JPS5831152A - Cushion material using polyester fiber nep yarn - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a cushioning material made of polyester fiber nep yarn.

Cushion materials currently used in the furniture and bed fields are mostly urethane foam.

However, urethane foam has to be manufactured with a hard grain because it undergoes large changes over time due to heat aging (TL).
As a result, there are disadvantages such as the feeling that the price is low immediately after production and the feeling that the product has bottomed out and is disliked.

An object of the present invention is to eliminate these drawbacks and provide a cushioning material made of polyester fiber nep yarn that is durable and exhibits excellent performance.

The present invention has a fineness of 1 to 20 denier and a fiber length of 30 to 100.
NEP of high melting point polyester stable of 1.5 mm and opened polyester stable having a melting point 50°C or more lower than the polyester stable in a ratio of 95:5 to 70:3.
A cushioning material made of polyester fiber neps having a density of 0°005 to 0.159/c, 4, containing a weight BtJt of 0 and the neps are three-dimensionally and continuously joined to each other by a molten mass of low melting point polyester staples. It becomes more.

The photograph in the accompanying drawing is an enlarged photograph of the cushioning material of the present invention, which is made of 80% nap of high melting point polyester staple with a fineness of 3d and a length of 51 mm, and 20% of a low melting point polyester staple with a fineness of 6ci and a length of 51 mm. As seen in this photo, NEP is J to the molten mass of low melting point staple.
: are fixed to each other, and it can be seen that the neps are connected three-dimensionally and continuously. Since the inside of the nep retains its own elasticity, it is fully utilized for the cushioning benefit obtained.

The cushioning performance of the present invention does not change over time due to moist heat aging, and by changing the mixing ratio of high melting point polyester nap and low melting point polyester staple, cushions ranging from soft to hard can be manufactured according to preference. be able to. Further, by partially changing the mixing ratio, it is possible to produce a cushioning material that has a soft surface and a hard interior.

The method for manufacturing the cushioning material of the present invention will be described. First, high melting point polyester stable neps and opened low melting point polyester stable are mixed at a predetermined ratio. NEP refers to a group of tangled fibers, or a pill, and can be formed by adding moisture to polyester fibers during carding or by changing the carding operation.

Generally, such a nep is used for spinning-1:T! , 'i. Therefore, if the neps produced in each spinning process are used in the present invention, it is possible to manufacture inexpensive cushions 4i.

Examples of high-melting point polyester fibers include ordinary polyethylene terephthalate, polyhethylene terephthalate, polytetramethylene terephthalate, poly 1,4-dimethylcyclohexane terephthalate-1, polyhivalolactone, or copolymer esters or conjugates thereof. Examples include composite fibers produced by spinning. The cross-sectional shape of the high melting point polyester fiber may be circular, irregular or hollow. On the other hand, low melting point polyester fibers are made of fatty acid dicarboxylic acids such as adipic acid and sepatic acid, aromatic dicarboxylic acids such as phthalic acid, isophthalic acid, and naphthalene dicarboxylic acid, and/or hegizahydroterephthalic acid and hegizahydroisophthalic acid. Contains a predetermined number of alicyclic dicarboxylic acids (and aliphatic or alicyclic diols such as diethyl-3-glycol, polyethylene glycol, propylene glycol, and para-gysilylene glycol, and optionally contains para-hydroxybenzoic acid). It is a copolymerized ester to which oxyacids such as acids are added. For example, a polyester obtained by copolymerizing isophthalic acid and 1,6-hexanediol with terephthalic acid and ethylene glycol is used. High melting point and low melting point polyester fibers The length may be between 30 and 100, which is the usual staple length, and the fineness may be between 1 and 20 deniers.

The mixing ratio of the high melting point polyester fiber, T NEP, and the low melting point polyester fiber is 95:5 to 70:30, and if the mixing ratio of the NEP and low melting point polyester fiber is changed appropriately within this range, the comparison terms and conditions will be You can obtain everything from wood to slightly harder cushioning materials. In this case, if the NEP mixing ratio exceeds 95%, the cushioning properties tend to decrease because the heat fusion between the NEP fibers of the manufactured mat is insufficient, while on the other hand, if the NEP mixing ratio exceeds 70%. If it is less than the Mats made with too many ingredients are hard and have a poor feel.

The obtained NEP mixture is filled to a predetermined thickness and then heated. At 1 o'clock of this charging, the density of the NEP mixture is 0.0.
05~(1,], 59/cyl, preferably 0
．． (11 to 0.10 f;' /c7I. When filled to such a density, the rebound resilience of the manufactured mat becomes a value suitable for use as a cushioning material.Next, the heating temperature of the filling mixture should be set to NEP The temperature is between the melting point of the high melting point polyester fiber and the melting point of the low melting point polyester fiber.In this case, preferably the melting point of the high melting point polyester fiber is 200°C or higher, and the melting point of the low melting point polyester fiber is is 50°C lower than that of the high-melting point polyester fiber used at the same time, so the heating temperature must be determined according to the melting points of both polyester fibers.Heating methods include hot water, steam, and high-pressure steam. For example, the NEP mixture filled in a mold is preferably formed into a mat using high-pressure steam. In this case, a dry heat means such as hot air may be used as the heating means.

By this heating, the high melting point polyester fibers are melted and the naps of the high melting point polyester fibers are thermally fused.

The cushioning material of the present invention is stronger than urethane foam, so it has the advantage that even if it is used alone as a pinerest, it does not feel bottomed out and is comfortable to sleep on. This mat also has excellent durability due to little change over time due to moist heat aging, and there is no need to manufacture it with a hard grain like urethane foam.

As a result, a soft cushion material or a hard cushion material can be manufactured according to preference.

The cushioning material of the present invention may be used as a cushioning material for bed mattresses, furniture seats, etc., and may also be used as a carpet underlay material.

Next, the present invention will be explained with reference to Examples and Comparative Examples.

Example 1 Fineness 10 denier tefa as high melting point polyester fiber
A polyethylene terephthalate stable (melting point 257° C.) with a length of 51 mm is used, and it is made into straight chips m diameter 3 to 5 ρ neps by adding water and changing the operation of a roller card. On the other hand, as the low melting point polyester fiber, a copolymer ester stable (melting point 110° C.) of terephthalic acid and isophthalic acid with a copolymerization ratio of 60:40 and a fiber size of 6 denier and 1351 mm is used.

The high melting point polyester fiber NEP and the low melting point polyester fiber are mixed at a ratio of 95:5.

The above NEP mixture was packed into a stainless steel box (length: 100 Qm x width: 50 cm x height: 50 cm) with punched holes for good heat conduction so that the density was 0.06 p/d. After covering with a lid, place in a double high-pressure can. After emptying the inside of this can, the temperature is 130°C.
Matt molding is performed using high-pressure steam for 10 minutes. As a result, a mat is obtained in which the low melting point polyester fibers are melted and fused to the contact areas of the high melting point polyester fibers. When this mat is sliced into 10 cm thick pieces, the mat has good cushioning properties (7-) and is suitable as a relatively soft cushioning material.

Example 2 A mat is produced in the same manner as in Example 1, except that the mixing ratio of the high melting point polyester fiber NEP and the low melting point polyester fiber is 80,720. The obtained mat exhibits excellent cushioning properties as a cushioning material for furniture.

Example 3 A mat is produced in the same manner as in Example 1 except that the mixing ratio is 70:30. The obtained mat has good cushioning properties and is suitable as a slightly hard cushioning material.

Comparative Example 1 A mat is produced in the same manner as in Example 1 except that the mixing ratio is 96:4. Since the obtained mat has insufficient fusion between each nep, repeated compression causes peeling between the nep and reduces cushioning properties.

Jt Comparative Example 2 8- A mat is produced in the same manner as in Example 1 except that the mixing ratio is 65:35. The obtained mat contains too much of the fused component and is hard and has a poor feel, and the cushioning properties of the fiber naps are not sufficiently expressed, making it unsuitable as a cushioning material.

[Brief explanation of drawings]

The drawing is a photograph showing an enlarged view of the cushioning material of the present invention. Patent applicant: Kanebo Co., Ltd. Kanebo Gosen Co., Ltd.

Claims (1)

[Claims] Contains a high melting point polyester stable nep with a fineness of 1 to 20 denier and a fiber length of 30 to 100 mm, and an opened polyester staple with a melting point lower than that of the polyester staple by 95:5 to 70:30 in a weight ratio of 95:5 to 70:30. A cushioning material made of polyester fiber naps having a density of 0005 to 0°15 y/m, the naps being three-dimensionally and continuously joined to each other by a molten mass of low-melting point polyester staples.