KR101282296B1 - Elastic cushion and method of fabricating the same - Google Patents

Abstract

The present invention relates to an elastic cushioning agent and a method for manufacturing the same, specifically, the content of the hollow polyester fiber having a hollow ratio of 20 to 60% is A, a polyester polymer having an intrinsic viscosity of 0.63 to 1.30 and an intrinsic viscosity of 0.45 to 0.56. A: B: C = 10-70: 20- When the content of the stretch fiber including the composite fiber which consists of polyester polymers is B, and the heat-sealing binder polyester fiber which has melting | fusing point 110-180 degreeC is C, Upper outer layer comprising a nonwoven fabric comprised of 80: 5-20 (wt%); A: B: C = 20-80: 10-70: upper intermediate layer comprising a nonwoven fabric comprised of 5-20 (wt%); A : B: innermost layer containing the nonwoven fabric which consists of C = 25-55: 25-55: 10-40 (weight%); And A: B: lower outer layer comprising a nonwoven fabric consisting of C = 10 to 70:20 to 80: 5 to 20 (wt%); laminated to a light, soft touch and exhibiting excellent elasticity and durability. It relates to an environment-friendly elastic cushioning agent and a manufacturing method thereof.

Description

Elastic cushioning agent and its manufacturing method {ELASTIC CUSHION AND METHOD OF FABRICATING THE SAME}

The present invention relates to an environmentally friendly elastic cushion and a method for producing the same.

Generally, polyurethane foam (commonly referred to as "sponge ") is the most widely used material for cushioning materials used in daily life, and is widely used because of its lightness, elasticity and cost. However, the polyurethane foam foamed with the polyurethane resin spontaneously has a peculiar smell, yellowing occurs with time, deterioration of elasticity due to corrosion of the foamed cell itself, generation of dust, and difficulty in recycling there was.

Therefore, although much attention has been paid to the material to replace the polyurethane foam, a material showing a satisfactory effect has not been presented yet.

Korean Patent Laid-Open Publication No. 1990-8073 discloses a fiber-forming polymer having a melting point of 100 ° C to 220 ° C and having at least one hollow continuous with the fiber axis, wherein the hollow fiber has a hollow ratio of 5-80% A thermally adhesive fiber having a single fiber fineness of 0.5-30 denier and having a number of crimps of 3 to 40 fibers per inch and a fiber length of 10 to 150 mm has been proposed. However, the fiber is insufficient in elasticity, .

In addition, Korean Patent Invention No. 908340 discloses 10 to 70% by weight of polyester conjugate fiber, 10 to 70% by weight of polyester conjugate fiber surface-treated with oil containing silicon, It is composed of 10 to 70% by weight of low melting point heat-sealing binder fiber and 10 to 70% by weight of the sheath type composite fusion fiber made of polyester or polystyrene, and each web is mixed and carded to laminate a web in a single layer or multiple layers. Next, the laminated web is bonded by needle punching using a needle with a barb to form a sheet, and the sheet is passed through a dry box and a heating roller to be fusion bonded. Although a highly elastic nonwoven fabric has been proposed, it is produced by mixing webs by mixing two kinds of conjugate fibers and heat-sealed binder fibers to produce a nonwoven fabric. Greater possibility degrees repeat durability of the elastic structure is dropped during use to be elastic and resilient recovery degraded away, the touch feeling of greater concern is different from the polyurethane foam surface.

Korean Patent Laid-Open Publication No. 2008-80144 discloses a molded product obtained by thermoforming a fiber spherical body in a mold, wherein the fiber spherical body has a melting point lower than the melting point of the non-elastic polyester and the inelastic polyester by 40 占 폚 or more , Wherein the inelastic polyester is exposed so as to occupy 25 to 49% of the surface of the composite staple fiber, and (b) a staple fiber comprising a polytrimethylene terephthalate staple fiber and an elastic thermoplastic elastomer And a part of its fiber inter-woven points is thermally adhered at a flexible open / close place. However, since a special equipment for forming a spherical body is required, an increase in manufacturing cost is incurred do.

In addition, when the nonwoven fabric is simply laminated with a conventional short-fiber fiber, and heat-treated, and taken out of the mold, the surface touch of the nonwoven fabric has a hard disadvantage.

In addition, Korean Patent No. 896214 discloses a process for producing a multi-layer nonwoven fabric comprising a single-spun nonwoven fabric and a long-spun nonwoven fabric; Attaching the multi-layer nonwoven fabric composed of the single-fiber nonwoven fabric and the long-fiber nonwoven fabric to the adhered portion of the upper body, attaching the single-fiber nonwoven fabric to the adhesive portion and positioning the long-fiber nonwoven fabric downward; Supplying a foamed liquid to a lower body that is downwardly separated from the upper body; And the foaming liquid supplied to the lower body is foamed to produce a sheet foam pad, wherein the foaming liquid is not impregnated with the multi-layer nonwoven fabric due to the long fibrous nonwoven fabric when foaming the foaming liquid. However, the long fiber nonwoven fabric constituting the multi-layer nonwoven fabric should have a smaller fiber diameter and a smaller unit weight (weight per unit area) than the short fiber nonwoven fabric.

Therefore, the existing equipment can be used as much as possible to improve the applicability and economy as cushioning materials such as car seat cover pads, vehicle interior linings, bedding mattresses, cushion pads, bra wicks, ski clothes or winter wear padding materials. It is required to develop a material that can be manufactured by using, and has a high rebound elasticity and durability while showing a light touch and a soft unit weight.

In order to solve the above problems, an object of the present invention is to provide a lightweight, soft and resilient elasticity, form stability and durability, environmentally friendly elastic cushioning agent and its manufacturing method.

In order to achieve the above object, the present invention provides a composite of a polyester fiber having a content of hollow polyester fiber having a hollow ratio of 20 to 60% A, an intrinsic viscosity of 0.63 to 1.30, and a polyester polymer having an intrinsic viscosity of 0.45 to 0.56. A: B: C = 10-70: 20-80: 5-20 (weight) when the content of the stretch fiber containing the fiber is B, and the heat-sealing binder polyester fiber having a melting point of 110-180 ° C is C. An upper outermost layer comprising a nonwoven made of%); A: B: C = 20-80: 10-70: 5-10 (weight%) upper intermediate layer containing a nonwoven fabric; A: B: C = 25-55: 25-55: 10-40 (weight%) innermost layer containing the nonwoven fabric; And A: B: C = 10 ~ 70: 20 ~ 80: 5 ~ 20 (wt%) The lower outermost layer comprising a non-woven fabric; provides an elastic cushioning laminated.

In addition, the present invention is characterized in that the composite fiber is selected from the group consisting of side-by-side type, sheath-core type, eccentric sheath-core type.

In addition, the present invention satisfies all of the following formula.

1) Upper outer layer or lower outer layer is B> A> C

2) The upper middle layer is A> B> C

3) C of upper outermost layer or lower outermost layer <C of innermost layer

4) C in the upper middle layer C

In addition, the present invention is the elastic cushioning agent is a lower middle layer comprising a nonwoven fabric consisting of A: B: C = 20 ~ 80: 10 ~ 70: 5 ~ 20 (% by weight) between the innermost layer and the lower outermost layer; An elastic cushioning agent is provided.

Moreover, this invention satisfy | fills all the following formulas of the said elastic cushioning agent.

1) Each layer of the uppermost outermost layer or the bottom outermost layer is B> A> C

2) The upper middle layer is A> B> C

3) C of each layer of the uppermost outermost layer or lower outermost layer C

4) C in the upper middle layer C

5) The lower middle layer is A> B> C

6) C in the lower middle layer C

In addition, the present invention includes that the heat-sealing binder polyester fiber is a hollow heat-sealing binder polyester fiber.

In addition, the present invention is the hollow polyester fiber is strength 2 ~ 5g / d, elongation 30 ~ 60%, compression rate 10 ~ 50%, compression recovery rate 80 ~ 100%, the polyester stretch fiber is 2 ~ 5g strength / d, elongation 40 ~ 80%, crimp number 10 ~ 17, crimping degree 14 ~ 20, shrinkage 2 ~ 10%, fiber length 20 ~ 90mm, the heat-sealed polyester fiber has a strength of 2 ~ 5g / d, Elongation 20 to 60%, crimp number 5 to 15, crimping degree 10 to 20, shrinkage of 2 to 8%, characterized in that each of the preferred strength is 3 to 4g / d.

In addition, the present invention is characterized in that the hollow polyester fiber is 4 to 15 denier in thickness, the polyester stretch fiber is 2 to 9 denier, the heat-sealed binder polyester fiber is 2 to 10 denier do.

In addition, the present invention is a nonwoven fabric included in each layer of the upper outermost layer, the upper middle layer, the innermost layer, the lower middle layer or the lower outermost layer is 5 ~ 50mm thick, each layer has a non-woven fabric having the thickness is elastic The total thickness of the cushioning agent is characterized in that 100 ~ 200mm.

Further, in the present invention, the middle layer of each of the upper middle layer, the lower middle layer is composed of more layers than the outermost layer of each of the upper outermost layer or the lower outermost layer and consists of more layers than the innermost layer, so that each of the upper middle layer or the lower middle layer The thickness of the cushion is thicker than the thickness of each of the upper outermost layer or the lower outer layer and thicker than the thickness of the innermost layer, so that the weight of the cushioning agent is lighter and excellent elasticity is exhibited.

In addition, the present invention comprises a composite fiber consisting of a polyester polymer having a content of hollow polyester fibers having a hollow ratio of 20 to 60% A, an intrinsic viscosity of 0.63 to 1.30, and a polyester polymer having an intrinsic viscosity of 0.45 to 0.56. When the content of the stretch fiber is B, and the heat-sealing binder polyester fiber having a melting point of 110 to 180 ° C is C, the upper outermost layer is A: B: C = 10 to 70:20 to 80: 5 to 20 (weight %), Upper middle layer A: B: C = 20 ~ 80: 10 ~ 70: 5 ~ 20 (wt%), innermost layer A: B: C = 25 ~ 55: 25 ~ 55: 10-40 (weight %), The lower outermost layer A: B: C = 10 ~ 70: 20 ~ 80: 5 ~ 20 (wt%) by mixing the fibers configured in each layer to form a fiber mixture; A non-woven fabric manufacturing step of producing a respective non-woven fabric by subjecting the fiber mixture contained in each layer to carding and heat treatment; It provides a manufacturing method of the elastic cushion comprising a; non-woven fabric, the upper outer layer, the upper middle layer, the innermost layer, the lower outermost layer laminated in the order of forming the mold heat treatment.

The present invention also provides a method for producing an elastic cushioning agent, wherein the composite fiber is a fiber selected from the group consisting of side-by-side type, sheath-core type, and eccentric sheath-core type.

In addition, the present invention is configured to further include a lower intermediate layer A: B: C = 20 ~ 80: 10 ~ 70: 5 ~ 20 (% by weight) between the innermost layer and the lower outermost layer in the fiber mixing step, It provides a method of manufacturing an elastic cushioning agent to be laminated so that the lower middle layer is further included between the innermost layer and the lower outermost layer in the lamination step.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. First, it should be noted that, in the drawings, the same components or parts have the same reference numerals as much as possible. In describing the present invention, detailed descriptions of related well-known functions or configurations are omitted in order not to obscure the subject matter of the present invention.

The terms "about "," substantially ", etc. used to the extent that they are used herein are intended to be taken to mean an approximation of, or approximation to, the numerical values of manufacturing and material tolerances inherent in the meanings mentioned, Accurate or absolute numbers are used to help prevent unauthorized exploitation by unauthorized intruders of the referenced disclosure.

1 is a cross-sectional view of an elastic cushioning agent according to an embodiment of the present invention. Referring to Figure 1, the elastic cushioning agent of the present invention has a hollow polyester fiber, polyester-based stretch fiber, heat-sealing binder polyester-based fibers different content (a) the elastic cushion 110 is the upper outermost layer 11, the upper middle layer 31, the innermost layer 50, the lower outermost layer 13 (b) the elastic cushion 130 is laminated so that the lower middle layer 33 is further included between the innermost layer 50 and the lower outermost layer 13 (upper outer layer 11, Upper middle layer 31, innermost layer 50, lower middle layer 33, lower outer layer 13), the upper outer layer or lower outer layer provides soft touch and elasticity, the upper middle layer or lower middle layer provides cushioning and light weight, and the inner layer provides morphological stability. do.

The elastic cushioning agent of the present invention is a composite fiber made of a hollow polyester fiber 5 to 80% by weight of 20% to 60% of a hollow ratio, a polyester polymer having an intrinsic viscosity of 0.63 to 1.30 and a polyester polymer having an intrinsic viscosity of 0.45 to 0.56. Nonwoven fabric comprising 5 to 80% by weight of stretch fibers and 5 to 80% by weight of a heat-sealing binder polyester fiber having a melting point of 110 to 180 ° C., the upper outermost layer 11, the upper middle layer 31, the innermost layer 50, and the lower outer layer 13 The laminated nonwoven fabric of each layer may be configured differently according to the mixing ratio or content of the hollow polyester fiber, the binder polyester fiber and the stretch fiber so that the characteristics of each fiber are highlighted. In addition, the elastic cushioning agent of the present invention may further increase the resilience of the cushioning agent by further including a lower intermediate layer 33 between the innermost layer 50 and the lower outermost layer 13.

In the present invention, the fibers included in each layer are all composed of polyester-based fibers, and low-melting-point heat-sealed binder fibers included in the nonwoven fabric are used without the use of an adhesive containing a separate organic solvent in the adhesion between the fiber and the nonwoven fabric. As it is heat-bonded, polyurethane that exhibits the unique smell of polyurethane foam used in the past, yellowing phenomenon occurs over time, elasticity is degraded due to corrosion of the foam cell itself, and dust is generated, and it is difficult to recycle. Not only does it solve the disadvantages of urethane foams, it also provides an environmentally friendly elastic cushioning agent having similar or superior elasticity, form stability and chemical stability as compared to polyurethane foams.

First, the hollow polyester fiber having a hollow ratio of 20 to 60% is possible to manufacture a product that is lighter than a product that does not include hollow fiber due to the hollow in the fiber, and plays a role of exerting high elasticity. It is manufactured by spinning using two to six leaf hollow nests and mainly using three leaf hollow nests. The hollow ratio can be calculated according to the following equation.

Hollow rate (%) = cross section of hollow part / shear area of fiber (including hollow section) 단면 100

The hollow polyester fiber of the present invention has a hollow ratio of 20 to 60%, preferably 30 to 40%. If the porosity is less than 20%, the size of the fiber cross-section is large, the elasticity is low, there is a fear that the cushioning properties are not exhibited high. There is a problem. The hollow polyester fiber of the present invention is suitable for exhibiting elasticity while maintaining the strength required to have a strength of 2 to 5 g / d, an elongation of 30 to 60%, a compression rate of 10 to 50%, and a compression recovery rate of 80 to 100%.

In addition, stretch fibers including a composite fiber made of a polyester polymer having an intrinsic viscosity of 0.63 to 1.30 and a polyester polymer having an intrinsic viscosity of 0.45 to 0.56 serve to exhibit elastic modulus and compression recovery, and the composite fiber has a form It may be a side-by-side type, sheath-core type, eccentric sheath-core type. Preferably, the side by side type stretch fiber composed of polytrimethylene terephthalate (PTT) having an intrinsic viscosity of 0.90 to 1.30 and polyethylene terephthalate (PET) having an intrinsic viscosity of 0.45 to 0.56 may exhibit high elasticity. The composite fiber form having the viscosity of the two forms may be excellent in elasticity because the different properties of the polymer having each of the viscosity appears according to the difference in viscosity. If it is out of the above range, the stability in the spin pack is lowered, so that the bonding strength between the polymer is bad or the spinning workability is poor due to the bending of the polymer due to the melt viscosity difference during spinning, so that the viscosity range of each polymer constituting the fiber to be maintained It is important to maintain compatibility with each other. The stretch fiber of the present invention exhibits excellent elasticity of 2 to 5 g / d, 40 to 80% elongation, 10 to 15 crimps, 14 to 20 crimps, 2 to 10% shrinkage, and 20 to 90 mm long fiber. good.

In addition, the heat-sealing binder polyester fiber having a melting point of 110 ~ 180 ℃ to maintain the shape stability by bonding between fibers at low temperatures, similar to the heat treatment at a low temperature than conventional polyester of about 250 ℃ It has physical properties and can be subjected to low temperature heat treatment, thereby reducing the heat treatment cost for fusion. If the melting point is less than 110 ℃, there is a fear that the heat resistance during the manufacturing of the product is lowered, if it exceeds 180 ℃ there is no effect of reducing the heat treatment cost. On the other hand, the present invention may be used as the heat-sealing binder polyester fiber, a hollow heat-sealing binder polyester fiber, the hollow fiber having a melting rate of 110 ~ 180 ℃ and 5 to 50% Compared with the existing heat-adhesive fiber, the additional effect contributes to the weight reduction due to the hollow effect inside the yarn even after heat sealing. Heat-sealed polyester fiber of the present invention has a strength of 2 ~ 5g / d, 20 ~ 60% elongation, 5 ~ 15 crimps, 10 ~ 20 crimping, 2 ~ 8% shrinkage to maintain morphological stability when manufacturing the product It is good to show light weight, soft touch.

Further, the present invention is characterized in that the hollow polyester fiber has a thickness of 4 to 15 Denier, the polyester-based stretch fibers are 2 to 9 denier, and the heat-sealing binder polyester fibers are 2 to 10 denier is good elasticity and strength of the final product, showing a soft touch, comprising the nonwoven fabric of the present invention If the thickness of the fiber is less than the above range, respectively, the strength and elongation of the fiber is low, and if it exceeds the above range, the weight is too large and the surface touch may be rough when the final product is manufactured.

The present invention is a stretch fiber comprising a composite fiber made of a polyester polyester polymer having an intrinsic viscosity of 0.63 to 1.30, and a polyester polymer having an intrinsic viscosity of 0.45 to 0.56 with a content of hollow polyester fiber having a hollow ratio of 20 to 60%. When the content of B, and the heat-sealing binder polyester fiber having a melting point of 110 ~ 180 ℃ C as

An upper outermost layer 11 composed of A: B: C = 10 to 70: 20 to 80: 5 to 20 (wt%);

An upper intermediate layer 31 composed of A: B: C = 20 to 80: 10 to 70: 5 to 20 (wt%);

An innermost layer 50 composed of A: B: C = 25 to 55: 25 to 55: 10 to 40 (wt%);

A lower outermost layer 13 composed of A: B: C = 10 to 70: 20 to 80: 5 to 20 (% by weight);

The elastic cushioning agent 100 laminated | stacked in this is suitable for exhibiting the elasticity, strength, and durability of an elastic cushioning agent. If it is out of the above range, the elasticity of each layer is not harmonized, there is a fear that only the characteristics of any one of the fibers may be highlighted, so the elasticity, strength is not supported, it can not be applied as a cushioning agent.

In addition, the present invention further comprises a lower intermediate layer 33 consisting of A: B: C = 20 to 80:10 to 70: 5 to 20 (wt%) between the innermost layer 50 and the lower outermost layer 13; The elasticity can be further increased.

In the present invention, the upper outermost layer, the lower outermost layer, and the upper middle layer or the lower middle layer each include a higher content of the hollow polyester fiber and the stretch fiber than the heat-sealing binder polyester fiber compared to the innermost layer to increase elasticity. The innermost layer is stably attached to the substrate to be applied because the content of the heat-sealed binder polyester fiber is high, thereby increasing the shape stability.

More preferably, the elastic cushioning agent of the present invention is characterized by satisfying all of the following formulas.

1) The upper outermost layer 11 or the lower outermost layer 13 has B> A> C

2) The upper middle layer 31 is A> B> C

3) C of the uppermost outermost layer 11 or the lowermost outermost layer 13 C of the innermost layer 50

4) C of the upper intermediate layer 31 C

In addition, when the lower middle layer is further included in the elastic cushioning agent of the present invention, all of the following formulas are satisfied.

1) Each layer of the uppermost outermost layer or the bottom outermost layer is B> A> C

2) The upper middle layer is A> B> C

3) C of each layer of the uppermost outermost layer or lower outermost layer C

4) C in the upper middle layer C

5) The lower middle layer is A> B> C

6) C in the lower middle layer C

Therefore, by increasing the content of stretch fibers in each layer of the upper outermost layer or the lower outermost layer to soften the feel of the surface when applied as a cushioning agent and at the same time excellent in the elastic expression, hollow poly in each layer of the upper middle layer or lower middle layer By increasing the content of the ester fiber, the weight of the overall cushioning agent is reduced, and there is an effect of increasing the feeling of cushioning. In addition, since the heat-sealing binder polyester fiber is contained in a higher content in each layer of the upper outermost layer, lower outermost layer, upper middle layer, or lower middle layer than innermost layer, morphological stability is provided when applied to a substrate, thereby providing an optimal elastic cushioning agent. It will play a role.

In addition, for the required physical properties, it is preferable to adjust the ratio of each fiber within the above-mentioned range in accordance with the application.

The hollow polyester fiber of the present invention, the polyester-based stretch fiber and the heat-sealing binder polyester fiber is a short-fiber heat-sealed nonwoven fabric produced at a mixing ratio suitable for the purpose can be easily manufactured with conventional nonwoven fabric manufacturing equipment It is suitable for various applications requiring elasticity. The thickness of each nonwoven fabric of each layer of the uppermost outermost layer, the uppermost intermediate layer, the innermost layer, the lower intermediate layer, and the lowermost outermost layer of the present invention is preferably in the range of 5 to 50 mm for exhibiting elasticity and buffering properties. There is a possibility that the elasticity effect is weakened when pressed by a hand, and when it is more than 50 mm, the heat stability of the nonwoven fabric is difficult due to the heat transfer to the inside. In particular, each layer may be composed of one layer of nonwoven fabric constituting each layer, but may be composed of various layers. Each layer of the upper middle layer or the lower middle layer is composed of more layers than each of the upper outermost layer or the lower outer layer, and is composed of more layers than the innermost layer so that the thickness of each middle layer of the upper middle layer or the lower middle layer is the upper outer layer or The cushion agent, which is thicker than the thickness of the outermost layer of each of the lower outermost layers and thicker than the thickness of the innermost layer, has a higher content of hollow yarns, resulting in a lighter weight of the cushioning agent and excellent resilience.

In addition, the elastic cushioning agent of the present invention is composed of the nonwoven fabric of 5 ~ 50mm thickness included in each layer in a multi-layer, the total thickness is 100 ~ 200mm than the non-woven fabric of each layer thicker than the cushioning properties and shape stability and It is good to maintain the strength for a long time, and particularly preferably applied to a car seat, but the use is not limited thereto.

Figure 2 is a manufacturing process of the elastic cushioning agent according to an embodiment of the present invention. Referring to Figure 2, the elastic cushioning agent of the present invention may be prepared including a fiber mixing step S100, non-woven fabric manufacturing step S200 and lamination step S300. Elastic cushioning agent of the present invention by controlling the fiber mixing ratio and the heat treatment temperature without using a new device, by using a conventional non-woven fabric manufacturing apparatus is easy to manufacture non-woven fabrics, it is possible to reduce the cost, molding mold for molding Any type of use for which the cushioning agent of the present invention is used can be easily molded for various applications.

Specifically, in the fiber mixing step S100, the content of the hollow polyester fiber having a hollow ratio of 20 to 60% to A, a polyester polymer having an intrinsic viscosity of 0.63 to 1.30 and a polyester polymer having an intrinsic viscosity of 0.45 to 0.56 When the content of the stretch fiber comprising a composite fiber made of B, and the heat-sealing binder polyester fiber having a melting point of 110 ~ 180 ℃ C,

And the uppermost outermost layer is A: B: C = 10 to 70: 20 to 80: 5 to 20 (% by weight)

The upper intermediate layer was formed by mixing A: B: C = 20 to 80:10 to 70: 5 to 20 (% by weight)

And the innermost layer was A: B: C = 25 to 55:25 to 55:10 to 40 (wt%),

And the lower outermost layer is composed of A: B: C = 10 to 70:20 to 80: 5 to 20 (% by weight), and the fibers constituting each layer are mixed to form a fiber mixture to adjust the mixing ratio to meet the required physical properties Followed by mixing to produce a short fiber mixture. In addition, in the fiber mixing step, the lower middle layer between the innermost layer and the lower outermost layer A: B: C = 20 to 80: 10 to 70: 5 to 20 (wt%) to further comprise a rebound of the cushioning agent The elasticity can be further increased.

Next, in the nonwoven fabric manufacturing step S200, the fiber mixture contained in each of the layers is subjected to heat treatment at 80 to 200 DEG C after carding, and the nonwoven fabric manufacturing step of each layer is progressed. The heat treatment is performed at the above temperature by a conveyor belt method It is preferable that the nonwoven fabric manufacturing step is carried out by heat treatment and the heat treatment is performed again on the final roller. It is preferable that the temperature is maintained so as not to lower the physical properties of each fiber and maintain the tactile sensation, It is good to make one drying.

Thereafter, in the laminating step S300, the nonwoven fabric is laminated in the order of the upper outermost layer, the upper middle layer, the innermost layer, and the lower outermost layer, and in the fiber mixing step, the lower intermediate layer A: B : C = 20 ~ 80: 10 ~ 70: 5 ~ 20 (wt%) When configured to further include each of the non-woven fabric in the upper outer layer, upper middle layer, innermost layer, lower middle layer, lower outermost layer It is possible to complete the elastic cushioning agent of the present invention that can be produced in a variety of forms by using a molding mold suitable for the required form by heat treatment in a.

As described above, the elastic cushioning agent of the present invention includes a hollow polyester fiber, a polyester stretch fiber, and a heat-sealing binder polyester fiber in which the nonwoven fabric whose content is adjusted to suit the characteristics of each fiber is the outermost layer and the intermediate layer, respectively. It is manufactured for the innermost layer, and the nonwoven fabric of each layer manufactured is laminated, and has a light, soft touch and excellent elasticity, shape stability, and durability.

In addition, the elastic cushioning agent of the present invention by varying the mixing ratio of each fiber constituting the outermost layer, the middle layer, the innermost layer for each layer to facilitate the various characteristics of each fiber, various needs for There is an effect that can be applied.

In addition, the elastic cushioning agent of the present invention is because the fibers included in each layer is composed of all polyester-based fibers, and is heat-bonded by the low melting point heat-sealed binder fibers contained in the nonwoven fabric without the use of a special adhesive when bonding between the fiber and the nonwoven fabric It has similar or superior elasticity to existing polyurethane foams, but also exhibits form stability and chemical stability and has an environmentally friendly effect.

In addition, the method of the present invention is easy to manufacture non-woven fabrics by using the existing apparatus and there is a cost saving effect.

In addition, since the method of the present invention is manufactured by applying a molding die, the shape of the cushioning agent can also be variously configured to suit the purpose.

Elastic cushioning agent of the present invention has an effect that is applied to the cushioning material, such as car seat cover pads, vehicle interior materials, bedding mattresses, cushion pads, bra wicks, ski clothes or winter clothing padding material.

1 is a cross-sectional view of an elastic cushioning agent according to an embodiment of the present invention.
Figure 2 is a manufacturing process of the elastic cushioning agent according to an embodiment of the present invention.
Figure 3 is a schematic diagram of a measuring device for the elastic sample of the present invention (a) permanent compression rate measuring machine, (b) rebound elasticity measuring machine.

Through the following examples will be described in more detail.

Production Example 1

Hollow Poly 34%, Fineness 8.0 Denier, Strength 3.3g / d, Elongation 51%, Compression 46%, Compression Recovery 91%, Hollow 30%, Hollow Polyethylene Terephthalate (PET) Fiber 64mm Fiber (Fiber A) 45 PolyTrimethylene Terephthalate (PTT) with weight%, fineness 2.5 denier, strength 2.8 g / d, elongation 105%, crimp elongation 52%, recovery rate 32%, shrinkage 96%, fiber length 64mm, intrinsic viscosity 0.95 45% by weight of side by side stretch fiber (fiber B) composed of polyethylene terephthalate (PET) having an intrinsic viscosity of 0.52, fineness 4.4 denier, strength 3.6 g / d, elongation 40%, crimping water 9.4, crimping Figure 16.5, shrinkage rate of 6.4%, filament length 64mm heat-sealing binder polyethylene terephthalate fiber (fiber C) by mixing 10% by weight to form a short fiber mixture and mixing in a carding machine, the carding step of manufacturing the mixture into a web After this, it is conveyed by 170 ℃ hot air After the heat treatment by the ear belt method, and further heat treatment at the final roller at 150 ℃ and cooled at room temperature to prepare a non-woven fabric having a thickness of 15mm and a weight of 330 g / m ² .

Production Example 2

70% by weight of fiber A, 20% by weight of fiber B and 10% by weight of fiber C were prepared as in Example 1 to prepare a nonwoven fabric having a thickness of 15 mm and a weight of 300 g / m ² .

Production Example 3

20% by weight of fiber A, 70% by weight of fiber B and 10% by weight of fiber C were prepared as in Example 1 to prepare a nonwoven fabric having a thickness of 15 mm and a weight of 350 g / m ² .

Production Example 4

Fiber A was prepared by mixing in 35% by weight, fiber B 35% by weight and fiber C 30% by weight to prepare a nonwoven fabric having a thickness of 15mm and weight 410 g / m ² .

Comparative Production Example 1

Fiber A was carried out in the same manner as in Comparative Preparation Example 1 except that 4% by weight, fiber B was 11% by weight, and fiber C was 85% by weight.

Comparative Production Example 2

Fiber A was carried out in the same manner as in Comparative Preparation Example 1 except that 85% by weight, fiber B was 5% by weight, and fiber C was 10% by weight.

Example 1

Upper outermost layer, upper middle layer, so that the uppermost outer layer with Preparation Example 3 as two layers, upper middle layer with Preparation Example 2 as four layers, innermost layer with Preparation Example 4 as three layers, and outermost outer layer with Preparation Example 3 as one layer, After laminating in the innermost layer, the lower outermost layer, and put in a mold for automobile seats and molding heat treatment for 20 minutes at 170 ℃ to prepare an elastic cushioning agent having a total thickness of 150mm, weight 4.3kg / m ² .

Example 2

Production Example 2 as the uppermost outer layer, Production Example 1 as the uppermost middle layer, Production Example 4 as the innermost layer with three layers, Production Example 1 with the lower middle layer, Production Example 2 with the lowermost layer An elastic cushioning agent having a total thickness of 150 mm and a weight of 3.8 kg / m ² was prepared in the same manner as in Example 1, except that the outer layer was laminated so as to form an outer layer.

Example 3

Production Example 3 as the uppermost outer layer, Production Example 2 as the uppermost middle layer, Production Example 4 as the innermost layer with three layers, Production Example 2 with the innermost lower layer, Production Example 3 with the lowermost outer layer An elastic cushion having a total thickness of 150 mm and a weight of 3.5 kg / m ² in the same manner as in Example 1, except that the outermost layer, the upper middle layer, the innermost layer, the lower middle layer, and the lower outermost layer were laminated so as to be the outer layer. The agent was prepared.

Comparative Example 1

Comparative manufacturing example 1 as the uppermost outer layer, comparative manufacturing example 2 as the upper middle layer, manufacturing example 4 as the innermost layer in three layers, comparative manufacturing example 2 as the lower middle layer, comparative manufacturing example 1 as 1 In the same manner as in Example 1, except that the upper outer layer, the upper middle layer, the innermost layer, the lower middle layer, and the lower outermost layer were laminated so as to form the lower outermost layer, the total thickness was 150 mm, and the weight was 3.5 kg / An elastic cushioning agent having m ² was prepared.

Comparative Example 2

Comparative Production Example 2 as one layer, uppermost outer layer, Production Example 1 as three layers, upper middle layer, Production Example 4 as three layers, innermost layer, Production Example 1 as two layers, lower intermediate layer, and Comparative Preparation Example 2 as one layer An elastic cushioning agent having a total thickness of 150 mm and a weight of 3.8 kg / m ^{2 was} prepared in the same manner as in Example 1, except that the lower outermost layer was laminated.

Comparative Example 3

Except for laminating in order of the outermost layer, the innermost layer, and the outermost layer so that Preparation Example 3 became the uppermost outer layer, Manufacturing Example 4 the innermost layer with four layers, and Manufacturing Example 3 became the lower outermost layer with two layers. Prepared in the same manner as in Example 1, an elastic cushioning agent having a total thickness of 150 mm and a weight of 3.9 kg / m ² was prepared.

* Test Methods

1) Permanent Compression Reduced

The test piece was made in a square of 50 mm or more in length and 20 mm or more in thickness, and was compressed and fixed to 50% of the thickness of the test piece with a compression plate, and maintained for 22 hours in a constant temperature or 70 ° C constant temperature bath. After leaving for 30 minutes at room temperature, the thickness was measured and calculated by the following equation.

C = ( t ₀ - t ₁ ) / t ₀ × 100

C: permanent compression rate (%)

t ₀ and t ₁ : Thickness of test piece before and after test (mm)

2) resilience

The test piece was made into a square with a side length of 50 mm or more and a thickness of 50 mm or more. A steel ball with a weight of 16 g and a diameter of 16 mm was dropped on the test piece at a height of 500 mm, and the maximum rebound height was measured. At least three times or more of rebound values were measured continuously, and the median value was made into the rebound elastic value (%).

3 is a schematic diagram of a measuring device for an elastic sample of the present invention, showing (a) a permanent compression rate measuring machine and (b) a rebound elasticity measuring machine.

3) Air resistance (Air permeability)

As a measurement standard, ASTM F778-88 or JIS P 8117 (average twice) was used, but in the present invention, JIS P 8117 (average twice) was used.

In the measurement method, first measure the thickness of the sample twice to find the average value (unit: mm), and then prepare the specimen in the size of 2.5cm × 2.5cm. The prepared dry sample is mounted on an automated permporometer (manufacturer: Porous Materials Inc.), model name: CFP-1200-AEL, and connected to an air inlet line. do.

After that, click Execute autotest button in the main menu of the computer program connected to the device, and click show advanced settings. Enter the file location, name, sample name, and sample thickness. Select air permeametry from the test type and start the test. When the report is finished after the analysis, select the coefficients to be expressed in the permeability test report (Darcy, Gurley, Frazier, Rayl), and then report the Gurley method (JIS P 8117). ) The average value of two times is described.

 Calculation

4) Emotional Evaluation

The softness was evaluated by pressing the nonwoven surface.

division Production Example 1 Production Example 2 Production Example 3 Production Example 4 compare
Production Example 1 compare
Production Example 2 Fiber A (% by weight) 45 70 20 35 4 85 Fiber B (% by weight) 45 20 70 35 11 5 Fiber C (% by weight) 10 10 10 30 85 10 Nonwoven Thickness (mm) 15 15 15 15 15 15 Heat treatment temperature (캜) 150 150 150 150 150 150 Permanent compression
(70 ℃,%) 57 75 42 70 30 82 Resilience (%) 65 57 46 72 20 53 Air resistance (sec / 100ℓ) 0.19 0.15 0.17 0.26 0.45 0.13 Weight (g / m ² ) 330 300 350 410 550 270 Emotional Evaluation
Nonwoven surface pressed Softness a little
crustiness Extremely
Softness crustiness crustiness a little
Softness

division Example 1 Example 2 Example 3 compare
Example 1 compare
Example 2 compare
Example 3 Location of Preparation Example 1
Lamination thickness (mm) - Upper middle layer / 45
Lower middle layer / 30 - - Upper middle layer / 45
Lower middle layer / 30 - Location of Preparation Example 2
Lamination thickness (mm) Upper middle layer / 60 Upper outermost layer / 15
Lower outer layer / 15 Upper middle layer / 45
Lower middle layer / 30 - - - Location of Preparation Example 3
Lamination thickness (mm) Upper outermost layer / 30
Lower outer layer / 15 - Upper outermost layer / 15
Lower outer layer / 15 - - Upper outermost layer / 60
Lower outer layer / 30 Location of Preparation Example 4
Lamination thickness (mm) Innermost layer / 45 Innermost layer / 45 Innermost layer / 45 Innermost layer / 45 Innermost layer / 45 Innermost layer / 60 Position of Comparative Production Example 1
Lamination thickness (mm) - - - Upper outermost layer / 15
Lower outer layer / 15 - - Position of Comparative Production Example 2
Lamination thickness (mm) - - - Upper middle layer / 45
Lower middle layer / 30 Upper outermost layer / 15
Lower outer layer / 15 - Cushion
Total thickness (mm) 150 150 150 150 150 150 Molding Heat Treatment Temperature (℃) 170 170 170 170 170 170 Molding Heat Treatment Time
(sec) 30 30 30 30 30 30 Weight (kg / m ² ) 4.3 3.8 3.5 3.5 3.8 5.5 Resilience (%) 50 42 36 31 28 22 Compressive permanent wrinkle rate
(70 ℃,%) 48 47 42 36 30 27

As a result of Table 2, as the nonwoven fabric of Preparation Example 2 having a high content of hollow PET fibers was laminated in the upper middle layer or the lower middle layer, that is, the total weight of the Manufacturing Example 2 having a thick upper middle layer or lower middle layer This is lighter. In addition, it can be confirmed that the nonwoven fabric having a high ratio of stretch yarns is present in the upper outermost layer and the lower outermost layer to have excellent resilience.

In addition, it was confirmed that exhibited better elasticity than the comparative example.

It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the inventions. It will be clear to those who have knowledge of.

100; Elastic cushions
11; Upper outermost layer
31; Upper middle layer
50; Innermost layer
33; Lower middle layer
13; Lower outermost layer

Claims (13)

The content of the hollow polyester fiber having a 20% to 60% hollow fiber ratio is A, the content of the stretch fiber comprising a composite fiber composed of a polyester polymer having an intrinsic viscosity of 0.63 to 1.30 and a polyester polymer having an intrinsic viscosity of 0.45 to 0.56. When B, and the content of the heat-sealing binder polyester fiber having a melting point of 110 ~ 180 ℃ C
A: B: C = 10-70: 20-80: 5-20 (weight%) upper outermost layer containing the nonwoven fabric;
A: B: C = 20-80: 10-70: 5-10 (weight%) upper intermediate layer containing a nonwoven fabric;
A: B: C = 25-55: 25-55: 10-40 (weight%) innermost layer containing the nonwoven fabric; And
A: B: C = 10-70: 20-80: 5-20 (weight%) lower outermost layer containing a nonwoven fabric;
Elastic cushioning laminated. The method of claim 1,
The composite fiber is an elastic cushioning agent is a fiber selected from the group consisting of side-by-side type, sheath-core type, eccentric sheath-core type. The method of claim 1,
The elastic cushioning agent is an elastic cushioning agent that satisfies all of the following formula.
1) Each layer of the uppermost outermost layer and the bottom outermost layer is B>A> C
2) The upper middle layer is A>B> C
3) C of each layer of the uppermost outermost layer and the lowermost outermost layer C
4) C in the upper middle layer C The method of claim 1,
The elastic cushioning agent is between the innermost layer and the lower outermost layer.
An elastic cushioning agent further comprising A: B: C = 20-80: 10-70: 5-20 (weight%) lower middle layer containing a nonwoven fabric. 5. The method of claim 4,
The elastic cushioning agent is an elastic cushioning agent that satisfies all of the following formula.
1) Each layer of the uppermost outermost layer and the bottom outermost layer is B>A> C
2) The upper middle layer is A>B> C
3) C of each layer of the uppermost outermost layer and the lowermost outermost layer C
4) C in the upper middle layer C
5) The lower middle layer is A>B> C
6) C in the lower middle layer C The method according to claim 1 or 4,
The heat-sealing binder polyester fiber is an elastic cushioning agent is a hollow heat-sealing binder polyester fiber. The method according to claim 1 or 4,
The hollow polyester fiber has a strength of 2 ~ 5g / d, elongation 30 ~ 60%, compression rate 10 ~ 50%, compression recovery 80 ~ 100%, the polyester stretch fiber has a strength of 2 ~ 5g / d, elongation 40 ~ 80%, 10-15 crimps, 14-20 shrinkage, 2-10% shrinkage, 20-90mm fiber length, the heat-sealed polyester fiber has a strength of 2-5g / d, elongation 20-60% , Elastic cushion agent of 5-15 crimping number, crimping degree 10-20, shrinkage rate 2-8%. The method according to claim 1 or 4,
The hollow polyester fiber has a thickness of 4 to 15 denier, the polyester stretch fiber is 2 to 9 denier, the heat-sealing binder polyester fibers are 2 to 10 denier. 5. The method of claim 4,
The nonwoven fabric included in each layer of the upper outermost layer, upper middle layer, innermost layer, lower intermediate layer, or lower outermost layer has a thickness of 5 to 50 mm, and each layer has a nonwoven fabric having the thickness in a multi-layered structure. Elastic cushion material with thickness of 100-200mm. delete The content of the hollow polyester fiber having a 20% to 60% hollow fiber ratio is A, the content of the stretch fiber comprising a composite fiber composed of a polyester polymer having an intrinsic viscosity of 0.63 to 1.30 and a polyester polymer having an intrinsic viscosity of 0.45 to 0.56. When B, and the content of the heat-sealing binder polyester fiber having a melting point of 110 ~ 180 ℃ C
The upper outermost layer is A: B: C = 10-70: 20-70: 5-20 (wt%),
The upper intermediate layer was formed by mixing A: B: C = 20 to 80:10 to 70: 5 to 20 (% by weight)
Innermost layer A: B: C = 25-55: 25-55: 10-40 (wt%),
A fiber mixing step of forming a fiber mixture by mixing the lower outer layer with A: B: C = 10-70: 20-70: 5-20 (wt%) to mix the fibers configured in each layer;
A non-woven fabric manufacturing step of producing a respective non-woven fabric by subjecting the fiber mixture contained in each layer to carding and heat treatment;
A step of laminating each of the nonwoven fabrics in the order of an uppermost outermost layer, an uppermost intermediate layer, an innermost layer, and a lowermost outermost layer,
Method of manufacturing an elastic cushion comprising a. The method of claim 11,
The composite fiber is a side-by-side type, sheath-core type, eccentric sheath-core type is a method for producing an elastic cushioning agent fibers selected from the group consisting of. The method of claim 11,
Wherein the lower intermediate layer is further comprised of A: B: C = 20 to 80: 10 to 70: 5 to 20 (% by weight) between the innermost layer and the lowermost outermost layer in the fiber mixing step,
The method of manufacturing an elastic cushion to laminate so that the lower middle layer is further included between the innermost layer and the lower outermost layer in the laminated molding step.

Images