absorbed by energy conversion. Since it receives the deformation stress with a low repulsive force due to rubber elasticity,
It exhibits a preferable body shape holding function capable of preventing extreme local depression and supporting the body shape with a soft gripping force on the human body. The betting mat is also required to have a vibration absorbing function. The cushion layer made of the mesh body of the present invention absorbs and attenuates most of the vibration applied from the outside by the vibration absorbing function of the thermoplastic elastic resin at the time of bed-in or turning over,
A preferable vibration absorbing function is also developed. When the deformation stress is released, the rubber elasticity of the thermoplastic elastic resin has a function of easily recovering the original shape, and therefore the sag resistance is also good. Furthermore,
The porosity is high, and the ventilation hole diameter is extremely large, so the ventilation resistance is low and the ventilation is extremely good. When the deformation stress changes due to rolling over, etc., the linear line having the rubber elasticity of the thermoplastic elastic resin is a three-dimensional structure. Since the structure is fused and integrated, the entire structure is compressed and recovered by deformation, and the air containing steam and heat accumulated in the cushion layer that has permeated through the wadding layer is discharged during compression and fresh during recovery. The mats have a pump function of exchanging with the outside air, so that heat and steam can be easily transferred between the wadding layer and the cushion layer, and the mats can provide comfortable sleeping that is hard to stuff. From this purpose,
The wire diameter of the thermoplastic elastic resin having good vibration absorption and elastic recovery forming the mesh body of the present invention is 5 mm or less. 5 mm when the apparent density is 0.2 g / cm ² or less
If it exceeds, the number of constituents decreases, a density unevenness is generated, and a structure having poor durability is partially formed, and fatigue due to stress concentration increases and durability deteriorates, which is not preferable. If the wire diameter of the filament made of the thermoplastic elastic resin of the present invention is too small, the anti-compression property becomes too low and the stress absorbability due to deformation decreases, so it is 0.01 mm or more. It is 3 mm or less so as not to impair compactness. More preferably, it is 0.05 mm or more and 2 mm or less. The average diameter of the continuous loop random loops forming the reticulate body of the present invention is preferably 50 mm or less, and particularly preferably 2 to 25 mm in order to achieve the object. When the apparent density of the reticulate body of the present invention is 0.005 g / cm ³ , the repulsive force is lost, the deforming stress absorbing ability and the vibration absorbing ability are insufficient, and the cushioning function may not be easily expressed. If it is cm ³ or more, the repulsive force may be too high and the sitting comfort may be poor, but in the present invention, it is 0.10 g / cm ³ or less for the purpose of reducing the weight and improving the handleability. It is preferably 0.01 g / cm ³ or more and 0.08 g / cm ³ or less, more preferably 0.02 g / cm ³ or more 0.0, in which the function as a cushion body is easily expressed by utilizing the vibration absorbing ability and the deformation stress absorbing function.
It is 6 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 linear shapes having different wire diameters are combined with an apparent density to have an optimum configuration can be selected. The thickness of the mesh body of the present invention is required to be 5 mm or more. If the thickness is less than 5 mm, the stress absorbing function and the stress dispersing function are deteriorated, which is not preferable. A preferable thickness is 10 mm or more, more preferably 20 mm or more, as a surface function for dispersing force and a function of absorbing vibration and deformation stress.
It is less than 00 mm. If the thickness of a single plate is 500 mm or more, the bendability described below deteriorates. Therefore, when a thicker cushion layer is desired, a cushion layer having a thin thickness of 500 mm or less, preferably 200 mm or less is not bonded as desired. By stacking with, it is possible to prevent the bending property from being impaired. In the case of stacking so as to have a thickness of 500 mm or less, the interface may be joined, and even if it is not joined, since the surface is flat, the transmission of stress is transmitted by the surface, so there is no problem in deformability. If the surface of the mesh body is not substantially flattened, the local external force transmitted from the wadding layer cannot receive the deformation stress on the surface, and the surface line and the bonding point are selectively exposed. The stress concentration may occur because the function to disperse the deformation stress is reduced, and the stress concentration may occur against such external force, which may cause fatigue due to stress concentration. . 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, but the body shape retention function is also deteriorated as the fatigue is advanced. In the case of non-elastic resin, stress concentrates on the bonding point as it is, causing structural destruction and cannot be recovered. Furthermore, if the surface is not substantially flattened and has irregularities, it gives a feeling of foreign matter to the back, buttocks, etc. when the person sleeps, which is unfavorable because it makes the sleeping comfort worse. When the linear shape is not continuous, the adhesive point of the filament becomes a stress transmitting point, so that remarkable stress concentration occurs at the adhesive point and structural destruction occurs, resulting in poor heat resistance and durability, which is not preferable. There is a problem that the compression resistance is inferior even at the stage where the structure is not destroyed, and the body shape retention property is inferior.If the density is increased to solve this problem, the porosity decreases, the air permeability decreases and the comfort decreases, and the weight also decreases. It becomes heavy and the handling is extremely poor. If not fused,
Since the shape cannot be maintained and the structure does not deform integrally, fatigue phenomenon occurs due to stress concentration and durability is poor, and at the same time,
It is not preferable because the shape is deformed and the body shape cannot be maintained. The more preferable degree of fusion bonding of the cushion layer of the present invention is
Most of the parts where the filaments are in contact are in a fused state,
Most preferably, the contact portions are all fused. In a net-like body composed of known filaments made only of non-elastic resin, when it receives a large deformation stress that cannot be absorbed by the surface layer, it does not have rubber elasticity and it does not easily deform and shows a large repulsive force. In addition, since it exhibits a strong repulsive force, it gives an unpleasant body-supporting feeling and exhibits an unfavorable body-shape holding function. Further, due to the compressive deformation, plastic deformation occurs and the recovery is lost, and the durability is poor. Further, since it has almost no pump function by compression recovery, the function of reducing stuffiness is inferior. The cross-linkable polyurethane has excellent vibration absorption function and sag resistance because it is an elastic resin, but it has a structure that facilitates stress transmission, so it can easily follow local deformation to prevent extreme local subsidence. Occurs, and the function of maintaining body shape is poor. Further, the foamed polyurethane is a cushioning layer which becomes a mat or the like which is apt to be stuffy because it has extremely poor air permeability and does not provide comfortable sleeping comfort. The mats of the present invention move sweat and moisture from the skin surface through the wadding layer as quickly as possible and do not give a stuffy feeling, and hold the figure with proper heat retention and a favorable fit, and permanently provide a comfortable sleep. In order to do so, a wadding layer made of hard cotton having an apparent density of 0.1 g / cm ³ or less, which is joined with fibers having a natural fiber as a main matrix and a thermoplastic elastic resin as a heat-adhesive component, is provided on one side of the cushion layer, or And mats that are composed of a cushion body laminated on the back side and are individually divided and taken out at the time of washing, and can be laminated and stored after washing and wrapped with a side material. Since the wadding layer uses natural fibers as a matrix, the excellent hygroscopicity and water absorption of the natural fibers allow the sweat and water vapor, whose temperature has risen to the body temperature on the skin surface, to move from the skin surface to the wading layer through the lateral surface. Then, the cushion layer has a pump function to replace with fresh air, so the heat and moisture transferred to the wadding layer are released to the outside through the cushion layer. It also reduces the stuffy feeling as the temperature decreases. Thus, when the natural fiber absorbs water or absorbs heat, heat is generated, heat transfer is reduced, and excessive cooling can be prevented. Further, since natural fiber maintains a constant vapor pressure once it absorbs or absorbs water, the moving speeds of heat and moisture are suppressed, and an appropriate vapor pressure can be maintained on the skin surface to maintain the heat retaining effect. The wadding layer has an apparent density of 0.1 by being bonded with a thermal adhesive component made of a thermoplastic elastic resin.
Since it is made of hard cotton of g / cm ³ or less, the wadding layer itself also has the same pump function as the cushion layer due to the elongation recovery of the thermoplastic elastic resin, and the natural fibers that are difficult to dry absorb water that has absorbed or absorbed water. Since it is efficiently discharged to the cushion layer, it is possible to prevent the water vapor pressure of the wadding layer from becoming extremely high. When the apparent density exceeds 0.1 g / cm ³ , the pumping function of the wadding layer is extremely deteriorated. Therefore, the apparent density from the pumping function is preferably 0.06 g / cm 3.
^{It is 3} or less, more preferably 0.04 g / cm ³ or less.
Thus, the synergistic effect of the wadding layer and the cushion layer makes it possible to develop a mat function that is resistant to stuffiness and has excellent heat retention. Another function of the wadding layer is that the thermoplastic elastic resin forms a three-dimensional three-dimensional structure in which natural fibers are joined and integrated, so that even if a local deformation stress is applied, the entire structure deforms and the energy is reduced. Since the deformation stress is absorbed by the conversion, the deformation stress can be received with a low repulsive force due to rubber elasticity, so that the human body can be supported by a soft gripping force against the human body. Since the laminated structure with the cushion layer has a synergistic effect, it can receive a deformation stress with a low repulsive force due to rubber elasticity, so that a local high compressive stress point in contact with the human body is less likely to be formed, and thus a wadding function that is less likely to cause congestion. Can be expressed. This function sends fresh air to the surface of the skin through the lateral side, and as a further synergistic effect, effectively works to prevent floor rubs. In order to impart such a particularly remarkable effect, it is desirable that the ventilation rate of the air exhausted from the surface of the wadding layer to the side surface of the cushion layer is 50 cc / cm ² seconds or more. If the apparent density of the hard cotton constituting the wadding layer of the present invention is too high, the congestion preventing function is deteriorated due to the increase of the high compression stress supporting area, and the breathability and the pump function are poor and the anti-steaming effect is also deteriorated. 1 g /
cm ³ or less is required. When the apparent density is too low, the anti-compression property is lowered and the function of the wadding layer is deteriorated. Therefore, the preferable apparent density is 0.01 g / cm ³ or more and 0.06 g / cm ³ or more.
³ or less, more preferably an apparent density of 0.03 g / cm ³
It is above 0.05 g / cm ³ . If the thickness of the wadding layer is less than 2 mm, the function of the wading layer will deteriorate. 30 mm
In the above, the useful function of the synergistic effect with the cushion layer and the function of retaining the body shape and the function of absorbing vibration by supporting the body with a proper depression and soft gripping force are reduced. Preferred thickness is 3 mm
It is 15 mm or less and more preferably 5 mm or more and 10 mm or less. The natural fiber in the matrix fiber used for the wadding layer of the bed of the present invention is, as described above, dryness at the time of washing, flame retardancy and combustion gas toxicity, as well as heat retention and stuffiness depending on preference. You can change the type and mixing ratio. For example, when a person who is relatively chilly desires warm eyes, the mixture ratio of protein fibers such as wool, genuine cotton (silk), and feathers in the matrix fiber is preferably 60% or more, and 80% or more 1
00% is more preferable. When a soft touch and good heat retention are desired, it is preferable that the mixing ratio of cotton (silk) and feathers in the matrix fiber is 70% or more.
% Or more and 100% or more is more preferable. On the other hand, when a slightly cooler sleeping comfort is desired, it is preferable to increase the mixing ratio of cellulosic fibers such as hemp and cotton in the matrix fiber, and particularly the amount of dust is small, and the mixing ratio of hemp having a large fiber diameter is 80%. It is more preferable to set it as above. Depending on the taste, the desired different wadding layers may be laminated on both sides of the cushion layer to use them differently in summer and winter. Further, other materials may be laminated on the cushion layer and / or the wadding layer as long as the basic function of the present invention is not lost. If the mixing ratio of the fibers containing the thermoplastic elastic resin in the wadding layer as a thermal adhesive component is 5% or less, a three-dimensional three-dimensional structure in which natural fibers are joined and integrated is formed and subjected to local deformation stress. Also, the entire structure is deformed to absorb the deformation stress by energy conversion, and the function of receiving the deformation stress with a low repulsive force due to rubber elasticity and the pump function are poor. On the other hand, if the mixing ratio is 50% or more, the number of matrix fibers is reduced and the functional effect of natural fibers is reduced, which is not preferable.
The mixing ratio of the fibers containing the thermoplastic elastic resin in the wadding layer of the present invention as a thermal adhesive component is preferably 10% or more, more preferably 20% or more and 40% or less. The heat-bonding fiber having a thermoplastic elastic resin as a heat-bonding component is not particularly limited as long as the heat-bonding component is formed of a thermoplastic elastic resin and the thermoplastic elastic resin can form a heat-bonding point with the matrix fiber. . For example, a thermoplastic elastic resin is used for the sheath component of the sheath / core fiber or one component of the side-by-side fiber, and a thermoplastic non-elastic resin is used for the other component,
Examples thereof include a single component made of only a thermoplastic elastic resin. However, in the case where the thermoplastic non-elastic resin is used as the other component, the thermoplastic non-elastic resin component may be deteriorated in heat resistance due to plastic deformation. If the thermoplastic elastic resin alone is melted during the adhesive treatment and loses its fiber form, the number of constituent fibers of the structure may decrease, and appropriate repulsive stress may not be exhibited. Therefore, in the present invention, it is most preferable to use a fiber in which both the components of the sheath and the core are made of thermoplastic elastic resin. As the heat-adhesive component, if the melting point or the flow starting temperature is less than 100 ° C, the heat resistance is poor,
When the temperature is 200 ° C. or higher, the heat resistance of natural fibers may be exceeded and thermal adhesion is difficult to occur. Therefore, a temperature of 100 ° C. or higher and 200 ° C. or lower is preferable. More preferably, when using a cellulosic fiber having a temperature of 140 ° C. or higher and 180 ° C. or lower, 130 ° C.
It becomes possible to sterilize by steam. 110 ℃ for protein fiber
If the one having a temperature of 150 ° C. or higher is used, sterilization of ethylene oxide gas at a temperature of lower than 100 ° C. is possible. The fineness of the heat-bonding fiber is not particularly limited, but it is preferable to use a fiber having a fineness close to that of the natural fiber to be used because the fiber mixing becomes easy. For example, when using cotton or silk, 1 denier to 4
When using denier or wool * linen, it is preferable to use 2 to 6 denier. The fibers mixed with the natural fibers in the matrix fibers are not particularly limited as long as they can be mixed with the natural fibers. The fibers mixed with the natural fibers in the matrix fibers are added to the wadding layer in order to add characteristics not found in the natural fibers, for example, anti-mitic agents, antibacterial agents,
Fibers containing deodorants, flame retardants, fragrances, etc. are mixed to enhance the function, and water-repellent and hydrophobic properties are used to improve draining and drying properties. It is desirable to mix fibers to be mixed with fibers that can impart a function such as doubling the characteristics and characteristics of natural fibers. The fineness of the fiber is selected as desired, but the fineness that can be used in ordinary card opening is from 0.5 denier to 100 denier. In special cases, fineness up to 500 denier can be selected. The material is selected as necessary, but usually polyester fiber may be used. The wadding layer and cushion layer may be joined together, but the draining property after washing is slightly inferior to the wadding layer, so if washed in a circle or washed in the joined state, they will not be joined with the cushion layer and will be separated individually. By reducing the thickness of the wadding layer, the drying time is slightly longer than that of the structure capable of increasing the drainability and the drying speed. (Of course, compared with mats composed of webs and mats composed only of hard cotton using a matrix with a large wire diameter, the drying time is much shorter, so the draining property is excellent.) , When bonded, the wadding layer functions to increase the surface rigidity, and the bendability is slightly lower than that of the unbonded one. Therefore, it is desirable that the cushion layer and the wadding layer are not bonded because the drainage property and bendability during washing are improved. Therefore, it is preferable. Thus, the laminated cushion bodies are individually separated, taken out, re-laminated, and wrapped in the sewn side fabric so that they can be inserted into the side fabric, thereby forming the mats of the present invention. In the present invention, for the above reason, the cushion layer and the wadding layer are separately taken out and provided with an opening / closing port that can be closed to the side so that the cushion layer and the wadding layer can be stacked and inserted after washing. This allows the cushion body to be easily washed and dried. The mats of the present invention, in addition to the above-mentioned characteristics, have the characteristics that they are bendable, can be washed, and have good drainage properties during washing. That is, since the cushioning material is made of a thermoplastic elastic resin, it can be bent by taking advantage of its elasticity, and can be used for a bed for care or the like which needs to raise the head or upper body. When used as a thin mattress, it can be folded and stored. The good washability is that the cushion layer made of normal fibers has a fiber diameter of 0.001 mm or less.
The wire diameter of the cushion layer that constitutes the majority of the cushion body of the present invention is 0.01 mm or more, and the hard cotton of the wadding layer has a large fiber surface weave, but the average number of the whole cushion body is small. Since the surface area of the filament is remarkably small, the moisture adhering to the surface of the filament can be reduced, resulting in excellent drainability. Since it has good draining property, the drying time can be shortened.
Therefore, the bed mat of the present invention can be washed frequently, and as a result, a clean bed mat can always be used. The bed mat of the present invention can be washed in a round manner, but for the above-mentioned reason, it is preferable to separately divide the side layer, the cushion layer and the wadding layer for washing. If the cushion layer is made of non-elastic resin, it is difficult to bend. If a material made of a hard material is bent forcibly, the bent portion may be broken, and if a material made of a soft material is plastically deformed and the cushion is dented near the bent portion, it will break due to bending fatigue if repeatedly bent. Because of the laminated structure of the cushioning layer of the present invention made of an elastic resin and the wadding layer having a high degree of freedom for deformation, it is bendable, and it is hard to be plastically deformed against repeated bending and has excellent durability. It is a different point. In order to improve the bending property, a structure having a bending structure has been proposed. However, unlike the cushion layer of the present invention, the non-elastic resin is used for the cushion layer, so that the durability is poor. Commercial beds may be sterilized as needed. For sterilization, ethylene oxide gas below 100 ° C or steam at 130 ° C is generally used. In a preferred embodiment of the mats of the present invention, it is possible to sterilize without deforming by applying sterilization for less than 15 minutes without applying compressive stress. However, known olefin-based or vinyl chloride-based materials are used. When used, it is different from the present invention in that it has poor heat resistance and plastically deforms due to heating during sterilization to cause bulk reduction.
In addition, by performing the above-mentioned pseudo crystallization treatment at any stage from the step of forming the net body and the laminated cushion to the product, the component made of the thermoplastic elastic resin in the net body is melted by a differential scanning calorimeter. It is more preferable that the curve has an endothermic peak at a temperature of room temperature or higher and melting point or lower, because the stretchability and heat resistance of the thermoplastic elastic resin are remarkably improved, and the heat resistance and durability of the product are remarkably improved.

The cross-sectional shape of the filaments of the net-like body that constitutes the cushion layer of the present invention is not particularly limited, but a preferable anti-compression property (repulsive force) and touch can be imparted by forming a hollow cross section or a modified cross section. It is particularly preferable because it is possible. The compression resistance can be adjusted by adjusting the fiber diameter and the modulus of the material used to make the wire diameter thinner, and for soft materials, the hollowness and irregularity can be increased to adjust the gradient of the initial compression stress, and the wire diameter can be made slightly thicker. Or, if the material has a slightly high modulus, the hollowness and the degree of irregularity are lowered to give the good anti-compression property with good sleeping comfort. As another effect of the hollow cross section and the irregular cross section, by increasing the hollow ratio and the degree of irregularity, it is possible to reduce the weight even when the same anti-compression property is given, and it is possible to replace the mats for betting, the duvet, the cushion, etc. In this case, handling property at the time of raising and lowering is improved. 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, in particular, 50% or more of the linear surface is made of a soft thermoplastic elastic resin in order to obtain a three-dimensional structure in which vibration and deformation stress that cannot be energy-converted even if the cushion layer is largely deformed can be energy-converted and recovered. And a side-by-side structure and a combination thereof. In the sheath core structure, the sheath component is a thermoplastic elastic resin with a large content of soft segments that can easily convert energy into vibration and deformation stress, and the core component is a thermoplastic elastic resin with a small content of soft segments that exhibits anti-compression properties. It is made of resin and can give a comfortable touch to contact parts such as the back and buttocks due to an appropriate degree of 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 in which the proportion of thermoplastic elastic resin occupying a linear surface and having a large amount of soft segment is increased (metaphorically, a structure in which a thermoplastic elastic resin is arranged in an eccentric sheath-core structure) ), The proportion of the thermoplastic elastic resin occupying the linear surface and having a large soft segment content is 80%.
The above-mentioned ones are particularly preferable, and most preferable 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 points is improved, and the heat resistance and durability are further improved. On the other hand, when the sheath core component, which is the most preferred embodiment of the heat-bonding fiber constituting the wadding layer of the present invention, is made of thermoplastic elastic resin, the sheath component energy-converts vibration and deformation stress. A high-melting point component that uses a thermoplastic elastic resin with a high soft segment content as a heat-adhesive component and a thermoplastic elastic resin with a low soft segment content that shows the anti-compression property of the core component as a reticulated form retention function. And the melting point of the heat-adhesive component is 10
The heat resistance and durability of the wading layer are further improved by using the one whose temperature is lowered by 50 ° C. from 50 ° C. The mats of the present invention have natural fibers as a main matrix on one side of the cushion layer, and a wading layer laminated integrally by a thermo-adhesive component made of a thermoplastic elastic resin is laminated on the other side of which, a short fiber web, a non-woven fabric, a knitted fabric, A cushion body or a product can be manufactured by laminating and integrating cloths and the like. A cushion body obtained by laminating a cushion layer and a wadding layer and joining them by using non-bonding or an adhesive agent is used for vehicle seats, ship seats, vehicle beds, ship beds, hospital beds and other commercial and household beds and furniture. It is also useful as a cushion body for office chairs, office chairs, duvets, seats and the like.

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 a continuous linear loop is achieved in a molten state. Then, each loop is 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 heat is applied to the upper, lower, both sides or one side of the obtained three-dimensional structure. This is a method for producing a bed mat in which a double Russell knit made of a plastic resin is laminated to cover a side material. 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 8 ° C. from the melting point of the thermoplastic elastic resin.
The temperature is 0 ° C. higher. 80 from the melting point of the thermoplastic elastic resin
If the melting temperature is higher than 0 ° C, thermal decomposition will be remarkable and the rubber elasticity of the thermoplastic elastic resin will be deteriorated. 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 temperature, more preferably 25 ℃ to 40 ℃ above the melting point
It is a high temperature. 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 and fused to form a three-dimensional structure, and are sandwiched by a take-up net, and the winding winding filaments in the molten state on the surface of the mesh body are bent 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 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 melt viscosity at the time of forming the reticulate body is preferably 500 poises to 10000 poises, and when it exceeds 20000 poise, It is not preferable because the forming speed becomes slower and it becomes difficult to form a dense network structure.), And the desired loop diameter and wire diameter can be determined by the hole diameter of the orifice and the discharge amount. A pair of take-up conveyors with adjustable intervals installed on the cooling medium sandwich and hold the molten discharge filaments to fuse the parts that are in contact with each other and continuously draw in the cooling medium to solidify them. 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. Then, in the present invention, after the reticulate body is once cooled, it is continuously or discontinuously pseudo-crystallized to be cut into a predetermined size, or pseudo-crystallized after cutting, or a wadding layer. After stacking, pseudo crystallization is performed. On the other hand, the most preferable thermoadhesive fiber of the thermoplastic elastic resin forming the wadding layer as an adhesive component is a low melting point thermoplastic elastic resin and a high melting point thermoplastic elastic resin are individually melted,
A finished yarn can be obtained by spinning and stretching with a known composite spinning. However, in this method, since the melting point of the heat-adhesive component is low,
Since heat setting cannot be performed at a high temperature during stretching, only a high shrinkage ratio of 30% to 80% can be obtained, and therefore, when the web is thermoformed, a molding dimension defect due to web shrinkage occurs.
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. Then
A crimp 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 matrix fiber (synthetic fiber) made of a synthetic resin other than natural fiber mixed with the matrix of the wadding layer is a known method in which a thermoplastic non-elastic resin is imparted with a latent crimping ability by an asymmetric cooling method or a composite spinning method, and stretched. A three-dimensional crimp is developed and cut by post-heat treatment, or a three-dimensional crimp is developed by heat treatment after cutting. Since synthetic fibers are also required to have sag resistance and heat resistance, those having an initial tensile resistance of at least 35 g / denier and an initial tensile resistance at 70 ° C. of at least 10 g / denier are preferred. preferable. 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-bonding fibers and the synthetic fibers thus obtained are mixed and opened with a desired blending amount with the natural fibers which are the main matrix of the wadding layer. 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 mixing ratio of the heat-bonding fibers and the matrix fibers is preferably 10/90 to 50/50, and the mixing ratio of the natural fibers and the synthetic fibers is 100/0. As a 50/50 weight ratio, pre-opening mixing was performed with an opener and the like, followed by opening with a card or the like to form an opening web having a three-dimensional structure, and an apparent density of 0.1 g / cm ³ Hereinafter, the apparent density is preferably 0.01 g / so that the thickness is 2 mm or more.
Laminate compression is performed so that the thickness is from cm ³ to 0.06 g / cm ³ and the thickness is from ³ mm to 15 mm, the pieces are joined and integrated by thermoforming, and cut into a predetermined size to obtain a wadding layer. The quasi-crystallization treatment of the wadding layer can be performed alone or after laminating with the cushion layer. Then, the wadding layer is laminated on both sides or one side of the cushion layer to form a cushion body,
If necessary, a pseudo-crystallization treatment is performed at this stage, and the cushion body is inserted into a side material sewn into a structure that can be individually taken out separately to obtain the mats of the present invention. In the crystallization treatment in the present invention, Ta is lower than at least the melting point (Tm) of the thermoplastic elastic resin by 10 ° C. or more in any step leading to commercialization.
It is performed at or above the α dispersion rising temperature (Tαcr) of nδ.
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 from (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. When the reticulate body is once cooled and then subjected to a drying step, the drying temperature is set to
By setting the ring temperature, it is possible to simultaneously perform the pseudo crystallization treatment. Also, a pseudo crystallization treatment can be separately performed in the process of commercialization.

When the heating for adhesion described in Japanese Patent No. 075 is carried out, 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 case of a hollow cross section, if the hollow ratio exceeds 80%, the cross section tends to be crushed, so that it is possible to exhibit the effect of weight reduction, preferably 10% or more and 70% or less, more preferably 2%.
It is 0% or more and 60% or less. The pitch between the holes of the orifice needs to be a pitch with which the loop formed by the line can sufficiently contact. To make a dense structure, shorten the pitch between holes,
The pitch between the holes is increased to obtain a dense 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, 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. Incidentally, 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 melt viscosity at the time of forming the mesh body is preferably 500 poises to 10000 poises,
If it exceeds 20000 poise, the loop forming speed becomes slow and it becomes difficult to form a dense network structure, which is not preferable. ), The desired loop diameter and wire diameter can be determined by the hole diameter of the orifice and the discharge amount. A pair of take-up conveyors with adjustable intervals installed on the cooling medium sandwich and hold the molten discharge filaments to fuse the parts that are in contact with each other and continuously draw in the cooling medium to solidify them. 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. Then, in the present invention, after the reticulate body is once cooled, continuously, or
Pseudo-crystallization treatment is performed discontinuously to cut into a predetermined size, or pseudo-crystallization treatment after cutting, or pseudo-crystallization treatment after stacking with a wadding layer. On the other hand, the most preferable thermo-adhesive fiber of the thermoplastic elastic resin forming the wadding layer as an adhesive component is a low melting point thermoplastic elastic resin and a high melting point thermoplastic elastic resin are individually melted, a known composite A finished yarn can be obtained by spinning and spinning. But,
In this method, since the heat-adhesive component has a low melting point, it cannot be heat-set at a high temperature during stretching, so that the shrinkage rate is 30% to 80%.
Therefore, when the web is thermoformed, a molding dimension defect due to the shrinkage of the web occurs. 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 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 matrix fiber (synthetic fiber) made of a synthetic resin other than natural fiber mixed with the matrix of the wadding layer is a known method in which a thermoplastic non-elastic resin is imparted with a latent crimping ability by an asymmetric cooling method or a composite spinning method, and stretched. A three-dimensional crimp is developed and cut by post-heat treatment, or a three-dimensional crimp is developed by heat treatment after cutting. Since the synthetic fibers are required to have sag resistance and heat resistance, the initial tensile resistance is at least 35 g /
Those having a denier or more and an initial tensile resistance at 70 ° C. of at least 10 g / denier or more are preferable. The crimp degree of the three-dimensional crimp is preferably 15% or more, and the number of crimps is preferably 10 to 25 crimps / inch from the viewpoint of bulkiness and anti-compression property. The heat-bonding fibers and the synthetic fibers thus obtained are mixed and opened with a desired blending amount with the natural fibers which are the main matrix of the wadding layer. 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 matrix fibers is 10/90 to 50/50 by weight, and the mixing ratio of the natural fibers and the synthetic fibers is 100/0. As a 50/50 weight ratio, pre-opening mixing was performed with an opener and the like, followed by opening with a card or the like to form an opening web having a three-dimensional structure and an apparent density of 0.1 g / cm ^3. Hereafter, lamination compression is performed so that the apparent density is 0.01 g / cm ³ to 0.06 g / cm ³ and the thickness is ³ mm to 15 mm so that the thickness is 2 mm or more, and the joining is integrated by thermoforming. Then, cut into a predetermined size to obtain a wadding layer. The quasi-crystallization treatment of the wadding layer can be performed alone or after laminating with the cushion layer. Then, the wadding layer is laminated on both sides or one side of the cushion layer to form a cushion body, and if necessary, pseudo crystallization is performed at this stage, and the cushion body is sewn into a structure in which the cushion body can be separately taken out. The mats of the present invention are obtained by inserting the mats of the present invention. The crystallization treatment according to the present invention is performed at any step leading to commercialization by lowering the melting point (Tm) of the thermoplastic elastic resin by at least 10 ° C.
The temperature is higher than the dispersion rising temperature (Tαcr). 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.

In the mats of the present invention, in addition to beds, mats, cushions, mats for furniture, etc., only the cushion body or the cushion layer can be used by utilizing its function. For example, it can be used for vehicle seats, boat seats, chairs, furniture, etc. simply by molding it 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 covering the side ground. 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, the molded product is processed from the manufacturing process to the extent that performance is not deteriorated, and at any stage of commercialization, it becomes flame retardant, insecticidal, antibacterial, heat resistant, water / oil repellent, colored, aromatic, etc. It is possible to perform the processing such as the addition of chemicals to add the function.

[0019]

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. 1. Melting point (Tm) and endothermic peak below melting point The endothermic peak (melting peak) is measured from the endothermic curve measured using a Shimadzu TA50, DSC50 type differential thermal analyzer at a heating rate of 20 ° C / min. -H) The temperature was determined. 2. Tαcr polymer is heated to a melting point of + 10 ° C to a thickness of 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 heating rate of 1 ° C./min. Tan δ (the ratio of the imaginary elastic modulus M ″ to the real part M ′ of the elastic modulus M ″ / The rising temperature of α dispersion corresponding to the transition temperature from the rubber elastic region to the melting region of M ′). 3. Room temperature elongation recovery rate Polymer is heated to melting point + 10 ° C and thickness is about 300μm.
Of the film, using Tensilon UTM4 type manufactured by Orientec Co., Ltd., the strain was returned to 0% after stretching 300% at a stretching speed of 100%, and was allowed to stand for 2 minutes and then stretched to break again. Elongation rate at which stress develops is 300
The value obtained by dividing the elongation rate subtracted from% by 300% is shown in%. (N = 3) 4. 70 ° C. elongation recovery rate Polymer is heated to a melting point + 10 ° C. to have a thickness of about 300 μm.
24 film was prepared by using Tensilon UTM4 type manufactured by Orientec Co., Ltd. and applying a 10% elongation strain at a elongation rate of 100% in a heating oven in an atmosphere of 70 ° C.
After holding for a period of time, the strain is returned to 0%, and after being left for 5 minutes and then stretched to break again, the value obtained by subtracting the stretch rate at which stress develops again at 10% from the stretch rate at 10% is divided by 10%. Shown in%. (N = 3) 5. Apparent Density The sample is cut into a size of 15 cm × 15 cm, the heights at four locations are measured, the volume is calculated, and the weight of the sample is divided by the volume. (Average value of n = 4) 6. Fiber diameter of filaments Each filament portion is cut out from 10 locations, embedded with acrylic resin, the cross section is cut out to make a section, and a cross-section photograph is obtained. The value obtained by obtaining the wire diameter from the enlarged cross-sectional photograph and enlarging it with the magnifying power (n = 10 average value) 7. Fusing By hand, check the fibers that are adhered to each other to see if the sample is fused or not. It is judged whether or not something that cannot be removed is fused by pulling. 8. Heat resistance and durability (residual strain at 70 ° C) Cut the 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, cool it to remove the compression strain, and leave it for one day after leaving it. The ratio of the difference in thickness before treatment to the thickness before treatment is shown in% (n = 3 average value) 9. Cyclic compression strain The sample was cut into a size of 15 cm x 15 cm, and the lateral side, wadding layer, and cushion were cut. In order to prevent the layers from slipping and coming off, the four corners of the interface were joined with sewing thread, and compression recovery was performed at a cycle of 1 Hz to a thickness of 50% in a room at 25 ° C and 65% RH with a Servo pulsar manufactured by Shimadzu Corporation. The ratio of the difference between the thickness after standing for 1 day and the thickness before the treatment and the thickness before the treatment of the sample after repeating 20,000 times is shown in%. (Average value of n = 3) 10. Air permeability Sample (laminate of cushion layer and wadding layer) has a diameter of 1
It is punched out into a cylinder of 0 cm, put in a metal tube with an inner diameter of 10 cm and a height corresponding to the thickness of the side that can be sealed in a state of 5% compression, and the top and bottom are sealed with a packing of 5% compression thickness. A sample was prepared to prevent side leakage, and the air flow rate (cc / cm ² seconds) measured using a high-pressure type air flow rate measuring device manufactured by Techno World Co., Ltd. (Cosmo instrument design product) is shown as the air permeability. 11. Bendability A cushion mat made by laminating a cushioning layer and a wadding layer is covered with a side cloth of polyester fabric made of Toyobo Co., Ltd. made by Toyobo Co. The length until extrusion and contact with a sloped surface notched at 45 ° is shown below. Less than 100 cm: ◎, less than 130 cm: ○, less than 150 cm: Δ, more than 150 cm: × 12. Drainability After measuring the weight of the bed mat, it was immersed in a water tank and taken out 10 minutes later, and the weight was measured without draining as much as possible. After that, the water was drained, and after standing for 12 hours on a wall in a room with an atmosphere of 30 ° C. and RH of 65%, the weight was measured and the amount of residual water was determined, and evaluated according to the following criteria. 5% residual moisture
Below: ◎, residual water content is 7% or less: ○, residual water content is 10%
The following: △, residual water content is 10% or more: × 13. Comfortable sleep A cushion body made by laminating a cushioning layer and a wadding layer is covered with a side fabric of a polyester woven fabric made of TOYOBO HEIM that is sewn to a predetermined size. Set the prepared bed mat on the bed frame, 28 ℃ RH75
% The paneler was laid down in the room and the following evaluation was performed.
(N = 5) Sheets are laid on the bed mat, and down / feather: 90/10 mixed feathers are used for the comforter.
The pillow weighed 8kg and was the same as the one used at home. (1) Feeling uncomfortable: The degree of "feeling uncomfortable on the back" when sleeping was qualitatively and qualitatively evaluated. No feeling; ◎, almost no feeling; ○, slightly felt; △, felt; × (2) Depression: The degree of body retention when sleeping was sensitized qualitatively. Very comfortable with moderate subduction;
◎, slightly depressed or slightly large, comfortable; ○, slightly depressed or large, slightly lacking in comfort; △, too deep or not submerging and does not feel comfortable; × (3) Feeling of stuffiness: A qualitative qualitative evaluation was performed on the stuffiness felt on the buttocks, the back, and the like in contact with the bed mat after sleeping for 2 hours. Almost no feeling: ◎, slightly stuffy; ○, slightly stuffy; △, remarkably stuffy; × (4) Pressure of body pressure: how much you can endure without moving after sleeping: 30 minutes or less; ×, 1 hour or less; △, 2 hours or less; ○, 2 hours or more; ◎ (5) Comprehensive evaluation: 4 points out of ◎ from (1) to (5)
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. -The heat obtained by forming a terester block copolymer elastomer, then adding and mixing 1% of an antioxidant and 10% of a flame retardant (phosphorus content: 5000 to 10000 ppm), pelletizing, and vacuum drying at 50 ° C for 48 hours. Table 1 shows the formulation of the plastic elastic resin raw material.

[0022]

[Table 1]

On the effective surface of the nozzle having a width of 120 cm and a length of 10 cm, the pitch of the holes in the width direction is 5 mm, and the pitch of the holes in the length direction is 10 mm.
The zigzag array of orifices has an outer diameter of 2 mm and an inner diameter of 1.
The obtained thermoplastic elastic resin raw material is melted in a separate extruder into a nozzle having a hollow-forming cross section of a triple bridge of 6 mm, and A-1 is used as a sheath component and A-2 is used as a core component. Dispensing just before the orifice, the discharge rate per single hole is 2.0 g / min (A-1: 1 g /
Min., A-2: 1 g / min), the cooling water is placed 12 cm below the nozzle surface, and a pair of take-up conveyors are placed parallel to each other with an endless net made of stainless steel having a width of 140 cm at intervals of 10 cm. The melted discharge line is bent to form a loop and the contact portions are fused together to form a three-dimensional network structure. While sandwiching both sides with a take-up conveyor, it is drawn into cooling water at 25 ° C. at a speed of 1 m / min to solidify and flatten both sides, then taken off, drained, and continuously 120 ° C.
After passing through a setter in which heated air is circulated for 15 minutes to cool and then cutting to a predetermined size, the reticulated body has a triangular cross-sectional hollow cross-section with a cis core structure and a hollow ratio of 40. %, The filament having an endothermic peep at 126 ° C. in addition to the melting point of 1.2 mm is almost joined by fusion bonding at the contact points of the formed loops, and both sides are substantially flattened. Average apparent density 0.046 g / cm ² , thickness 9.
5 cm, cyclic compression strain 2.8%, heat resistance durability 11.2%
Met. Separately, the thermoplastic elastic resin A-4 is individually melted by a conventional method so that the thermoplastic elastic resin A-4 becomes the sheath component and A-2 becomes the core component, and distributed immediately before the orifice,
Each discharge rate is 50/50 weight ratio, 1.6g / per hole
Spinning temperature 2 as splitting holes (0.6 g / min: 0.6 g / min)
Discharge from C type orifice at 45 ° C, spinning speed 350
Fineness obtained at 0 m / min is 3.1 denier, dry heat 160 ° C.
The yarn having a shrinkage ratio of 7% was converged, mechanically crimped with a crimper in a tow shape, and cut into 64 mm to obtain a heat-bonded fiber made of a thermoplastic elastic resin having a sheath core cross section. Synthetic fiber is PET with the intrinsic viscosity of 0.63 and 0.56 by the conventional method.
Was distributed in a weight ratio of 50/50 to form 3.0 g / min per hole (1 g / min: 1 g / min) at a spinning temperature of 265 ° C., and a composite spinning was performed at a spinning speed of 1300 m / min.
And a drawn yarn obtained by drawing two stages at 180 ° C. is cut into 64 mm and free-heat-treated at 170 ° C. to develop a three-dimensional crimp, and a fineness of a sheath core structure having a hollow section of 32% with a hollow ratio of 6%.
A synthetic fiber having a denier, an initial tensile resistance of 38 g / denier, a crimp degree of 20% and a crimp number of 18 / inch was obtained. Then, as the matrix fiber, the epilayer on the surface of the cuticle layer was removed, and the flame-retarded merino wool, the synthetic fiber and the heat-bonding fiber were mixed at a weight ratio of 60/10/30 to form an opener.
The web obtained by pre-opening with a card was laminated and compressed to have an apparent density of 0.05 g / cm ² and a thickness of 8 mm, and heat-treated with hot air at 150 ° C. for 5 minutes and then cooled. As a result, a wadding layer having flat surfaces on both sides was obtained. Then 120
Heat treatment was carried out for 15 minutes in a setter in which heated air of ℃ was circulated, and after cooling, cut into a predetermined size and laminated on both sides of the two mesh bodies. Then, the wadding layer and the cushion layer are individually taken out, have an opening / closing port through which the wadding layer and the cushion layer can be inserted, and the wadding layer and the cushion layer are inserted into a side fabric made of polyester fiber made of Toyobo Co. Got Table 2 shows the evaluation results of the obtained mat for betting. As clearly shown in Table 2, heat resistance, durability, breathability,
It is a mat for betting that is excellent in bending and draining properties and has good sleeping comfort. The mat for this bed showed flame retardancy, and the toxicity index of combustion gas was 5.8. From this, it can be seen that the mat for betting is highly safe in case of fire.

[0024]

[Table 2]

Example 2 A nozzle having a width of 120 cm and a length of 5 cm and 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 a nozzle effective surface is a nozzle having an outer diameter of 1 mm and a round cross section. The obtained thermoplastic elastic resin raw material A-5 was melted by an extruder, and the discharge amount per single hole was 2.0 g at a melting temperature of 245 ° C.
Discharge at the bottom of the nozzle at a rate of 1 / min, and place cooling water 15 cm below the nozzle surface, and a pair of take-up conveyors partially exit above the water surface in parallel with a stainless endless net with a width of 140 m at intervals of 4.5 cm. The melted discharge line is bent to form a loop to fuse the contact portions to form a three-dimensional network structure, and both sides of the molten network are drawn. While sandwiching it with a conveyor, it is drawn into cooling water at 25 ° C at a speed of 1 m / min to be solidified and flattened on both sides, then taken off, drained, and then in a setter in which heated air at 120 ° C is continuously circulated for 15 minutes. The reticulate body obtained by passing and cooling and then cutting it to a predetermined size has a round cross-section, and a linear filament having an endothermic peak at 126 ° C is formed in addition to a melting point of 0.9 mm. -The contact points of the Surface is substantially flattened, the apparent density of the average 0.048 g / cm ^2, thickness 4.5 cm,
The cyclic compression strain was 7.5%, and the heat resistance durability was 18.4%. Then, the thermoplastic elastic resin A-1 is used as a sheath component, A
-2 of the heat-bonded fiber obtained in the same manner as in Example 1 except that each of -2 was individually melted and distributed immediately before the orifice had a fineness of 3.1 denier and a shrinkage ratio at a dry heat of 160 ° C. 5
%Met. Next, formalin-processed lami-cotton with spread cotton, the synthetic fiber used in Example 1 and the heat-bonded fiber were mixed with each other.
The web obtained by mixing at a weight ratio of 0/10/30, pre-opening with an opener and then opening with a card has an apparent density of 0.05 g / cm ² and a thickness of 8 mm. Laminated and compressed
After heat treatment with hot air at 200 ° C. for 5 minutes and cooling, a wadding layer having flat both sides was obtained. Then, heat treatment was carried out for 15 minutes in a setter in which heated air of 120 ° C. was circulated, and after cooling, cut into a predetermined size and laminated on both sides of the four mesh bodies. Then, the wadding layer and the cushion layer are individually taken out, have an opening / closing port through which the wadding layer and the cushion layer can be inserted, and the wadding layer and the cushion layer are inserted into a side fabric made of polyester fiber made of Toyobo Co. Got
Table 2 shows the evaluation results of the obtained mat for betting. Table 2
As is clear from the above, it is a bed mat which is excellent in heat resistance, durability, breathability, bendability and drainage, and has a good sleeping comfort. The matte had a combustion gas toxicity index of 5.0. From this, it can be seen that the mat has good safety in case of fire.

Example 3 A staggered array of orifices having an outer diameter of 2 mm and an inner diameter of 1.6 mm was formed on a nozzle effective surface having a width of 120 cm and a length of 5 cm 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. The obtained thermoplastic elastic resin A-3 was melted in an extruder with a nozzle having a triple bridge hollow forming cross section, and the melting temperature was 2
3. Discharge at a discharge rate of 2.0 g / min per single hole at 35 ° C. below the nozzle, arrange cooling water 12 cm below the nozzle surface, and make stainless endless nets 140 cm wide in parallel.
A pair of take-up conveyors are arranged at intervals of 5 cm so as to partially protrude above the surface of the water, and the discharge line in the molten state is bent to form loops to fuse the contact portions to form a three-dimensional net structure. Was formed, and was drawn into cooling water at 25 ° C. at a rate of 1 m / min for solidification, then taken off, drained, and passed through a setter in which heated air at 120 ° C. was continuously circulated for 15 minutes to cool, The net-like body obtained by cutting into a predetermined size and having both sides substantially flat is a hollow rice ball-shaped cross section, and a wire having an endothermic peak at 126 ° C in addition to a melting point of 1.2 mm. The contact points of the loops formed by the stripes are almost joined by fusion bonding, and the average apparent density is 0.048 g /
cm ² , thickness 4.5 cm, cyclic compression strain 5.8%, heat resistance durability 10.8%. Then, under the same conditions as in Example 1, except that the cotton wool cut into a cut length of 65 mm, the synthetic fiber obtained in Example 1 and the heat-bonded fiber obtained in Example 1 were mixed in a weight ratio of 50/20/30. The wadding layer was cut into a predetermined size, and then, as in Example 2, the evaluation results of the betting mat of the present invention are shown in Table 2. As is clear from Table 2, the bed mat is excellent in heat resistance, durability, breathability, bending property, and water draining property, and has good sleeping comfort. This bed mat has a combustion gas toxicity index of 5.6.
Met. From this, it is understood that the mat for betting has good safety in case of fire.

Example 4 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.

[0028]

[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 a hollow in the shape of a triangular rice ball. In addition to the melting point with a rate of 40% and a wire diameter of 1.1 mm, the filaments that have an endothermic peak at 126 ° C are joined by fusion bonding at the contact points of the loops formed, and both sides are substantially flattened. The average apparent density is 0.047 g / cm ² , and the thickness is 9.
5 cm, cyclic compression strain 3.6%, heat resistance durability 7.5%. Next, the quasi-crystallization treatment used in Example 2 and a wading layer cut into a predetermined size were laminated on both surfaces of the reticulate body. Next, Table 2 shows the evaluation results of the betting mats obtained in the same manner as in the examples. As is clear from Table 2, this bet mat is excellent in heat resistance, durability, breathability, bendability, and water draining property, and has a good sleeping comfort.

Comparative Example 1 A reticulate body obtained in the same manner as in Example 2 except that only the polypropylene (PP) single component having a melt index of 12 had a melting temperature of 250 ° C. has a solid round cross section and a wire diameter of 1 .8m
Wires that do not have an endothermic peak at 126 ° C other than the melting points of m and m are joined by fusion bonding at most contact points of the loops, and both sides are substantially flattened, and the average apparent density is Was 0.047 g / cm ² , thickness was 4.5 cm, cyclic compression strain was 30.2%, and heat resistance durability was 49.5%. Then, the scoured Indian cotton, the synthetic fiber used in Example 1 and the heat-bonded fiber were mixed at a weight ratio of 60/10/30, and then mixed.
The web obtained by pre-opening with a planer and then with a card was laminated and compressed to have an apparent density of 0.05 g / cm ² and a thickness of 8 mm, and heat-treated with hot air at 200 ° C. for 5 minutes. After cooling, a wadding layer having flat surfaces on both sides was obtained. Then
Heat treatment was performed for 15 minutes in a setter in which heated air of 120 ° C. was circulated, and after cooling, cut into a predetermined size and laminated on both sides of the four mesh bodies. Next, Table 2 shows the evaluation results of the betting mats obtained in the same manner as in Example 2. Table 2
As is clear from the above, since it is a reticulated body made of an inelastic olefin, it is excellent in breathability and drainage, but it has heat resistance, durability,
It is a bed mat that is extremely inferior in sleeping comfort other than bendability and stuffiness, and also has a problem of flame retardance, which causes problems during a fire.

COMPARATIVE EXAMPLE 2 A nozzle having a width of 120 cm and a length of 10 cm and 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 the nozzle has an outer diameter of 1 mm and a round cross section. ,
The obtained thermoplastic elastic resin raw material A-5 was melted with an extruder, and the melting amount was 235 ° C., and the discharge amount per single hole was 3.0 g.
/ Min, and the cooling water is placed under the nozzle surface 5 cm, and a pair of take-up conveyors are partially projected on the water surface in parallel with the stainless endless net of width 140 cm at intervals of 9.5 cm. The melted discharge line is bent to form a loop and the contact portions are fused to form a three-dimensional network structure, and both sides of the melted network are drawn. While being sandwiched by a conveyor, it is drawn into cooling water at 25 ° C. at a speed of 1 m / min to be solidified and flattened on both sides, then taken out, drained, and cut into a predetermined size. In the cross section, the filaments having no endothermic peak other than the melting point of 5.9 mm in diameter are formed by joining most of the contact points of the loops formed by fusion bonding and substantially flattening both sides. Average apparent density is 0.074g / cm
² , the thickness was 9.5 cm, the cyclic compression strain was 18.3%, and the heat resistance was 28.4%. Then, the wading layer used in Comparative Example 1 was laminated on both sides of the two mesh bodies. Then, Table 2 shows the evaluation results of the mat for betting obtained * in the same manner as in Example 1. As is apparent from Table 2, the bet mat is excellent in breathability, drainability, and less dampness, but is inferior in sleeping comfort other than heat resistance, durability, bendability, and dampness. The combustion gas toxicity index of this bed mat was 5.1.

Comparative Example 3 A reticulate body obtained in the same manner as in Comparative Example 2 except that a take-up conveyor net was placed 30 cm below the nozzle surface at a melting temperature of 245 ° C. and the take-up speed was 0.3 m / min. Is a round cross-section with a wire diameter of 1.9 mm, which has no endothermic peak other than the melting point, and the contact points of the loops formed are almost joined by fusion, and both sides are substantially Is flattened,
Average apparent density is 0.24 g / cm ² , thickness is 9.5 cm,
The cyclic compression strain was 19.8% and the heat resistance durability was 29.4%. Then, Table 2 shows the evaluation results of the bet mats obtained in the same manner as in Comparative Example 2. As is clear from Table 2, it is excellent in breathability, drainability, and less dampness, but heat resistance,
A mat for betting that is inferior in sleep comfort other than durability, bendability, and dampness. The bed gas mat had a combustion gas toxicity index of 5.1.

COMPARATIVE EXAMPLE 4 The discharge amount per single hole was 0.3 g / min, a take-up conveyor net was placed 5 cm below the nozzle surface, and the take-up speed was 1.9.
The reticulate body obtained by the same method as in Comparative Example 3 except that m / min was a cross section having a round cross section, and a line having no endothermic peak other than the melting point of 0.4 mm was formed. Almost all contact points of the loops are joined by fusion bonding, both sides are substantially flattened, and the average apparent density is 0.004 g / cm ² ,
The thickness was 9.5 cm, the cyclic compression strain was 13.6%, and the heat resistance durability was 22.4%. Next, Table 2 shows the evaluation results of the betting mats obtained in the same manner as in Comparative Example 2. As is clear from Table 2, it has excellent breathability, bendability, and drainability,
It is a bed mat that has poor heat resistance, durability, and sleeping comfort.

Comparative Example 5 At a melting temperature of 230 ° C., the discharge amount per single hole was 1.5 g /
Minutes, a take-up conveyor net was placed 60 cm below the nozzle surface, and the take-up speed was set to 1 m / min. The filament has no endothermic peak other than the melting point of 1.9 mm, but the filament does not form a loop and almost no contact point is formed.
No reticulate was formed. Forcing this wire into a web with an apparent density of 0.05 g / cm ² and a thickness of 9.5 cm,
Next, Table 2 shows the evaluation results of the betting mats obtained in the same manner as in Comparative Example 2. As is clear from Table 2, when the contact points are not joined, the bed mat is inferior in sleeping comfort.
Since this bed mat has poor sleeping comfort, no other evaluation was made.

Comparative Example 6 At a melting temperature of 245 ° C., the discharge amount per single hole was 1.5 g /
In the same manner as in Comparative Example 2, except that a take-up conveyor net was placed 20 cm below the nozzle surface and the surface of one side of the conveyor net had irregularities of 5 mm, and the take-up speed was 1 m / min. The obtained reticulate body has a round cross section,
Wires having no endothermic peak other than the melting point of the wire diameter of 0.9 mm, the contact points of the loops to be formed are almost joined by fusion, and one side is substantially flattened. The other surface has irregularities, the average apparent density is 0.035 g / cm
² , thickness of the thickest place 9.5cm, repeated compressive strain 1
The heat resistance and durability were 9.5% and 29.2%, respectively. Next, Table 2 shows the evaluation results of the betting mats obtained in the same manner as in Comparative Example 2. As clearly shown in Table 2, breathability, bendability,
It is a mat for betting, which excels in drainability, stuffiness, and pressure but is slightly inferior in heat resistance and durability. In addition, the toxicity index of the combustion gas of this bed mat is 5.1.
Met.

Comparative Example 7 A nozzle having a width of 120 cm and a length of 1 cm and a staggered arrangement with a hole-to-hole pitch of 5 mm in the width direction and a hole-to-hole pitch of 5 mm in the length direction on a nozzle effective surface was used. Used,
The discharge rate per single hole is 0.3 g / min, a take-up conveyor net is placed 5 cm below the nozzle surface, and a pair of take-up conveyors are placed at 0.4 cm intervals so that they partially come out on the water surface. The reticulate body obtained in the same manner as in Comparative Example 3 except that the speed was 1.0 m / min had a round cross section and a wire diameter of 0.
The filaments having no endothermic peak other than the melting point of 4 mm are formed by almost fusion-bonding the contact points of the formed loops, substantially flattening both surfaces, and an average apparent density of 0.
064 g / cm ² , thickness 0.4 cm, cyclic compressive strain 18.
It was 6% and the heat resistance durability was 29.8%. Next, Table 2 shows the evaluation results of the betting mats obtained in the same manner as in Comparative Example 2. As is clear from Table 2, the bed mat is excellent in breathability, bending property, and water draining property, but inferior in heat resistance and durability, and the cushion layer is too thin to remarkably sleep.

Comparative Example 8 The characteristics of the reticulate body obtained in the same manner as in Example 2 except that the pseudo crystallization treatment was not carried out were that the cross-sectional shape was a round cross section and the wire diameter was 0.9 mm.
In addition to the melting point of, the filaments that have no endothermic peak at 126 ° C
Almost all the contact points of the loops to be formed are joined by fusion bonding and both sides are substantially flattened, the average apparent density is 0.048 g / cm ² , the thickness is 4.5 cm, and the cyclic compression strain is 16.5. %, And the heat resistance durability was 26.4%. Separately, the scoured Indian cotton, the synthetic fiber used in Example 1 and the heat-bonded fiber were mixed in a weight ratio of 60/10/30 to form an opener.
The web obtained by pre-opening with a card is opened and laminated so as to have an apparent density of 0.15 g / cm ² and a thickness of 8 mm, heat treated with hot air at 200 ° C. for 5 minutes and then cooled. Then
Then, heat treatment was carried out for 15 minutes in a setter in which heated air of 120 ° C. was circulated, and after cooling, cut into a predetermined size to obtain a wadding layer having both sides flat. Next, Table 2 shows the evaluation results of the betting mats obtained in the same manner as in Example 2. As is clear from Table 2, since the density of the wading layer was too high, the mat for a bed was poor in breathability and bending property and inferior in sleeping comfort.

Comparative Example 9 Commercially available polyester hard cotton having an apparent density of 0.05 g / cm ³ was sliced to a thickness of 5 mm and cut into a predetermined size.
The hard rubber laminated by applying a commercially available rubber-based adhesive adhesive on both surfaces of the two nets used in Comparative Example 8 was adhered to the net.
Table 2 shows the evaluation results of the betting mat obtained by inserting the mat into the side material made of polyester fiber sewn into a predetermined size.
Shown in As is clear from Table 2, the bed mat is slightly comfortable to sleep but inferior in heat resistance, durability, breathability, bendability and drainability.

Comparative Example 10 A bed obtained by inserting commercially available polyester hard cotton having a thickness of 10 cm and an apparent density of 0.05 g / cm ³ into a cushion material and inserting it into a side cloth made of polyester fiber sewn to a predetermined size. Table 2 shows the evaluation results of the mat. As is clear from Table 2, the mat for betting has a good sleeping comfort but little sinking, and is inferior in heat resistance, durability, breathability, bendability and drainability.

COMPARATIVE EXAMPLE 11 A commercially available polyurethane foam having a thickness of 10 cm and an apparent density of 0.05 g / cm ³ was used as a cushioning material, and the wadding layer used in Comparative Example 2 was laminated on the polyester fiber sewn to a predetermined size. Table 2 shows the evaluation results of the mat for betting obtained by inserting it into the side ground. As is clear from Table 2,
It has excellent heat resistance and durability, but is breathable, bendable,
It is a bed mat that is inferior in drainability and sleep comfort.

Example 5 A mattress was obtained by laminating the wadding layers used in Example 1 on both sides of the mesh body obtained in Example 2 and inserting the wadding layer in a side cloth made of polyester fiber sewn to a predetermined size. It was As a result of evaluation of the obtained mattress, the mattress was excellent in heat resistance, durability, breathability, bendability, drainability, and sleeping comfort.

Example 6 The wadding layer used in Example 1 was laminated on both sides of the mesh body obtained in Example 2 and inserted into a side fabric made of polyester fiber sewn to a predetermined size to obtain a seat cushion. It was The result of evaluation of the obtained zakka was that it was excellent in heat resistance, durability, breathability, drainability and sitting comfort.

[0043]

[Effects of the Invention] A net-like body having a flattened surface in which filaments made of a thermoplastic elastic resin having good elongation recovery is fused and integrated to form a cushion layer to improve the characteristics of natural fibers and the elongation recovery of the thermoplastic elastic resin. The mats are made by layering hard cotton that is used on the wadding layer, and the manufacturing method makes it difficult to get stuffy and comfortable to sleep in. Occasionally, it produces less toxic gas and can be washed to remove germs such as MRSA and has good drainage properties. Suitable for household use, hospital use, hotel use, etc. It is possible to provide a mat useful as a cushion body suitable for furniture and a manufacturing method.

Claims (15)

[Claims] 1. A matting material in which a wadding layer is laminated on at least an upper surface of a cushion layer and the entire surface is covered with a side material, and the cushion layer is made of a thermoplastic elastic resin and has a continuous wire diameter of 5 mm or less. Formed into a three-dimensional three-dimensional network having a contact portion of each loop fused to form a random loop, and the three-dimensional three-dimensional network has upper and lower surfaces. Are substantially flattened, and the apparent density is 0.005 to 0.1.
0 g / cm ³ , thickness 5 mm or more, the wadding layer has a natural fiber as a main matrix, and the thermoplastic adhesive resin as a thermal adhesive component is dispersed and mixed in the matrix to form a fiber crossing point. Partly form a fixed point, and the apparent density of the wadding layer is 0.1 g /
Mats characterized by being less than or equal to cm ³ . 2. The thermoplastic elastic resin constituting the cushion layer has a recovery rate after room temperature elongation of 300% (room temperature elongation recovery rate) of 20% or more and after holding 10% elongation at 70 ° C. for 24 hours. The mat according to claim 1, wherein the recovery rate (70 ° C extension recovery rate) is 30% or more. 3. The reticulate body constituting the cushion layer has a wire diameter of 0.01 mm or more, an apparent density of 0.01 g / cm ³ to 0.08 g / cm ³ , and a thickness of 10 mm or more. Mats. 4. The wire diameter of the net-like body constituting the cushion layer is 0.1 mm or more and 2 mm or less, and the apparent density is 0.02 g / cm.
The mat according to claim 1, which has a thickness of ³ to 0.06 g / cm ³ and a thickness of 20 mm or more and 500 mm or less. 5. The mat according to claim 1, wherein the wadding layer has a porosity of 90% or more and a thickness of 2 mm or more and 10 mm or less. 6. The mat according to claim 1, wherein the cushion layer and the wadding layer are laminated and integrated via a cloth. 7. A reticulated body having an endothermic peak at a temperature above room temperature and below its melting point in a melting curve of a component comprising a thermoplastic elastic resin measured by a differential scanning calorimeter in the cushion layer. Mats. 8. The cross-sectional shape of the filaments of the net-like body forming the cushion layer is a hollow cross section or an irregular cross section.
The listed mats. 9. The mat according to claim 1, wherein the cushion body has an air permeability of 50 cc / cm ² seconds or more. 10. The mat according to claim 1, wherein the thermoplastic elastic resin constituting the cushion layer is polyester. 11. The mat according to claim 1, wherein the natural fiber is silk. 12. The mat according to claim 1, wherein the natural fiber is wool. 13. The mat according to claim 1, wherein the natural fiber comprises hemp. 14. A continuous linear loop in a molten state in which a thermoplastic elastic resin is discharged downward from the nozzle at a melting temperature 20 ° C. to 80 ° C. higher than the melting point of the multi-row nozzle having a plurality of orifices. Is formed, and each loop is brought into contact with each other and fused to form a three-dimensional structure,
After being sandwiched by a take-up device and cooled in a cooling tank, the three-dimensional structure obtained was bonded to the upper, lower, or one side of the three-dimensional structure using natural fibers as a matrix and thermoplastic elastic resin as a heat-bonding component. A method for producing mats, which is characterized by laminating cotton and covering the sides. 15. The matte according to claim 14, wherein the pseudo-crystallization treatment by annealing is performed at a temperature of at least 10 ° C. or lower than the melting point of the thermoplastic elastic resin forming the reticulated body in any step leading to commercialization. Manufacturing method