JPH09757A - Mat and its production - Google Patents

Abstract

PURPOSE: To provide a mat which hardly gets sweaty, has excellent heat insulating and bodily shape retaining properties, is comfortable to lie in, is highly durable and foldable, is washable, remains clean at all times, is easy to recycle and is most adequately suitable for beds, mattress, cushions, furniture, etc., in general home, hospitals, hotels, etc., and process for producing the mat. CONSTITUTION: A three-dimensional stereoscopic structure fused with the greater part of contact parts is formed by bringing continuous wires consisting of a thermoplastic elastomer and having a wire diameter of <=5mm into contact with each other while bending these wires to form loops. The mat is formed by laminating a wadding layer consisting of a web of polyester fibers having an apparent density of <=0.1g/cm<3> on the front surface side or rear surface side of a cushion layer consisting of a net-like material having substantially flattened both surfaces, an apparent density of 0.005 to 0.10g/cm<3> and a thickness of >=5mm, covering the entire surface with side fabrics and sewing these fabrics. This process comprises producing such mat.

Description

Detailed Description of the Invention

[0001]

INDUSTRIAL APPLICABILITY The present invention is resistant to stuffiness, has excellent heat retention and body shape retention, has a good sleeping comfort, has excellent durability and bendability, can be washed, can always maintain cleanliness, and can be recycled. The present invention relates to a bed mat most suitable for beds for general households, hospitals, hotels and the like, a mat also suitable for cushioning materials such as bedding, cushions, furniture and pillows, and a manufacturing method thereof.

[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, it is necessary to wash the bed mat due to the problem that hospital beds become hot beds such as MRSA, but urethane, which has poor water permeability, has become a social problem because it cannot be washed.

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
No. publication. 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.

Japanese Unexamined Patent Publication (Kokai) No. 6-269345 discloses a pad for a futon in which a cotton material is sandwiched between sheets and quilted, which covers a bedding member such as a non-woven fabric having a far infrared radiation function. There is a problem that attention is not paid to improvement of sleeping comfort such as a holding function and a stuffiness preventing function, heat resistance and durability, washability such as draining property and drying property, and bending property. Actual Kaihei 6
Japanese Patent No. 48453 discloses a comforter wrapped in a quilted stuffed cotton-filled wrapping cloth made of hard cotton with folds. As a mattress, it has good foldability and heat retention, but it is inferior in breathability, tends to get stuffy, has insufficient body retention, and does not take into consideration washability such as heat resistance and durability, draining and drying. .

[0008]

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.
It is an object of the present invention to provide an optimal mat for a bed, a mattress, a seat cushion, a furniture cushion that can be recycled if separated, and a manufacturing method thereof.

[0009]

Means for solving the above problems, that is, the present invention is a mat in which a wading layer is laminated on at least the upper surface of a cushion layer, and the entire surface is covered with side cloth and sewn. The cushion layer is a three-dimensional three-dimensional structure in which a continuous line made of a thermoplastic elastic resin and having a diameter of 5 mm or less is bent to form a random loop, and most of the contact portions of each loop are fused. The three-dimensional structure network is formed of a structural network, the upper and lower surfaces of which are substantially flattened, and the apparent density is 0.00
The mat is characterized by having a thickness of 5 to 0.10 g / cm ³ , a thickness of 5 mm or more, a wadding layer made of a polyester fiber web, and an apparent density of 0.1 g / cm ³ or less. Furthermore, the thermoplastic elastic resin forming the cushion layer has a recovery rate after room temperature elongation of 300% (room temperature elongation recovery rate) of 20% or more, and recovery after holding 10% elongation at 70 ° C. for 24 hours. Rate (70 ° C elongation recovery rate) is 30% or more, the wire diameter of the net-like body forming the cushion layer is 0.01 mm or more, and the apparent density is 0.01 g /
cm ³ to 0.08 g / cm ³ , thickness 10 mm to 100 mm
The mat is as follows, 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.
It is a mat having a thickness of 20 g / cm ³ to 0.06 g / cm ³ and a thickness of 20 mm or more and 80 mm or less. A mat using a reticulated body having an endothermic peak, wherein the cross-sectional shape of the filaments of the reticulated body constituting the cushion layer is a hollow cross section and / or a modified cross section, and the wadding layer is needle punched and has a thickness Is 3 mm
15mm or less and an apparent density of 0.01g / cm ³
A mat of 0.06 g / cm ³ or less, a thermoplastic elastic resin of polyester, a natural fiber of silk, and a polyethylene glycol component of 0.05% by weight or more on the fiber surface. It is a mat composed of a web whose main matrix is contained polyester fibers, and a thermoplastic elastic resin is discharged downward from a multi-row nozzle having a plurality of orifices at a melting temperature 20 to 80 ° C. higher than its melting point. Then, the continuous linear loops were formed in a molten state, and the loops were brought into contact with each other and fused to form a three-dimensional structure, which was sandwiched by a take-up device and cooled in a cooling tank. This is a method of manufacturing a mat in which polyester fiber webs are laminated on the top, bottom, or one side of a three-dimensional structure, and the entire surface is covered with side material. This is a method for producing a mat in which 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 reticulate body, and the polyethylene glycol is 1 wt% or more and 10 wt% This is a method for producing a mat using a web whose main matrix is polyester fibers mixed and made into fibers.

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 8 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 1 of an alicyclic dicarboxylic acid such as 1,4-cyclohexanedicarboxylic acid, an aliphatic dicarboxylic acid such as succinic acid, adipic acid, and sebacic acid dimer acid, or a dicarboxylic acid selected from these ester-forming derivatives 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 with a number average molecular weight of 1000 to 6000 in the presence or absence of a usual solvent (dimethylformamide, dimethylacetamide, etc.). ) A typical example is a polyurethane elastomer obtained by reacting a polyisocyanate containing an organic diisocyanate as a main component with a prepolymer having isocyanate groups at both ends and (C) extending the chain with a polyamine containing a diamine as a main component. Can be illustrated as (A) Polyester, Polyester
The tellers have an average molecular weight of about 1000 to 6000,
Preferably from 1300 to 5000 polybutylene adipates
Copolyester, polyethylene glycol, polypropylene glycol, polytetramethylene glycol
Polyalkylenediol such as glycol and ethylene oxide-propylene oxide copolymer glycol is preferable, and as the polyisocyanate of (B), a conventionally known polyisocyanate can be used. An isocyanate mainly composed of 4'diisocyanate may be used, and if necessary, a trace amount of conventionally known triisocyanate may be added and used. As the polyamine (C), known diamines such as ethylenediamine and 1.2 propylenediamine are mainly used, and if necessary, trace amounts of triamine and tetraamine may be used in combination. These polyurethane elastomers may be used alone or in combination of two or more. The melting point of the thermoplastic elastic resin of the present invention is preferably 140 ° C. or higher at which heat resistance and durability can be maintained,
It is more preferable to use a material having a temperature of 160 ° C. or higher because the heat resistance and durability are improved. 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 mat of the present invention, the phosphorus content (Bppm) in the thermoplastic elastic resin is the soft segment content (A% by weight).
On the other hand, it is preferable to satisfy the relationship of 60A + 200 ≦ B ≦ 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. A preferable phosphorus content (Bppm) is 30A + with respect to the soft segment content (A weight%).
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 also preferably 6 or less, more preferably 5.5 or less, and most preferably 5 or less. 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 mat 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 endothermic peak is more clearly expressed in the melting curve measured by a differential scanning calorimeter of the reticulated body thus treated 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 polyester fiber in the present invention is, for example, polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polycyclohexylene dimethylene terephthalate (PCHDT), polycyclohexylene dimethylene naphtha. Examples thereof include rate (PCHDN), polybutylene terephthalate (PBT), polybutylene naphthalate (PBN), polyarylate, and copolymerized polyesters thereof. In the present invention, it is preferable to use one having a glass transition temperature of at least 40 ° C or higher. When polyester is used for the side material of the mat used in the present invention, PET, PEN, PB can be recycled without separation when discarded and have good heat resistance.
Polyesters such as N and PCHDT are particularly preferable. Furthermore, a flame-retardant polyester (hereinafter abbreviated as flame-retardant polyester) obtained by polycondensation with PET, PEN, PBN, PCHDT or the like to copolymerize a phosphorus-containing ester forming compound or a phosphorus-containing flame retardant is preferable. , For example, JP-A-51-
82392, JP-A-55-7888, JP-B-55-41610, and the like. 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. In the present invention, one of the other purposes of using the polyester fiber is to reduce the moisture content of the fiber, but since the sweated water needs to be quickly transferred from the skin surface, the fiber surface is hydrophilized to release water. It is preferable to increase it, for example, polyethylene oxide (PEO) or polyethylene glycol (P
It is preferable that at least 0.05% by weight or more of a reaction product of a polyether such as EG), a copolymer thereof, or a phosphorus compound is present on the fiber surface. It is more preferably 0.1% by weight or more and 1% by weight or less. When it is present in an amount of 2% by weight or more, the friction coefficient of the fiber becomes high and the openability is deteriorated, which is not preferable. Although it may be applied by post-processing, it is preferably mixed with polyester in order to maintain durability against washing.
As a mixing method, a method of adding at the time of polymerization, a method of kneading with a polymer blend, and a method of melt kneading with kneading at the time of spinning can be used. In the case of PEG, the addition amount is
It is preferable to add a polymer having a molecular weight of 5,000 to 20,000 in an amount of 1% by weight to 10% by weight. If it is less than 1% by weight, sufficient water discharge cannot be imparted, and if it is 15% by weight or more,
It is not preferable because the modulus of the fiber is lowered. Furthermore, it is more preferable that the cross section of the fiber is a modified cross section or a hollow modified cross section to more efficiently give water discharge by the siphon effect. A modified cross-section is a preferred embodiment because durability can be imparted even in post-processing.

In the basic cushion layer of the mat of the present invention, continuous filaments made of a thermoplastic elastic resin having a fiber diameter of 5 mm or less are bent and brought into contact with each other, and most of the contact portions are fused and integrated. Since the three-dimensional three-dimensional structure is formed and the mesh body is substantially flat on both sides, even when externally applied deformation through the wadding layer, especially when a large deformation stress is locally applied, The flattened mesh surface receives the deformation stress and disperses the deformation stress, and the filaments made of thermoplastic elastic resin form a three-dimensional three-dimensional structure and are fused and integrated, so that the entire structure is deformed. By absorbing the deformation stress by energy conversion and receiving the deformation stress with a low repulsive force due to rubber elasticity, it prevents extreme local depression and supports the body with a soft gripping force against the human body. DOO expresses preferred type holding function possible. The betting mat is also required to have a vibration absorbing function. The cushion layer made of the net-like body of the present invention absorbs and attenuates most of the vibration applied from the outside at the time of bed-in or turning over by the vibration absorbing function of the thermoplastic elastic resin, and also exhibits a preferable vibration absorbing function. 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, since the porosity is high and the ventilation hole diameter is extremely large, the ventilation resistance is low and the ventilation is extremely good, and when the deformation stress is changed due to rolling over, etc., the linear line having the rubber elasticity of the thermoplastic elastic resin has a three-dimensional shape. As the structure is formed and 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 recovered. Since the mat has a pump function of replacing with fresh air at the time, heat and steam can be easily transferred between the wadding layer and the cushion layer, and the mat can provide comfortable sleeping that is hard to get damp. For this purpose, the wire diameter of the filament made of thermoplastic elastic resin having good vibration absorption and elastic recovery forming the mesh body of the present invention is 5 mm or less.
When the apparent density is 0.2 g / cm ² or less, if the thickness exceeds 5 mm, the number of components will be small, density unevenness will occur, and a structure with poor durability can be partially formed, and fatigue due to stress concentration will increase and durability will increase. It is not preferable because it decreases. 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 more than cm ³ , the repulsive force may be too high and the sitting comfort may be poor. In the present invention, the apparent density of the reticulated body of the present invention is 0.10 g / cm ³ or less for the purpose of reducing the weight and improving the handleability. 0.01g that can easily develop the function as a cushion body by utilizing the vibration absorption capacity and the deformation stress absorption function
/ Cm ³ or more and 0.08 g / cm ³ or less are preferable, and more preferably 0.02 g / cm ³ or more and 0.06 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 5 as a surface function for dispersing force and a function for absorbing vibration and deformation stress.
00 mm or less, more preferably 20 mm or more and 200 mm
It is the following. When the thickness of the short plate is 500 mm or more, the bendability described later is lost. When a thicker cushion layer is desired, a cushion layer having a thin thickness of 200 mm or less, preferably a mesh body of 100 mm or less is laminated in a non-bonded state to prevent the bendability from being impaired. It is also possible to obtain a mat of cushion layers. When the layers are laminated so that the thickness is 200 mm or less, the interfaces may be joined, and even if they are 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 is not substantially flattened, the local external force transmitted from the wadding layer through the lateral ground cannot receive the deformation stress on the surface, and the lines and bonding points on the surface. Since the function to disperse the deformation stress is selectively transmitted up to the part, stress concentration may occur, and fatigue due to stress concentration may occur against such external force, resulting in sag resistance. It may decrease. In addition,
When the filaments are made of thermoplastic elastic resin, the entire structure is deformed in the three-dimensional structure, so that stress concentration is relieved.
As the tiredness progresses, the body shape retention function also decreases. In the case of non-elastic resin, stress concentrates on the bonding point as it is, causing structural destruction and cannot be recovered. Further, if the surface is not substantially flattened and has irregularities, it gives a feeling of foreign matter to the back and buttocks when sleeping, which is unfavorable because it makes the sleep uncomfortable. 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 they are not fused, the shape cannot be maintained and the structure does not deform integrally, resulting in a fatigue phenomenon due to stress concentration and poor durability, and at the same time deforming the shape and making it impossible to maintain the body shape, which is not preferable. . The more preferable degree of fusion bonding of the cushion layer of the present invention is a state in which most of the portions in contact with the filaments are fused, and most preferably all the contact portions are 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 an unfavorable body-retaining function, and it has almost no pump function by compression recovery, so that the stuffiness reducing function is inferior. Further, due to the compressive deformation, plastic deformation occurs and the recovery is not achieved, and the durability is poor. 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 which is apt to be stuffy and does not provide comfortable sleeping because the air permeability is extremely poor. The mat of the present invention is a mat in which a wadding layer made of a polyester fiber web having an apparent density of 0.1 g / cm ³ or less is laminated on the front surface side and / or the back surface side of the cushion layer, and the entire surface is covered with a side material. is there. The polyester fiber is not particularly limited, but as described above, sweat and moisture are moved from the skin surface through the wadding layer as quickly as possible without giving a stuffy feeling, and the body shape is kept comfortable with proper heat retention and a favorable fit. In order to permanently provide sleep, the web surface is preferably heated to the body temperature on the skin surface by using a web that preferably has a hydrophilic surface on the fiber surface, and more preferably has a modified cross-section to improve the water discharge and uses polyester fiber as the main matrix. The sweat and water vapor that has migrated from the skin surface to the wadding layer via the lateral layer immediately migrates from the wadding layer to the cushion layer surface. Next, since the cushion layer has a pump function of replacing with fresh air, the heat and water transferred to the surface of the cushion layer are released to the outside through the cushion layer. With the decrease in temperature, the stuffiness is reduced. The polyester fiber in the web constituting the wadding layer preferably has a mixing ratio of the hydrophilized polyester fiber of at least 50.
It is at least wt%, more preferably 75 wt%, and most preferably 100 wt%. Apparent density is 0.1g
If it exceeds / cm ³ , the wadding layer has reduced air permeability and moisture permeability, so the apparent density from the moisture permeability is preferably 0.06 g / cm ³ or less, more preferably 0.04 g / cm ^3.
It is not more than cm ³ . 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. Since the individual fibers of the wadding layer made of the web of the mat of the present invention are not fixed, the individual fibers have a high degree of freedom with respect to the deformation stress, and when the fibers are subjected to the local deformation stress transmitted through the lateral land, It is compressed and deformed while moving, and the deformation stress is transmitted to the cushion layer. Since the cushion layer absorbs the transmitted deformation stress by the elasticity of the thermoplastic elastic resin while the entire structure is deformed and the deformation stress is absorbed by energy conversion, the cushion layer can receive the deformation stress with a low repulsive force due to rubber elasticity. Due to the synergistic effect of supporting the human body with a soft gripping force against the human body, local high compressive stress points in contact with the human body are less likely to be formed, and 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 wadding layer to the side surface of the cushion layer through the side ground is 10 cc / cm ² seconds or more. The air permeability of the side cloth covered with the mat of the present invention is not particularly limited, but the air permeability of the knitted fabric constituting the side cloth is preferably 30 in order to impart the floor rubbing prevention effect.
cc / cm ² seconds or more. The side material that constitutes the mat of the present invention is preferable because the side surface of the mat is constituted by only the knitted fabric and the breathability between the cushion layer and the outside air is improved, so that the pump function of the cushion layer can be more effectively utilized. . Web of apparent density is too high and high compressive stress apparent density so also decreases stuffiness prevention effect inferior drop and breathability of congestive prevention function due to an increase in the support area of 0.1 g / cm ³ constituting a wadding layer of the present invention You need the following: If 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.
³ to 0.06 g / cm ³ or less, more preferably an apparent density is 0.03 g / cm ³ or more 0.05 g / cm ³ or less. If the thickness of the wadding layer is less than 2 mm, the function of the wading layer will deteriorate. When the thickness is 30 mm or more, the useful function described above, which has a synergistic effect with the cushion layer, and a proper sinking and a soft gripping force for supporting the body are reduced. A preferred thickness is 3 mm or more and 15 mm or less, more preferably 5 mm or more and 10 mm or less. The fineness of the polyester fiber used in the wadding layer of the mat of the present invention is selected as desired, and the fineness that can be used in ordinary card opening is 0.5 denier to 100 denier. , Preferably 2 to 30 denier, more preferably 4
Denier to 15 denier. 500 for special cases
Fineness up to denier can be selected. Further, the cross-sectional shape of the polyester fiber used in the wadding layer of the mat of the present invention is not particularly limited, but the irregularity of the modified cross-section is 1.2 or more, the hollow ratio of the hollow cross-section is 10% or more, or the irregularity of the hollow modified cross-section is 1 or more. It is preferable that the ratio is 0.2 or more and the hollow ratio is 5% or more because the bulkiness, heat retention and anti-compression property are improved. The crimping form is not particularly limited to mechanical crimping or three-dimensional crimping as long as the web is an open web and the entanglement can be maintained, but in three-dimensional crimping, the crimping degree is 5% or more and 30% or less, and the number of crimping is 5 / An inch or more and 15 pieces / inch or less is preferable because the soft bulkiness is improved, and the crimping degree is 3% or more and 20% or more in three-dimensional crimp
It is preferable that the number of crimps be 16 or more and 30 or less, because the compression resistance can be improved. The fiber length can be card-opened or air-opened as long as it is 15 mm or more and 150 mm or less, and is not particularly limited, but preferably 30 mm or more and 100 mm or less, which is easy to open and entangled. 8 to 2 denier for a slightly soft texture
It is preferable to use a fineness of 6 denier to 30 denier in order to use a fineness of denier and a slightly hard texture. To have a soft texture with a soft waist,
1/9 to 5/5 with a fineness of 0.5 denier to 5 denier and a fineness of 6 denier to 15 denier
It is preferable to use mixed fibers. It is possible to impart softness, sag resistance, and water discharge while suppressing bulkiness by mixing fibers having a crimped form that is easily crimped by mechanical crimping and one that is hydrophilically processed by three-dimensional crimping. In order to add other properties to the wadding layer, for example, anti-mitic agents, antibacterial agents, deodorants, flame retardants,
Use polyester fibers that have been imparted with a fragrance, etc. at the same time as making them hydrophilic, or separately add polyester fibers containing them to enhance the function, and utilize the properties such as water repellency and hydrophobicity to improve draining and drying properties. It is desirable to mix fibers that can be improved to give a function such as a defect or a doubled feature. Depending on the taste, desired different wadding layers made of polyester fibers may be laminated on the cushion layer surface to be used properly 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. The mat of the present invention has better washability than known mats. That is, compared with a cushion layer made of ordinary fibers having a fiber diameter of 0.001 mm or less, the wire diameter of the cushion layer constituting most of the cushion body of the present invention is 0.01 mm or more, and the web of the wadding layer is made of fibers. Has a large surface area, but the average number of constituents in the entire cushion body is small, and the surface area of the filaments is extremely small, so that the moisture adhering to the surface of the filaments can be reduced, resulting in excellent drainage. Since it has good draining property, the drying time can be shortened. If desired, the lateral side and the cushion body are connected by a button stopper. Preferred densities of the button stop is two / m ² or more 8 / m ^2, preferably the thickness of the button locking portion is stopped so as to hold the 80% or more of a predetermined thickness. Even if it is buttoned,
The web constituting the wadding layer of the present invention has a large degree of freedom because individual fibers are not sufficiently fixed, and may sometimes become felt when kneading compression during washing is significantly applied. The web is preferably lightly entangled with a needle punch or the like to prevent the formation of felt. When a needle-punched web is used for the wadding layer, even if it is washed by washing, it is less likely that the web will be biased or become entangled. The density of the needle punch is not particularly limited, but if the punch density is too high, the degree of freedom of the fibers in the web disappears,
Since the above effect is lost, it is preferable that the number is 5 / cm ² or more 3
0 line / cm ² or less is preferable. This treatment allows the mats of the invention to be washed frequently, resulting in a clean mat that is always available. In addition, the mat of the present invention is further improved in bendability because the cushioning layer has the stretchability of the thermoplastic elastic resin, and the cushioning layer and the wadding layer made of a web having a high degree of deformation are laminated. This function can be used for a bed for care or the like that requires the user to raise the head or upper body. When used as a thin mattress, it can be folded and stored. If the cushion layer is made of a hard material made of non-elastic resin, the bending part may be destroyed if it is forcibly bent, and if the cushion layer is made of a soft non-elastic resin material, the cushion is bent by plastic deformation. The wadding layer has a dent in the vicinity and breaks due to bending fatigue when repeatedly bent, but the wadding layer made of a web having a high degree of freedom for deformation is a non-bonded laminated structure of the cushion layer of the present invention made of a thermoplastic elastic resin, and thus the wading layer is a surface It does not have a rigidity function, it can be bent, and even with repeated bending, the wadding layer sandwiched between the side ground and the cushion layer is also freely deformable, so it is difficult to plastically deform and the durability is excellent. This is a major difference from hard cotton. In order to improve the foldability of hard cotton, a fold structure has been proposed, but unlike the cushion layer of the present invention, a non-elastic resin is used for the cushion layer, so that the durability is poor.
Commercial beds may be sterilized as needed.
Sterilization is ethylene oxide gas below 100 ° C or 13
It is common to use 0 ° C. steam. The mat of the present invention can be sterilized without being deformed by sterilizing with steam at 130 ° C. for less than 90 minutes without applying compressive stress, but a known olefin-based or vinyl chloride-based material was used. In this case, it is different from the present invention in that the heat resistance is inferior and plastic deformation is caused by heating during sterilization, resulting in loss of bulk. By performing the above-mentioned pseudo-crystallization treatment at any stage from the reticulated body forming step to a commercialized product, the components composed of the thermoplastic elastic resin in the reticulated body are measured at room temperature on a melting curve measured by a differential scanning calorimeter. It is more preferable to have an endothermic peak at a temperature equal to or lower than the melting point, because the stretchability and heat resistance of the thermoplastic elastic resin are remarkably improved, and the heat resistance durability of the product is 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 irregular cross section, by increasing the hollow ratio and the degree of irregularity, it is possible to reduce the weight even if the same anti-compression property is given, and in the case of replacing the mat for the bed, the duvet, the cushion, etc. Improves the handleability when raising and lowering. As another preferable method for imparting preferable anti-compression property (repulsive force) and touch, there is a method of forming the filament of the reticulated body of the present invention into a composite structure. Examples of the composite structure include a score core structure, a side-by-side structure, and a combination structure thereof. However, 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 occupying the linear surface and having a large soft segment content 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. The mat of the present invention has a cushion layer on one side of which a web made of polyester fibers having a main matrix of hydrophilized polyester fibers is laminated, and on the other side, hard cotton, a natural fiber web,
It is also possible to install a non-woven fabric, a knitted fabric, a cloth and the like, and cover and integrate them with a side fabric made of a knitted fabric. The mat of the present invention is particularly useful for commercial seats such as ships' seats, vehicles, ships, hospitals, and hospital beds, futons, cushions, furniture mats, etc., but also seats for vehicles, chairs for furniture, It is also useful as a cushion for office chairs.

Next, the manufacturing method of the present invention will be described. Multiple Oriffs
Melting point of thermoplastic elastic resin from a multi-row nozzle
Below the nozzle at a melting temperature of 20 ° C to 80 ° C higher than
Discharge toward one side and contact each other in a molten state to fuse
While forming a three-dimensional structure, it is sandwiched by a take-up device and cooled.
After cooling in the waste tank, polyester fiber on both sides or one side
A method of manufacturing mats that are laminated with fibrous webs and covered on all sides
Is the heat that forms the reticulate body in any process leading to commercialization.
A temperature of at least 10 ° C or lower than the melting point of the plastic elastic resin
Method for producing mat by pseudo crystallization by annealing
And 1% by weight or more of polyethylene glycol, 10
The main material is polyester fiber that has been mixed by weight to form fiber.
This is a method of making a mat used for web as a trick.
The reticulate body of the present invention is a general melt-pressed thermoplastic elastomer resin.
Multi-row nozzle with multiple orifices that melts using an engine
And discharge it downward from the orifice. At this time
The melting temperature is 20 ° C. to 80 ° C. higher than the melting point of the thermoplastic elastic resin.
℃ is a high temperature. 80 ° C from the melting point of the thermoplastic elastic resin
If the melting temperature is higher than 10 ° C, thermal decomposition will be remarkable and
This is not preferable because the rubber elastic properties of the plastic elastic resin deteriorate.
Yes. On the other hand, higher than the melting point of the thermoplastic elastic resin by 10 ° C or more
Otherwise, melt fracture will occur and normal striation formation
It becomes impossible to make contact with the loop forming after discharge.
When fusing, the temperature of the filaments decreases and the filaments fuse together.
There is a case where it disappears and a reticulate body with insufficient adhesion is preferable.
No The preferred melting temperature is 20 ° C to 60 ° C above the melting point
Higher temperature, more preferably 25 ° C to 40 ° C above melting point
Temperature is high. The shape of the orifice is not particularly limited
However, it has a hollow cross section (for example, triangular hollow, round hollow,
Shaped to be hollow, etc.) and / or modified cross section (eg three
Shapes with high secondary cross-section moment such as prismatic, Y-shaped and star-shaped
In addition to the above effects, the molten discharge line is
The formed three-dimensional structure makes it difficult for the flow to relax, and conversely at the contact point
Since it can hold the fluidizing time of for a long time and strengthen the adhesive point,
Preferred. Of the adhesive described in JP-A-1-2075
When heating for heating, the three-dimensional structure easily relaxes
It is preferable because it becomes a planar structure and it becomes difficult to make a three-dimensional structure.
Not good. The effect of improving the properties of the net-like material is apparent bulk.
It is possible to increase the
It can be improved in sex and becomes difficult. The hollow section has a hollow ratio of 8
If it exceeds 0%, the cross section tends to be crushed, so it is preferably light.
10% or more and 70% or less, which can express the effect of quantification, and is more preferable.
It is preferably 20% or more and 60% or less. Orifice hole
The inter-pitched pitch is such that the loop formed by the linear shape can be sufficiently contacted.
It is necessary to make a decision. Pitch between holes for a fine structure
To shorten the length and make the structure denser, increase the pitch between holes.
You. The pitch between the holes of the present invention is preferably 3 mm to 20 mm.
More preferably, it is 5 mm to 10 mm. In the present invention,
The same density and different fineness can be achieved. Pitch between rows or between holes
Configuration with different pitch, and pitch between both rows and holes
The different density layer can be formed by changing the method. Also,
Change the cross-sectional area of the fiss to give a pressure loss difference during discharge
And melted thermoplastic elastic resin from the same nozzle
The discharge amount extruded by pressure causes a large pressure loss.
In the longitudinal section, the orientation
Nozzle having at least a plurality of rows having different cross-sectional areas
To produce a reticulated structure composed of filaments of different fineness.
it can. Then, discharge downward from the nozzle,
While forming a loop, fuse them by contacting each other in a molten state
Sandwiched by a take-up net while forming a three-dimensional structure
Winding wire on the surface of the net
Bend over 45 ° to deform and flatten the surface
At the same time, the contact point with the discharge line that is not bent is bonded
After forming the structure, the cooling medium is continuously supplied (usually water at room temperature).
The cooling rate can be increased by using
The three-dimensional three-dimensional network structure of the present invention
A reticulated body is obtained. The distance between the nozzle surface and the collection point
The discharge line is cooled by making it at least 40 cm or less.
It is preferable to prevent the contact portion from being fused. vomit
If the discharge rate of the filament is 5g / hole or more, 10cm-40
cm is preferable, and the discharge amount of the discharge line is less than 5 g / min.
If not, it is preferably 5 cm to 20 cm. The thickness of the net is molten
Of the take-up net that sandwiches both sides of the three-dimensional structure
It is determined by the opening width (the distance between the take-up nets). In the present invention
For the above reasons, the opening width of the take-up net should be 5 mm or more.
You. Next, it is drained and dried, but a surfactant or the like is added to the cooling medium.
If added, it will be difficult to drain water and dry,
The plastic elastic resin may swell, which is not preferable. still,
The take-off installed on the cooling medium that solidifies the nozzle surface and resin
Distance from the conveyor, melt viscosity of the resin (when forming a mesh
Melt viscosity is preferably 500 poises to 10,000 poises
And the loop forming speed when it exceeds 20000 poise.
Is slowed down, and it becomes difficult to form a dense mesh structure, which is preferable.
Not good. ), Depending on the orifice diameter and discharge amount
The desired loop diameter and wire diameter can be determined. Installed on the cooling medium
Melted state with a pair of take-up conveyors with adjustable spacing
Contacting each other by sandwiching the discharge line of
While melting the parts, it is continuously drawn into the cooling medium and solidified.
When forming a mesh body, adjust the interval of the above conveyor
By adjusting the thickness, the thickness of the fused mesh can be adjusted while it is in the molten state.
Knots are possible and the desired thickness is obtained. Conveyor
A) If the speed is too fast, the formation of contact points becomes insufficient
And cooled until the fusion point is sufficiently formed
May be insufficiently fused. Also, the speed is too slow
If this happens, the melt will stay too much and the density will increase, so the desired
It is necessary to set the conveyor speed suitable for the apparent density.
You. Next, in the present invention, the reticulate body is once cooled and then continuously
, Or discontinuously pseudo-crystallize it to a predetermined size.
Pseudo crystallization is performed by cutting or after cutting. other
However, the polyester fiber of the wadding layer can be obtained by a known method.
In the present invention, a hydrophilic agent and
Polyester coated with polyester on the fiber surface
It is preferable to use fibers, and as a hydrophilizing agent, a polyethylene ether is used.
Fiber made from polyester in which the polyester is kneaded is especially preferred.
Good. Hydrophilizing agent which is a particularly preferred embodiment of the present invention
As the method of kneading,
Kneading an ester resin using an extruder with a kneading function
Method of making and using resin containing and during melt spinning
There is a method of directly mixing and kneading. In the present invention, for example
For example, in the method of directly mixing and kneading during spinning, the extruder
For compression parts and tip metal ring parts of cru
Twin-screw extrusion with kneading function such as dullage and cross saw
Using polyester or single-screw extruder with polyester
10 ° C or higher than the melting point of polyester while quantitatively supplying the amount
Method of melt-kneading at a temperature below 30 ° C, polyester
Melt the resin at a temperature of 20 ° C or more and less than 50 ° C above its melting point.
Melt, and then push the tip metal from the compression section of the extruder.
Between the ring parts, melting at the melting temperature of the polyester
And quantitatively supply polyethylene glycol as a hydrophilizing agent
In the present invention, there is a method (direct melt blending method)
The latter is more desirable. Kneading amount of hydrophilizing agent is 1 weight
% To 10% by weight, for example polyethylene glycol
Number average molecular weight that can maintain melt-mixing viscosity
5,000 or more and less than 50,000 is preferable, 8,000 or more
Less than 20,000 is more preferable. The kneading state is Polyes
Incompatible mixture with tel as the main matrix. Or
Molten polyester resin kneaded with a hydrophilizing agent
Of polyester from the nozzle while measuring with a metering pump
Polyester is spun at a temperature of 10 ° C to less than 50 ° C above the melting point.
Get tell fiber. In the present invention, the fiber cross section is preferably different.
The orifice shape of the nozzle, which can be shaped or hollow
select. More preferably, a nozzle having a modified hollow cross section
Select the orifice shape of. Polyester fiber is unpaired
The latent crimping ability is given by the elephant cooling method or the composite spinning method, and the
Cut or cut by developing a three-dimensional crimp by heat treatment after stretching
It is preferable to obtain a three-dimensional crimp by heat treating after cutting.
Yes. The polyester fiber is also required to have sag resistance and heat resistance.
The initial tensile resistance is at least 35 g / denier.
-Or more, the initial tensile resistance at 70 ℃ is at least
It is preferably 10 g / denier or more. Bulkiness and
The crimp degree of the three-dimensional crimp is 15% or more from the anti-compression property, and the number of crimps is
Is preferably 10 to 25 pieces / inch. Thus obtained
The hydrophilic polyester fiber is the main material of the wadding layer.
Desired blending amount with other polyester fibers as a trick
Open the mixture by mixing. Hydrophilized polyester fiber and other poly
Mixing ratio of ester fiber is 100/0 to 50/50 weight
As a ratio, after pre-opening and mixing with an opener etc., a card etc.
To open the fiber to form an open web with a three-dimensional structure.
When the thickness is changed from 3mm to 10mm, the apparent density is 0.1g
/cm^ThreeBelow, preferably, the apparent density is 0.01 g / cm
^ThreeTo 0.06 g / cm^ThreeWebs laminated to be
As a wadding layer, preferably by a conventional method
Apparent density is 0.01g when the thickness is changed from 3mm to 10mm
/cm^ThreeTo 0.06 g / cm^ThreeTo the web so that
Punch density 5 / cm²More than 30 pieces / cm ²Needle pad
Punched to stabilize the morphology as a wadding layer.
Laminate on the front and / or back of the body, then the entire surface
Covered with knitted fabric, the apparent density is 0.1 g / cm^ThreeLess than
Lower, preferably with an apparent density of 0.01 g / cm^ThreeFrom
0.06g / cm^ThreeInserted while being compressed so that
Then, the mat of the present invention is obtained. The mat of the present invention is
By configuring the side surface so that only knitted fabric is installed,
Cushion that enhances breathability on the side and replaces fresh air
It is preferable because the pump function of the layer can be further enhanced. Lateral land
Is the mat that was previously sewn into the specified shape,
Cover the cushion with a cushioning layer and a wadding layer.
The insertion slot and then press the button as desired.
May be. Button stops start from 2 per mat area
8 / m²It is preferred that Button stopper is thick
It is preferable to do it while holding down to keep 80% or more.
Yes. To process the side ground, cover the corners with another cloth and
You can also sew. The crystallization treatment in the present invention
The reason is that in any process leading to commercialization,
Even if it is lower than the melting point (Tm) by 10 ° C or more,
It is performed at the α dispersion rising temperature (Tαcr) or higher. This place
As a result, it has an endothermic peak below the melting point and is treated by pseudo crystallization.
Heat resistant and resistant than those that do not have heat absorption peaks
Remarkably improved. Preferred pseudo-crystallization treatment of the present invention
The theoretical temperature is from (Tαcr + 10 ° C) to (Tm-20 ° C)
is there. Heat resistance and resistance when pseudo-crystallized by simple heat treatment
Improves easiness. However, 10% or more compression deformation
By applying and annealing, the heat resistance and the sag resistance are remarkable.
It is more preferable because it is improved. In addition, once the mesh is cooled
If the product undergoes a drying process after being rejected, the drying temperature is annealed.
By setting the temperature, it is possible to perform the pseudo crystallization process at the same time.
You. In addition, a pseudo crystallization process is separately performed in the process of commercialization.
Can be.

In the mat of the present invention, only a cushion body can be used by utilizing its function in addition to a bed, a mattress, a seat cushion, a furniture mat and the like. For example, the cushion layer is molded 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 then a wadding layer is laminated and sewn on the side fabric to sew on a vehicle seat or a ship. It can be used for seats, chairs, furniture, etc. 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.

[0018]

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 the value obtained by subtracting the elongation rate obtained by subtracting the elongation rate at which stress develops again from 10% when it is allowed to elongate to fracture again after leaving it for 5 minutes, 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 places, embedded with acrylic resin, the cross section is cut out, and a section is prepared to obtain a cross-section photograph. 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 between the thickness difference before treatment and the thickness before treatment is shown in% (average value of n = 3) 9. Cyclic compressive strain A sample was cut into a size of 15 cm × 15 cm, and a Shimadzu-made servo pulsar was used. At 25 ° C, 65%, RH room, 50%
The compression recovery was repeated at a cycle of 1 Hz to the thickness of 20,000 times, and the sample after 20,000 times was left for one day, and the ratio of the difference between the thickness before the treatment and the thickness before the treatment is shown in%. (Average value of n = 3) 10. Air permeability The air flow rate measured by using a high air pressure type air flow rate measuring device manufactured by Techno World Co., Ltd. ² seconds) is shown as the air permeability. The amount of ventilation that can be discharged from the side ground through the wadding layer to the mesh is 10 cm in diameter for a sample in which one side of the wadding layer is covered with a knitted fabric.
Punched into a cylindrical shape, and put in a 5% compressed state in a metal tube with an inner diameter of 10 cm whose height corresponds to the thickness of the side that can be sealed. A sample was prepared so as not to leak, 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. (designed by Cosmo Instruments) is shown as air permeability. 11. Bendability Extrude the created mat from the horizontal surface with one end suppressed, 4
The length until contacting the sloped surface cut out at 5 ° is shown by the following criteria. Less than 100 cm: ◎, less than 130 cm: ○, 15
Less than 0 cm: △, 150 cm or more: × 12. Drainability After measuring the weight of the prepared mat, immerse it in a water tank after 10 minutes, remove it as much as possible, and drain at 30 ° C RH 65%
After standing for 24 hours in a room with the atmosphere described above, the weight was measured after standing for 24 hours, and the amount of residual water was determined and evaluated according to the following criteria.
Residual water content is 5% or less: ◎, Residual water content is 7% or less: ◯, Residual water content is 10% or less: △, Residual water content is 10% or more: × 13. Comfortable sleep Set the created mat on the bed frame, 28 ° C
The following evaluation was performed with the paneller laid down in a RH 75% room. (N = 5) Sheets were laid on the bed mats, 1.8 / kg down / feather: 90/10 mixed feathers were put in the comforter, and pillows used at home were used. (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: Within 30 minutes; × within 1 hour; △ within 2 hours; ○, over 2 hours; ◎

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. The formulation of the plastic elastic resin raw material is shown in Table-1.

[0021]

[Table 1]

On the effective surface of the nozzle having a width of 120 cm and a length of 10 cm, the pitch between the holes in the width direction is 5 mm and the pitch between 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, polyester fiber was used as an acid component having an intrinsic viscosity of 0.63 and 0.56 in 10 extruders (2, 3・ Hydroxyethoxy) -carbonylpropyl] 9 / 10-dihydro-9-oxa-1
PET, which was copolymerized with 0 phosphaphenalence-10 oxylo so as to have a phosphorus content of 1200 ppm, was supplied, melted at 280 ° C., and PEG melted at 270 ° C. from the compression part was added in an amount of 5% by weight. Each of the polyesters melted and kneaded by a direct melt blending method at 280 ° C. by a plunger pump is distributed in a weight ratio of 50/50 to obtain 3.0 g / min. / Min: 1.5 g / min) spinning temperature 280
At 0 ° C., a composite yarn is spun at a spinning speed of 1300 m / min from a nozzle that is a fiber having a hollow orifice shape and three protrusions, and then drawn at two stages at 70 ° C. and 180 ° C. It is cut into 64 mm and free-heat-treated at 170 ° C to develop a three-dimensional crimp, and in a deformed hollow section with three protrusions, the degree of deformation (circumscribed circle area / section area) is 2.0 and the hollow ratio is 1
6% side-by-side structure fineness 6 denier, initial tensile resistance 35 g / denier, crimp 23%, crimp number 1
Six polyester fibers per inch were obtained. Then, the polyester fiber was pre-opened with an opener and then opened with a card so that the apparent density when the web had a thickness of 8 mm was 0.05 g / cm ^2. Punch density 1
0 present / cm ² D - Dorupanchi a cushion body obtained by stacking the wadding layer which is cut to a predetermined size on the front and back of the net-like body, made of polyester fibers manufactured by Toyobo Heim permeability 30 cc / cm ² sec Insert Broad into the side sewn to the specified size, close the insertion opening, and slightly compress it to 8 pieces /
Buttoning was applied at a density of m ² to obtain a betting mat of the present invention. Table 2 shows the evaluation results of the obtained mat for betting. As is clear from Table 2, the bed mat is excellent in heat resistance, durability, bendability, drainability, breathability, and comfortable to sleep. The mat for bet showed flame retardancy, and the combustion gas toxicity index was 5.0. From this, it can be seen that the mat for betting is highly safe in the event of a fire.

[0023]

[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 has 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, place cooling water 15 cm below the nozzle surface, and put a pair of take-up conveyors on the water surface in parallel with the stainless endless net with a width of 140 cm at intervals of 4.5 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 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 into a predetermined size has a round cross-section, and a linear line having an endothermic peak at 126 ° C is formed in addition to the melting point of the wire diameter 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, using PET having an intrinsic viscosity of 0.63, a single-hole discharge rate of 3.0 g / min was spun at 285 ° C. from a nozzle that forms a hollow cross section with a C-shaped orifice by a conventional method. The three-dimensional crimp obtained in the same manner as in Example 1 except that the latent crimping ability was imparted by the asymmetric cooling method, the hollow section had a hollow ratio of 36%, a fineness of 6 denier, and an initial tensile resistance of 38 g / denier. A polyester fiber having a crimp degree of 25% and a crimp number of 14 / inch was obtained. Using this polyester fiber, the web obtained by pre-opening with an opener and then opening with a card was punched at a density of 10 fibers / cm ² so that the apparent density was 0.05 g / cm ² . A cushion body in which a wadding layer cut by a needle punch and cut to a predetermined size was laminated on the front and back of the reticulated body was used to make a predetermined cushion using a broad cloth made of polyester fiber manufactured by Toyobo Co., Ltd. with a permeability of 30 cc / cm ² seconds. Table 2 shows the evaluation results of the mat for betting obtained by inserting it into the side fabric sewn into a shape. As is clear from Table 2, the bed mat is excellent in heat resistance, durability, bending property, drainability, breathability and comfortable to sleep. In addition,
This mat 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 water surface, and the discharge line in the molten state is bent to form loops to fuse the contact portions and to form a three-dimensional mesh 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 then 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 a heat absorption 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, the polyester fiber obtained in Example 1 and the polyester fiber obtained in Example 2 were mixed with 70
A web of a wadding layer obtained in the same manner as in Example 1 was laminated on the front and back surfaces of the mesh body to be the cushion layer, and the air permeability of the Heim polyester fiber manufactured by Toyobo was 30 cc / Table 2 shows the evaluation results of the betting mat obtained by inserting the mat into the side ground sewn into a predetermined shape using a broad of ² cm. As is clear from Table 2, the bed mat is excellent in heat resistance, durability, bending property, drainability, breathability and comfortable to sleep. The bed gas mat had a combustion gas toxicity index of 5.1.
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.

[0027]

[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%. Then, the cushion body obtained by laminating the needle punched wadding layer used in Example 2 on the cushion layer was formed into a predetermined shape by using a broad cloth having a permeability of 30 cc / cm ² seconds made of Heim polyester fiber manufactured by Toyobo. Table 2 shows the evaluation results of the mat for betting obtained by inserting it into the sewn side fabric. As is clear from Table 2, this bet mat is excellent in heat resistance, durability, bendability, drainability, breathability and sleep comfort.

Comparative Example 1 A reticulate body obtained in the same manner as in Example 2 except that only the single component polypropylene (PP) having a melt index of 12 had a melting temperature of 220 ° C. has a solid round cross section and a wire diameter of 1 .8m
The filaments having no endothermic peak other than the melting points of m and m are joined by fusion bonding at the contact points of the formed loops, the both surfaces are substantially flattened, and the average apparent density is 0.
047 g / cm ² , thickness 4.5 cm, cyclic compressive strain 39.
It was 6% and the heat resistance durability was 49.8%. The polyester fiber obtained in Example 1 was pre-opened with an opener and then opened with a card to give a web having an apparent density of 0.05 g / cm ² at a thickness of 6 mm. A cushion body obtained by nidding punching with a punch density of 10 punches / cm ² and cutting it to a predetermined size is laminated on the front and back surfaces of the cushion layer, and the cushion body is made of TOYOBO HEIM polyester fiber. Table 2 shows the evaluation results of the betting mat obtained by inserting the mat into the side material sewn into a predetermined shape using a broad having an air permeability of 30 cc / cm ² seconds. As is clear from Table 2, since it is a reticulated body made of non-elastic olefin, it is a bed mat which is excellent in drainability, but has good heat resistance, durability, bending property, and breathability, but is inferior in sleeping comfort other than stuffiness, It is a bed mat that also fails flame retardancy and presents problems during a fire.

Comparative Example 2 A nozzle having a width of 120 cm and a length of 10 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 having a circular cross section with an outer diameter of 1 mm. ,
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%. Next, Table 2 shows the evaluation results of the mat for betting obtained in the same manner using the wadding layer obtained in Example 2. As is clear from Table 2, the mat for betting is excellent in drainage and less dampness, but inferior in sleep comfort other than heat resistance, durability, bendability and dampness.
The toxicity index of the combustion gas of this bed mat is 5.
It was one.

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%. 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, although excellent in drainage and less dampness, heat resistance, durability,
It is a mat for betting that is inferior in sleeping comfort other than bendability and dampness. The bed gas mat had a combustion gas toxicity index of 5.1.

Comparative Example 4 A discharge rate per single hole was 0.3 g / min, a take-up conveyor net was placed 5 cm below the nozzle surface, and a 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 /
And the take-up conveyor net was placed under the nozzle surface 60 cm and the take-up speed was 1 m / min. The net-like body obtained in the same manner as in Comparative Example 2 had a round cross-section and a wire diameter of 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. The surface of the side surface of this mat became uneven and became unattractive. As is clear from Table 2, it is excellent in terms of bendability, drainability, stuffiness, and pressure but it is slightly inferior in heat resistance and durability. It's Matt. The combustion gas toxicity index of this bed mat was 5.1.

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 was used as the orifice shape. 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 bendability and drainability, but inferior in heat resistance and durability, and the cushion layer is too thin, resulting in remarkably inferior sleeping comfort.

Comparative Example 8 Obtained in the same manner as in Example 2 except that the pseudo crystallization treatment was not performed.
The characteristic of the mesh is that the cross section is round and the wire diameter is 0.9mm.
In addition to the melting point of, the filaments that have no endothermic peak at 126 ° C
The contact points of the forming loops are almost joined by fusion.
And both sides are substantially flattened, with an average apparent density
Is 0.048 g / cm², Thickness 4.5 cm, cyclic compression strain
The heat resistance and durability were 16.5% and 26.4%, respectively. Separately,
The polyester fiber used in Example 2 was prepared with an opener.
Apparently dense web obtained by opening with a card after opening.
Degree 0.12g / cm²Punch density 10 /
cm ²Wadded with a needle punch and cut into a specified size.
Comparative Example 2 by laminating a cushioning layer on the front and back sides of the cushion layer.
Of the mat for betting obtained by inserting it into the side ground obtained in the same manner as
Table 2 shows the evaluation results. As is clear from Table 2,
Since the density of the wing layer is too high, breathability and bendability are poor.
It was a bed mat which was bad and inferior in sleeping comfort.

Comparative Example 9 The scoured Indian cotton and the polyester fiber used in Example 2 were mixed at a weight ratio of 70/30, pre-opened with an opener and then opened with a card. as apparent density web is 0.05 g / cm ² punch density of ten / cm ²
Beds obtained by laminating the cushioning layers obtained in Comparative Example 8 on the front and back of the cushioning layer obtained by Comparative Example 8 by needle punching with Table 2 shows the evaluation results of the mat. As is clear from Table 2, the mat for a bed had good sleeping comfort, but was poor in drainability because the wadding layer contained other than polyester fibers. The mat of Example 1 and the mat of Comparative Example 9 were coarsely crushed, dried, and re-fiberized. The mat of Example 1 was able to form fibers, but the mat of Comparative Example 9 was spun. The yarn was severely broken and could not be formed into fibers. From this, it can be seen that it is difficult to directly product-recycle mats containing materials other than polyester.

Comparative Example 10 The mesh used in Comparative Example 8 was obtained by inserting it into a side fabric sewn into a predetermined shape using a broad cloth made of TOYOBO HEIM polyester fiber with an air permeability of 30 cc / cm ² seconds. Table 2 shows the evaluation results of the mats for betting. As is clear from Table 2, the mat for betting had good bendability and sleeping comfort, but poor heat resistance and durability.

Comparative Example 11 A 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 to form a wadding layer, and the reticulated body obtained in Comparative Example 8 was obtained. Table 2 shows the evaluation results of the mat for betting obtained by laminating on the same as in Comparative Example 8. As is clear from Table 2, the mat for bed is slightly comfortable to sleep but inferior in heat resistance, durability, bendability and drainability.

Comparative Example 12 Rice cotton was laminated as a card web and the apparent density was 0.
Table 2 shows the evaluation results of the betting mats obtained by inserting cotton wool having a thickness of 05 g / cm ³ and a thickness of 10 cm into the side fabric made of polyester fibers sewn to a predetermined size. As is clear from Table 2, the mat for bed is slightly comfortable to sleep but inferior in heat resistance, durability, bendability and drainability.

Comparative Example 13 A bed obtained by using a commercially available polyester hard cotton having a thickness of 10 cm and an apparent density of 0.05 g / cm ³ as a cushioning 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 is a bed mat which is slightly comfortable but has little sinking and is inferior in heat resistance, durability, bendability and drainability.

Comparative Example 14 Table 2 shows the evaluation results of a betting mat obtained in the same manner as in Comparative Example 2 using a commercially available foamed polyurethane having a thickness of 10 cm and an apparent density of 0.05 g / cm ³ as a cushioning material. As is clear from Table 2, this bed mat has excellent heat resistance and durability, but has good bendability, drainability, and breathability, but is inferior in sleeping comfort.

Example 5 The mattress obtained in the same manner as in Example 1 except that the thickness of the reticulate body obtained in Example 2 was changed showed the heat resistance, durability, and
It was a mattress with excellent foldability, drainability, and sleeping comfort.

Example 6 The results of the evaluation of the saccus obtained in the same manner as in Example 1 except that the thickness of the reticulate body obtained in Example 2 was changed were excellent in heat resistance, durability, drainability, and sitting comfort. It was a zakkadan.

[0045]

EFFECT OF THE INVENTION A mat in which a wadding layer made of a polyester fiber web is laminated on a cushion layer made of a net-like body in which filaments made of a thermoplastic elastic resin having a good elongation recovery property are fused and integrated to have a flat surface, and a method for producing the mat. Therefore, it does not get damp easily and has good sleeping comfort, and it has excellent heat resistance and durability, shape retention and cushioning properties, and also has good bending properties. It is possible and easy to recycle, and it is possible to provide an optimal mat for a household, a hospital, a hotel, etc., a bed, a cushion, and a mat, and a manufacturing method.

Claims (12)

[Claims] 1. A mat in which a wadding layer is laminated on at least the upper surface of a cushion layer, and the entire surface is covered with side cloth and sewn, and the cushion layer is made of a thermoplastic elastic resin and has a continuous wire diameter of 5 mm or less. The three-dimensional three-dimensional network is formed by winding the formed filaments into a random loop, and most of the contact portions of the respective loops are fused, 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 is 5 mm or more, and the wadding layer is
It consists of a web of polyester fibers and has an apparent density of 0.
A mat characterized in that it is 1 g / cm ³ or less. 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, which has a recovery rate (70 ° C extension recovery rate) of 30% or more. 3. The net-like 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 and 100 mm or less. The listed mat. 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 80 mm or less. 5. A reticulated body having an endothermic peak at a temperature above room temperature and below the melting point in a melting curve of a component comprising a thermoplastic elastic resin measured by a differential scanning calorimeter in the cushion layer. mat. 6. The cross-sectional shape of the filaments of the net-like body that constitutes the cushion layer is a hollow cross section or an irregular cross section.
The listed mat. 7. The wadding layer is needle punched and has a thickness of 3 mm or more and 15 mm or less and an apparent density of 0.01.
g / cm ³ or more 0.06 g / cm ³ or less mat of claim 1, wherein. 8. The mat according to claim 1, wherein the thermoplastic elastic resin is polyester. 9. The mat according to claim 1, wherein the composition of the wadding layer is a web mainly composed of a polyester fiber containing 0.05% by weight or more of a polyethylene glycol component on the fiber surface. 10. A thermoplastic elastic resin is discharged downward from a multi-row nozzle having a plurality of orifices at a melting temperature 20 to 80 ° C. higher than its melting point to form a continuous linear loop in a molten state. After being formed, the respective loops were brought into contact with each other and fused to form a three-dimensional structure, which was sandwiched by a take-up device and cooled in a cooling tank.
A method for producing a mat in which webs of polyester fibers are laminated on the upper and lower surfaces or one surface of a three-dimensional structure and the entire surface is covered with a side material. 11. The method for producing a mat according to claim 10, 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. . 12. A web using a polyester fiber as a main matrix, which is formed by mixing polyethylene glycol in an amount of 1% by weight or more and 10% by weight.
How to make the described mat.