WO2016189879A1 - 三次元桟構造体 - Google Patents
三次元桟構造体 Download PDFInfo
- Publication number
- WO2016189879A1 WO2016189879A1 PCT/JP2016/002565 JP2016002565W WO2016189879A1 WO 2016189879 A1 WO2016189879 A1 WO 2016189879A1 JP 2016002565 W JP2016002565 W JP 2016002565W WO 2016189879 A1 WO2016189879 A1 WO 2016189879A1
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- WIPO (PCT)
- Prior art keywords
- polyethylene
- based thermoplastic
- dimensional
- thermoplastic elastomer
- thermoplastic resin
- Prior art date
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/05—Filamentary, e.g. strands
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C16/00—Stand-alone rests or supports for feet, legs, arms, back or head
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/12—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with fibrous inlays, e.g. made of wool, of cotton
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/12—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with fibrous inlays, e.g. made of wool, of cotton
- A47C27/121—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with fibrous inlays, e.g. made of wool, of cotton with different inlays
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47G—HOUSEHOLD OR TABLE EQUIPMENT
- A47G9/00—Bed-covers; Counterpanes; Travelling rugs; Sleeping rugs; Sleeping bags; Pillows
- A47G9/10—Pillows
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/30—Extrusion nozzles or dies
- B29C48/345—Extrusion nozzles comprising two or more adjacently arranged ports, for simultaneously extruding multiple strands, e.g. for pelletising
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/165—Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y80/00—Products made by additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B68—SADDLERY; UPHOLSTERY
- B68G—METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
- B68G5/00—Resilient upholstery pads
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
- D04H3/03—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments at random
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
- D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C71/00—After-treatment of articles without altering their shape; Apparatus therefor
- B29C71/02—Thermal after-treatment
- B29C2071/022—Annealing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/09—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/12—Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
- B29C48/919—Thermal treatment of the stream of extruded material, e.g. cooling using a bath, e.g. extruding into an open bath to coagulate or cool the material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C71/00—After-treatment of articles without altering their shape; Apparatus therefor
- B29C71/02—Thermal after-treatment
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D99/00—Subject matter not provided for in other groups of this subclass
- B29D99/0092—Producing upholstery articles, e.g. cushions, seats
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
- B29K2023/04—Polymers of ethylene
- B29K2023/08—Copolymers of ethylene
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/0005—Condition, form or state of moulded material or of the material to be shaped containing compounding ingredients
- B29K2105/0014—Catalysts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/0085—Copolymers
Definitions
- the present invention relates to a three-dimensional beam structure having a three-dimensional beam structure used for mattresses, cushions and the like.
- the conventional three-dimensional network structure with good air permeability has the property that loops are formed randomly and shrink when heated. For this reason, for example, when used for mattresses, if the disinfection at high temperature is repeated, the three-dimensional network structure contracts, so the cover tends to wrinkle, the user feels uncomfortable, and pressure ulcers may occur due to long-term use. It was. In particular, in the longitudinal direction with a long length, when the three-dimensional network structure contracts, the influence is large, and it is easy to wrinkle.
- the conventional three-dimensional network structure may not be able to exhibit functions that match the characteristics of the human body.
- the human body controls posture while sleeping, stretches the body, changes position, loosens muscles and body, and evenly balances the burden on the body, resetting the body distortion
- the structural characteristics of the corresponding three-dimensional network structure were insufficient.
- the demands for products that use a three-dimensional network structure are diversified, and the quality requirements for the products are high, but there is a problem that it is difficult to ensure product quality for such diverse requirements that match the characteristics of the human body.
- the present invention realizes a structure with the property of extending in the longitudinal direction by heat, enables cleaning at high temperature, and has hysteresis loss and elastic characteristics that match the characteristics of the human body, thereby meeting various quality requirements. The issue is to ensure.
- the present invention comprises a polyethylene-based thermoplastic resin having a longitudinal direction corresponding to the extrusion direction, a transverse direction perpendicular to the extrusion direction, and a thickness direction, by forming continuous loops by randomly welding the continuous filaments, It is a three-dimensional crosspiece structure made of a polyester-based thermoplastic elastomer or a mixture of a polyethylene-based thermoplastic resin and a polyethylene-based thermoplastic elastomer.
- the rebound resilience of the three-dimensional crosspiece structure is 13 cm or more and the hysteresis loss is 34%. Not exceeding 13%, in the case of a polyethylene-based thermoplastic resin, at a temperature of 90 ° C.
- Thermal elongation degree before test is a three-dimensional bar structure which is 0-8%.
- the thermal elongation before and after the dry hot air test is preferably 0 to 8% in the transverse direction.
- the three-dimensional crosspiece structure has anisotropic thermal elongation characteristics in which the thermal elongation rates in the longitudinal direction and the lateral direction are different.
- the impact resilience change rate after a constant load repeated test is 25% or less, and in the case of a polyester thermoplastic elastomer, the resilience change rate after a constant load repeat test is 20% or less. Is preferred.
- the apparent density of the three-dimensional crosspiece structure is 0.025 g / cm 3 to 0.2 g / cm 3 , the thickness is 5 mm to 500 mm in a single layer and multiple layers, and the wire diameter is 0.1 mm to 1. 5 mm is preferable.
- the polyethylene-based thermoplastic resin is preferably polyethylene or an ethylene / ⁇ -olefin copolymer resin mainly composed of ethylene and an ⁇ -olefin having 3 or more carbon atoms.
- the mixture of the polyethylene-based thermoplastic resin and the polyethylene-based thermoplastic elastomer is a mixture of an ethylene / ⁇ -olefin copolymer resin mainly composed of ethylene and an ⁇ -olefin having 3 or more carbon atoms and a polyethylene-based thermoplastic elastomer, and the mixture
- the content of the polyethylene-based thermoplastic elastomer is preferably 45% or less by weight.
- the three-dimensional cross structure is for cushions, cushion sheets, cushions, pillows, care products, bed cushions or mattresses.
- the three-dimensional crosspiece structure is provided with a plurality of surfaces, and preferably two, three, or four surfaces are formed, and if necessary, are formed into a curved surface shape or an irregular shape.
- the three-dimensional crosspiece structure is preferably a laminate of a three-dimensional network structure made of a polyethylene-based thermoplastic resin and a three-dimensional network structure made of a polyethylene-based thermoplastic elastomer.
- the three-dimensional crosspiece structure according to the present invention is an excellent three-dimensional crosspiece structure that has a low hysteresis loss and a soft high resilience characteristic, and can provide elastic characteristics that match the characteristics of the human body. Because of this superior property, it can adapt to the characteristics of the human body, and can respond to diversification of demands for elastic properties of products, and sophistication of quality requirements for products, medical care products, bedding, furniture, or vehicles. It has become possible to provide a three-dimensional crosspiece structure suitable for cushion materials or skin materials used for seats and the like. For example, an application example of a mattress for medical / nursing care can realize an appropriate elastic characteristic of a three-dimensional crosspiece structure, and can respond to natural adjustment functions of the human body during sleep, etc. Easy to get up. In addition, caregivers can achieve their objectives with little force using the repulsive force of the mattress when changing the patient's position.
- the three-dimensional crosspiece structure of the present embodiment (hereinafter simply abbreviated as a structure) will be described.
- This three-dimensional cross structure is constituted by a plurality of filaments entangled randomly in a loop shape and heat-welded.
- the structure is a three-dimensional network structure having a cross-shaped sparse and dense structure in which a rough portion and a dense portion alternately appear in the extrusion direction during production.
- Structs can have various forms such as those with hard ends, those with different surface layer thicknesses on the front and back sides, those with different softness on the front and back sides, and those with holes in the inside. Also, the hardness can be changed depending on the site depending on the purpose of use.
- the structure of the present invention preferably has a hysteresis loss of 34% or less.
- a small hysteresis loss means that the return force after release is fast and large.
- a hysteresis loss of 34% or less is preferable because the resilience is large and the object of the present invention is soft and highly repulsive. If it exceeds 34%, the elastic repulsion force becomes slow and weak, which is not preferable. More preferably, it is 15 to 34%, and further preferably 20 to 34%.
- the apparent density (bulk density) of the structure of the present invention is an important factor that determines soft and high resilience, and is designed as necessary, but is preferably 0.025 g / cm 3 to 0.00. It is 2 g / cm 3 , more preferably 0.04 g / cm 3 to 0.09 g / cm 3 . If the apparent density is less than 0.025 g / cm 3 , the shape cannot be maintained, and if it exceeds 0.20 g / cm 3 , it is not suitable as a mattress.
- the structure has a dense and dense band-shaped portion repeated in the extrusion direction, and the ratio of the number of junction points per unit weight of the dense band-shaped portion based on the sparse band-shaped portion is 0.96 to 1.33.
- the apparent density of the dense band-shaped portion with respect to the portion has a difference of 0.005 g / cm 3 or more.
- the number of joint points per unit weight is cut into a rectangular parallelepiped shape so that the sample is cut in a width of 2 cm in a direction orthogonal to the extrusion direction and includes two dense band portions and two sparse band portions in the extrusion direction. I made a piece. After measuring the height of the four corners of each piece, the volume (cm 3 ) was determined, and the apparent density (g / cm 3 ) was calculated by gradually decreasing the weight (g) of the sample by volume.
- Count the number of junction points of the piece and divide this number by the volume of the piece to calculate the number of junction points per unit volume (pieces / cm 3 ), and divide the number of junction points per unit volume by the apparent density.
- the number of junctions per unit weight (pieces / g) was calculated.
- the joint point was a fusion part between two filaments, and the number of junction points was measured by pulling the filament and peeling the fusion part until it became one filament.
- the structure of the present invention is a continuous linear random loop comprising a thermoplastic resin or a thermoplastic elastomer or a mixture of a thermoplastic resin and a thermoplastic elastomer having a filament diameter (diameter) of 0.3 mm to 1.5 mm.
- the wire diameter may be irregular or hollow, but it is an important factor for obtaining a soft touch. If the wire diameter is small, the hardness required for cushioning cannot be maintained, and conversely, if the wire diameter is too large, it becomes hard. Therefore, it is necessary to set an appropriate range.
- the loop length of the loop is preferably 5 to 50 mm, particularly 8 to 15 mm.
- the surface loop may be laid to form a high-density surface layer, or a high-density surface layer may not be formed.
- the thickness of the structure of the present invention is greatly related to softness and high resilience, and is preferably 5 mm to 500 mm, more preferably 10 to 150 mm, and even more preferably 30 to 110 mm. If it is less than 5 mm, the high resilience is low, which is not preferable. If it exceeds 500 mm, the resilience becomes too high, which is not preferable.
- the vertical and horizontal dimensions of this structure are, for example, a width of 600 to 2000 mm, a length of 1300 to 2500 mm, a height of 30 to 120 mm for a mattress, a cushion, and the like, and a width of 250 to 500 mm, a length of 300 to 800 mm for a pillow.
- a thickness of 40 to 120 mm can be exemplified. Further, it can be used as a single material, a composite material or a multilayer material for the skin material. Although the dimension illustrated the typical dimension, it is not necessarily restricted to the dimension.
- the material of the structure is preferably a polyethylene resin, a polyester thermoplastic elastomer, or a mixture of a polyethylene resin and a polyethylene thermoplastic elastomer.
- the thermal elongation rate in the longitudinal and lateral directions before and after the 90 ° C. dry hot air test is preferably 0% or more and 8% or less, preferably 3% or less. Further preferred. If the thermal elongation rate before and after the 90 ° C. dry hot air test exceeds 8%, it is difficult to enter the cover. If the thermal elongation rate before and after the 90 ° C. dry hot air test is less than 0%, it is not preferable because the length of the product is shortened and the cover is wrinkled when disinfected at a high temperature.
- the longitudinal and transverse thermal elongation rates before and after the 130 ° C. dry hot air test are preferably 0% or more and 8% or less, preferably 3% or less. Further preferred. If the thermal elongation rate before and after the 130 ° C. dry hot air test exceeds 8%, it is difficult to enter the cover. If the thermal elongation rate before and after the 130 ° C. dry hot air test is less than 0%, the length of the product is shortened and the cover is wrinkled when disinfected at a high temperature, which is not preferable.
- the thermal elongation rate in the longitudinal and lateral directions before and after the 90 ° C. dry hot air test is 0% or more and 8%. The following is preferable, and 3% or less is more preferable. If the thermal elongation rate before and after the 90 ° C. dry hot air test exceeds 8%, it is difficult to enter the cover, which is not preferable. If the thermal elongation rate before and after the 90 ° C. dry hot air test is less than 0%, it is not preferable because the length of the product is shortened and the cover is wrinkled when disinfected at a high temperature.
- the structure of the present invention is used for a cushioning material, it is necessary to appropriately select a resin, a wire diameter, a loop diameter, a surface layer, a bulk density, and a shape to be used depending on the purpose of use and a use site.
- the raw materials are selected in a timely manner according to the hardness preference in the country of use.
- an appropriate bulk density is selected depending on whether it is a surface layer or an intermediate layer.
- it can be molded into a shape suitable for the purpose of use using a molding die or the like to such an extent that the three-dimensional structure is not impaired, and can be used for a vehicle seat, an aircraft seat, a ship seat, a chair, furniture, and the like.
- the polyethylene-based thermoplastic resin used in the structure of the present invention is preferably a low-density polyethylene resin having a bulk density of 0.94 g / cm 3 or less, particularly ethylene composed of ethylene and an ⁇ -olefin having 3 or more carbon atoms.
- -It is preferably made of an ⁇ -olefin copolymer resin.
- Use of a raw material exceeding 0.94 g / cm 3 is not preferable because the cushion material tends to be hard. More preferably 0.935 g / cm 3 or less, still more 0.91 g / cm 3 or less is more preferred.
- a floor of 0.8 g / cm 3 or more in view of the strength retention is more preferably 0.85 g / cm 3 or more.
- the ethylene / ⁇ -olefin copolymer is preferably a copolymer described in JP-A-6-293813, and is obtained by copolymerizing ethylene and an ⁇ -olefin having 3 or more carbon atoms.
- Examples of the ⁇ -olefin having 3 or more carbon atoms include propylene, butene-1, pentene-1, hexene-1, 4-methyl-1-pentene, heptene-1, octene-1, nonene-1, and decene.
- This copolymer can be obtained by copolymerizing ethylene and ⁇ -olefin using a catalyst system having a basic structure composed of a specific metallocene compound and an organometallic compound.
- the polyester-based thermoplastic elastomer used in the structure of the present invention comprises a high-melting-point crystalline polymer segment (a) mainly composed of a crystalline aromatic thermoplastic polyester elastomer unit, an aliphatic polyether unit and / or
- the thermoplastic polyester / elastomer block copolymer (A) is mainly composed of a low-melting polymer segment (b) composed of an aliphatic thermoplastic polyester / elastomer unit.
- thermoplastic elastomers a polyester block copolymer having a crystalline aromatic polyester unit as a hard segment and an aliphatic polyether unit such as poly (alkylene oxide) glycol and / or an aliphatic polyester unit such as polylactone as a soft segment.
- a polymer (polyester elastomer) has characteristics that are excellent in low-temperature and high-temperature characteristics, and is characterized by relatively low temperature dependency of rigidity.
- the bulk density of the polyester thermoplastic elastomer is preferably 1.01 to 1.60 g / cm 3 , more preferably 1.05 to 1.20 g / cm 3 .
- Polyester thermoplastic elastomers are preferably used because they can reduce temperature dependence over a wide temperature range.
- the polyester-based thermoplastic elastomer includes a high-melting-point crystalline polymer segment (a1) composed of a crystalline aromatic polyester unit, a low-melting-point polymer segment (a2) composed of an aliphatic polyether unit and / or an aliphatic polyester unit.
- the high-melting crystalline polymer segment (a1) is mainly composed of an aromatic dicarboxylic acid or an ester-forming derivative thereof and a diol or an ester-forming derivative thereof.
- aromatic dicarboxylic acids that are polyesters include terephthalic acid, isophthalic acid, phthalic acid, naphthalene-2,6-dicarboxylic acid, naphthalene-2,7-dicarboxylic acid, anthracene dicarboxylic acid, diphenyl-4,4 ′; ⁇ -dicarboxylic acid, diphenoxyeta Dicarboxylic acid, 4,4 '; - diphenyl ether dicarboxylic acid, 5-sulfoisophthalic acid, and 3-like sodium sulfoisophthalate and the like.
- aromatic dicarboxylic acid is mainly used, if necessary, a part of the aromatic dicarboxylic acid may be converted into alicyclic dicarboxylic acid such as 1,4-cyclohexanedicarboxylic acid, cyclopentanedicarboxylic acid, 4,4 ′; -dicyclohexyldicarboxylic acid, etc. It may be substituted with an acid or an aliphatic dicarboxylic acid such as adipic acid, succinic acid, oxalic acid, sebacic acid, dodecanedioic acid, and dimer acid.
- aliphatic dicarboxylic acid such as adipic acid, succinic acid, oxalic acid, sebacic acid, dodecanedioic acid, and dimer acid.
- ester-forming derivatives of dicarboxylic acids such as lower alkyl esters, aryl esters, carbonates, and acid halides can be used equally.
- the diol include diols having a molecular weight of 400 or less, for example, aliphatic diols such as 1,4-butanediol, ethylene glycol, trimethylene glycol, pentamethylene glycol, hexamethylene glycol, neopentyl glycol, decamethylene glycol, , 1-cyclohexanedimethanol, 1,4-dicyclohexanedimethanol, tricyclodecane dimethanol and the like, and xylylene glycol, bis (p-hydroxy) diphenyl, bis (p-hydroxy) diphenylpropane, 2,2 ′; -bis [4- (2-hydroxyethoxy) phenyl] propane, bis [4- (2-hydroxyethoxy) phenyl] sulfone, 1,1
- a preferable high-melting crystalline polymer segment (a1) is a polybutylene terephthalate unit derived from terephthalic acid and / or dimethyl terephthalate and 1,4-butanediol. Also preferred are those comprising polybutylene terephthalate units derived from terephthalic acid and / or dimethyl terephthalate and polybutylene isophthalate units derived from isophthalic acid and / or dimethyl isophthalate and 1,4-butanediol. .
- the low-melting polymer segment (a2) of the polyester-based thermoplastic elastomer used in the present invention is an aliphatic polyether and / or an aliphatic polyester bag.
- Aliphatic polyethers include poly (ethylene oxide) glycol, poly (propylene oxide) glycol, poly (tetramethylene oxide) glycol, poly (hexamethylene oxide) glycol, copolymers of ethylene oxide and propylene oxide, poly (propylene oxide) Examples thereof include ethylene oxide addition polymers of glycol and copolymer glycols of ethylene oxide and tetrahydrofuran.
- Examples of the aliphatic polyester cocoon include poly ( ⁇ -caprolactone), polyenanthlactone, polycaprylolactone, polybutylene adipate, and polyethylene adipate.
- poly (tetramethylene oxide) glycol, poly (propylene oxide) glycol ethylene oxide adducts, ethylene oxide and tetrahydrofuran are preferably used such as copolymer glycol, poly ( ⁇ -caprolactone), polybutylene adipate, and polyethylene adipate, among which poly (tetramethylene oxide) glycol, poly (propylene oxide) glycol ethylene oxide adduct, and The use of a copolymer glycol of ethylene oxide and tetrahydrofuran is preferred.
- the number average molecular weight of these low-melting polymer segments is preferably about 300 to 6000 in the copolymerized state.
- the amount of copolymerization of the low melting point polymer segment (a2) in the polyester thermoplastic elastomer used in the present invention is not particularly limited, but is preferably about 10 to 90% by weight, more preferably about 30 to 85% by weight, About 50 to 80% by weight is particularly preferable.
- the copolymerization amount of the low melting point polymer segment (a2) is less than 10% by weight, the flexibility and the bending fatigue property are deteriorated.
- the copolymerization amount of the low melting point polymer segment (a2) exceeds 90% by weight, mechanical properties, high temperature characteristics, oil resistance, and chemical resistance are not sufficiently exhibited.
- the polyester-based thermoplastic elastomer used in the present invention can be produced by a known method. Specific examples thereof include, for example, a method of transesterifying a lower alcohol diester of a dicarboxylic acid, an excessive amount of a low molecular weight glycol and a low melting point polymer segment component in the presence of a catalyst, and polycondensing the resulting reaction product, and Any method such as a method in which a dicarboxylic acid, an excess amount of glycol and a low melting point polymer segment component are esterified in the presence of a catalyst and the resulting reaction product is polycondensed may be used.
- the above block copolymers may be used alone or in combination of two or more.
- a blended or copolymerized non-elastomeric component can be used in the present invention.
- a mixture of a polyethylene-based thermoplastic resin and a polyethylene-based thermoplastic elastomer used in the structure of the present invention comprises an ethylene / ⁇ -olefin copolymer resin mainly composed of ethylene and an ⁇ -olefin having 3 or more carbon atoms and a polyethylene-based thermoplastic elastomer. It is preferable that the polyethylene thermoplastic elastomer content in the mixture is 45% or less by weight. If the content of the polyethylene-based thermoplastic elastomer in the mixture exceeds 45% by weight, the hysteresis loss increases and it becomes difficult to turn over, which is not preferable.
- the polyethylene-based thermoplastic elastomer used in the structure of the present invention includes a thermoplastic elastomer in which ethylene-propylene rubber (EPDM, EPM) is finely dispersed, and two types of polyolefin composed of two types of catalysts in one molecule. It is preferable that they are alternately formed in a block shape.
- EPDM ethylene-propylene rubber
- EPM ethylene-propylene rubber
- the bulk density of the polyethylene-based thermoplastic elastomer is 0.92 ⁇ 0.85g / cm 3, more preferably 0.95 ⁇ 0.81g / cm 3. Since the end portion is damaged when the structure is washed at a high temperature, a product reinforced by increasing the bulk density of a necessary portion is preferable.
- the melting point of polyethylene is preferably 60 ° C to 120 ° C.
- the melting point of the thermoplastic elastomer is preferably 140 ° C. or higher because heat resistance can be maintained, and when the temperature is 160 ° C. or higher, the heat durability is improved.
- an antioxidant, a light-resistant agent and the like can be added to improve durability. It is also effective to increase the molecular weight of the thermoplastic resin in order to improve heat resistance and sag resistance.
- the melt flow rate (hereinafter abbreviated as MFR) of the polyethylene resin used in the structure of the present invention is 3.0 to 35 g / 10 min, and the MFR of the polyester thermoplastic elastomer is 3.0 to 45 g / 10 min.
- the MFR of the mixture of the polyethylene resin and the polyethylene thermoplastic elastomer is 6 to 35 g / 10 min.
- Capillograph 1D manufactured by Toyo Seiki Co., Ltd.
- the filament of the extruded material resin was cooled with an alcohol, the diameter of the filament was cut in cross-section and D 2.
- Wire diameter reduction rate D 2 / D 1
- the wire diameter reduction rate was measured according to the shear rate of the raw material resin.
- the measuring method and measuring apparatus for the wire diameter reduction rate of the polyester-based thermoplastic elastomer are the same as described above except that the temperature is 210 ° C.
- the measuring method and measuring device of the linear reduction rate of the mixed resin of polyethylene resin and polyethylene thermoplastic elastomer are the same as above except that the temperature becomes 190 ° C.
- the wire diameter decrease rate for shear rate 24.3Sec -1 is the 0.93 to 1.16
- the wire diameter decrease rate for shear rate 60.8Sec -1 Is 1.00 to 1.20
- the wire diameter reduction rate with respect to a shear rate of 121.6 sec ⁇ 1 is 1.06 to 1.23
- the wire diameter reduction rate with respect to a shear rate of 243.2 sec ⁇ 1 is 1. 11 to 1.30
- the wire diameter reduction rate for a shear rate of 608.0 sec ⁇ 1 is 1.15 to 1.34
- the wire diameter reduction rate for a shear rate of 1216 sec ⁇ 1 is 1.16 to 1.38. It is preferable that
- Wire diameter reduction rate of the polyester-based thermoplastic elastomer resin used in the present invention the wire diameter decrease rate for shear rate 60.8Sec -1 is the 1.10 to 1.38, the diameter decrease rate for shear rate 121.6Sec -1 1.12 to 1.39, the wire diameter reduction rate for the shear rate of 243.2 sec ⁇ 1 is 1.15 to 1.42, the wire diameter reduction rate for the shear rate of 608 sec ⁇ 1 is 1.17 to 1.43, and the wire diameter for the shear rate of 1216 sec ⁇ 1
- the reduction rate is preferably 1.19 to 1.47.
- the wire diameter reduction rate of the mixture of the polyethylene thermoplastic resin and the polyethylene thermoplastic elastomer resin used in the present invention is 1.02 to 1.25 with respect to a shear rate of 60.8 sec ⁇ 1 , and a shear rate of 121.6 sec.
- the wire diameter reduction rate for -1 is 1.11 to 1.30
- the wire diameter reduction rate for shear rate 243.2 sec -1 is 1.15 to 1.35
- the wire diameter reduction rate for shear rate 608 sec -1 is 1.20 to 1.40
- the wire diameter reduction rate with respect to a shear rate of 1216 sec ⁇ 1 is preferably 1.23 to 1.45.
- the continuous filaments made of the thermoplastic resin forming the structure of the present invention may be combined with other thermoplastic resins as long as the object of the present invention is not impaired.
- the filaments themselves may be combined.
- the compound structure which arranged can be mentioned.
- the structure of the present invention is appropriately selected from various structures such as those having different loop sizes, different wire diameters, different compositions, different densities, etc. Can be Whether the cushion is bonded or not is designed according to the application and the cover. In the case of multiple layers, if a structure made of a resin containing an elastomer component is placed on the surface layer, the heat resistance of the surface layer is increased, and heat is not easily transmitted to the structure of the inner layer. Since the heat resistance performance of the layered body as a whole increases, it is preferable. Composite and multi-layered structures can also be produced using several extruders.
- the structure of the present invention may be multilayered and may be bonded and integrated with a wadding layer made of side fabric, cotton, urethane, or nonwoven fabric by heat or ultrasonic waves. What was integrated by bonding is used as a cushion for a seat, for example.
- cotton and non-woven fabric are preferable since they have high durability, and the non-woven fabric is preferably one in which fibers and fibers are fused with a binder fiber or one having a straight structure with a support structure.
- raw materials mainly composed of polyethylene, polyester-based thermoplastic elastomer, or a mixture of polyethylene resin and polyethylene-based thermoplastic elastomer are 10 ° C. to 20 ° C. from their melting points.
- the raw material melted and melted at a high melting temperature is sent to the inside of the die, pressure is applied, and each filament discharged from the extrusion port of the lower die is made up of a plurality of arrays of extrusion holes. It becomes a line aggregate consisting of a plurality of lines and falls naturally.
- the temperature range inside the die can be set to 100 to 400 ° C., and the extrusion amount can be set to 20 to 200 Kg / HR.
- the pressure inside the die may be, for example, a discharge pressure of a 75 mm screw, and the pressure range is about 0.2 to 25 MPa.
- the diameter of the die inside the die corresponds to the wire diameter of the wire having the three-dimensional cross structure, preferably 0.2 to 4.0 mm, and more preferably 0.4 to 1.8 mm.
- the wire diameter is determined.
- the wire diameter (diameter) is 0.1 to 1.8 mm, and the average diameter (length) of the random loop is 5 mm to 50 mm.
- the filaments located on the longitudinal side surfaces of the outer circumference contact the inclined surfaces where the water of the pair of longitudinal shooters flows, thereby disturbing the vertical descent trajectory and adjacent to each other. While entangled with the filaments in a loop shape, it slides down the inclined surface while being washed with water supplied from the supply pipe or heated water. At this time, the filament is directly affected by gravity, and is entangled along the inclined surface to form a loop.
- a pair of short shooters may be provided. Also, an integral shooter may be provided.
- the water supply port is provided with a supply pipe in the longitudinal direction above each of the longitudinal shooters, and each of the inclined surfaces is heated with water or within a range of 10 to 90 ° C., preferably 40 to 60 ° C. Water is supplied.
- the supply pipe is connected upstream to a water supply source.
- the heated water may be supplied to the short shooter by adjusting the water flow from the supply pipe, or a similar supply pipe may be provided above the short shooter.
- the filament that descends without contacting any of the inclined surfaces of the shooter among the filament aggregate passes through the molding opening.
- those that pass near the lower side of the inclined surface come into contact with the filaments that slide down the inclined surface, and are entangled in a loop shape.
- the disturbance is propagated to some extent in the adjacent central line and descends.
- those that pass near the center of the molding opening land on the water surface, and the take-up speed by the take-up machine is slower than the descending speed of the filament assembly, so it has landed.
- Each filament is bent and entangled in a substantially loop shape near the water surface.
- the take-up machine speed is preferably 5 to 40 m / hour.
- the take-up machine uses a caterpillar-structured endless belt to take up the filament aggregate.
- the present invention is not limited to this, and a roller or the like can be used.
- a loop may be formed.
- the three-dimensional crosspiece structure is cooled in the water tank, and is taken down by the pair of take-up machines at a speed slower than the descent of the assembly, and is smaller than the gap in the short direction of the molding opening. It is pinched and receives an auxiliary compression action.
- the cooling and solidification of the filament aggregate due to submergence has not been completed yet, so that a compression molding effect is obtained by clamping with a take-up machine.
- the filament aggregate is taken out and sent out by the take-up machine, the filament aggregate in the molten state is cooled and solidified with water, finally the shape is fixed, and it is pulled out from the cooling tank by being sandwiched between rollers.
- the water level of the aquarium be equal to or higher than the height of the lower end of the inclined surface of the shooter. Regardless of the height of the shooter, the lower end of the inclined surface is set as a reference, and it is not a problem that a part of the take-up machine is exposed on the water.
- the water level is preferably set such that the height from the lower end of the inclined surface is 0 to 45 mm, more preferably 1 to 30 mm, and more preferably 3 to 22 mm. preferable.
- the water level includes the same height as that of the lower end of the inclined surface, and the present invention can be implemented as long as the water level is higher than that. It is preferable to set the water level height in consideration of variations in the water level during production, machine levelness, and the like.
- the water level is set to a height of 3 mm or more, it is possible to prevent the water level from becoming lower than the lower end of the inclined surface due to the influence of water pressure or the like.
- the water level exceeds 30 mm from the lower end of the inclined surface, depending on the conditions, the resin starts to solidify, and the fusion between the fibers deteriorates, and the surface roughness increases, which is inappropriate.
- the structure having the same shape as the molding opening in the cross section is drained, sent to a dry heat treatment tank by a roller, and annealed by a dry heat treatment with hot air.
- the take-up speed of the roller near the exit of the dry heat treatment tank is set lower than the take-up speed of the roller near the entrance of the dry heat-treatment tank.
- Annealing by this drying heat treatment is taken out from the water tank and the drained structure is performed at a drying temperature for a predetermined time.
- the drying temperature is preferably not higher than the melting point, and preferably 10 to 70 ° C. lower than the melting point.
- the temperature is preferably below the melting point of the polyester-based thermoplastic elastomer, and preferably 10 to 70 ° C. lower than the melting point.
- the temperature is preferably equal to or lower than the melting point of the mixture, and is preferably 10 ° C. to 30 ° C. lower than the melting point.
- Annealing may be performed by removing the mold after removing it from the water tank, draining the water, storing the three-dimensional bar structure in a compressed state in a frame, heat-treating it with hot air.
- the drying temperature is preferably below the melting point, and preferably 10 to 70 ° C. lower than the melting point.
- a thermoplastic elastomer it is preferably below the melting point of the thermoplastic elastomer, and preferably 10 to 70 ° C. lower than the melting point.
- the temperature is preferably equal to or lower than the melting point of the mixture, and preferably 10 ° C. to 70 ° C. lower than the melting point.
- additional annealing After forming the structure in the water tank as described above, it may be annealed in a later step (hereinafter referred to as additional annealing), or by adding warm water to the water tank, additional annealing ( Hereinafter, it may be referred to as “annealing during production”.
- the annealing during production is preferably performed at a temperature at least 10 ° C. to 70 ° C. lower than the melting point of the polyethylene thermoplastic resin or the polyester thermoplastic elastomer. In the case of a mixture of a polyethylene resin and a polyethylene thermoplastic elastomer, it is preferably 10 to 70 ° C. lower than the melting point.
- the warm water supplied to the shooters is in the range of 20 to 90 ° C. (preferably 20 to 80 ° C. or more, more preferably 25 to 50 ° C.).
- annealing may be performed while forming a random loop by randomly welding the filaments.
- warm water 25-50 ° C for low density polyethylene, 25-70 ° C for thermoplastic elastomer, 25-60 ° C for a mixture of polyethylene resin and polyethylene thermoplastic elastomer. Is preferred.
- Examples of the warming water include (A) heating the water flowing through the shooter, (B) heating the water tank itself, and (C) increasing the internal temperature by forming the shooter like a tank. Moreover, it is good also as those composites. If the temperature of the heated water supplied to the shooter is raised too much, the resin may stick to the shooter. Therefore, the temperature is preferably an appropriate temperature, for example, 10 to 60 ° C.
- the additional annealing is performed by lifting the three-dimensional beam structure from the water tank and then immersing it in hot water or hot air.
- Annealing may be performed either once, such as additional annealing by dry heat treatment or production annealing using warm water such as a water tank, or may be performed after production annealing and annealing in two stages. Further, additional annealing may be performed in two stages. In this case, the second additional annealing temperature is set higher than the first additional annealing temperature.
- the structure of the present invention realizes soft and highly repulsive characteristics and longitudinal and lateral thermal elongation characteristics by the above-described manufacturing method. Also, different thermal elongation characteristics are realized in the vertical and horizontal directions. According to the inventor's analysis, the elastic and thermal elongation characteristics, and the mechanism that leads to the anisotropic thermal elongation rate are complex and not all are clear, but the appropriate range of raw materials Wire diameter reduction rate, melt viscosity, MFR, extrusion process from hole diameter of die, wire loop formation process, wire cooling process, additional annealing by annealing and annealing during production As a result, when the wire naturally descends, entangles, and cools, basically, the tangling in the vertical and horizontal directions is caused by the characteristic fluctuation / oscillation of the thickness of the wire. We think that form is different.
- the reason why the heat stretches in the horizontal direction and the vertical direction is because the reduction factor of the diameter of the raw material, the diameter of the die, the take-up speed of the conveyor, annealing, and the like are factors.
- the structure of the present invention is processed from a resin production process to a molded body within a range that does not deteriorate the performance, and at any stage of commercialization, deodorant antibacterial, deodorant, antifungal, coloring, aroma, flame retardant, non-flammable, Functions such as moisture absorption and desorption can be imparted by processing such as drug addition.
- Wire diameter (mm) The resin yarn was cut out from the central portion of the sample, and the thickness of the resin yarn was measured 5 times with a caliper. The average value of the five measurements was taken as the wire diameter. Measured against S1 and S2. The wire diameter of the elastomer sample was estimated from the polyester measurement results. The temperature with annealing was 60 ° C., and the temperature without annealing was 23 ° C.
- sample thickness and bulk density (g / cm 3 ) The sample was cut into a size of 30 cm ⁇ 30 cm and allowed to stand for 24 hours with no load, and then the height at four locations was measured to obtain the average value as the sample thickness. The volume was determined from the sample thickness, and the value obtained by dividing the weight of the sample by the volume was taken as the bulk density of the sample.
- Rate of change in rebound resilience after constant load test (%) A sample is cut into a size of 30 cm (longitudinal) ⁇ 30 cm (horizontal), and the impact resilience (a) before the constant gravity repeat test is measured by the method described in (5). A constant gravity repeated compression test is performed on the sample whose impact resilience was measured. The constant gravity repeated compression test is performed in accordance with the JISK6400-4 repeated compression residual strain test method A (constant load method). The repeated compression test is performed at a temperature of 23 ⁇ 2 ° C and a relative humidity of 50 ⁇ 5%.
- Method A uses a pressure plate with a diameter of 25 cm to compress the sample 80,000,000 times repeatedly at a speed of 70 ⁇ 5 times per minute with a force of 750N ⁇ 20N.
- the time during which the maximum force 750 ⁇ 20N is applied is 25% or less of the time required for repeated compression.
- After the test leave the sample for 100 ⁇ 0.5 minutes without applying any force.
- the impact resilience (b) after the constant gravity test is measured by the method described in (5).
- Compression deflection coefficient (%) A sample was cut into a size of 30 cm (length) ⁇ 30 cm (width), and this test piece was measured by applying JIS K 6400-2: 2012 E method. The test temperature is 23 ° C. and the humidity is 50%.
- Hysteresis loss (%) A sample was cut into a size of 30 cm (length) ⁇ 30 cm (width), and this test piece was measured by applying JIS K 6400-2: 2012 E method.
- the thermal elongation before and after the dry hot air test was calculated by (25 ⁇ length obtained) / 25 ⁇ 100.
- the dry hot air test temperature of the polyethylene resin was 90 ° C.
- the dry hot air test temperature of the polyester thermoplastic elastomer was 130 ° C.
- the dry hot air test temperature of the polyethylene resin and the polyethylene thermoplastic elastomer was 90 ° C.
- Screw diameter of the extruder is 65mm, die temperature is 205 ° C, die width direction is 890mm, thickness direction is 75mm, hole pitch is 10mm, nozzle hole diameter is 1.6mm, air gap (distance from nozzle bottom surface to water surface) 67mm, main
- the raw material was hexane, hexene, and ethylene polymerized by a known method using a metallocene compound as a catalyst.
- the resulting ethylene / ⁇ -olefin copolymer had a linear diameter reduction rate of 1.05 with respect to a shear rate of 24.3 sec ⁇ 1 , a shear rate of 60
- the wire diameter reduction rate for .8 sec ⁇ 1 is 1.12
- the wire diameter reduction rate for shear rate 121.6 sec ⁇ 1 is 1.15
- the wire diameter reduction rate for shear rate 243.2 sec ⁇ 1 is 1.18
- the wire diameter for shear rate 608 sec ⁇ 1 Reduction rate is 1.23
- wire diameter reduction rate is 1.26 with a shear rate of 1216 sec- 1
- MFR is 12 g / 10 min
- dense A wire having a degree of 0.90 g / cm 3 at a melting temperature of 180 ° C.
- a pair of take-up conveyors are arranged in parallel so that the stainless steel conveyors are parallel to each other with an opening width of 71 mm on the water surface, and the molten discharge line is supplied on the shooter with 36 ° C warm water on the shooter.
- the solidification process is performed, and the three-dimensional cross structure is formed while the contact portions are intertwined to form a loop to fuse the contact portions, and both sides of the molten structure are sandwiched by a take-up conveyor.
- the obtained structural body is formed of strips having a quadrangular cross section and a line diameter of 0.6 to 1.1 mm, the surface is flattened, the bulk specific gravity is 53 kg / m 3 , and the thickness is 75 mm.
- Example 2 The screw diameter of the extruder is 40 mm, the die temperature is 190 ° C., the die width direction is 500 mm, the thickness direction is 25 mm, the hole pitch is 10 mm, the nozzle hole diameter is 1.6 mm, the air gap (distance from the nozzle bottom surface to the water surface) is 38 mm, ethylene -A olefin copolymer (raw material is the same as in Example 1) polyethylene is melted at a temperature of 160 ° C, and the filament is discharged at an extrusion rate of 13 Kg / h below the nozzle. The lower end of the shooter is 36 mm below the nozzle surface.
- the bottom end is submerged, and a stainless steel conveyor with a width of 55 cm is arranged in parallel so that a pair of take-up conveyors are partly exposed on the surface of the water at intervals of an opening width of 23 mm.
- the solidification process is performed by supplying warm water of 36 ° C onto the shooter at the same time, and the contact portions are intertwined to form a loop to fuse the contact portion.
- the obtained structure is formed of a wire having a square cross section and a line diameter of 0.6 to 1.1 mm, the surface is flattened, the bulk specific gravity is 70 kg / m 3 , and the thickness is 25 mm.
- Width 500 mm, 90 ° C., 30 minutes before and after the dry hot air test the thermal elongation rate is 1.87% in the vertical direction, 1.39% in the horizontal direction, 28.6% in the hysteresis loss, 33 cm of rebound resilience, constant gravity repeated test
- the subsequent impact resilience change rate was 6.1%.
- the temperature was 21 ° C. and the humidity was 48%.
- Example 3 The screw diameter of the extruder is 65 mm, the die temperature is 217 ° C., the die width direction is 900 mm, the thickness direction is 30 mm, the hole pitch is 10 mm, the nozzle hole diameter is 1 mm, the air gap (distance from the nozzle bottom surface to the water surface) is 69 mm, the main raw material thermoplastic elastomer (trademark "Hytrel”) wire diameter decrease rate for shear rate 60.8Sec -1 is 1.26, the diameter decrease rate for shear rate 121.6sec -1 1.28, for a shear rate 243.2Sec -1 as linear diameter reduction small ratio 1.30, diameter reduction rate is 1.30 for a shear rate of 608sec -1, wire diameter reduction rate is 1.33 for a shear rate of 1216 sec -1, MFR is 14 g / 10min, density 1.08 g / cm 3, a melting temperature At 195 ° C, the filaments are discharged at the bottom of the nozzle at an extrusion
- a stainless steel conveyor with a width of 105 cm is arranged in parallel so that a pair of take-up conveyors are partly exposed on the water surface at intervals of an opening width of 70 mm.
- the solidification process is performed by supplying hot water of 63 ° C onto the shooter, and the three-dimensional crosspiece structure is formed by melting the contact part by fusing the contact line to form a loop.
- the both sides of the structure in a state are sandwiched by a take-up conveyor and drawn and solidified at a take-up speed of 3.9 mm / sec, flattened on both sides, annealed with hot water at 80 ° C., and then cut into a predetermined size. Annealing was carried out with a hot air at 5 ° C.
- the resulting structure is formed of a wire having a square cross section and a line diameter of 0.5 to 1.0 mm, the surface is flattened, the bulk specific gravity is 71 kg / m3, the thickness is 30 mm, Width 900 mm, 130 ° C., 30 minutes before and after the dry hot air test, the thermal elongation rate is 0.78% in the vertical direction, 1.70% in the horizontal direction, 17.1% in hysteresis loss, the resilience is 33 cm, and after the constant repetition test The rebound resilience change rate was 0%. The temperature was 33 ° C. and the humidity was 48%.
- Example 4 The screw diameter of the extruder is 65 mm, the die temperature is 225 ° C., the die width direction is 900 mm, the thickness direction is 73 mm, the hole pitch is 10 mm, the nozzle hole diameter is 1.6 mm, the air gap is 69 mm (distance from the nozzle bottom surface to the water surface), heat A filament is discharged from a plastic elastomer (registered trademark “Hytrel”) (same raw material as in Example 3) at a melting temperature of 202 ° C., with an extrusion rate of 40 kg / h below the nozzle, and the lower end of the shooter is 69 mm below the nozzle surface.
- a plastic elastomer registered trademark “Hytrel”
- the bottom end is submerged, and a 105cm wide stainless steel conveyor is placed in parallel with an opening width of 72mm so that a part of the pair of take-up conveyors comes out on the water surface.
- Solidify by supplying 63 ° C warm water on the shooter, contact the tangled wires to form a loop and fuse the contact portion Then, the both sides of the melted structure are sandwiched by a take-up conveyor and drawn and solidified at a take-up speed of 2.7 mm / sec to flatten both sides, and then annealed with 80 ° C. hot water and cut into a predetermined size. Annealing was carried out with a hot air at 130 ° C. for 5 minutes to obtain a structure.
- the resulting structure is formed of strips having a quadrangular cross section and a line diameter of 0.5 to 1.2 mm, the surface is flattened, the bulk specific gravity is 63 kg / m 3 , the thickness is 73 mm, and before and after the dry hot air test.
- the thermal elongation ratio of the film was 1.22% in the vertical direction, 3.08% in the horizontal direction, 16.7% in the hysteresis loss, 34 cm in the rebound resilience, and 5.9% in the rebound resilience change rate after the constant gravity test.
- the temperature was 30 ° C. and the humidity was 44%.
- Example 5 The screw diameter of the extruder is 40 mm, the die temperature is 195 ° C., the die width direction is 500 mm, the thickness direction is 51 mm, the hole pitch is 10 mm, the nozzle hole diameter is 1 mm, the air gap (distance from the nozzle bottom surface to the water surface) is 38 mm, ethylene An ⁇ -olefin copolymer (same material as in Example 1) mixed with a main component and a non-combustible material was discharged at a melting temperature of 160 ° C., and a line was discharged below the nozzle at an extrusion rate of 23 kg / h.
- the bottom of the shooter is placed 38mm below, the bottom is submerged, and a stainless steel conveyor with a width of 55cm is arranged in parallel so that a pair of take-up conveyors are partly exposed on the water surface at intervals of an opening width of 40mm.
- the strip is solidified by supplying 36 ° C warm water onto the shooter, and at the same time, the strip is contacted and intertwined to form a loop. After forming the three-dimensional crosspiece structure while fusing the parts, the both sides of the molten structure are sandwiched by a take-up conveyor and drawn into 36 ° C.
- the obtained structure is formed of a wire having a square cross section and a line diameter of 0.7 to 1.3 mm, the surface is flattened, the bulk specific gravity is 50 kg / m 3 , the thickness is 51 mm, and the width is 400 mm.
- the elongation is 2.68% in the longitudinal direction, 1.28% in the transverse direction, 27.0% in hysteresis loss
- the impact resilience is 24 cm
- the impact resilience change after the constant gravity test The rate was 16.7%.
- the temperature was 15 ° C. and the humidity was 52%.
- Example 6 Extruder screw diameter 40mm, die temperature 195 ° C, die width direction 500mm, thickness direction 25mm, hole pitch 10mm, nozzle hole diameter 1mm, air gap (distance from nozzle bottom surface to water surface) 38mm, metallocene compound Hexane, hexene, and ethylene were polymerized by a known method using a catalyst as a catalyst, and the resulting ethylene / ⁇ -olefin copolymer (the same material as in Example 1) was mixed with a non-combustible material as a main component to a melting temperature of 160 ° C.
- the line is discharged below the nozzle at an extrusion rate of 17 Kg / h, the lower end of the shooter is placed 36 mm below the nozzle surface, the lower end is submerged, and a pair of stainless steel conveyors with a width of 55 cm are parallel with an opening width of 40 mm. Arrange the take-out conveyor so that it partially comes out on the surface of the water.
- the obtained structure is formed of a wire having a quadrangular cross section and a line diameter of 0.7 to 1.3 mm, the surface is flattened, the bulk specific gravity is 50 kg / m 3 , the thickness is 43 mm, and the width is 400 mm. , 90 ° C, 30 minutes dry hot air test before and after the thermal elongation rate of 2.06% in the vertical direction, 1.22% in the horizontal direction, 30.0% of hysteresis loss, rebound resilience of 32 cm, rebound after constant-gravity test The elastic change rate was 12.5%. The temperature was 21 ° C. and the humidity was 48%.
- Extruder screw diameter is 40mm
- die temperature is 205 ° C
- die width direction is 500mm
- thickness direction is 60mm
- hole pitch is 10mm
- nozzle hole diameter is 1mm
- air gap distance from nozzle bottom surface to water surface 38mm
- metallocene Hexane, hexene, and ethylene are polymerized by a known method using the compound as a catalyst, and the resulting ethylene / ⁇ -olefin copolymer (same material as in Example 1) and olefin block copolymer (polyethylene thermoplastic elastomer) are in a weight ratio.
- the wire is discharged under the nozzle at an extrusion rate of 22Kg / h, the lower end of the chute is placed 39mm below the nozzle surface, and a stainless steel conveyor with a width of 55cm is opened in parallel.
- a pair of take-up conveyors are arranged so as to partially come out on the water surface at intervals of 40 mm, and the solidified treatment is performed by supplying the molten discharge line on the chute and supplying warm water of 29 ° C on the chute.
- the structure is formed while the contact is entangled to form a loop and the contact part is fused, and the take-up speed is 29 ° at 4.5 mm / sec while sandwiching both sides of the melted structure with a take-up conveyor. After drawing into C hot water and solidifying to flatten both sides, it was cut to a predetermined size and dried and heat treated with hot air at 60 ° C. for 5 minutes to obtain a structure with a bulk density of 65 kg / m 3 .
- the obtained structure is formed by a strip having a square cross section and a line diameter of 0.8 to 1.5 mm, the surface is flattened, the bulk specific gravity is 65 kg / m 3 , the thickness is 50 mm, the width 405mm, 90 ° C, 30 minutes before and after drying hot air test, the thermal elongation rate is 3.04% in the longitudinal direction, 2.72% in the transverse direction, the hysteresis loss is 29.1%, the resilience is 16cm, the rate of change in the resilience after the constant-gravity test is 5.5 %Met. The temperature was 12 ° C and the humidity was 45%.
- the present invention since it has a thermal expansion property that thermally expands in the vertical direction and the horizontal direction, for example, when used in a mattress, even when disinfected at a high temperature, the mattress shrinks and the cover becomes wrinkled. The pressure ulcer caused by wrinkles is less likely to occur and is suitable.
- it since it has anisotropic thermal expansion characteristics with different thermal expansion rates in the vertical and horizontal directions, it can be adapted to the use of the structure and the characteristics of the human body in that application.
- the hysteresis loss is small and it has a soft and high resilience characteristic, it can provide elastic characteristics that match the characteristics of the human body, and it can respond to diversification of demands for the elastic characteristics of products and the advancement of quality requirements for products.
- the present invention has a small hysteresis loss, has a soft high resilience characteristic, has a thermal elongation characteristic that is thermally elongated by a dry hot air test in the longitudinal direction and the transverse direction, and has different thermal elongation characteristics in the longitudinal direction and the transverse direction.
- We can provide vehicle seats, cushions, mattresses, covers, etc. with elastic properties that fit the health consciousness.
- soft and easy-to-extend cushions such as pressure ulcers and nursing care can be provided. It can also be used for cushions used for vehicle seats, beds, mats, etc., and seats used for covers.
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Abstract
Description
試料の中心部分から樹脂糸を切り出し、ノギスで樹脂糸の厚みを5回測定した。5回の測定値の平均値を線径とした。S1とS2に対して測定した。エラストマー試料の線径は、ポリエステルの測定結果から推測した。アニーリング有りの温度は60℃、アニーリングなしは23℃とした。
試料を30cm×30cmの大きさに切断し、無荷重で24時間放置した後、4か所の高さを測定して平均値を試料厚みとした。試料厚みから体積を求め、試料の重さを体積で除した値を試料の嵩密度とした。
試料を20cm×20cmの大きさに切断し、押し出し方向表面に形成された不規則な形状のランダムループのループ円の直径が大きいほうを10か所測定を行い、平均値をミリ以下、切り捨て、ランダムループの平均直径とした。
試料を30cm(縦)×30cm(横)の大きさに切断し、この試験片をJIS K 6400-2:2012 A法を準用して計測した。試験温度20℃、湿度65%である。
試料を30cm(縦)×30cm(横)の大きさに切断し、この試験片をJIS K 6400-3:2011を準用して測定を行った。鋼球は直径が41.5mm、重さ290gのものを使用した。落下高さ500mmとした。試験温度23℃、湿度50%である。
試料を30cm(縦)×30cm(横)の大きさに切断し、(5)に記載の方法で定重繰返し試験前の反発弾性(a)を測定する。反発弾性を測定したサンプルに対して定重繰返し圧縮試験を実施する。定重繰り返し圧縮試験はJISK6400-4の繰返し圧縮残留ひずみ試験A法(定荷重法)に準拠して実施する。繰り返し圧縮試験は温度23±2℃、相対湿度50±5%で実施する。A法(定荷重法)は直径25cmの加圧板を用いてサンプルに750N±20Nの力で、毎分70±5回の早さで80000万回の繰返し圧縮を行う。最大の力750±20Nを加圧している時間は、繰り返し圧縮に要する時間の25%以下とする。試験終了後、サンプルに力のかからない状態で100±0.5分放置する。定重繰返し試験後の反発弾性(b)を(5)に記載の方法で測定する。定重繰返し試験後の反発弾性変化率(%)は、定重繰返し試験後の反発弾性を定重繰返し試験前の反発弾性で除す下記式にて算出される。
(定重繰返し試験後の反発弾性変化率(%))=(1-(b)/(a))×100
試料を30cm(縦)×30cm(横)の大きさに切断し、この試験片をJIS K 6400-2:2012 E法を準用して測定した。試験温度23℃、湿度50%である。
試料を30cm(縦)×30cm(横)の大きさに切断し、この試験片をJIS K 6400-2:2012 E法を準用して測定した。
試料を30cm(縦)×30cm(横)の大きさに切断し、試験片の縦方向と横方向の各2箇所に25cmとなるようにマーキングを行った。乾燥熱風試験後でも容易に識別できるペンでマーキングした。マーキングを行った試験片を熱風乾燥炉に30分間入れた。その後、熱風循環乾燥炉から試料を取り出し、22℃の室温で30分間冷却した。冷却後に縦方向と横方向のマーキング距離を各2箇所計測し、各2箇所の平均値を、試験後の縦長さ、試験後の横長さとした。全ての長さの測定は、0.01cmまで読み取れる計測器を用いた。乾燥熱風試験前後の熱伸長率は、(25-得られた長さ)/25×100で計算した。ポリエチレン系樹脂の乾燥熱風試験温度は90℃、ポリエステル系熱可塑性エラストマーの乾燥熱風試験温度は130℃、ポリエチレン樹脂とポリエチレン系熱可塑性エラストマーの乾燥熱風試験温度は90℃とした。
試料を20cm(縦)×5cm(横)の大きさに切断し、この試験片を固定金具間が10cmになるように治具に固定した。引張速度は10cm/minとした。測定時の室温は20℃、湿度は65%である。熱可塑性エラストマーは厚みがあるため固定するための治具を用いた。同一試料に対して縦横それぞれ2回の測定を行い、最大点荷重を測定値とした。
押出機のスクリュー径が65mm、ダイス温度が205℃、ダイスの幅方向890mm、厚み方向75mm、孔間ピッチ10mm、ノズル穴径が1.6mm、エヤーギャップ(ノズル下面から水面までの距離)67mm、主原料はメタロセン化合物を触媒としてヘキサン、ヘキセン、エチレンを公知の方法で重合し、得られたエチレン・α-オレフィン共重合体、せん断速度24.3sec-1に対する線径減少率が1.05、せん断速度60.8sec-1に対する線径減少率が1.12、せん断速度121.6sec-1に対する線径減少率が1.15、せん断速度243.2sec-1に対する線径減少率が1.18、せん断速度608sec-1に対する線径減少率が1.23、せん断速度1216sec-1に対する線径減少率が1.26、MFRが12g/10min、密度0.90g/cm3を溶融温度180℃にて、ノズル下方に押出量が86Kg/hにて線条を吐出させ、ノズル面36mm下にシューター下端を配し下端を水没させ、幅105cmのステンレス製コンベアを平行に開口幅71mm間隔で一対の引取りコンベアを水面上に一部出るように配して、溶融状態の吐出線条をシューターの上で36℃の加温水をシューター上に供給することにより固化処理を行うとともに、線条を接触絡合させてループを形成して接触部分を融着させつつ三次元桟構造を形成し、溶融状態の構造体の両面を引取コンベアで挟み込みつつ引取速度が6.7mm/secで36℃の温水へ引込み固化させ両面をフラット化した後、所定の大きさに切断して、60℃の熱風にて5分間乾燥熱処理によるアニーリングを行い、構造体を得た。得られた構造体は、断面形状が四角形、線経が0.6~1.1mmの線条で形成されており、表面は平坦化されており、嵩比重が53kg/m3、厚みが75mm、幅890mm、90℃、30分間乾燥熱風試験前後の伸長率が縦方向で2.31%、横方向で1.52%、ヒステリスロスが28.7%、反発弾性31cm、定重繰返し試験後の反発弾性変化率0%であった。なお、気温19℃、湿度42%であった。
押出機のスクリュー径が40mm、ダイス温度が190℃、ダイスの幅方向500mm、厚み方向25mm、孔間ピッチ10mm、ノズル穴径が1.6mm、エヤーギャップ(ノズル下面から水面までの距離)38mm、エチレン・α-オレフィン共重合体(原料は実施例1と同一)のポリエチレンを溶融温度160℃にて、ノズル下方に押出量が13Kg/hにて線条を吐出させ、ノズル面36mm下にシューター下端を配し下端を水没させ、幅55cmのステンレス製コンベアを平行に開口幅23mm間隔で一対の引取りコンベアを水面上に一部出るように配して、溶融状態の吐出線条をシューターの上で36℃の加温水をシューター上に供給することにより固化処理を行うとともに、線条を接触絡合させてループを形成して接触部分を融着させつつ三次元桟構造を形成し、溶融状態の構造体の両面を引取コンベアで挟み込みつつ引取速度が4.1mm/secで36℃の温水へ引込み固化させ両面をフラット化した後、所定の大きさに切断して60℃の熱風にて5分間乾燥熱処理によるアニーリングを行い、構造体を得た。得られた構造体は、断面形状が四角形、線経が0.6~1.1mmの線条で形成されており、表面は平坦化されており、嵩比重が70kg/m3、厚みが25mm、幅500mm、90℃、30分間の乾燥熱風試験前後の熱伸長率が縦方向で1.87%、横方向で1.39%、ヒステリスロスが28.6%、反発弾性33cm、定重繰返し試験後の反発弾性変化率6.1%であった。気温21℃、湿度48%であった。
押出機のスクリュー径が65mm、ダイス温度が217℃、ダイスの幅方向900mm、厚み方向30mm、孔間ピッチ10mm、ノズル穴径が1mm、エヤーギャップ(ノズル下面から水面までの距離)69mm、主原料として熱可塑性エラストマー(登録商標「ハイトレル」)、せん断速度60.8sec-1に対する線径減少率が1.26、せん断速度121.6sec-1に対する線径減少率が1.28、せん断速度243.2sec-1に対する線径減 少率が1.30、せん断速度608sec-1に対する線径減少率が1.30、せん断速度1216sec-1に対する線径減少率が1.33、MFRが14g/10min、密度1.08g/cm3、を溶融温度195℃にて、ノズル下方に押出量が27.5Kg/hにて線条を吐出させ、ノズル面69mm下にシューター下端を配し下端を水没させ、幅105cmのステンレス製コンベアを平行に開口幅70mm間隔で一対の引取りコンベアを水面上に一部出るように配して、溶融状態の吐出線条をシューターの上で63℃の温水をシューター上に供給することにより固化処理を行うとともに、線条を接触絡合させてループを形成して接触部分を融着させつつ三次元桟構造を形成し、溶融状態の構造体の両面を引取コンベアで挟み込みつつ引取速度が3.9mm/secで引込み固化させ両面をフラット化した後、80℃の湯でアニーリングし、その後、所定の大きさに切断して130℃の熱風にて5分間乾燥熱処理によるアニーリングを行い、構造体を得た。得られた構造体は、断面形状が四角形、線経が0.5~1.0mmの線条で形成されており、表面は平坦化されており、嵩比重が71kg/m3、厚みが30mm、幅900mm、130℃、30分間乾燥熱風試験前後の熱伸長率が縦方向で0.78%、横方向で1.70%、ヒステリスロスが17.1%、反発弾性33cm、定重繰返し試験後の反発弾性変化率0%であった。気温33℃、湿度48%であった。
押出機のスクリュー径が65mm、ダイス温度が225℃、ダイスの幅方向900mm、厚み方向73mm、孔間ピッチ10mm、ノズル穴径が1.6mm、エヤーギャップ69mm(ノズル下面から水面までの距離)、熱可塑性エラストマー(登録商標「ハイトレル」)(実施例3と同一原料)を溶融温度202℃にて、ノズル下方に押出量が40Kg/hにて線条を吐出させ、ノズル面69mm下にシューター下端を配し下端を水没させ、幅105cmのステンレス製コンベアを平行に開口幅72mm間隔で一対の引取りコンベアを水面上に一部出るように配して、溶融状態の吐出線条をシューターの上で63℃の加温水をシューター上に供給することにより固化させ、線条を接触絡合させてループを形成して接触部分を融着させつつ構造体を形成し、溶融状態の構造体の両面を引取コンベアで挟み込みつつ引取速度が2.7mm/secで引込み固化させ両面をフラット化した後、80℃の湯でアニーリングし、所定の大きさに切断して130℃の熱風にて5分間乾燥熱処理によるアニーリングを行い、構造体を得た。得られた構造体は、断面形状が四角形、線経が0.5~1.2mmの線条で形成され、表面は平坦化されており、嵩比重が63kg/m3、厚みが73mm、乾燥熱風試験前後の熱伸長率が縦方向で1.22%、横方向で3.08%、ヒステリスロスが16.7%、反発弾性34cm、定重繰返し試験後の反発弾性変化率5.9%であった。気温30℃、湿度44%であった。
押出機のスクリュー径が40mm、ダイス温度が195℃、ダイスの幅方向500mm、厚み方向51mm、孔間ピッチ10mm、ノズル穴径が1mm、エヤーギャップ(ノズル下面から水面までの距離)38mm、エチレン・α-オレフィン共重合体(実施例1と同一材料)主成分と不燃材を混合したものを溶融温度160℃にて、ノズル下方に押出量が23Kg/hにて線条を吐出させ、ノズル面38mm下にシューター下端を配し下端を水没させ、幅55cmのステンレス製コンベアを平行に開口幅40mm間隔で一対の引取りコンベアを水面上に一部出るように配して、溶融状態の吐出線条をシューターの上で36℃の加温水をシューター上に供給することにより固化処理を行うとともに、線条を接触絡合させてループを形成して接触部分を融着させつつ三次元桟構造を形成し、溶融状態の構造体の両面を引取コンベアで挟み込みつつ引取速度が6.8mm/secで36℃の温水へ引込み固化させ両面をフラット化した後、所定の大きさに切断して60℃の熱風にて5分間乾燥熱処理して、嵩密度45kg/m3の構造体を得た。得られた構造体は、断面形状が四角形、線経が0.7~1.3mmの線条で形成されており、表面は平坦化されており、嵩比重が50kg/m3、厚みが51mm、幅400mm、90℃、30分間乾燥熱風試験前後の伸長率が縦方向で2.68%、横方向で1.28%、ヒステリスロスが27.0%、反発弾性24cm、定重繰返し試験後の反発弾性変化率16.7%であった。気温15℃、湿度52%であった。
押出機のスクリュー径が40mm、ダイス温度が195℃、ダイスの幅方向500mm、厚み方向25mm、孔間ピッチ10mm、ノズル穴径が1mm、エヤーギャップ(ノズル下面から水面までの距離)38mm、メタロセン化合物を触媒としてヘキサン、ヘキセン、エチレンを公知の方法で重合し、得られたエチレン・α-オレフィン共重合体(実施例1と同一材料)主成分とし不燃材を混合した原料を溶融温度160℃にて、ノズル下方に押出量が17Kg/hにて線条を吐出させ、ノズル面36mm下にシューター下端を配し下端を水没させ、幅55cmのステンレス製コンベアを平行に開口幅40mm間隔で一対の引取りコンベアを水面上に一部出るように配して、溶融状態の吐出線条をシューターの上で36℃の加温水をシューター上に供給することにより固化処理を行うとともに、線条を接触絡合させてループを形成して接触部分を融着させつつ三次元桟構造を形成し、溶融状態の構造体の両面を引取コンベアで挟み込みつつ引取速度が4.5mm/secで36℃の温水へ引込み固化させ両面をフラット化した後、所定の大きさに切断して60℃の熱風にて5分間乾燥熱処理して、嵩密度65kg/m3の構造体を得た。得られた構造体は、断面形状が四角形、線経が0.7~1.3mmの線条で形成されており、表面は平坦化されており、嵩比重が50kg/m3、厚みが43mm、幅400mm、90℃、30分間の乾燥熱風試験前後の熱伸長率が縦方向で2.06%、横方向で1.22%、ヒステリスロスが30.0%、反発弾性32cm、定重繰返し試験後の反発弾性変化率12.5%であった。気温21℃、湿度48%であった。
押出機のスクリュー径が40mm、ダイス温度が205°C、ダイスの幅方向500mm、厚み方向60mm、孔間ピッチ10mm、ノズル穴径が1mm、エヤーギャップ(ノズル下面から水面までの距離)38mm、メタロセン化合物を触媒としてヘキサン、ヘキセン、エチレンを公知の方法で重合し、得られたエチレン・α-オレフィン共重合体(実施例1と同一材料)とオレフィン ブロック コポリマー(ポリエチレン系熱可塑性エラストマー)を重量比20%混ぜ溶融温度200°Cにて、ノズル下方に押出量が22Kg/hにて線条を吐出させ、ノズル面39mm下にシュート下端を配し、幅55cmのステンレス製コンベアを平行に開口幅40mm間隔で一対の引取りコンベアを水面上に一部出るように配して、溶融状態の吐出線条をシュートの上で29°Cの加温水をシュート上に供給することにより固化処理を行うとともに、線条を接触絡合させてループを形成して接触部分を融着させつつ構造体を形成し、溶融状態の構造体の両面を引取コンベアで挟み込みつつ引取速度が4.5mm/secで29°Cの温水へ引込み固化させ両面をフラット化した後、所定の大きさに切断して60°Cの熱風にて5分間乾燥熱処理して、嵩密度65kg/m3の構造体を得た。得られた構造体は、断面形状が四角形、線経が0.8~1.5mmの線条で形成されており、表面は平坦化されており、嵩比重が65kg/m3、厚みが50 mm、幅405mm、90°C、30分間の乾燥熱風試験前後の熱伸長率が縦方向で3.04%、横方向で2.72%、ヒステリスロスが29.1%、反発弾性16cm、定重繰返し試験後の反発弾性変化率5.5%であった。気温12°C、湿度45%であった。
他社製マットレスのポリエステル系熱可塑性エラストマー製の網状構造体(厚みが45mm、幅400mm)について各試験を行った結果、嵩比重が40kg/m3、130℃、30分間の乾燥熱風試験前後の熱伸長率が縦方向で-0.32(収縮)、横方向で-0.12%(収縮)、ヒステリスロスが70.4%、反発弾性22cm、定重繰返し試験後の反発弾性変化率68.2%であった。
比較例1とは別の他社製マットレスのポリエステル系熱可塑性エラストマー製の網状構造体(厚みが25mm、幅400mm)について各試験を行った結果、嵩比重が50kg/m3、130℃、30分間の乾燥熱風試験前後の熱伸長率が縦方向で-0.28(収縮)、横方向で-0.20%(収縮)、ヒステリスロスが81.0%、反発弾性21cm、定重繰返し試験後の反発弾性変化率4.8%であった。
Claims (11)
- 連続線条が部分的にランダムに溶着することによりループを形成し、押出方向に対応する縦方向、前記押出方向と直交する横方向と厚み方向を有する、ポリエチレン系熱可塑性樹脂、ポリエステル系熱可塑性エラストマー、又はポリエチレン系熱可塑性樹脂とポリエチレン系熱可塑エラストマーの混合物からなる、三次元桟構造体であり、
前記三次元桟構造体の反発弾性が13cm以上であり、
ヒステリシスロスが34%を超えず、13%を下回らず、
ポリエチレン系熱可塑性樹脂の場合に温度90℃で30分間、ポリエステル系熱可塑性エラストマーの場合に130℃で30分間、又はポリエチレン系熱可塑性樹脂とポリエチレン系熱可塑エラストマーの混合物の場合に90℃で30分間の乾燥熱風試験後、前記縦方向において乾燥熱風試験前後の熱伸長率が0~8%である三次元桟構造体。 - ポリエチレン系熱可塑性樹脂の場合に温度90℃で30分間、ポリエステル系熱可塑性エラストマーの場合に130℃で30分間、又はポリエチレン系熱可塑性樹脂とポリエチレン系熱可塑エラストマーの混合物の場合に90℃で30分間の乾燥熱風試験後、前記横方向において、乾燥熱風試験前後の熱伸長率が0~8%である請求項1の三次元桟構造体。
- 前記縦方向と前記横方向の熱伸長率が異なる非等方性の熱伸長特性を有する請求項1または請求項2の三次元桟構造体。
- ポリエチレン系熱可塑性樹脂の場合は、定荷重繰返し試験後の反発弾性変化率が25%以下、ポリエステル系熱可塑性エラストマーの場合は、定荷重繰返し試験後の反発弾性変化率が20%以下、である請求項1から3までのいずれかに記載の三次元桟構造体。
- 前記三次元桟構造体の見掛け密度が、0.025g/cm3~0.2g/cm3であり、厚みが単層及び複層において5mm~500mmで、線径が直径0.1mm~1.5mmである請求項1から4までのいずれかに記載の三次元桟構造体。
- 前記ポリエチレン系熱可塑性樹脂が、ポリエチレン、または、主としてエチレンと炭素数3以上のαオレフィンからなるエチレン・α-オレフィン共重合体樹脂である請求項1から5までのいずれかに記載の三次元桟構造体。
- 前記ポリエチレン系熱可塑性樹脂とポリエチレン系熱可塑性エラストマーの混合物は、主としてエチレンと炭素数3以上のαオレフィンからなるエチレン・α-オレフィン共重合体樹脂とポリエチレン系熱可塑性エラストマーの混合物であり、前記混合物中の前記ポリエチレン系熱可塑性エラストマーの含有量は重量比率で45%以下である、請求項1から5までのいずれかに記載の三次元桟構造体。
- クッション、クッションシート、座布団、枕、介護用品、ベッド用クッションまたはマットレス用であることを特徴とする請求項1から7までのいずれかに記載の三次元桟構造体。
- 複数の面を備え、そのうちの2面、3面、または、4面が成形され、又は曲面が形成された請求項1から8までのいずれかに記載の三次元桟構造体。
- ポリエチレン系熱可塑性樹脂からなる三次元網状構造と、ポリエチレン系熱可塑性エラストマーからなる三次元網状構造を積層したものである請求項1ないし9いずれかに記載の三次元桟構造体。
- 前記三次元網状構造が押出方向に粗密の帯状部分が繰り返され、疎の帯状部分を基準とする密の帯状部分の単位重さあたりの接合点数の比率が0.96~1.33であり、前記疎の帯状部分の見掛け密度に対して、密の帯状部分の見掛け密度が0.005g/cm3以上の差のある請求項1ないし10いずれかに記載の三次元桟構造体。
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