JPH0951994A - Cushion composite body - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a relatively light weight and easy-to-handle cushion composite material, excellent in a cushioning function, pressure distribution uniformity, gas permeability and durability, and preferable for bedding, a vehicular seat, a chair seat, a seat for a kneeling cushion, a reception room set, a sport material, and particularly preferable for the bedding. SOLUTION: This cushion composite body has the cushion layer A made of a woven fabric layer, and the cushion layer B made of a resin expanded layer or a filament group layer, each stacked on top of each other. In this case, the cushion layer A has mean thickness of 5-50mm, gas permeability at least 50cc/sec.cm<2> , and 25% compressive stress of 20-100g/cm<2> . Furthermore, the cushion layer B has mean thickness of 10-80mm, 3% to 50% hole parts having the cross sectional area of thicknesswise through-holes of 0.2-100cm<2> to an area ratio, and 25% compressive stress of 20-80g/cm<2> .

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cushion composite which is resistant to stuffiness when used and has excellent stress dispersibility. More specifically, the present invention is, for example, bedding for elderly people or hospitals used for a long time, seats for vehicles, seats for chairs, seats for cushions, seats for reception sets, sports materials, etc., breathability, stress dispersion, The present invention relates to a cushion composite body that can be suitably used in a field requiring durability.

[0002]

2. Description of the Related Art Conventionally, as a cushion material, a cushion material made of resin foam represented by urethane foam,
Cushion material made into an aggregate by fusing and bonding short fibers with a low melting point component (Japanese Patent Laid-Open No. 5-76388), and cushion material having a three-dimensional structure cloth using a high shrinkage yarn as a warp in a multiple woven structure ( JP-A-6-128837) and the like are known. However, each of these cushioning materials has drawbacks in actual use, and further improvement is desired.

A cushion material made of resin foam has been proposed in which the surface of the cushion material is processed to have irregularities so as to disperse the compressive stress pressure, but the internal space of the cushion material is made of foam resin. Therefore, there is a problem that the movement of air is blocked and the air permeability is poor. Further, it is not preferable to open a through hole in the thickness direction in order to solve this problem, because a discomfort is caused when the hole directly contacts the skin.

The aggregate of short fibers cannot satisfy the stress dispersibility and air permeability with ordinary constituent single fiber fineness and density, so that it tends to cause a feeling of stuffiness and also tends to cause local deformation, resulting in poor durability. . Also, in the case of a three-dimensional fabric with a multi-woven structure, the ventilation capacity during use is excellent and the feeling of stuffiness does not easily occur, but there is a technical limit to the thickness as a cushioning material, and cushioning and stress Dispersibility tends to be insufficient.

As described above, the conventional cushioning material is provided with bedding, vehicle seats, chair seats, cushion seats,
When used as a sports material, it fully absorbs and releases moisture from heat and sweat generated by the human body, has excellent durability, and satisfies the conditions desired as a cushioning material with uniform pressure distribution. I couldn't say that.

[0006]

SUMMARY OF THE INVENTION The object of the present invention is to improve the above-mentioned drawbacks of the conventional cushioning materials and to provide excellent cushioning property, uniform pressure distribution, breathability and durability, and bedding, vehicle seats and chairs. An object of the present invention is to provide a relatively lightweight and easy-to-handle cushion composite, which is particularly suitable for bedding, such as a seat, a cushion sheet, a reception set, and sports materials.

[0007]

SUMMARY OF THE INVENTION The object of the present invention is as follows.
A cushion composite comprising a cushion layer A made of a woven and knitted layer and a cushion layer B made of a resin foam layer or a short fiber aggregate layer, the cushion layer A having an average thickness of 5 to 50 mm. , Air permeability of at least 50cc
/ Sec · cm ² , 25% compressive stress is 20 to 100 g /
cm ² and the cushion layer B has an average thickness of 10
〜80mm, the cross-sectional area through the thickness direction is 0.2〜1
The cavity of 00cm ² has 3 to 50% by area ratio, and 25% compressive stress is achieved by the cushion complex, which is a 20 to 80 g / cm ^2.

[0008]

BEST MODE FOR CARRYING OUT THE INVENTION The cushion composite of the present invention is a laminate in which a cushion layer A made of a woven or knitted layer and a cushion layer B made of a resin foam layer or a short fiber aggregate layer are laminated. The woven and knitted layer has an average thickness of 5 to 50 m.
m, preferably 10 to 30 mm. If the thickness is less than 5 mm, the cushioning property deteriorates and the hardness becomes coarse.
When it exceeds mm, there is a problem that the subduction during use becomes too large, and the productivity thereof is lowered, which is not practical. Air permeability of the woven / knitted layer is 50 cc / se
c · cm ² or more, preferably 100 to 300 cc / se
It should be c · cm ² . When the air permeability is less than this range, it is equivalent to a cushion material made of a normal short fiber aggregate or a resin foam, and a high stuffiness is generated during use, which is not preferable. If the air permeability is too high, the air flowability will be so good that it may not be desirable depending on the application.

The 25% compressive stress of the woven or knitted layer is 20 to
100 g / cm ^2, preferably it should be as 25~75g / cm ^2, together with the results in bottoming feeling because it is too soft in the case of less than this range, (sag resistance) durability also becomes insufficient Not preferable. On the other hand, if it exceeds this range, it is too hard and the stress dispersion becomes insufficient, so that stress concentration tends to occur, which is not preferable.

As the woven / knitted layer having such characteristics,
For example, a three-dimensional multi-woven knitted fabric (Japanese Patent Application No. 6-91888, Japanese Patent Application No. 5-236419), which has been previously proposed by the present inventors, and a three-dimensional Russell knitted fabric proposed in Japanese Utility Model Laid-Open No. 1-136191 are exemplified. be able to. Among them, the former three-dimensional multiple weave design is composed of a surface layer portion and an intermediate layer portion, and the intermediate layer portion has one or two layers having a large number of communicating hollow portions parallel to one direction. It is preferable to use a woven or knitted layer formed by laminating more than one layer. Especially,
It is preferable that one or both surfaces of the surface layer portion have corrugations, particularly corrugated irregularities having an average height of 2 to 15 mm and an average width of 2 to 30 mm, because the stress dispersibility is further improved.

The three-dimensional multi-woven structure is essentially composed of filament fibers, and for example, polyester fibers, polyamide fibers, aromatic polyamide fibers, etc. are used. Two or more kinds of these fibers can be used in combination, and in that case, it is preferable to use a polyester fiber and a nylon fiber in combination. The filament fiber may be either a monofilament or a multifilament, but the warp fiber constituting the woven structure is
Nylon fibers having a good deformation recovery property are particularly preferable.

The cushion layer A of the present invention has an extremely high porosity of 90% or more, preferably by having a three-dimensional multi-woven structure substantially composed of filament fibers and three-dimensionally organized as described above. Can be 93% or more, and it is possible to provide a cushion composite which is extremely lightweight as a whole.

Next, the other cushion layer B constituting the cushion composite of the present invention has an average thickness of 10 to 80 m.
m, preferably 30 to 50 mm and having a sectional area of 0.2 to 100 cm ² penetrating in the thickness direction, the area ratio (ratio of the total area of all the pores to the cushion layer area) is 3 And a 25% compressive stress is 20 to 80 g / cm ² , preferably 23 to 60 g /.
It may be a resin foam layer or a short fiber aggregate as long as it has a characteristic of cm ² . If the thickness is less than 10 mm, the cushion performance is deteriorated and the stress dispersion becomes insufficient. On the other hand, when it exceeds 80 mm, the sinking becomes large, which is not preferable.

In the present invention, as described above, it is important that the cushion layer B has a hole portion penetrating in the thickness direction and having a specific size. In the case where the pores have a cross-sectional area (opening) of less than 0.2 cm ² , when compressed at the time of use, clogging of the pores occurs, air permeability is lowered, and stuffiness easily occurs, so that the object of the present invention is achieved. Can not. On the other hand, 1
When it exceeds 00 cm ² , the pores are too large, the pressure dispersion is deteriorated, and a discomfort is caused even through the woven / knitted layer, and the strength as a cushion composite is also reduced, which is preferable. Absent.

The number of holes having the above-mentioned cross-sectional area must be in the range of 3 to 50% as a total area ratio occupied by the holes. When this ratio is less than 3%, the air permeability is insufficient and stuffiness is likely to occur. On the other hand, when it exceeds 50%, the mechanical properties of the cushion layer B deteriorate,
Not only is the durability deteriorated, but it becomes too soft and insufficient as a cushioning material.

Further, when the 25% compressive stress is less than 20 g / cm ² , it is too soft and causes a feeling of bottoming, and the durability is insufficient and it tends to easily set. On the other hand, when it exceeds 80 g / cm ² , the stress is too hard and the stress dispersion becomes insufficient. For example, when the composite is used as a bedding, the body pressure distribution is not good and the blood flow is hindered. The maximum stress when a person sleeps on the bedding is 100 g / cm ² or less, preferably 50 g / cm ² or less.

The material of the foamed resin layer used for the cushion layer B is not limited as long as the above-mentioned characteristics are satisfied, but urethane resin is particularly excellent in its cushioning performance durability. Is preferred,
For example, Toyo Franc 360 manufactured by Toyo Tire & Rubber Co., Ltd. can be exemplified.

As the short fiber aggregate, a fiber cushion material obtained by fusing and integrating with a low melting point adhesive short fiber, in particular, short fibers having a thermoplastic elastomer on the fiber surface are dispersed and mixed. Moreover, a short fiber aggregate that is integrated by fusion bonding of this elastomer is preferable because it has excellent elastic performance and durability. As such a short fiber aggregate, for example, a cushioning material proposed in WO91-19032, that is, a non-elastic polyester short fiber aggregate is used as a matrix, and a polyester constituting short fibers is contained in the short fiber aggregate. 4 above melting point
It is possible to use a cushion material made of a short fiber aggregate in which a short fiber having at least a thermoplastic elastomer having a low melting point of 0 ° C. or higher on the fiber surface is mixed and thereby fused and integrated. Here, the single fiber fineness of the short fibers is preferably 4 denier or more, preferably 4 to 500 denier, and particularly preferably 8 to 300 denier, and if the fineness is less than 4 denier, the cushioning property tends to deteriorate. If the fineness is too large, the number of constituent fibers in the obtained fiber assembly will be too small, and the cushioning performance will be insufficient. Advantageously, the number of crimps is 4 to 25 / inch, the crimping degree is 20 to 40%, and the fiber length is about 10 to 100 mm.

On the other hand, the thermoplastic elastomer having a low melting point for fusing and integrating the short fiber aggregate is not particularly limited as long as it has a melting point of 40 ° C. or more lower than the melting point of the polyester short fiber, but the cushion is not necessary. From the viewpoint of performance and adhesiveness with short fibers, it is preferable to use a polyester-based elastomer, for example, a polyester-based elastomer obtained by copolymerizing a polyester elastomer as a hard segment with a thermoplastic polyester as a soft segment and polyoxyalkylene glycol as a soft segment. Of these, a polyether ester block copolymer having polybutylene terephthalate as a hard segment and polyoxytetramethylene glycol as a soft segment is preferable.

Short fibers containing this low melting point elastomer are
Although it depends on the compressive stress required for the cushion layer B, the single fiber fineness is usually 2 to 100 denier, the fiber length is 10 to 100 mm, and the number of crimps is about 4 to 25 / inch. Mixing ratio of melting point fiber is 10-7
It is about 0% by weight.

The air permeability of the side covering the cushion composite is
If it is too small, it will hinder the movement of humidity and cause a stuffy feeling. Therefore, when it is used for bedding, cushion mats for wheelchairs, cushion sheets for cushions, etc., 20c
It is preferably c / sec · cm ² or more.

If the thickness of the cushion composite is too thick, the depression will be too large, and if it is too thin, the stress dispersion tends to be insufficient and the performance as a cushion will be reduced. Preferably 7
0 to 100 mm.

In the present invention, the cushion layer A
When laminating the cushion layer B with the cushion layer B, the cushion layer B may be divided into a plurality of parts. This is preferable because the product comprising the cushion composite, such as bedding, furniture, and sheets, can be packed and transported easily during transportation, and the cushion composite can be easily handled when washed. The cushion layer A may be divided into a plurality of parts, but in this case, the cushion layer A is usually
Since the side comes into contact with the human body at the time of use, it causes discomfort at the joint and also reduces stress dispersion.

[0024]

EXAMPLES The present invention will be specifically described with reference to the following examples. The following characteristics in the examples were measured by the following methods. <Air permeability> According to JIS-1079 (Fragile type air permeability tester), air was sucked so that the differential pressure became 1/2 inch, and the unit area and the amount of air flowing per unit time at that time were calculated. . <Compressive stress> According to the method of JIS-K-6401-5.4.2, the compression rate is compressed to 75% at a speed of 50 mm / min, the pressure is restored once, and then the pressure when 25% is compressed under the same condition is measured. did. <Stress Analysis> A TEX / SCAN tactile sensor system manufactured by Nitta Co., Ltd. was used to measure the stress distribution in the vicinity of the sacral region in the supine posture. The size of the pressure sensor is 43
cm × 48 cm, and the distance resolution is 10 mm.

[Example 1] A high-shrinkage yarn composed of a polyethylene terephthalate polymer in which 13 mol% of an isophthalic acid component was copolymerized and having a single fiber fineness of 4 denier and a total fineness of 1000 denier was used as a warp in three layers (each layer). 19 filaments / inch), 4 layers of nylon monofilament 330 denier (30 filaments / inch for each layer), 475 denier of polyester false twisted yarn / 144 filaments for the outermost layer (36 filaments / inch for each layer), each wound in 3 beams Had 3
From a heavy beam warped product to a modified five-layer weave with a rapier loom, the outermost layer weft is polyester false twisted yarn 475
Denier- / 144 filaments were used, and polyester monofilament 300 denier was used for the four layers of the intermediate layer portion to weave 60 layers / inch in total for each layer to obtain a fabric having the structure shown in FIG. The resulting fabric is set at 170 ° C for about 2 minutes and contracted by 38% in the length direction of the fabric to give a thickness of 3
Cushion material consisting of a fiber woven fabric layer having a cross section of 0 mm and a cross-sectional shape as shown in FIG. 2 (air permeability of 180 cc / sec · c
m ² , 25% compressive stress was 48 g / cm ² ) was obtained. It has a thickness of 50 mm and a diameter of 2.0c that penetrates in the thickness direction.
Urethane foam having m holes at 75 mm intervals in each of the vertical and horizontal directions (area ratio of holes is 5.6%, 25%
Laminated with a compressive stress of 41 g / cm ² and then meshed fabric (polyester false twisted yarn 475 denier / 1
Weaving density of 30 filaments / inch, weft density 25 filaments / inch with 44 filaments of 5 stitches: Air permeability of 200cc
/Sec.cm < ² >) to cover the whole with a lateral layer of the cushion composite body. The 25% compressive stress of this bedding was 45 g / cm ² . The weighing 70kg over the bedding, was measured the stress distribution when a person is sleeping height 175cm (body pressure distribution), all was 50 g / cm ² or less and good, also the ventilation degree of 180 cc / sec · c
m ² was good. Next, when the weight of the cushion composite body was measured 8 hours after a person fell asleep, it was only increased by 10 g, and almost no weight increase was observed.

Example 2 6 bars were used by a Russell knitting machine using a nylon monofilament having a single yarn fineness of 220 denier and a polyester multifilament of 150 denier 48 filament, and a knitting structure was 88,
00, 00, 8804, 44, 40, 008, 1
2, 4, 0 4, 0, 8, 1244, 40, 0
A fiber knitted fabric having a thickness of 6 mm was obtained by combining 0, 04 00, 00, 12, 12, 12, 12, 12.
Was a nylon monofilament having a single yarn fineness of 220 denier, and was a polyester multifilament having a 150 denier of 48 filaments. The internal void ratio of the obtained knitted fabric was 93% (fiber filling rate 7%). This knitted fabric has a thickness of 50 mm and a urethane foam having holes penetrating in the thickness direction and having a diameter of 5.0 cm at intervals of 100 mm in each of the longitudinal and transverse directions (area ratio of pores is 19.
6%, 25% compressive stress 37g / cm ² ) and laminated, then Teijin Ltd. Whitey Whitey (22.5 count spun yarn consisting of 30% polyester, 70% cotton, warp 69 yarns / inch A sheet woven with a weft of 57 yarns / inch was covered with a side material having air permeability of 80 cc / sec · cm ² ) to obtain a bedding made of a cushion composite. The stress distribution (body pressure distribution) when a person with a weight of 70 kg and a height of 175 cm fell asleep on this bedding,
All have good 60g / cm ² or less, and also have air permeability of 7
It was as good as 0 cc / sec · cm ² . Next, when the weight of the cushion composite body was measured 8 hours after a person fell asleep, it was found that the weight increase was not recognized even when the weight was increased by 20 g, and the water was discharged to the outside.

[Embodiment 3] A cushion material made of the same fiber woven layer as used in Embodiment 1 is provided with holes having a thickness of 50 mm and having a diameter of 6 mm penetrating in the thickness direction, spaced 20 mm each in the vertical and horizontal directions. Short fiber aggregates having a single fiber fineness of 12 denier, a polyester fiber having a denier of 12 denier, a polyether ester block copolymer as a sheath component, and a polyester having a fineness of 9 denier as a core-sheath composite low melting point adhesiveness Mixing and heat fusion with short fibers: Area ratio of pores is 7.0%,
25% compressive stress 64g / cm ² ) and then
Cotton broad (50 / -140 pieces / inch, weft 40 /-
The whole was covered with a side material composed of 70 pieces / inch) to obtain a bedding composed of a cushion composite. The 25% compressive stress of this bedding was 47 g / cm ² . The stress distribution (body pressure distribution) when a person with a weight of 70 kg and a height of 175 cm fell asleep on this bedding, and it was found to be good at 55 g / cm ² or less, and the air permeability was 70 cc / sec · cm.
It was as good as ² . Next, when the weight of the cushion composite body was measured 8 hours after a person fell asleep, it was only increased by 10 g, and almost no weight increase was observed.

[Comparative Example 1] Standard futon (with cotton cotton, 70
mm thickness), the stress distribution (body pressure distribution) when a person with a weight of 70 kg and a height of 175 cm fell asleep in the same manner as above, and the maximum stress was as high as 200 g / cm ² , and the air permeability was 20 cc / sec.・ It was as low as cm ² . Furthermore, the weight increase of the cushion composite after 8 hours when the person is asleep is 20
It is 0 g, and it can be seen that the water generated from the body is accumulated in the futon.

[Comparative Example 2] Mukawatsuton made by Nishikawa Sangyo (made of urethane foam having a thickness of 120 mm) and weight 70 k
g, the stress distribution when a person with a height of 175 cm fell asleep in the same manner as above, and the maximum stress was 100 g / cm.
² was relatively good, but the air permeability was 10 cc / sec
・ Low as cm ² and weight increase of 120 after sleeping for 8 hours
It was g, and the underbody had a sticky feeling.

[Comparative Example 3] In Example 2, the diameter of the pores of the urethane foam was set to 11.0 cm, and the pore spacing was set to the vertical direction.
A cushion composite was prepared in the same manner as in Example 2 except that the width was 15.0 cm. When this composite was evaluated in the same manner as above, the body was largely submerged and was not preferable as a cushioning material.

[0031]

According to the present invention, since the woven / knitted layer and the resin foam layer or the short fiber aggregate are laminated, a cushioning material having excellent stress dispersibility during use and low stuffiness is provided. It Therefore, by making use of these characteristics, it becomes possible to support fields such as bedding for hospitals and the elderly, seats for vehicles, cushions for wheelchairs, and mats for reception sets.

[Brief description of drawings]

FIG. 1 is a schematic sectional view of a woven fabric (unshrinked) obtained in Example 1.

FIG. 2 is a schematic sectional view of a cushion layer (woven fabric) obtained in Example 1.

Claims (6)

[Claims] 1. A cushion composite in which a cushion layer A made of a woven or knitted layer and a cushion layer B made of a resin foam layer or a short fiber aggregate layer are laminated, and the cushion layer A has an average thickness. 5 to 50 mm, air permeability of at least 50 cc / sec · cm ² , 25% compressive stress of 2
0 to 100 g / cm ² , the cushion layer B has an average thickness of 10 to 80 mm, and a pore area having a cross-sectional area of 0.2 to 100 cm ² penetrating in the thickness direction is 3 to 5 in area ratio.
0% and 25% compressive stress 20-80 g / cm ²
A cushion composite characterized by being: 2. The cushion composite according to claim 1, wherein the cushion layer B is a urethane foam layer. 3. The cushion layer B uses a polyester short fiber aggregate having a single fiber fineness of 4 denier or more as a matrix, wherein the short fiber aggregate has a melting point of 40 ° C. or higher than the melting point of the polyester constituting the short fiber. A cushion layer in which short fibers having a low melting point thermoplastic elastomer at least on the fiber surface are dispersed and mixed, and the short fiber aggregates are integrated by fusion bonding of the thermoplastic elastomer.
The cushion composite described. 4. The cushion composite according to claim 1, wherein the cushion layer A has a porosity of 90% or more. 5. The cushion composite body according to claim 1, wherein a corrugated convex portion is formed on one or both surfaces of the cushion layer A. 6. A bedding formed by covering the cushion composite according to claim 1 with a side material having an air permeability of 20 cc / sec · cm ² or more.