JPH0856785A - Highly air-permeable mat - Google Patents

Abstract

PURPOSE: To provide a highly air-permeable mat having a cushionability and a shape stability so as to be excellent in sweat absorption and in moisture adsorptiveness and desorptiveness in order to be used for all persons including babies and adult persons. CONSTITUTION: A mat having a structure of at least three layers, is composed of a surface layer part 2 made of mainly cotton, a middle layer part 3 mainly made of sweat-absorptive polyester fibers and a lower layer part 4 mainly made of sweat-absorptive polyester fibers, which are laminated with one another. The surface layer part 2 and the middle layer part 3 are integrally incorporated with each other by a needle punch, and several through-holes piercing these layer parts are formed. The middle layer part 2 and the lower layer part are bonded together by means of a hot-melt sheet.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a bedding mat having excellent breathability, and more particularly to an integrated high breathable mat having excellent shape stability.

[0002]

2. Description of the Related Art Various mats for bedding having excellent breathability have been devised to obtain comfortable sleep in hot and humid summers. For example, Japanese Utility Model Publication No. 60-167565 discloses a composite core material for bedding having a structure in which a buffering porous sheet material and a buffering sheet core material having a large number of protrusions are superposed. However, with this technology, in order to prevent the protrusions of the sheet core material from being crushed by the weight of the sleeping person, the cushioning protrusion sheet-shaped core material must be manufactured with a plastic film having considerable rigidity, and the ventilation in this layer is required. Gender was not considered at all. Also, as a cushioning porous sheet material corresponding to the surface layer portion, since cushioning properties, elasticity, flexibility, and appropriate strength are required, foaming of a hydrophobic polymer material such as polyethylene, polypropylene, polystyrene, or polyvinyl chloride is required. Although a sheet is used, even if it is made of such a material, it is hardly breathable even if it is made porous, and if it sleeps directly on this bedding, it will be slimy and uncomfortable when the sleeping person sweats. Met.

On the other hand, as an example focusing more on the air permeability, in Japanese Utility Model Publication No. 5-46704, a felt mat is integrally formed of a covering body without adhering to the upper and lower sides of a ventilation mat made of a three-dimensional mesh fiber structure. A matte bedding having a three-layer structure is disclosed. However, since these three layers are not adhered to each other, they tend to slip when the baby or the like turns over. Also,
The felt mat described in this publication is a felt layer made of simple polyester fiber,
It lacked hygroscopicity and was inferior in bulkiness.

[0004]

SUMMARY OF THE INVENTION The object of the present invention is to solve the above-mentioned problems of the prior art, and to excel in sweat absorption and absorption / humidity release.
It is to provide a highly breathable mat having cushioning properties and shape stability that can be used by infants and adults.

[0005]

The highly breathable mat of the present invention is a mat having at least a three-layer structure, and has a surface layer portion mainly composed of natural fibers and an intermediate layer portion and a lower layer mainly composed of sweat-absorbing polyester fibers. Part is laminated, the surface layer part and the middle layer part are integrated by needle punching, and a plurality of vent holes penetrating both layers are formed, and the middle layer part and the lower layer part are made of a breathable hot melt sheet. It is characterized in that it is bonded through.

The basis weight of the surface layer is 100 to 500 g / m ² ,
The basis weight of the middle layer is 700 to 1500 g / m ² , the basis weight of the lower layer is 1000 to 2000 g / m ² , and the basis weight of the middle layer is smaller than the basis weight of the lower layer.
The middle layer and the lower layer are formed by laminating card webs having a basis weight of 10 to 15 g / m ² mainly made of sweat-absorbent polyester fiber, and subjecting them to thermocompression bonding after needle punching, thereby improving breathability, cushioning property, and shape stability. It is a preferred embodiment for forming an excellent mat in all. It is preferable in view of hygiene to provide a highly hygroscopic deodorant antifungal layer on the outer side of the lower layer portion.

[0007]

In the present invention, since the sweat-absorbing polyester having excellent sweat absorbing / releasing property is used as the polyester fiber which is the main constituent component of the mat, it is higher than the conventional mat using only ordinary polyester fiber. It has excellent sweat absorption even when it is weighted. Therefore, by defining the basis weight of each layer, we succeeded in providing a mat excellent in all of sweat absorption, breathability and cushioning properties. In addition, since the cotton-based surface layer and the middle layer made of sweat-absorbent polyester are integrated by needle punching, the shape stability of the layer in which the vent holes are formed is improved, and the needle punching holes further improve breathability and water permeability. Sex increased. Further, since the lower layer portion made of a sweat-absorbent polyester having no ventilation hole and the middle layer portion are bonded by a breathable hot melt sheet, it can be easily manufactured without sacrificing breathability. it can.

[0008]

EXAMPLES The present invention will be described in more detail with reference to the examples shown in the drawings, but the following examples do not limit the present invention. FIG. 1 shows a perspective view of a highly breathable mat 1 corresponding to an example of a three-layer structure of the present invention, and FIG. 2 shows a sectional view. In FIGS. 1 and 2, 2 is a surface layer portion mainly made of natural fibers, 3 is a middle layer portion mainly made of sweat absorbing polyester, 4 is a lower layer portion mainly made of sweat absorbing polyester, and 5 is a breathable hot melt sheet (in FIG. 1). Invisible).

As the surface layer, it is preferable to use a felt-like mat mainly composed of cotton, which has a good texture and is excellent in hygroscopicity. Besides cotton, natural fibers such as hemp and wool can be used. The cotton is preferably combed cotton, and as other synthetic fibers that can be mixed with the cotton, known fibers such as polyester fiber and acrylic fiber can be used. Use 60% or more of cotton, and have a surface weight of 100 to 500 g / m ² (preferably 150 to 350).
g / m ² ) is recommended in terms of strength, hygroscopicity and texture. If the basis weight is too small, the surface layer may become weak. The thickness of the surface layer is not particularly limited, but is 0.1
It is preferably about 5 cm.

The middle layer portion is a mat having a basis weight of 700 to 1500 g / m ^{2 made} of fibers containing 60% or more of sweat absorbing polyester. If the basis weight is too small, good cushioning properties cannot be obtained. The sweat-absorbing polyester is characterized in that it has a better sweat-absorbing property than ordinary polyester fibers. For example, "Esmarble" manufactured by Toyobo Co., Ltd. is preferably used. In addition to sweat-absorbent polyester, it is recommended to mix ordinary polyester fibers, acrylic fibers, low-melting-point polyesters, polyolefins, and the like as heat-bonding fibers.

For the mat of the middle layer, a card web having a basis weight of about 10 to 15 g / m ^{2 is} prepared from fibers mainly composed of sweat-absorbent polyester, and the desired basis weight of 700 to 1500 g / m ² is obtained. It can be obtained by laminating and needle punching. By applying needle punching, the cushioning property lasts longer and "sag" is reduced. At this time, an appropriate amount (4
(0% or less), and by mating by thermocompression after needle punching, a mat having further excellent shape stability can be obtained. The shape stability is difficult to be obtained only by shaping with the heat-bonding fiber, and “sagging” may occur due to long-term use. Moreover, since many fine through holes are formed in the thickness direction by the needle punch, the air permeability and the water permeability are further improved. The middle layer has a thickness of about 1
It is preferable that the mat has a size of about 5 cm.

After the surface layer portion and the middle layer portion are integrated by needle punching, and before they are bonded to the lower layer portion (may be after bonding), they are perforated to provide ventilation holes. From the perspective of breathability, 5 to 30 vent holes with a diameter of 0.5 to 3 cm
It is preferable to provide 0 cm ² . Since cotton forming the surface layer has many fine through holes formed by needle punching, it has excellent water permeability.

The lower layer is made of the sweat-absorbing polyester 60
% By weight of 1000 to 2000 g / m
² mats. If the basis weight is too small, good cushioning properties cannot be obtained. It is desirable that the lower layer has a larger basis weight than the middle layer. This is because it is preferable that the lower layer portion have a smaller basis weight than the lower layer portion in order to secure appropriate hardness and elasticity of the mat, that is, cushioning properties, and the middle layer portion plays a role of absorbing and releasing sweat. The lower layer portion may have a thickness similar to that of the middle layer portion. The fibers that can be used with the sweat-absorbing polyester in the lower layer are the same as those exemplified in the middle layer, and the manufacturing method is also the same.

An air-permeable hot melt sheet is used for bonding the lower layer portion and the middle layer portion. The use of ordinary adhesives and the use of non-breathable hot melt sheets cannot be used because they impair the breathability of the mat of the present invention. Breathable hot-melt sheet is a spun-bonded spun-bonded non-woven fabric-like hot-melt adhesive, which is formed by spraying hot-melt fibers in a fairly sparse random network to form a single thin sheet. (For example, "Dynac" manufactured by Toyobo Co., Ltd.). It has good air permeability and workability, and contains no harmful substances at all, so it is suitable for use in the mat of the present invention. A polyamide-based or polyester-based resin having a basis weight of about 10 to 60 g / m ² can be used. The bonding method can be easily performed by sandwiching an air-permeable hot melt sheet between the lower layer portion and the middle layer portion and thermocompression bonding.

In the present invention, a mat having a four-layer structure as shown in FIG. 3 may be used. In the example of FIG. 3, a highly hygroscopic deodorant antifungal layer is provided outside the lower layer portion. If the modified acrylonitrile fiber "N-38" manufactured by Toyobo Co., Ltd. is used for the highly hygroscopic deodorant antifungal layer, the lowermost layer having both high hygroscopicity, deodorant and antifungal properties is formed. It does not create a bad environment such as a bad smell or mold.

The lowermost layer is not limited to the antifungal layer, and may be a water-absorbing and retaining layer containing a water-absorbing polymer. At this time, the sweat or urine that could not be released is absorbed in the lowermost layer. , The mats and tatami mats or boards will not get dirty. In addition, the bottom layer can be provided according to the application.

[0017]

Since the highly breathable mat of the present invention is constructed as described above, it exhibits the following operational effects. Since the surface layer near the skin of the sleeping person is mainly made of natural fibers such as cotton, the surface feels good and is safe and secure even for infants with sensitive skin and those with weak skin. Since the surface layer portion and the intermediate layer portion are integrated by needle punching, in the surface layer portion, the strength of the surface layer portion can be maintained even if the basis weight is lowered to further improve water permeability and air permeability, Only the part will not come off and be damaged. Further, the through hole of the needle punch further improved the air permeability and water permeability. Not only because there is a vent hole that penetrates the surface layer part and the middle layer part mainly made of cotton, and the through hole of the needle punch, because the polyester fiber itself that constitutes the middle layer part uses a material excellent in sweat absorption, Sweat easily moves from the surface layer to the middle layer,
Transferred sweat is very likely to diffuse from the ventilation holes. Further, the sweat-absorbing polyester fiber is excellent in not only the absorbability of sweat but also the release property thereof, so that it dries very quickly.

Since the lower layer portion is also provided with the sweat-absorbing polyester layer, and the middle layer portion and the lower layer portion are simply bonded by the breathable hot melt sheet,
Sweat can move from the middle layer to the lower layer, and the sweat can be evaporated from the entire side surface of the lower layer. Since polyester fibers with excellent sweat absorption are used for the middle and lower layers, water absorption and breathability will not be impaired even if the basis weight is increased, so make a mat with a high basis weight that has excellent cushioning properties. You can Also, the middle and lower layers are
Since each of them is needle punched by laminating dozens to hundreds of thin card webs, it has excellent shape stability and little "sag" even after long-term use. In addition, the through-holes of the needle punch can also benefit from the advantages of improved air permeability and water permeability. Since all three layers are integrated, there is no inconvenience such as slippage during sleep. If a highly hygroscopic deodorant antifungal layer is provided on the outer side of the lower layer, it does not create an unclean environment such as mold or bad odor.

The highly air-permeable mat of the present invention is useful as a bedding for adults as well as infants. By selecting the material, a mat that can be used in various seasons from midsummer to midwinter can be manufactured.

[Brief description of drawings]

FIG. 1 is a perspective explanatory view of a highly breathable mat according to the present invention.

FIG. 2 is a cross-sectional explanatory view of the highly breathable mat of the present invention.

FIG. 3 is a cross-sectional explanatory view showing another example of the highly air-permeable mat of the present invention.

[Explanation of symbols]

 1 Highly Breathable Mat 2 Surface Layer 3 Middle Layer 4 Lower Layer 5 Breathable Hot Melt Sheet 6 Vents 7 High Moisture Absorption Deodorant Mold Layer

Claims (5)

[Claims] 1. A mat having at least a three-layer structure, comprising:
A surface layer portion mainly composed of natural fibers, a middle layer portion mainly composed of sweat-absorbing polyester fibers, and a lower layer portion mainly composed of sweat-absorbing polyester fibers are laminated, and the surface layer portion and the middle layer portion are integrated by needle punching. A highly breathable mat, characterized in that a plurality of ventilation holes are formed through both layers, and the middle layer portion and the lower layer portion are adhered to each other via a breathable hot melt sheet. 2. The basis weight of the surface layer is 100 to 500 g / m.
^2. The highly breathable mat according to claim 1, wherein the weight of the middle layer is 700 to 1500 g / m ² and the weight of the lower layer is 1000 to 2000 g / m ² . 3. The highly breathable mat according to claim 2, wherein the weight of the middle layer is smaller than that of the lower layer. 4. The middle layer and the lower layer are formed by laminating card webs having a basis weight of 10 to 15 g / m ² which are mainly made of sweat-absorbent polyester fiber, and thermocompression-bonded after needle punching. Highly breathable mat as described in. 5. The highly breathable mat according to claim 1, further comprising a highly hygroscopic deodorant antifungal layer provided on the outer side of the lower layer portion.