JP2921638B2 - Cushion net structure and manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cushion-like reticulated structure made of thermoplastic elastic resin having durability and cushioning properties suitable for furniture, beds, vehicle seats, marine seats, etc., and Regarding its manufacturing method.

[0002]

2. Description of the Related Art At present, cushioning materials for furniture, beds, trains, automobiles, etc. are made of urethane foam, inelastic crimped fiber,
Resin cotton and hard cotton to which inelastic crimped fibers are bonded are used.

[0003] However, foamed-crosslinked urethane has good durability as a cushioning material, but is inferior in moisture permeation and water permeability and has heat storage properties, so that it is easy to humid. In addition, the damage to the incinerator is large, and the cost for removing toxic gas is high.
For this reason, landfills have been increased, but there is a problem in that it is difficult to stabilize the ground, so that landfill locations are limited and costs increase. Further, although the processability is excellent, there is a problem of pollution of chemicals used during the production. In addition, since the fibers are not fixed in the thermoplastic polyester bonded cotton, the shape during use is distorted, the fibers move, and the crimping is reduced, so that the sublimeness and the elasticity are reduced. become.

Japanese Patent Application Laid-Open Publication No. Sho 6 (1994) discloses a resin cotton in which polyester fibers are bonded with an adhesive, for example, a rubber using an adhesive as a rubber.
Nos. 0-11352, JP-A-61-141388 and JP-A-61-141391. Further, JP-A-61-1377 discloses a method using a crosslinkable urethane.
No. 32 publication. These cushioning materials are inferior in durability, are not thermoplastic, cannot be recycled because they are not a single composition, and have problems such as complicated workability and pollution of chemicals used during production. .

[0005] Polyester hard cotton, for example, JP-A-58-3
JP-A No. 1150, JP-A-2-154050, JP-A-3-220354, etc., are disclosed. However, since the fiber component of the heat-bonding fiber used is a brittle amorphous polymer (for example, see JP-A-58-158). 136828, JP-A-3-
There is a problem that the adhesive portion is brittle and the durability is poor such that the adhesive portion is easily broken during use and the form and elasticity are reduced. As an improved method, a method of performing confounding treatment has been proposed in Japanese Patent Application Laid-Open No. 4-245965, but there is a problem that the brittleness of the bonded portion is not solved and the elasticity is greatly reduced. In addition, there is also complexity in processing. Further, there is a problem that the bonded portion is hardly deformed and it is difficult to provide soft cushioning. For this reason, Japanese Patent Application Laid-Open No. 4-240219 proposes a heat-bonding fiber using a polyester elastomer whose adhesive portion is soft and recovers even when deformed, and a cushioning material using the fiber is disclosed in WO-91 / 19032. Have been. In order to lower the melting point, the polyester elastomer as the adhesive component used in this fiber structure contains 50 to 80 mol% of terephthalic acid in the acid component of the hard segment, and the content of polyalkylene glycol as the soft segment is 30 to 80%. 50% by weight, and other acid components such as isophthalic acid as in the case of the fiber described in JP-B-60-1404. Although the formation of the heat-bonded portion is improved as the melt viscosity to form an amoeboid-shaped bonded portion, there is a problem that the heat-resistant and compression-resistant properties are reduced due to easy plastic deformation.

A thermoplastic olefin network used for civil engineering is disclosed in JP-A-47-44839. However, unlike a cushion made of fine fibers, the surface is uneven and the touch is poor, and since the material is an olefin, the heat resistance and durability are extremely poor and cannot be used as a cushion material. In addition, a net-like structure using vinyl chloride has been proposed for door mats and the like, but it is unsuitable for cushioning materials because it is easily plastically deformed and toxic hydrogen halide is generated during combustion. .

[0007]

SUMMARY OF THE INVENTION In order to solve the above problems,
An object of the present invention is to provide a net structure for a cushion which can be made into a hard-to-steam cushion having excellent heat resistance, durability and cushioning property, and which can be easily recycled, and a method for producing the same.

[0008]

In order to solve the above-mentioned problems, the present invention is to form a random loop by winding a continuous linear body of 300 denier or more, and to contact the respective loops in a molten state with each other. At the very least, it is a three-dimensional random loop joining structure made by fusing most of the contact part, and the continuous linear body is mainly made of thermoplastic elastic resin,
An apparent density of 0.005 to 0.20 g / cm ³ , and
70 ° C. of residual strain (%) of mesh structure for the network structure and a cushion cushion, characterized in that 35% or less
When manufacturing the structure, the starting material
A thermoplastic elastic resin whose residual strain (%) at 70 ° C. of the structure is 35% or less is mainly used, and the thermoplastic elastic resin in a molten state is lowered from a plurality of orifices at a temperature higher by 10 ° to 80 ° C. than the melting point. To form a continuous linear body loop in the molten state, contact each other loop and fuse to form a three-dimensional random loop structure, sandwich it with a take-off device, and continue to cool A method for producing a mesh-like structure for a cushion, the method comprising:

The characteristic structure of the network structure of the present invention is as described above. In particular, the continuous linear body is mainly composed of a thermoplastic elastic resin, and has excellent heat resistance and durability as a cushioning material, which cannot be seen in a conventional network structure. The reticulated structure of the present invention has a residual strain at 70 ° C. which is such a parameter of heat resistance and durability at 35% or less, preferably 30% or less, more preferably 20% or less, particularly 15%.
In the following, surprisingly, it reaches 10% or less. Here, if the residual strain exceeds 35%, the desired properties as the cushioning material are not satisfied, which is not preferable.

[0010] The continuous linear body forming the network structure of the present invention is required to be mainly composed of a thermoplastic elastic resin. However, due to the required performance of the network structure, the residual strain is 35%.
May be mixed with a non-elastic resin other than the thermoplastic elastic resin.

The continuous linear body made of the thermoplastic elastic resin forming the network structure of the present invention has a residual strain not exceeding 35% in relation to the required performance of the network structure. It may be a composite form combined with an inelastic resin.
Examples of the composite form include a linear body such as a sheath-core type side-by-side type and an eccentric seascore type when the linear body itself is composited.

On the other hand, as a composite (integrally bonded structure) of the network structure layer, a sandwich structure of an elastomer layer / a non-elastomer layer / an elastomer layer, a two-layer structure of an elastomer layer / a non-elastomer layer, and an elastomer layer of a matrix are used. A composite structure in which a non-elastomeric layer is partially disposed inside is used.

In the network structure of the present invention, depending on the required performance, a network structure having a different loop size, a different denier, a different composition, a different density or the like is appropriately selected. Then, they may be laminated or mixed.

Further, a heat bonding layer (low melting point heat bonding fiber or low melting point heat bonding film) is provided on the surface of the laminated structure as necessary, and is bonded and integrated with the side lining and wading layer to form a seat cushion. The method also includes a method and a method in which a hard cushion (preferably made of a thermo-adhesive fiber using an elastomer) is used in combination with a wadding layer and heat-bonded to the side ground to form a cushion.

In order to make the network structure of the present invention particularly excellent in heat resistance and durability, the content of the linear body made of a thermoplastic elastic resin may be increased. In particular, it has been found that when formed from 100% thermoplastic elastic resin linear material and subjected to pseudo-crystallization treatment described below, the residual strain at 70 ° C. reaches 15% or less, particularly 10% or less.

[0016] The thermoplastic elastomeric resin in the present invention, click
35% residual strain (%) at 70 ° C
It is a resin capable of providing the following, and examples thereof include a polyester elastomer, a polyamide elastomer, and a polyurethane elastomer. By using a thermoplastic elastic resin, regeneration becomes possible by re-melting, so that recycling becomes easy.

For example, as a polyester elastomer, thermoplastic polyester is used as a hard segment,
Examples thereof include a polyester ether block copolymer having a polyalkylene diol as a soft segment and a polyester ether block copolymer having an aliphatic polyester as a soft segment. More specific examples of polyester ether block copolymers include terephthalic acid, isophthalic acid, naphthalene 2.6 dicarboxylic acid, naphthalene 2.7 dicarboxylic acid, diphenyl 4,
Aromatic dicarboxylic acids such as 4'-dicarboxylic acid, alicyclic dicarboxylic acids such as 1,4-cyclohexanedicarboxylic acid, aliphatic dicarboxylic acids such as succinic acid, adipic acid, sebacic acid, dimer acid, and ester-forming derivatives thereof At least one dicarboxylic acid selected from the group consisting of
Aliphatic diols such as butanediol, ethylene glycol, tremethylene glycol, tetramethylene glycol, pentamethylene glycol, hexamethylene glycol, etc., alicyclic diols such as 1.1 cyclohexane dimethanol, 1.4 cycloxan dimethanol, or these At least one diol component selected from ester-forming derivatives of the formula (I) and an average molecular weight of about 300 to
It is a ternary block copolymer composed of at least one of 5000 polyalkylene diols such as polyethylene glycol, polypropylene glycol, polytetramethylene glycol, and ethylene oxide-propylene oxide copolymer. The polyester ester block copolymer is a ternary block copolymer composed of at least one of the above dicarboxylic acids and diols and at least one of polyester diols such as polylactone having an average molecular weight of about 300 to 3,000. In consideration of thermal adhesion, hydrolysis resistance, stretchability, heat resistance, etc., terephthalic acid or naphthalene 2.6 dicarboxylic acid as a dicarboxylic acid, 1.4 butanediol as a diol component, and polyalkylene diol as a diol component. Is particularly preferably a triblock copolymer of polytetramethylene glycol or a triblock copolymer of polylactone as the polyester diol. In a special case, those incorporating a polysiloxane-based soft segment can also be used.
The above polyester elastomers can be used alone or in combination of two or more. Furthermore, polyester elastomer blended with non-elastomer components,
Copolymers and the like can also be used in the present invention.

As the polyamide-based elastomer, nylon 6, nylon 66, nylon 6,
10, nylon 612, nylon 11, nylon 12, and the like, and their copolymerized nylon. The soft segment contains polyethylene glycol, polypropylene glycol, polytetramethylene glycol, ethylene oxide-propylene oxide having an average molecular weight of about 300 to 5,000. A block copolymer composed of at least one kind of a polyalkylene diol such as a polymer may be used alone or as a mixture of two or more kinds. Further, those obtained by blending or copolymerizing non-elastomeric components can also be used in the present invention.

As the polyurethane-based elastomer, (A) a number average molecular weight of 1 can be obtained in the presence or absence of a usual solvent (dimethylformamide, dimethylacetamide, etc.).
A polyether and / or polyester having a hydroxyl group at a terminal of 000 to 6000 and (B) a polyisocyanate containing an organic diisocyanate as a main component are reacted with a prepolymer having both isocyanate groups at the both ends, and a diamine (C) as a main component. Polyurethane elastomer chain-extended with a polyamine to be described can be exemplified as a typical example. The polyester and polyether (A) have an average molecular weight of about 1000 to 6000, preferably 1300 to 5000.
Polyalkylene diols such as polybutylene adipate copolymerized polyester and polyethylene glycol, polypropylene glycol, polytetramethylene glycol, and ethylene oxide-propylene oxide copolymers are preferable. As the polyisocyanate (B), a conventionally known polyisocyanate is used. However, it is also possible to use a cisocyanate mainly composed of diphenylmethane 4.4 / 4 'diisocyanate, and to add a small amount of a conventionally known triisocyanate or the like, if necessary. As the polyamine (C), known diamines such as ethylenediamine and 1.2-propylenediamine are mainly used, and trace amounts of triamine and tetraamine may be used in combination as needed. These polyurethane elastomers may be used alone or in combination of two or more.

In the present invention, examples of the thermoplastic inelastic resin other than the thermoplastic elastic resin used as the raw material of the continuous linear body or the raw material of the composite linear body include polyester, polyamide, and polyurethane. The combination of a thermoplastic elastic resin and a thermoplastic inelastic resin is preferable from the viewpoint of recycling use of the cushion network structure, preferably a polyester elastomer and a polyester resin, a polyurethane elastomer and a polyurethane resin, a polyamide elastomer and a polyamide resin. Good combination with.

The polyester resin is polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polycyclohexylene dimethylene terephthalate (PCHDT), polycyclohexylene dimethylene naphthalate (PCHDN), polybutylene terephthalate (PBT). , Polybutylene naphthalate (PB
N) and the like, and their copolymerized polyesters. For polyamide resins, polycaprolactam (NY
6), polyhexamethylene adipamide (NY66), polyhexamethylene sebacamide (NY6-10), and their copolymerized polyamides.

The melting point of the thermoplastic elastic resin of the present invention is preferably 140 ° C. or higher, at which the heat resistance and durability can be maintained, and more preferably 160 ° C. or higher, since the heat resistance is improved. Here, the higher the melting point, the higher the heat resistance and durability, but conversely, difficulties arise in workability.
It is preferable to keep the temperature to about 0 ° C. If necessary,
The durability can be improved by adding an antioxidant, a light stabilizer, or the like. From the embodiment of the present invention, it is preferable to add at least 1% or more of an antioxidant to improve heat resistance.
Here, as the amount of the antioxidant added increases, the heat resistance improves, but the cost is increased, so it is preferably up to 10% by weight.

The continuous linear body made of the thermoplastic elastic resin constituting the network structure of the present invention preferably has an endothermic peak below the melting point in a melting curve measured by a differential scanning calorimeter. Those having an endothermic peak below the melting point have remarkably improved heat resistance and sag resistance than those having no endothermic peak. Although the reason for this is not clear, it is considered that pseudo-crystallization-like cross-linking points are formed and the heat resistance and sag resistance are improved. For example, terephthalic acid, naphthalene 2,6-dicarboxylic acid, or the like as an acid component is preferably 9 as a preferred polyester elastomer of the present invention.
After the transesterification of the glycol component with 0 mol% or more, more preferably the content of terephthalic acid or naphthalene 2.6 dicarboxylic acid is 95 mol% or more, particularly preferably 100 mol%, polymerization is carried out to a required degree of polymerization. And then
As the polyalkylene diol, preferably, a polytetramethylene glycol having an average molecular weight of 500 to 5,000, particularly preferably 1,000 to 3,000 is used.
% To 70% by weight, more preferably 30% by weight
When the copolymerization amount is not less than 60% by weight, if the content of terephthalic acid or naphthalene 2.6 dicarboxylic acid is large, the crystallinity of the hard segment is improved, the plastic segment is hardly deformed, and the heat resistance is improved. However, if an annealing treatment is performed at a temperature lower by at least 10 ° C. than the melting point after the fusion bonding, the heat resistance and set resistance are further improved. In this case, the melting curve of the continuous linear body measured by the differential scanning calorimeter (DSC) more clearly shows an endothermic peak at a temperature lower than the melting point other than the melting point. By analogy with this, it is considered that the hard segments are rearranged by the unringing, pseudo-crystal-like cross-linking points are formed, and the heat resistance is improved. Annealing for such a purpose in the present invention is hereinafter referred to as pseudo-crystallization treatment.

The reticulated structure of the present invention forms a large number of loops by winding a continuous linear body of 300 denier or more mainly composed of a thermoplastic elastic resin, and the respective loops are brought into contact with each other in a molten state. Are fused to each other to form a network structure composed of three-dimensional random loops. As a result, even if a large deformation is applied with a very large stress, the entire network structure consisting of the fused three-dimensional random loops is deformed to absorb the stress, and when the stress is released, the rubber of the elastic resin is released. Due to the development of elasticity, the structure can recover to its original shape. When a net-like structure made of a continuous linear body made of a known inelastic resin is used as a cushion material, plastic deformation occurs, and such recovery does not occur, so that heat resistance and durability are poor. If not fused, the shape cannot be maintained, and the structure does not deform integrally, so that fatigue phenomena occur due to stress concentration and the durability is deteriorated, and the shape is undesirably deformed. A more preferable degree of fusion according to the present invention is a state in which all contact portions are fused. If the fineness of the continuous linear body of the present invention is not more than 300 denier, the strength is low and the repulsion is reduced, which is not preferable. The preferred fineness of the continuous linear body of the present invention is 4
Not less than 00 denier and not more than 100000 denier,
If the denier is 0000 denier or more, the number of the linear members is reduced and the compression characteristics are deteriorated, so that the used portion may be limited. More preferably, it is 500 to 50,000 denier. The cross-sectional shape is not particularly limited. However, in the case of forming a continuous linear body having a fine fineness, a deformed cross section or a hollow cross section is preferable because the repulsive force is improved.

Three-dimensional run formed by the continuous linear body of the present invention
Reticulated structure where dam loops are in contact and mostly fused together
The apparent density of the body is 0.005g / cm^Three0.20g /
cm ^ThreeIt is as follows. The apparent density is 0.005g / cm^ThreeNot yet
When full, the resilience will be lost, making it unsuitable for cushioning
Yes, 0.20 g / cm^ThreeBeyond, elasticity becomes strong
It is not suitable for cushioning material because it makes sitting uncomfortable
It becomes something. The preferred apparent density of the present invention is 0.005.
~ 0.10g / cm^Three, More preferably 0.01 to 0.1.
05g / cm^ThreeIt is. The network structure of the present invention is
For use in cushioning materials, bulk retention when sitting in a seat
Comfortable seating that can maintain breathability and elasticity and maintain breathability
100g / cm as apparent density when compressed to fill the ground^Two
0.03g / cm under load^Three~ 0.25g / cm^Three
Having a bulkiness of 0.05 g / cm^Three
~ 0.20g / cm^ThreeThose having bulkiness are particularly preferred.
New Three-dimensional random loop forming the network structure of the present invention
The preferred average diameter of the loop is 50 mm or less. 50mm
Above this, the loop expands in the thickness direction and the porosity becomes uneven.
It may be easier to come and may have cushioned spots. Void
A more preferable average diameter in which the occurrence of spots is less likely is 2-2.
5 mm. The thickness of the mesh structure is not particularly limited.
Not easily function as a cushion
It is preferably at least 3 mm, more preferably at least 5 mm.
Particularly preferred.

Next, the production method of the present invention will be described. In the present invention, a thermoplastic elastic resin obtained by a known method such as Japanese Patent Application Laid-Open No. 55-120626, which is melted by using a general melt extruder, is heated to a temperature 10 to 80 ° C. higher than the melting point to obtain a molten state. The nozzle is discharged downward from a nozzle having a plurality of orifices, and is naturally lowered to form a loop.
At this time, the loop diameter and the fineness of the linear body are determined by the distance between the nozzle surface and a take-off conveyor provided on a cooling medium for solidifying the resin, the melt viscosity of the resin, the hole diameter of the orifice, and the discharge amount. A loop is generated by sandwiching and stopping the discharge linear body in a molten state by a pair of take-up conveyors that can be adjusted on the cooling medium, and a loop is generated, and a hole interval of the orifice is set to a hole interval that the generated loop can contact. The generated loops are brought into contact with each other, and the contact portions are fused while forming a random three-dimensional form by the contact. Next, the continuous linear body with the contact portions fused is continuously drawn into a cooling medium while forming a random three-dimensional form, and solidified to form a network structure. Next, it is cut into a desired length and shape, and is laminated and processed as needed, and used as a cushion material.
In the present invention, the thermoplastic elastic resin is heated to a temperature 10 to 80 ° C. higher than the melting point and discharged in a molten state downward from a nozzle having a plurality of orifices. If the temperature of the thermoplastic elastic resin is lower than the melting point by less than 10 ° C., the discharged linear body is cooled and becomes difficult to flow, and the fusion of the contact portion between the linear bodies becomes insufficient. On the other hand, melting at a temperature exceeding 80 ° C. from the melting point is not preferred because the decomposition of the thermoplastic elastic resin becomes remarkable and the rubber elasticity is significantly reduced by cutting the soft segment. By setting the melting temperature at the time of discharge to a temperature 30 to 50 ° C. higher than the melting point of the thermoplastic elastic resin, the melt viscosity can be maintained relatively high, and the loop formation is good, so that it is easy to form a random three-dimensional form and contact The portion is preferable because it can maintain a state in which it is easy to fuse.

In a preferred embodiment of the method of the present invention, as described above, the pseudo-crystallization treatment significantly improves the heat resistance and sag resistance. The pseudo-crystallization treatment is a process in which a continuous linear body whose contact portions are fused while forming a random three-dimensional form is continuously drawn into a cooling medium and solidified to form a network structure. By doing so, the pseudo-crystallization treatment can be performed simultaneously with the cooling. In addition, when a drying step is performed after cooling once, the pseudo crystallization treatment can be performed at the same time by setting the drying temperature to the annealing temperature. Further, a pseudo crystallization treatment can be separately performed. The pseudo-crystallization temperature is at least the melting point (T
m) at 10 ° C. or lower and at a temperature higher than the α-dispersion rising temperature (Tαcr) of Tan δ. This treatment has an endothermic peak below the melting point, and significantly improves heat resistance and sag resistance as compared with those without pseudo-crystallization treatment (without endothermic peak). The preferred pseudo-crystallization temperature of the present invention is (Tαc
r + 10 ° C) to (Tm-20 ° C). The endothermic peak temperature varies depending on various conditions, but appears in the range from the pseudo crystallization treatment temperature to the pseudo crystallization treatment temperature + 20 ° C.

The loop diameter and the fineness of the continuous linear body constituting the cushion net-like structure of the present invention are determined by the distance between the nozzle surface and the take-off conveyor provided on the cooling medium for solidifying the resin, It depends on the melt viscosity, the orifice hole diameter and the discharge amount. For example, under the condition that the discharge amount of the thermoplastic elastic resin is reduced or the melt viscosity at the time of discharge is reduced, the fineness of the linear body becomes thin and the average loop diameter of the random loop becomes small. Also, if the distance between the nozzle surface and the take-up conveyor set on the cooling medium for solidifying the resin is shortened, the fineness of the linear body becomes slightly thicker, and the average loop diameter of the random loop becomes larger. By combining such conditions, the fineness of the continuous linear body which is a preferable range of the present invention is from 500 denier to 50,000 denier, and the average diameter of the random loop is 50 mm or less, more preferably 2 deniers.
It is desirable to determine the conditions so as to be ２５25 mm. By adjusting the interval between the conveyors, the thickness can be adjusted while the fused net is in a molten state, and a desired thickness with a flattened surface is obtained. If the conveyor speed is too high, cooling will occur before fusing, and the contact portions will not be fused. On the other hand, if the speed is too slow, the melt will stay too much and the density will be high, so that the preferred desired apparent density of the present invention is 0.005 to 0.1 g / c.
It is desirable to set the interval between the conveyors and the conveyor speed so as to be m ³ , more preferably 0.01 to 0.05 g / cm ³ . The network structure of the present invention thus obtained is
When the cushioning material is used, the cushioning material has excellent heat resistance and durability that cannot be seen in the conventional cushioning material made of an aggregate of short fibers, and the heat resistance and durability, that is, the residual strain at 70 ° C. is 35% or less, preferably Is 30% or less, more preferably 2%
It reaches up to 0%, in particular up to 15%, and surprisingly up to 10%.

When the net-like structure of the present invention is used for a cushion material, a resin to be used depending on the purpose of use and the site of use,
It is necessary to select fineness, loop diameter and bulk density. For example, when used for wading of the surface layer, in order to provide a soft touch and a moderate sinking and swelling with tension, it is preferable to have a low-density, fine fineness, a fine loop diameter, and as a middle-layer cushion body In order to lower the resonance frequency, linearly change the appropriate hardness and the hysteresis at the time of compression to improve body shape retention and maintain durability, medium density, large fineness, and slightly larger loop diameter are preferable. . Further, it can be formed into a shape suitable for the purpose of use by using a molding die or the like so as not to impair the three-dimensional structure, covered with side lands, and used for vehicle seats, marine seats, beds, chairs, furniture and the like. Of course, in order to meet the required performance in relation to the application, it is also possible to use in combination with another padding material, for example, a rigid cushion material made of a short fiber aggregate or a nonwoven fabric. In addition, at any stage from the production process of the polymer to the processing into a molded article, treatments such as addition of chemicals can be performed for imparting functions such as flame retardancy, antibacterial property, heat resistance, water / oil repellency, coloring, and aroma.

[0030]

The present invention will be described in detail with reference to the following examples.

The evaluation in the examples was performed by the following method. (1) Melting point (Tm) and endothermic peak below melting point The endothermic peak (melting peak) temperature is determined from an endothermic curve measured at a heating rate of 20 ° C./min using a TA50, DSC50 type differential thermal analyzer manufactured by Shimadzu Corporation. I asked. (2) Use Tαcr Orientec's Vibron DDVII type,
Tan δ (ratio of imaginary elastic modulus M ″ to real part M ′ of elastic modulus ″ / M ′) measured at 0 Hz and a heating rate of 1 ° C./min corresponds to a transition point temperature from a rubber elastic region to a melting region. α dispersion rise temperature. (3) Apparent bulk density A sample is cut into a size of 15 cm × 15 cm, the height is measured at four locations, the volume is obtained, and the value is obtained by dividing the weight of the sample by the volume. (Average value of n = 4) (4) Fusing It is determined whether or not the sample is fused by visual judgment. Judge that (5) Fineness A sample was cut into a size of 20 cm × 20 cm, and the specific gravity measured at 40 ° C. using a density gradient tube of a linear body collected at 10 places was photographed with a microscope magnified 30 times. The length of the linear body determined by multiplying by the cross-sectional area of the determined linear body is 9000.
It is indicated by a value converted to the weight of m. (Average value of n = 10) (6) Average diameter of random loop A sample is cut into a size of 20 cm × 20 cm, and a loop drawn up to a 360 ° turning point of an irregularly shaped random loop formed in the longitudinal direction. The average diameter of the inscribed circle and the circumscribed circle was determined. (Average value of n = 20) (7) Residual strain at 70 ° C. (heat resistance and durability) A sample was cut into a size of 15 cm × 15 cm, compressed by 50%, allowed to stand in dry heat at 70 ° C. for 22 hours, and then cooled to compressive strain. The thickness (b) after standing for 1 day is calculated except for the above, and the thickness (a) before the treatment is calculated from the following formula, that is, (ab) / (a) × 100: unit% (average of n = 3) (8) Cyclic compression strain A sample was cut into a size of 15 cm × 15 cm, and the sample was cut at 25 ° C. and a 65% RH room with a servo pulser manufactured by Shimadzu Corporation.
The compression recovery was repeated at a cycle of 1 Hz to a thickness of 0%, and the thickness (b) of the sample after 20,000 times was left for one day was obtained. From the thickness (a) before the treatment, the following formula was obtained, that is, (ab) / (A) ×
Calculated from 100: unit% (average value of n = 3) (9) 50% compression repulsion A sample is cut into a size of 20 cm × 20 cm, and 65% with a φ150 compression plate using Orientex Tensilon.
The resilience at 50% compression of the stress-strain curve obtained by compressing to 50% is shown. (Average value of n = 3) (10) Apparent bulk density under a load of 100 g / cm ^{2 A} sample was cut into a size of 20 cm × 20 cm, and 40 kg using a compression plate of 25 cm × 25 cm by Orientex Tensilon. The apparent volume obtained by measuring the thickness of the net-like structure obtained by compressing to the maximum is shown by the value obtained by dividing the apparent volume by the weight of the cut sample. (Average value of n = 4)

Examples 1 to 3 Dimethyl terephthalate (DMT) or dimethyl naphthalate (DMN) and 1,4-butanediol (1.4B
D) was charged with a small amount of a catalyst, transesterified by a conventional method, polytetramethylene glycol (PTMG) was added, and polycondensation was performed while raising the temperature and reducing the pressure to form a polyetherester block copolymer elastomer, and then an antioxidant Table 1 shows the formulation of the thermoplastic elastic resin raw material obtained by adding 1%, mixing, kneading, pelletizing, and vacuum drying at 50 ° C. for 48 hours.

[0033]

[Table 1]

The obtained thermoplastic elastic resin raw material is fed with a width of 50 c.
m, from a nozzle in which orifices having a hole diameter of 0.5 mm are arranged at an interval of 5 mm between holes on a nozzle effective surface having a length of 5 cm.
Melt at a temperature 40 ° C. higher than the melting point of each thermoplastic elastic resin, change the single hole discharge amount from 0.5 to 1.5 g / min and discharge it. 60c
m stainless steel endless nets are placed in parallel at intervals of 5 cm, and a pair of take-up conveyors are arranged so as to partially emerge above the water surface. The take-up conveyors are taken out, and while the contact portions are fused, the speed is 1 m / min while sandwiching both sides. After being pseudo-crystallized while being drawn into cooling water heated to 70 ° C. and solidified, the resultant was cut into a predetermined size to obtain a network structure. Table 2 shows the characteristics of the obtained net-like structure having a flat surface. The fineness of the linear body and the average diameter of the loop of each net-like structure were 4 in Example 1.
300 denier and 7.5 mm, Example 2 was 12600
Denier and 9.8 mm, Example 3 had 13400 denier and 10.2 mm. Example 1 is a net-like structure suitable for a cushioning material which is soft, has moderate sinking, and has good heat resistance and durability. Examples 2 and 3 are slightly hard and have good shape retention and heat resistance durability. It is a net-like structure suitable for a cushion material.

[0035]

[Table 2]

Comparative Examples 1-2 Polypropylene (PP) having a melt index of 35 and polyethylene terephthalate (PE) having an intrinsic viscosity of 0.63
T) was melted at 220 ° C. and 280 ° C. from a nozzle having orifices with a hole diameter of 0.5 mm arranged at an interval of 5 mm between holes on an effective surface of a nozzle having a width of 50 cm and a length of 5 cm. Discharged at 5 g / min, cooling water was placed 50 cm below the nozzle surface, and a pair of take-up conveyors were placed in parallel with a stainless steel endless net having a width of 60 cm at intervals of 5 cm at a distance of 5 cm. After taking into contact and fusing the contact portions, sandwiching both surfaces, the mixture was drawn into cooling water at 20 ° C. at a speed of 1 m / min, solidified, and then cut into a predetermined size to obtain a net-like structure. Table 2 shows the characteristics of the obtained network structure. Comparative Example 1 is an example in which a non-elastic resin and polypropylene having low heat resistance are used, and is inferior in heat resistance and unsuitable for a cushion material. Comparative Example 2 is an example in which polyethylene terephthalate, which is a non-elastic resin and has good heat resistance, is used.

Comparative Examples 3 to 5 The discharge rate was 0.3 g / min and the take-up conveyor speed was 2 m.
/ Min, except that the reticulated structure was obtained in the same manner as in Example 1, the discharge rate was 6.5 g / min, and the speed of the take-off conveyor was 50 cm / min. Table 2 shows the characteristics of the network structure in the same manner as in Example 2 except that the positions of the structure and the take-off conveyor were set below the cooling water level. Comparative Example 3 is an example in which the apparent bulk density is low, and is not suitable for a cushioning material having a remarkable floor feeling due to a low repulsive stress at the time of compression and having poor sitting comfort. Comparative Example 4 is difficult to use as a cushioning material having a high density and a repulsion force that is too hard to be felt and has a slightly poor sitting comfort. Comparative Example 5
Is an example in which fibers are not fused to each other, and has extremely poor shape retention and is not suitable for a cushion material.

Example 4 Table 2 shows the characteristics of the reticulated structure obtained in the same manner as in Example 2 except that the single hole discharge rate was 7 g / min. Example 4 is an example in which the density is slightly higher and the resonance frequency can be lowered, and is a net-like structure suitable for a cushioning material having a somewhat hard resilience and good heat resistance and durability.

Comparative Example 6 A nozzle having a width of 50 cm and a length of 5 cm was formed on a nozzle effective surface with a hole diameter of 0.5 m.
m orifices are arranged at a pitch of 2 mm between the holes, the discharge rate of single holes is set to 0.06 g / min, the speed of the take-off conveyor is set to 150 cm / min, cooling water is arranged 10 cm below the nozzle surface, and the width is 60 cm. The characteristics of the net-like structure obtained by the same method as in Comparative Example 1 except that a pair of take-up conveyors were arranged so that a part of the stainless steel endless net was parallel to the surface of the water at intervals of 5 cm and were taken out. It is shown in Table 2.
The fineness of the linear body of the net-like structure and the average diameter of the loop are 2
60 denier and 3.0 mm. In Comparative Example 6, the fineness of the linear body was fine, the sinking was large, and the body shape was deteriorated, and the linear body was somewhat unsuitable for a cushion material.

Examples 5 to 6 Polyester elastomer (P150B manufactured by Toyobo Co., Ltd.)
And A made by Toyobo as polyurethane elastomer
Using 1064D, spinning is performed at a discharge rate of 0.8 kg / min from a nozzle having 50 holes with a single hole diameter of 0.6 mm within a range of 30 cm in width and 5 cm in a thickness direction, and then cooled 50 cm below the discharge surface of the nozzle. Distribute water and width 50
cm stainless steel endless conveyors were installed in parallel at 5 cm intervals. A pair of conveyors were set up at various angles to the water surface so as to partially emerge above the water surface. The extruded linear shape was taken into water at a speed to form a net-like aggregate having a three-dimensional structure, and after being solidified in water as it was fused at each contact point, cut into a predetermined size. Cushion material with average fineness of 7000 denier, average loop diameter of 20 mm, porosity of 94% and average fineness of 10,000 denier, average loop diameter of 2
A cushion material having a porosity of 5 mm and a porosity of 93% was obtained. Table 2 shows the performance of the obtained cushion material. Examples 5 and 6 are cushion materials that have a slightly higher density, can lower the resonance frequency, have a repulsive force, and have heat resistance and durability that can be used for seats.

Example 7 Using the net-like cushion material obtained in Example 2, it was cut into a seat shape, and thermoformed at 160 ° C. to produce a bucket seat-like cushion molded product, which was set on a seat frame, and was made of polyester. The seat was created by wrapping it around the fiber moquette. This seat was brought into a room at 30 ° C. and 75% RH, and a panelist was seated on the seat for 4 hours to evaluate the feeling of flooring, the feeling of stuffiness, and the fatigue of the waist qualitatively. It was a comfortable seat with little tiredness.

Comparative Example 7 With the seat prepared in the same manner as in Example 7 using the mesh cushion material obtained in Comparative Example 1, the sitting comfort evaluated in the same manner as in Example 7 was such that the buttocks became warm and a little stuffy feeling was felt. The floor feeling and waist fatigue were remarkable, and I could not sit even if I put up in the seat for only about 1 hour. The seat using the cushion material deviating from the present invention is a seat having a poor sitting comfort.

Example 8 The nozzle effective surface was set to 120 cm in width and 12 cm in length, and the stainless steel endless net of the take-up conveyor was set to 140 in width.
The characteristics of the net-like structure cut to 2 m in length obtained in the same manner as in Example 2 except that the net-like structure was taken out in parallel at 12 cm intervals, and the fineness of the linear body and the average diameter of the loop were the same as those in Example 2. there were. This net-like structure was cut into a width of 110 cm, and placed in a quilted side sewn to 110 cm in width, 200 cm in length, and 12 cm in thickness made of flame-retardant polyester fiber to prepare a mattress. The mattress was placed on a bed, and four panelists used it for 7 hours in a room at 25 ° C. and 65% RH for a sensory evaluation of sleeping comfort. The bed is covered with sheets, and the comforter is 1.8kg down /
Feather: 90/10 was filled with batting, and pillows were worn by panelists every day. The result of the evaluation was that the bed had a comfortable bed with no feeling of flooring, moderate sinking, and no stuffiness. For comparison, a density of 0.04
Create a similar mattress in foamed urethane plate-like body with a thickness of 10cm in g / cm ^3, the results of the evaluation of the comfort installed in the bed, the floor with a sense of bad small but the comfortable feel greatly somewhat stuffy sinks bed Met.

Comparative Example 8 The nozzle effective surface was 120 cm in width and 12 cm in length.
Comparative Example 1 except that the sample was taken in parallel at 12 cm intervals.
The characteristics, the fineness of the linear body and the average diameter of the loop obtained in the same manner as in Comparative Example 1 were the same as those of Comparative Example 1. This net-like structure was cut into a width of 110 cm, and placed in a quilted side sewn to 110 cm in width, 200 cm in length, and 12 cm in thickness made of flame-retardant polyester fiber to prepare a mattress. The mattress was placed on the bed and the sensory evaluation of the sleeping comfort was performed in the same manner as in Example 8. As a result, it was hard to sink and the feeling of flooring was large because it was hard. Feeling uncomfortable and uncomfortable bed.

Example 9 The reticulated structure obtained in Example 8 was 58 cm wide and 58 cm long.
Example 7: A cushion with a quilt at four places and a back part at four places was prepared and placed on the seat part and the back part of the sofa. As a result of evaluating the sitting comfort in the same manner as above, the back showed a moderate rebound when leaned, and the seat was a comfortable sofa with little feeling of flooring and stuffiness and little feeling of waist fatigue. Was.

Comparative Example 9 A cushion similar to that of Example 9 was prepared from the net-like structure obtained in Comparative Example 8, and the cushion was installed on the seat and back of the sofa.
As a result of evaluating the sitting comfort in the same way as above, the back part felt hard and foreign body feeling when leaned, and the seat part was noticeable with floor feeling and stuffiness,
The sofa was inferior in sitting comfort because the buttocks hurt and I could not sit for a long time.

Example 10 The net-like structure obtained in Example 6 was 38 cm wide and 40 cm long.
The rounded corners were rounded and cut, and a moquette made of polyester fiber was hung on the side, installed on an office chair, and evaluated for sitting comfort in the same manner as in Example 7. The office chair was comfortable and comfortable, with no feeling of tiredness.

Example 11 Polyester thermoplastic elastic resin obtained in Example 1
Fusion (A-1) and relative viscosity as thermoplastic inelastic resin
1.08, polybutylene terephthalate having a melting point of 239 ° C
(PBT) is melted by two extruders, width 50 cm, length
5cm long nozzle effective surface with 906 holes in the length direction
Nozzles with 11 rows of holes with the next pitch between holes
The pitch between rows is 5 mm in the length direction, and the first to sixth rows
And the pitch between the holes in the 11th row is 5 mm and the orifice diameter is
0.8mm, pitch between 7th and 10th rows
Nozzle with a 10 mm orifice diameter of 1.0 mm
And A-1 is distributed from the first column to the third and eleventh columns,
The PBT was distributed from the fourth row to the tenth row, and the melting temperature was 26.
At 5 ° C., the single hole discharge amount was 1.26 g / min for A-1, P
BT: 0.84 g / min for 4th to 6th rows, 7th row
In the 10th row, discharge at 2.00 g / min.
Distribute cooling water 10cm below, made of stainless steel 60cm in width
The endless net is parallel and at a 5cm interval,
Arranging the conveyor so that it partially emerges above the water surface,
1m per minute while sandwiching both sides while fusing the touching part
At 70 ° C. into a 70 ° C. cooling bath to solidify.
Table 3 shows the characteristics obtained by cutting to the specified size with
You. The average apparent density is 0.047 g / cm^Three, Of each layer
Apparent density and thickness are the first to third rows of the A-1 layer
(Table) is 0.061 g / cm^ThreeAbout 12.5mm, 1
The first row layer (back) is 0.102 g / cm ^ThreeAbout 3mm,
The fourth to sixth rows of the PBT layer have 0.033 g / cm.^Three
About 15mm and the 7th to 10th rows are 0.041g /
cm^ThreeAbout 20 mm, the layer of A-1 is substantially flattened
It was a densified layer with a large number of components. Obtained
Table 3 shows the characteristics of the reticulated structure. Example 11
Good heat resistance and durability, suitable for cushioning
The properties are good.

[0049]

[Table 3]

Example 12 As the nozzle hole arrangement, the fifth to fifth and fifth to fifth and fifth to fifth and twelfth rows in the fifth row, and the fifth to twelfth and fifth rows in the sixth row
The first to 58th, the fourth to ninth and the 42nd to 48th in the 7th row, the 8th to 10th rows use PBT (poly) for the 4th to 48th orifices. Butylene terephthalate)
And push out each single hole discharge amount of PBT by φ
1.3g / min hole from 0.8mm orifice, φ1.0
mm orifice, 2.0 g / min hole, the discharge amount of each single hole of A-1 was 1.3 g / min hole from φ0.8 mm orifice, and 2.0 g / min hole from φ1.0 mm orifice. A net-like structure was obtained under the same conditions as in Example 11. The average apparent density of the obtained reticulated structure was 0.057.
g / cm ³ . Table 3 shows the characteristics of the obtained network structure.
Shown in When this structure is cut to a length of 50 cm, the side lining is covered, and it is attached to a seat frame to see the sitting comfort, the buttocks are appropriate to sink, and the sides have a slight repulsive force. It was a reticulated structure suitable for.

Example 13 An orifice having a pitch between rows of 5 mm and a pitch between holes of each row of 10 mm was arranged on an effective surface of a nozzle having a width of 50 cm and a length of 5 cm, and the orifice was formed by a composite spinning nozzle capable of being distributed to a sheath core. (A-1) to the sheath component at 265 ° C.
50 wt% / PBT (same as in Example 11) in the core component
A net-like structure was obtained under the same conditions as in Example 11 except that discharge was performed at 50 wt% at a single hole discharge rate of 2 g / minute. Table 3 shows the properties of the obtained network structure. The reticulated structure obtained in this example had a good my grade at the bonding point, and the settling during repeated compression was relatively good even when a non-elastomer was used in combination.

[0052]

The net-like structure for a cushion of the present invention is heat-resistant and durable, is bulky, has an appropriate compression repulsion, and is easy to recycle because it is hard to get stuffy because it is a net-like material and is suitable for a cushioning material having good sitting comfort. It is a structure, and can provide comfortable vehicle seats, marine seats, furniture cushions, and bedding products.

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int. Cl. ⁶ , DB name) B68G 3/00 A47C 27/12 D04H 3/03

Claims (29)

(57) [Claims] 1. A three-dimensional random loop formed by winding a continuous linear body of 300 denier or more to form a random loop, bringing the respective loops into contact with each other in a molten state, and fusing most of the contact portions. It is a joint structure, and the continuous linear body is mainly made of a thermoplastic elastic resin, has an apparent density of 0.005 to 0.20 g / cm ³ , and has an apparent density of 70 ° C.
A net structure for a cushion, wherein a residual strain (%) is 35% or less . 2. The cushion-like net structure according to claim 1, wherein the thermoplastic elastic resin is a polyester-based elastomer, a polyurethane-based elastomer, or a polyamide-based elastomer. 3. The residual strain (%) at 70 ° C. of the network structure is 30.
%. The cushion netting structure according to claim 1, which is not more than%. 4. The residual strain (%) at 70 ° C. of the network structure is 20.
%. 5. The residual strain (%) at 70 ° C. of the network structure is 15%.
%. 6. The residual strain (%) at 70 ° C. of the network structure is 10%.
%. 7. The cushion netting structure according to claim 1, wherein the continuous linear body has an endothermic peak below the melting point in a melting curve measured by a differential scanning calorimeter. 8. The cushion netting structure according to claim 1, wherein the continuous linear body is made of a mixture of a thermoplastic elastic resin and a thermoplastic inelastic resin. 9. The cushion netting structure according to claim 1, wherein the continuous linear body has a laminated structure of a netting structure made of thermoplastic elastic resin and a netting structure made of thermoplastic inelastic resin. 10. The cushion net structure according to claim 1, wherein the continuous linear body is a composite linear body of a thermoplastic elastic resin and a thermoplastic inelastic resin. 11. The fineness of a continuous linear body is 400 to 1000.
The cushion netting structure according to claim 1, which has 0 denier. 12. The fineness of a continuous linear body is 500 to 5000.
The cushion netting structure according to claim 1, which has 0 denier. 13. The cushion net-like structure according to claim 1, wherein the diameter of the random loop is 50 mm or less. 14. The apparent density of the network structure is 0.005 to 0.005.
Cushion net structure of claim 1, wherein a 0.10 g / cm ^3. 15. The apparent density of the network structure is 0.01 to 0.01.
Cushion net structure of claim 1, wherein a 0.05 g / cm ^3. 16. The cushion net structure according to claim 1, wherein the thickness of the net structure is 3 mm or more. 17. The cushion netting structure according to claim 1, wherein the thickness of the netting structure is 5 mm or more. 18. An automobile seat using the net-like structure according to claim 1 as a cushion material. 19. A marine seat using the net-like structure according to claim 1 as a cushion material. 20. A bed using the net-like structure according to claim 1 as a cushion material. 21. Furniture using the net-like structure according to claim 1 as a cushion material. 22. A method of manufacturing a cushion netting structure.
At this time, the starting material was left at 70 ° C.
A thermoplastic resin whose yield (%) can be 35% or less is mainly used.
The molten thermoplastic elastic resin is discharged downward at a high temperature of 0 ° C to form a continuous linear loop in the molten state, and the respective loops are brought into contact with each other and fused to form a three-dimensional random loop. While forming the structure, sandwich it with the take-off device,
A method for producing a mesh-like structure for a cushion, characterized by being cooled continuously. 23. The method according to claim 22, wherein the thermoplastic resin is a polyester-based elastomer, a polyurethane-based elastomer, or a polyamide-based elastomer. 24. After cooling once, at least 10
23. The method according to claim 22, wherein the annealing is performed at a temperature lower than or equal to ° C. 25. The fineness of the continuous linear body is 400 to 1000.
The method for producing a mesh structure for a cushion according to claim 22, wherein the denier is 0 denier. 26. The fineness of the continuous linear body is 500 to 5000
The method for producing a mesh structure for a cushion according to claim 22, wherein the denier is 0 denier. 27. The method according to claim 22, wherein the diameter of the random loop is 50 mm or less. 28. The apparent density of the network structure is 0.005 to 0.005.
0.10 g / cm ³ exits claim 22 Preparation of the cushion for network structure according. 29. The apparent density of the network structure is 0.01 to
0.05 g / cm ³ a method of a cushion for the network structure according to claim 22, wherein.