JPH09313307A - Bed mat - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain an efficiently recycleable bed mat provided with a comfortable using feeling with bending and a deodorization property. SOLUTION: For many of the constitution fibers of the mat inner material of this bed mat, a fiber axial direction is arrayed almost parallelly to the cross section (bdef) of the thickness direction of the mat inner material and they are arrayed in a random direction inside the cross section (bdef) of the thickness direction of the mat inner material. For the mat inner material, a deflection amount measured by a method written in the text is 5-20cm. Also, the mat inner material for constituting the bed mat, the cover of the mat, the sewing thread of the cover and accessories are all constituted of fibers or resin composed of the polymer of the same group.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a bed mat that is easy to recycle and has excellent deodorant properties and flexibility required for medical beds and the like.

[0002]

2. Description of the Related Art In recent years, due to two needs, that is, environmental protection of the earth and efficient use of resources, the problem of treatment and reuse of industrial waste and general household waste has been increasing in importance. In many areas, many people are interested. However, in the field of bed mats, most used bed mats have been incinerated or landfilled so far, and recycling technology is still in the development stage.

Conventionally, the recycling techniques proposed for textile products are roughly classified into the following three types.

[0004] The first is thermal recycling. In this method, products are cut into appropriate forms, burned, and reused as in-house power generation and various types of heat energy. However, this method is not preferable from the viewpoint of resource reuse.

[0005] The second is material recycling. This method differs from the following chemical recycling in that the pellets are physically and mechanically pelletized. When this recycled pellet is reused, it is divided into two cases. One is to develop a product as a new material in consideration of the fact that various materials are mixed, such as flower beds, pots for bonsai, and decorative piles for sidewalks. The other is disclosed in Japanese Unexamined Patent Publication Nos. Hei 5-212935 and Hei 6-123052.
In this case, it is composed of 0% of the same material, collected, pelletized, melted and reused.

The third is chemical recycling. The chemical recycling that best matches the basic concept of recycling is chemical recycling, which collects products, decomposes them, and returns them to their original raw materials. However, since few fiber products are generally made from a single material and the material composition is diverse, it takes some time to develop an economical depolymerization system. Means for solving this problem, for example, in the case of carpet products, is described in Japanese Patent Application Laid-Open No. 5-117441. As an auxiliary means for improving the efficiency of depolymerization, the carpet is divided into small pieces, and a separator is used to separate the pieces containing nylon 6 which is the pile material and the other pieces, and the small pieces containing nylon 6 are supplied to the depolymerization system. In this way, the raw material ε-caprolactam is recovered. However, even if the fiber product is made into small pieces and separated by a mechanical means such as a difference in specific gravity due to a cyclone, it is difficult to efficiently recycle them.

On the other hand, a resin foam such as polyurethane has generally been mainly used as a matting material for bed mats. However, the resin foam has a problem in terms of environment, such as using CFC gas or its substitute gas during foaming and generating toxic gas during combustion. Further, it has low air permeability and moisture permeability, is easily steamed, and has a low water permeability when exposed to a solution such as water or urine.

A cushion material (fiber stuffing material) is used as a matting material for solving these problems.
2155, Japanese Patent Publication No. 1-18183, Japanese Patent Publication No. 4-33478, Japanese Patent Application Laid-Open No. 3-140185. These cushion materials use a low-melting point fiber as a heat-adhesive fiber, or use a high-melting point thermoplastic resin as a core part and a low-melting point thermoplastic resin as a sheath part. Although some results have been obtained by using, it is desired to improve further. Further, there has not been disclosed a bed mat having a deodorant property and flexibility required for medical use and the like.

[0009]

SUMMARY OF THE INVENTION An object of the present invention is to provide a bed mat that is easy to recycle, has excellent flexibility and deodorant properties, and has a comfortable feeling of use.

[0010]

The bed mat of the present invention has the following constitution in order to solve the above-mentioned problems.

That is, most of the constituent fibers of the matte mattress of the bed mat are cross-sections (bde) in the thickness direction of the matte mattress.
The fiber axis direction is arranged substantially parallel to f) and arranged in a random direction within the cross section (bdef) in the thickness direction of the mat intermediate material, and the mat intermediate material is measured by the method described in the text. The amount of flexure is 5 to 20 cm, and the mat intermediate material, the mat cover, the cover sewing thread, and the accessories that compose the bed mat are all made of fibers or resins made of the same type of polymer. And the bed mat.

[0012]

BEST MODE FOR CARRYING OUT THE INVENTION A bed mat according to the present invention will be described in detail below with reference to the drawings and embodiments.

The present invention is a bed mat that is easy to recycle. As described above, a general bed mat has a structure in which a resin foam such as polyurethane is used as an inner material of the bed mat, and the core material is wrapped with a cover such as cotton or polyester. Further, as for the cover, a fabric such as cotton or polyester is composed of sewing threads having different chemical compositions, fasteners and quality indicating labels.
Although it is not easy to recycle a bed mat composed of these various materials, the bed mat of the present invention is to obtain a bed mat that is easy to recycle while maintaining the original required quality of the bed mat.

In the bed mat of the present invention, the bed mat intermediate material is a fiber molded body, and further, the cloth, the sewing thread, the fastener, and the accessories such as the quality display label constituting the cover of the bed mat are all fibers made of the same polymer. Alternatively, the bed mat is made of resin and can be easily recycled. It should be noted that accessories do not include those that are removed and used by consumers when they are used.

The bed mat of the present invention can be recycled by any of material recycling, chemical recycling and thermal recycling. If the fiber or resin made of the same type of polymer is used as a polyester polymer for the accessories such as labels, it has excellent compression characteristics (compression recovery), thermal adhesive fixation, low combustion gas toxicity, and cuts the recovery bed mat. Material recycling, which is opened, melted and pelletized for reuse, is easy and preferable. More preferably,
If nylon 6 fiber or resin is used as an accessory such as the bed mat intermediate material, the cloth constituting the cover of the bed mat, the sewing thread, the fastener, and the quality display label, the recovered bed mat is cut and opened, for example, Japanese Patent Publication No. 42-18476. It can be depolymerized and purified by the method described in Japanese Patent Application Publication No. Hei 6-127468, etc., recovered as ε-caprolactam, and reused again as a raw material for nylon 6.

FIG. 1 is a perspective view showing an example of a fiber arrangement in a block shape of a fiber molding for a mat intermediate material of a bed mat according to the present invention.

The fiber molded body is a fiber molded body composed of two or more kinds of fibers, contains at least deodorized nylon 6 fiber A, contains nylon 6R2 as a core component, and has a deodorizing melting point. Thermoplastic polymer R1 lower than the melting point of processed nylon 6 fiber A or nylon 6R2 by 20 ° C or more
Of the composite fiber C having at least the fiber surface side and the deodorized nylon 6 fiber A, or the composite fiber C, the deodorized nylon 6 fiber A and the deodorized nylon Composed of 6 fibers B,
At least a part of the contact points between the composite fibers C and between the composite fibers C and the nylon 6 fibers A and B are bonded and molded, and most of the constituent fibers of the mat intermediate material are in the thickness direction of the mat intermediate material. The fiber axis direction is arranged substantially parallel to the cross section (bdef) so that the cross section (bde) in the thickness direction of the mat middle material
It is arranged in a random direction in f).

Here, in order to enhance the flexibility of the matting material, most of the constituent fibers are arranged substantially parallel to the fiber axial direction with respect to the cross section (bdef) in the thickness direction of the fiber molding as shown in FIG. And in the cross section in the thickness direction of the fiber molding (bd
ef) are arranged in a random direction, and when used as a cushion body, a large number of fibers are arranged substantially parallel to the thickness direction, that is, the direction of receiving a compression action, so that compression recovery and repulsion force are increased. It also has a structure that raises.

Most of the constituent fibers are arranged in the fiber axial direction substantially parallel to the cross section (bdef) in the thickness direction of the fiber molding as shown in FIG. 1, and within the cross section (bdef) in the thickness direction of the fiber molding. ), The main purpose of arranging the beds in a random direction is, for example, a bed that can change the bed from the sleeping position to the sitting position, such as a medical bed. The purpose is to deform so that only the bed mat does not rise from the bed body. For that purpose, the longitudinal direction of the mat mat material for the bed mat (cushion material) is made to coincide with the ab line direction of the fiber molded body, and the fiber axis direction is substantially parallel to the cross section (bdef) in the thickness direction of the mat mat material. Array
In addition, the fiber axis direction is arranged in a random direction in the cross section (bdef) in the thickness direction so that the longitudinal direction of the bed mat is easily bent. The degree of flexibility is such that the amount of flexure measured by the characteristic evaluation method described later is 5 to
It is important that it is 20 cm. If it is less than 5 cm, the mat may float from the bed due to poor flexibility and wrinkles may occur. If it exceeds 20 cm, there is a problem in that the handleability when moving the mat for washing or the like is deteriorated.

Further, most of the constituent fibers are arranged with their fiber axis directions substantially parallel to the cross section (bdef) in the thickness direction of the fiber molded body, and within the cross section (bde) in the thickness direction of the fiber molded body.
By arranging them in a random direction in f), the fiber molding has high durability even after being washed and used, and has high moisture permeability and water permeability even though it has good flexibility, and is highly comfortable to use. The body is obtained.

Here, although there are many cross-sections in the thickness direction, such as a surface at an angle along line ae and a surface at an angle along line ab in FIG. 1, cross-sections in the thickness direction in which fibers are arranged substantially in parallel ( bdef) is only the surface of the angle along the line be, and the fibers are arranged substantially parallel to the surface of this angle. Therefore, when the fiber molded body is stretched or distorted, it is comparatively more than the surface of other angles. It refers to a surface with an angle that facilitates peeling.

As the bed mat intermediate material structure, the intermediate material having the above-mentioned fiber arrangement is preferable, but in addition, the fibers to be used are mixed and opened, and then further mixed with a card to be opened into a web shape, and then formed into cotton. Bed mat middle material with improved flexibility by forming a laminated web with a machine and then folding the web into a wave shape and fixing it with low melting point fibers in the fibers used so that the wave height of the wave is the thickness of the mat Is obtained.

Deodorized nylon 6 fiber A, deodorized nylon 6 fiber B and composite fiber C
The ratio of Nylon 6 treated with deodorant from the viewpoint of deodorant
It is preferable that the content of the fiber A is 40% by weight or more, and the nylon 6 fiber B not subjected to the deodorizing treatment contains less than 80% by weight in the total weight of the nylon 6 fiber A subjected to the deodorizing treatment.
Shape retention and durability of the fiber molding of the bed matting material,
The content of the composite fiber C is preferably 20% by weight or more and less than 60% by weight in terms of cushioning property, soft feeling, deodorizing property and the like. Particularly, the range of 20 to 50% by weight is preferable.

The composite fiber C is composed of the two components R1 and R2, and as R1, for example, a polyolefin or olefin such as polyethylene, polypropylene, ethylene propylene copolymer, ethylene butene copolymer, ethylene vinyl acetate copolymer and the like. At least one polymer selected from the group consisting of copolymers, polyesters such as polyhexamethylene terephthalate, polyhexamethylene butylene terephthalate and polyhexamethylene terephthalate isophthalate, or thermoplastic polymers such as copolymerized polyesters can be used. Although R2 is not particularly limited, for example, terephthalic acid, 2,6-naphthalenedicarboxylic acid or an ester thereof as a main dicarboxylic acid component, and ethylene glycol or tetramethylene glycol as a main glycol component, polyethylene terephthalate, polybutylene terephthalate,
Alternatively, polyester such as polyethylene 2,6-naphthalate can be used.

In addition, nylon 6 (R2) is usually used as a core component, and nylon 6 fiber A that has been deodorized and nylon 6 fiber B that has not been deodorized and nylon 6 heat having a lower melting point than R2. It is also preferable to use a composite fiber C having a sheath component of a thermoplastic polymer (R1), for example, a thermoplastic polymer obtained by copolymerizing nylon 6 with nylon 6 in a small amount.

In the selection of R1, the melting point is made lower than the lowest melting point among the fibers A, the other fibers B and R2, and it is preferably 20 ° C. or more from the viewpoint of thermal adhesiveness, and 50 ° C. More preferably, it is lower.

From the viewpoint of the effect of adhesion and prevention of thermal deterioration, the melting point of R1 is preferably in the range of 80 to 170 ° C, and more preferably in the range of 100 to 170 ° C.

The weight ratio represented by R1 / R2 in the composite fiber C is 20 in terms of shape retention and durability of the fiber molded product for bed mat intermediate material, cushioning property, recovery efficiency in the case of recycling, cost and the like. It is preferably in the range of / 80 to 60/40.

If necessary, the composite fiber C may be R
In addition to pigments such as titanium oxide and carbon black other than 1 and R2, antioxidants, anti-coloring agents, light fastness agents, antistatic agents and the like may of course be added. Such a composite fiber C can be produced by a usual composite spinning method.

Next, in order to impart bulkiness and a soft feeling to the fiber molding of the present invention and improve the recovery property against compression,
The composite fiber C preferably has a mechanical crimp or the like. The number of crimps may be appropriately selected depending on the intended use of the fiber molding, but the number of crimps is 3 to 10 peaks / 25 mm, and the degree of crimp is 5 to 30.
% Is preferable.

The composite fiber C constituting the fiber mixture has a fineness of 0.5 to 3 from the viewpoint of bulkiness and softness.
Short fibers having 0 denier and a fiber length of 10 to 100 mm are preferably used.

The deodorized nylon 6 fiber A used in the fiber molded article of the present invention may be of a type in which a deodorant component is kneaded into a polymer as described in JP-A-3-124809. However, as described in JP-A-62-6978, a method of applying a deodorant component by post-processing may be used. The deodorized nylon 6 fiber A can also be obtained by grafting a free acidic group by graft polymerization, for example, as a method of applying a deodorant component in a post-processing. The acidic group in this method means a carboxyl group or a sulfonic acid group, and the content of the acidic group is 3.2 × 10 ⁻⁴ from the viewpoint of imparting durable deodorant performance.
9. Gram equivalent / gram fiber or more is preferable, and
More than 3 × 10 ⁻⁴ gram equivalent / g fiber is more preferred. Incidentally, the end of the introduced acidic group by graft polymerization -COOH or -SO ₃ but those H state is preferred, some alkali metals or alkaline earth metals,
Further, it may be substituted with a general metal or an ionic organic substance such as a quaternary ammonium salt. It is preferable to distribute a large amount of acidic groups on the surface of the fiber by such graft polymerization, because the malodors such as ammonia, hydrogen sulfide and mercaptans, which are said to be the source of malodor, can be efficiently absorbed.

The cross-sectional shape of the deodorant-treated nylon fiber A and other fibers B used in the bed matting material of the present invention may be a round cross section. It may be a cross section or a hollow cross section thereof. The hollow cross section is more preferable because it improves the bulkiness of the fiber molded body.

The deodorant-treated nylon fibers A and other fibers B used in the bed matting material of the present invention impart bulkiness and a soft feeling to the bed matting material and improve recovery property against compression. In order to improve the cotton making property at the same time, it is preferable to have a mechanical crimp. The number of crimps may be appropriately selected, but the number of crimps is 3 to 10 peaks / 25 m.
m, and the crimping degree is preferably 5 to 30%. In order to impart more bulkiness, it is more preferable that this crimp is a three-dimensional crimp that is developed during spinning, for example, a side-by-side composite fiber of polymers of the same system but different properties, or asymmetric cooling during spinning. preferable. Further, from the viewpoint of softness, bulkiness, elasticity and cotton-making property, the fineness is 0.5 to 30.
Denier and short fibers having a fiber length of 10 to 100 mm are preferably used. In addition, pigments such as titanium oxide and carbon black, as well as various antioxidants, if necessary,
It is also preferable to add an anti-coloring agent, a light-proofing agent, an antistatic agent and the like.

Further, it is also preferable to use deodorant fibers for the cover fabric of the bed mat in order to effectively exert the deodorant property.

Next, a method for producing the fiber molded body which is the mat intermediate material of the bed mat of the present invention will be described. FIG.
FIG. 3 is a vertical cross-sectional view of a mold of an apparatus used in an example of the method for producing a fiber molded body of the present invention.

Fiber A and composite fiber C that have been subjected to the deodorizing process
Alternatively, the fiber A, the other fiber B and the composite fiber C,
Sufficiently mix and open the fibers with a cotton-feeding machine, a cotton-mixing machine, and a fiber-spreading machine used in the normal spinning process, and then blow it into a breathable formwork that has a shape according to the purpose together with a gas such as an air flow from a cotton-blowing fan to fill To do.

In order to blow and fill each fiber as described above, a mold having an appropriate air permeability is used. For example, when measured by JIS L 1079-1966 Frazier type breathability tester,
The air permeability is preferably in the range of 5 to 200 cc / cm ² · sec.

As such a mold, for example, dies 1 and 2 using a punching metal plate shown in FIG. 2 can be used. The fiber mixture 4 blown from the blowing port 3 into the air-permeable mold is in a state of being randomly arranged in the length, width, and thickness directions.

The filled fiber mixture is then compressed to the proper density. Density is 0.025-0.055g /
It is preferably cm ³ . Density is 0.025g / cm ³
If it is less than the above range, the fiber molded product may be too soft, resulting in poor morphological stability and difficulty in cutting and molding into a desired shape.
If it exceeds 0.055 g / cm ³ , the soft feeling of the fiber molded product may deteriorate. In addition, this compression treatment also has an action of enhancing the target bendability by arranging the compression treatment in a direction substantially parallel to the cross section (bdef) in the thickness direction of the fiber molding using the fiber axis direction of the fiber molding of the present invention.

The compressed packing is heat treated to give a composite fiber C.
The shapes are fixed by adhering some of the contact points between the fibers C and the fibers A and the other fibers B to each other. The heat treatment temperature may be a temperature at which R1 of the fiber C melts and adheres, and generally 80 to 200 ° C. is preferable.

Further, the thermoplastic polymer R1 of the composite fiber C is used.
At a temperature lower than the melting point of, the secondary compression treatment is performed once or more in the range of 5 to 80% in two directions in two directions perpendicular to the compression direction after the blow filling or in one direction in two directions. It is also preferable to use the fiber molding of the present invention. The fiber molded article of the present invention has excellent compression elasticity, flexibility, moisture permeability, and water permeability, and therefore, the constituent fibers are applied to the surface in the direction in which it is subjected to a compression action in the intended use, for example, sitting or sleeping. Many of the fiber axis directions are arranged substantially parallel to each other. For that purpose, the application in which the secondary compression treatment direction during the production of the fiber molded body is used,
For example, the direction in which the person is seated or lying down receives a compressive action, that is, the thickness direction of the application. In this case, the secondary compression treatment has an effect of previously removing unnecessary bonding points melt-bonded at R1 of the fiber A to improve soft feeling and compression recovery when using the fiber molded body.

[0043]

Next, the present invention will be described more specifically with reference to examples. The measuring methods of various characteristics described in the present invention are as follows.

(1) Deflection amount Three rectangular test pieces having a width of 10 cm, a thickness of 5 cm and a length of 50 cm (sampled so that the length direction of the test piece coincides with the longitudinal direction of the bed mat) were prepared. Place on a horizontal table, slide the test piece, and measure 30c from the edge of the table.
After standing for 1 minute in the state of m, the difference in height between the upper surface of the table and the lower surface of the tip of the test piece (deflection amount mm) was read on a scale and expressed as an average value of three times.

(2) Deodorizing property Method A: Ammonia gas detector tube method was used to open the glass column at any part of the cushion of the bed mat, and 3 g of the fiber therein was filled to give 1000 ppm of ammonia gas. Passing a concentration of gas at a ventilation rate of 3.3 cm / sec,
The breakthrough time and the breakthrough adsorption amount were measured (the breakthrough adsorption amount is preferably 12 mg / g or more even after washing with domestic water in order to exert deodorant properties).

Method B: 3 × 6 cm of about 5% ammonia water
After impregnating 0.25 ml of the filter paper of No. 1 into a glass container of 150 ml, at the same time, open any part of the cushion of the bed mat, put 0.5 g of the fiber in it and seal it, leave it for 4 hours. Sensory evaluation of the change in odor afterwards (no odor,
It was evaluated in four grades of slightly odor, odor and strong odor. ).

However, the washing is carried out with a commercially available neutral detergent of 2 g / l,
It was washed at 40 ° C. for 5 minutes under the condition of the desire ratio of 1:50, washed with water and dried.

(3) Fineness The fineness was measured according to the method of JIS L1015-7-51A.

(4) Average fiber length (cut length) JIS L1015A method (staple diagram method)
It measured according to.

(5) Number of crimps and degree of crimp The number of crimps and the degree of crimp are JIS L1015-7-12-
1 and the method of JIS L1015-7-12-2.

(6) Packing density Test piece (vertical: 20 cm, horizontal: 20 cm, thickness: 20
cm) was allowed to stand in an atmosphere of 20 ° C. × 65% RH for 24 hours, and the weight (w) was measured and determined by the following equation. Density (g / cm ³ ) = w / 8000 [Example 1] A polyethylene terephthalate chip having a normal melting point of 255 ° C is used as a fiber for a bed mat intermediate material, a spinning temperature of 280 ° C, a take-up speed of 1350 m / min, and a hollow A hollow cross-section structure having a rate of 30% was used, and a normal asymmetric cooling treatment was performed directly below the spinneret to spun undrawn cotton fiber. Then, the undrawn yarn is drawn at a drawing bath temperature of 80 ° C.,
Machine crimping was applied with a crimper, a finishing oil was applied, and the product was cut and then set and dried with a heat setter at 145 ° C. to obtain a staple for a bed mat intermediate material having a fineness of about 8 denier and a cut length of 30 mm. Separately, as the low-melting fiber for the bed mat intermediate material, R2 is usually polyethylene terephthalate having a melting point of 255 ° C., and R1 is polyethylene terephthalate-based polyester having a melting point of 110 ° C. copolymerized with 40 mol% of isophthalic acid. Spinning temperature 28
An unstretched yarn of concentric conjugate fiber C having a core of R2 and a sheath of R1 having a weight ratio of 50/50 represented by R1 / R2 at 5 ° C., a take-up speed of 1350 m / min, was spun. Next, this unstretched yarn was stretched at a stretching bath temperature of 80 ° C. and mechanical crimped by a crimper. Furthermore, after drying with a heat setter at 70 ° C, apply a finishing oil agent and cut length 64 m.
By cutting into m, a composite fiber C having a fineness of about 4.1 denier and a melting point of the surface layer of about 110 ° C. was obtained.

The above-mentioned fibers for the bed matting medium and the low melting point fibers for the bed matting medium are mixed and further mixed and opened with a roller card, and the width of the inner surface punched on each side of this fiber mixture × Length x depth is 82 x 84 x 100 cm
The lower mold was blown with an airflow from the mold inlet to fill the lower mold. The blown fiber mixture is compressed with an upper die having punched surfaces, and the packing density is 0.04 g / c.
It was fixed at m ³ and a thickness of 50 cm. The fiber mixture filled in the mold and compressed was heat-set at 130 ° C. for 25 minutes by steaming using a heat setter used for setting spun yarn to obtain a fiber molded body.

The direction in which the fiber molding is compressed by the upper mold,
That is, the depth direction was sliced to a thickness of 7 cm as the upper surface or the lower surface of the bed mat intermediate material, and the sliced material was adhered and cut into a bed mat intermediate material having a length x width x thickness of 192 x 82 x 7 cm. The amount of flexure of this matte material was 6.5 cm.

Further, as a cover for the bed mat (flower pattern print side), a double-sided circular knitted fabric using false twisted yarn of polyester 75 denier is sewn with a polyester spun sewing thread, and the quality or handling label is polyester. Was used as a bed mat. This bed mat is attached to a medical gadget, that is, a bed that can be easily changed from a sleeping position to a sitting position by raising the head or lowering the legs by electric operation. As a result of investigating the followability of the bed mat with respect to the change, a good followability was shown.

After the bed mat has been used for one year, the cover, sewing thread, quality and handling label and bed mat intermediate material are spread by a fiber-removing machine, the spread fiber is melted and pelletized, and melt-spun and stretched again. And then 8 denier, 5
It was a 0 mm polyester staple. The obtained staple is a slightly reddish polyester staple,
Although the strength was slightly lower than that of commercially available ordinary polyester staples, it was sufficiently usable as a stuffed cotton.

[Examples 2 to 4 and Comparative Examples 1 and 2] As a fiber for a bed mat intermediate material, an ordinary nylon 6 chip was melt-spun and stretched to obtain a melting point of 215 ° C, a fineness of 13 denier, and a cut length of 51 mm. Circular hollow (hollow ratio 17%)
Nylon 6 staples were used. Furthermore, this staple is made into acrylic acid 19% owf and methacrylic acid 30% ow.
f, ammonium persulfate 1% owf, super light C
(Manufactured by Mitsubishi Gas Chemical Co., Inc.) 3% owf, a bath ratio of 1:14, and heated from room temperature to 80 ° C. at a rate of 1 ° C./min.
Graft polymerization was performed at 60 ° C. for 60 minutes to obtain deodorant nylon 6 fiber A.

The methacrylic acid graft ratio of 100% of this deodorant nylon 6 fiber A was determined from the weight increase rate, and the amount of carboxyl groups was determined to be 3.27 × 10 ^-2 gram equivalent / gram fiber. The cross section of the fiber was cut, dyed with a cationic dye, and examined for the distribution of carboxyl groups. As a result, it was confirmed that a large amount of carboxyl groups were present on the fiber surface. This deodorant nylon 6 fiber 100
% Deodorant is 34.7 mg before washing with the breakthrough adsorption amount of Method A
/ G, 31.3 mg / g after washing, and method B was odorless both before and after washing, showing extremely high deodorant properties. Note that A
The breakthrough time before washing according to the law was 47 minutes.

Separately from this, an ordinary nylon 6 chip with a core of 50% by weight, a nylon 6 copolymerized nylon 66 with a melting point of 110 ° C. and a sheath of 50% by weight were combined into a fineness of 4 denier and a cut length of 51 mm. A low melting point composite fiber C having a circular cross section was produced.

Further, as shown in Table 1, the deodorant nylon 6 fiber A is 35 to 82% by weight, and the composite fiber C is 65 to 65% by weight.
18% by weight of cotton mixed, further mixed and opened with a roller card, and the fiber mixture is punched on each side. Inner surface width x length x depth 82 x 84 x 100 cm The mold was blown with an airflow from the blow-in port of the mold to fill the mold. The blown fiber mixture was compressed with an upper die having punched surfaces, and the packing density was 0.04 g / cm ³ ,
The thickness was fixed at 50 cm. The fiber mixture filled in the mold and compressed was heat set by steaming at 125 ° C. for 25 minutes using a heat setter used for setting spun yarn, to obtain a fiber molded body.

The direction in which the fiber molded body is compressed by the upper mold,
That is, the depth direction was sliced to a thickness of 7 cm as the upper surface or the lower surface of the bed mat intermediate material, and the sliced material was adhered and cut into a bed mat intermediate material having a length x width x thickness of 192 x 82 x 7 cm. Further, in Examples 3 and 4 and Comparative Example 2, the finishing compression treatment was performed 5 times in the thickness direction of the bed mat intermediate material at a compression rate of 50%.

Further, as the cover (side material) of the bed mat, a double-sided circular knitted fabric using 70-denier false twisting yarn of nylon 6 is sewn with a span sewing thread of nylon 6, and nylon is used as a quality or handling label. The taffeta fabric of No. 6 was used as a bed mat.

The bed mats after use in Examples 2 to 4 were collected and defibrated with an anti-fluffing machine, and then the defibrated fibers were converted into Japanese Examined Patent Publication No.
No problem was found when depolymerized and purified by the method described in JP-A No. 2-18476 and recovered as ε-caprolactam.

Table 1 shows the processing methods and properties of the bed mat intermediate materials of Examples 2 to 4 and Comparative Examples 1 and 2.

[0064]

[Table 1] [Example 5] In Example 2, when the deodorized nylon 6 fiber A was manufactured, the staples not subjected to the deodorant treatment were nylon 6 fiber B, and 40% by weight of the deodorized nylon 6 fiber A was deodorized. A bed mat was used in the same manner as in Example 2 except that 20% by weight of Nylon 6 fiber B and 40% by weight of composite fiber C which were not applied were mixed and used for 1 year. The bed mat is flexible, deodorant, and easy to handle in washing,
It was excellent in drainability during washing, had good moisture permeability and water permeability, and had a comfortable feeling of use.

The bed mat after use in Example 5 was collected and defibrated with an anti-fluffing machine, and then the defibrated fiber was used.
Depolymerization and purification by the method described in JP-A-18476
-There was no particular problem when recovered to caprolactam.

Table 1 shows the processing method and properties of the bed matting material of Example 5.

[0067]

According to the present invention, it is possible to obtain a bed mat which can be efficiently recycled and which has flexibility and deodorant properties and a comfortable feeling of use.

[Brief description of drawings]

FIG. 1 is a schematic perspective view showing a model of an example of a fiber molded body used in the present invention.

FIG. 2 is a schematic cross-sectional view showing a model of an example of a manufacturing apparatus for a fiber molded body used in the present invention.

[Explanation of symbols]

 1: Lower mold 2: Upper mold 3: Gas inlet 4: Fiber mixture

Claims (11)

[Claims] 1. A cross section in the thickness direction of a mat middle material, in which most of the constituent fibers of the mat middle material of a bed mat are arranged with their fiber axis directions substantially parallel to the cross section (bdef) in the thickness direction of the mat middle material. bdef) arranged in random directions, the matting material has a flexure amount of 5 to 20 cm measured by the method described in the text, and matting material constituting the bed mat, a mat cover, A bed mat in which both the sewing thread and the accessories of the cover are made of fibers or resins made of the same type of polymer. 2. The bed mat according to claim 1, wherein the same type of polymer is a polyester type. 3. The bed mat according to claim 1, wherein the same type of polymer is a nylon 6 type. 4. The bed mat according to claim 3, wherein the matting material of the bed mat contains at least nylon 6 fiber A subjected to deodorization processing. 5. The bed mat according to claim 4, wherein the proportion of the deodorized nylon 6 fiber A contained in the mat mat material of the bed mat is 40% by weight or more. 6. The matting material of the bed mat is nylon 6
A fiber molded product containing a composite fiber C of R2 and a nylon 6 thermoplastic polymer R1 having a melting point lower than any of the melting points of deodorized nylon 6 fiber A and nylon 6R2. At least a part of the contact points between the fibers C and between the composite fibers C and the deodorized nylon 6 fibers A are bonded and molded. Bed mat as described. 7. The bed mat according to claim 6, wherein the composite fiber C is a core-sheath composite fiber containing nylon 6R2 as a core component and nylon 6-based thermoplastic polymer R1 as a sheath component. 8. The bed mat according to claim 6 or 7, wherein the weight ratio represented by R1 / R2 of the composite fiber C is in the range of 20/80 to 60/40. 9. The bed mat according to any one of claims 6 to 8, wherein the proportion of the composite fiber C contained in the matting material of the bed mat is 20% by weight or more and less than 60% by weight. . 10. A mat molded material of a bed mat is a fiber molded body composed of two or more kinds of fibers, and deodorized nylon 40 fiber A of 40% by weight or more is deodorized. The bed mat according to any one of claims 4 to 9, which is a fiber molded body containing less than 80% by weight of the total amount of the nylon 6 fibers B and the nylon 6 fibers A. 11. A nylon 6 fiber A which has been deodorized
3.2 × 1 of free carboxyl groups by graft polymerization
0 ^-4 mattress according to any one of claims 4 to 10, characterized in that it contains gram equivalent / gram fiber or greater.