JPH08336443A - Bed mattress and manufacturing method - Google Patents
Bed mattress and manufacturing methodInfo
- Publication number
- JPH08336443A JPH08336443A JP7143579A JP14357995A JPH08336443A JP H08336443 A JPH08336443 A JP H08336443A JP 7143579 A JP7143579 A JP 7143579A JP 14357995 A JP14357995 A JP 14357995A JP H08336443 A JPH08336443 A JP H08336443A
- Authority
- JP
- Japan
- Prior art keywords
- bed mat
- layer
- cushion layer
- elastic resin
- cushion
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Landscapes
- Mattresses And Other Support Structures For Chairs And Beds (AREA)
Abstract
Description
【０００１】[0001]
【産業上の利用分野】本発明は、優れたクッション性と
耐久性及び蒸れ難く、折り曲げ性にも優れ、洗濯が可能
で、洗濯後の水切り性も良好で乾燥が早く、常に清潔性
を保持できる一般家庭用、病院用及びホテル用等のベッ
トに最適なベットマット及び、敷布団等のクッション材
にも適したベットマットに関する。INDUSTRIAL APPLICABILITY The present invention has excellent cushioning properties, durability, stuffiness, foldability, washability, good drainability after washing, quick drying, and always maintaining cleanliness. The present invention relates to a bed mat suitable for general household use, hospital use, hotel use, etc. and a bed mat suitable for cushioning materials such as bedding.
【０００２】[0002]
【従来技術】現在、ベッド用のベットマットはクッショ
ン層に硬鋼線スプリング又は発泡スチロール等の発泡体
を用い、ワディング層に発泡ウレタンや非弾性捲縮繊維
を接着した樹脂綿や硬綿などが積層一体化されたもの、
及びクッション体が同一組成のウレタン等の発泡体や非
弾性捲縮繊維を接着した樹脂綿又は硬綿のみで構成され
たものが使用されている。2. Description of the Related Art At present, bed mats for beds use a hard steel wire spring or a foamed material such as styrofoam for a cushion layer, and a wadding layer laminated with resin cotton or hard cotton with adhered urethane foam or inelastic crimped fiber. Integrated,
Also, a cushion body made of only a foamed material such as urethane having the same composition or a resin cotton or a hard cotton to which an inelastic crimped fiber is adhered is used.
【０００３】しかしながら、クッション層に硬鋼線スプ
リングを用いたものは、サポ−ト性は著しく優れている
が、折り曲げ性に劣り、又、廃棄時に硬鋼線スプリング
を分離して処理するための煩雑さが大きい問題となって
いる。クッション層又はワディング層又はクッション体
に発泡−架橋型ウレタンを用いたものは、クッション体
としての耐久性は極めて良好だが、透湿透水性に劣り蓄
熱性があるため蒸れやすく、折り曲げ性もやや劣り、か
つ、熱可塑性では無いためリサイクルが困難となり焼却
される場合、焼却炉の損傷が大きく、かつ、有毒ガス除
去に経費が掛かる。このため埋め立てされることが多く
なったが、地盤の安定化が困難なため埋め立て場所が限
定され経費も高くなっていく問題がある。また、加工性
は優れるが製造中に使用される薬品の公害問題などもあ
る。また、最近、病院用ベットがＭＲＳＡ等の温床とな
る問題からベットマットの洗濯が必要だが、透水性に劣
るウレタンは洗濯ができないため社会問題になってい
る。However, the one using a hard steel wire spring for the cushion layer is remarkably excellent in supportability, but is inferior in bending property, and the hard steel wire spring is separated and treated at the time of disposal. Complexity is a big problem. The cushion layer or wadding layer or the one using foam-crosslinking type urethane for the cushion body has very good durability as a cushion body, but it has poor moisture permeability and heat storage property, so it easily gets damp and slightly bendable. In addition, since it is not thermoplastic and it is difficult to recycle it and it is incinerated, the incinerator is greatly damaged and the cost of removing toxic gas is high. For this reason, landfilling has become more frequent, but it is difficult to stabilize the ground, and there is a problem that landfilling sites are limited and costs increase. Further, although it has excellent processability, it also has a problem of pollution of chemicals used during manufacturing. In addition, recently, bed mats need to be washed due to the problem that hospital beds become hot beds such as MRSA, but urethane, which has poor water permeability, cannot be washed, which has become a social problem.
【０００４】クッション層又はワディング層又はクッシ
ョン体がポリエステル繊維を接着剤で接着した樹脂綿、
例えば接着剤にゴム系を用いたものとして特開昭６０−
１１３５２号公報、特開昭６１−１４１３８８号公報、
特開昭６１−１４１３９１号公報等がある。又、架橋性
ウレタンを用いたものとして特開昭６１−１３７７３２
号公報等がある。これらをクッション層又はワディング
層に用いたものは、通気性をよくして蒸れを軽減できる
が、耐久性と折り曲げ性に劣り、且つ、熱可塑性でな
く、単一組成でもないためリサイクルも出来ない等の問
題、及び加工性の煩雑さや製造中に使用される薬品の公
害問題などもある。また、洗濯は可能だが、水切り性が
悪い問題がある。A resin cotton, in which a cushion layer or a wadding layer or a cushion body is formed by adhering polyester fibers with an adhesive,
For example, as an adhesive using a rubber system, Japanese Patent Laid-Open No. 60-
11352, JP-A-61-141388,
There is JP-A-61-141391. In addition, as one using a crosslinkable urethane, Japanese Patent Laid-Open No. 61-137732
There is a bulletin, etc. Those using these as a cushion layer or a wadding layer can improve breathability and reduce stuffiness, but are inferior in durability and bendability, and are not thermoplastic or single composition and therefore cannot be recycled. There are also problems such as complexity of processability and pollution of chemicals used during manufacturing. Also, although it can be washed, it has a problem of poor drainage.
【０００５】クッション層又はワディング層又はクッシ
ョン体にポリエステル硬綿、例えば特開昭５８−３１１
５０号公報、特開平２−１５４０５０号公報、特開平３
−２２０３５４号公報等があるが、用いている熱接着繊
維の接着成分が脆い非晶性のポリマ−を用いるため（例
えば特開昭５８−１３６８２８号公報、特開平３−２４
９２１３号公報等）接着部分が脆く、使用中に接着部分
が簡単に破壊されて形態や弾力性が低下するなどの耐久
性が劣る問題がある。更に折り曲げ性が劣るものであ
る。また、洗濯は可能だが、水切り性が悪い問題があ
る。耐久性の改良法として、交絡処理する方法が特開平
４−２４５９６５号公報等で提案されているが、接着部
分の脆さは解決されず弾力性の低下が大きく、折り曲げ
性も劣る問題がある。また、加工時の煩雑さもある。更
には接着部分が変形しにくくソフトなクッション性を付
与しにくい問題もある。このため、接着部分を柔らか
い、且つある程度変形しても回復するポリエステルエラ
ストマ−を用い、芯成分に非弾性ポリエステルを用いた
熱接着繊維が特開平４−２４０２１９号公報で、同繊維
を用いたクッション体がＷＯ−９１／１９０３２号公
報、特開平５−１５６５６１号公報、特開平５−１６３
６５４号公報等で提案されている。この繊維構造物に使
われる接着成分がポリエステルエラストマ−のソフトセ
グメントとしてはポリアルキレングリコ−ルの含有量が
３０〜５０重量％、ハ−ドセグメントの酸成分にテレフ
タル酸を５０〜８０モル％含有し、他の酸成分組成とし
て特公昭６０−１４０４号公報に記載された繊維と同様
にイソフタル酸を含有して非晶性が増すことになり、融
点も１８０℃以下となり低溶融粘度として熱接着部分の
形成を良くしてアメーバー状の接着部を形成しているが
塑性変形しやいため、及び芯成分が非弾性ポリエステル
のため、特に加熱下での塑性変形が著しくなり、耐熱抗
圧縮性が低下する問題点、及び折り曲げ性が劣り、洗濯
は可能だが、水切り性が悪い問題点がある。耐久性を更
なる改良法として、特開平５−１６３６５４号公報にシ
−ス成分にイソフタル酸を含有するポリエステルエラス
トマ−、コア成分に非弾性ポリエステルを用いた熱接着
複合繊維のみからなる構造体が提案されているが上述の
理由で加熱下での塑性変形が著しくなり、耐熱抗圧縮性
が低下し、クッション体に使用するには問題がある。
又、硬綿の母材にシリコ−ン油剤を付与して繊維の摩擦
係数を下げて耐久性を向上し、風合いを良くする方法が
特開昭６３−１５８０９４号公報で提案されている。
が、熱接着繊維の接着性に問題があり、耐久性が劣るの
でクッション体に使用するには好ましくない。他方、折
り曲げ性の改良法として、折り畳み構造にする方法が特
開昭５５−３６３７３号公報、特開平２−１４２５１３
号公報、特開平５−３８９４号公報等で提案されている
が、折り曲げ性は改良されたが、耐久性や洗濯時の問題
は何ら改良されず、クッション体として用いるには問題
が多いものである。又、折り曲げ部分に空洞を作って折
り曲げ性を改良したものとして、例えば特開平５−２８
５０３１号公報等があるが、ウレタン等の発泡体の問
題、又は硬綿の問題を何ら解決できていない。Polyester hard cotton for the cushion layer or the wadding layer or the cushion body, for example, JP-A-58-311.
50, JP-A-2-154050, JP-A-3
However, since an amorphous polymer in which the adhesive component of the heat-adhesive fiber used is brittle is used (for example, JP-A-58-136828 and JP-A-3-24).
(Patent No. 9213, etc.) There is a problem that durability is inferior such that the bonded portion is brittle and the bonded portion is easily broken during use, and the form and elasticity are lowered. Furthermore, it is inferior in bendability. Also, although it can be washed, it has a problem of poor drainage. As a method for improving durability, a method of entanglement treatment has been proposed in Japanese Patent Laid-Open No. 4-245965 and the like, but brittleness of an adhesive portion is not solved and elasticity is largely reduced, and there is a problem that bending property is poor. . In addition, there is complexity during processing. Further, there is a problem that the bonded portion is hard to be deformed and soft cushioning is hard to be imparted. Therefore, a heat-bonded fiber using a polyester elastomer which is soft and recovers even if it is deformed to some extent and uses an inelastic polyester as a core component is disclosed in JP-A-4-240219, and a cushion using the fiber is disclosed. The body is WO-91 / 19032, JP-A-5-155651, JP-A-5-163.
No. 654, etc. The adhesive component used in this fiber structure contains 30 to 50% by weight of polyalkylene glycol as the soft segment of polyester elastomer, and 50 to 80 mol% of terephthalic acid as the acid component of the hard segment. However, similar to the fiber described in JP-B-60-1404 as another acid component composition, isophthalic acid is added to increase the amorphous property, and the melting point becomes 180 ° C. or lower, resulting in low melt viscosity and thermal bonding. The amoebar-shaped adhesive part is formed by improving the part formation, but it is easy to plastically deform, and because the core component is an inelastic polyester, the plastic deformation becomes remarkable especially under heating, and the heat resistance and compression resistance are high. There is a problem that it deteriorates, and it is inferior in bendability and can be washed, but it has a problem that drainability is poor. As a method of further improving the durability, a structure comprising only a polyester polyester elastomer containing isophthalic acid as a sheath component and a heat-bonding conjugate fiber using an inelastic polyester as a core component is disclosed in JP-A-5-163654. Although proposed, the plastic deformation under heating becomes remarkable due to the above-mentioned reason, the heat resistance and compression resistance are lowered, and there is a problem in using it for the cushion body.
Further, Japanese Patent Laid-Open No. 63-158094 proposes a method in which a silicone oil is added to a hard cotton base material to lower the coefficient of friction of fibers to improve durability and improve the texture.
However, there is a problem with the adhesiveness of the heat-adhesive fiber and the durability is poor, so it is not preferable for use in a cushion body. On the other hand, as a method of improving the bendability, a method of forming a folding structure is disclosed in JP-A-55-36373 and JP-A-2-142513.
As disclosed in Japanese Patent Laid-Open No. 5-3894 and Japanese Patent Laid-Open No. 5-3894, the bending property is improved, but the durability and the problem at the time of washing are not improved, and there are many problems when used as a cushion body. is there. In addition, a cavity is formed in the bent portion to improve the bendability, for example, Japanese Patent Laid-Open No. 5-28.
Although there is a publication such as Japanese Patent No. 5031, the problem of foam such as urethane or the problem of hard cotton cannot be solved at all.
【０００６】土木工事用に使用する熱可塑性のオレフィ
ン網状体が特開昭４７−４４８３９号公報に開示されて
いる。それらを用いたクッション体として、実開昭５８
−９３２７０号公報に硬い構造と柔らかな構造を積層さ
れたものが実開昭５８−９５７６０号公報には、硬い構
造の網状体内部に空調部を有するもの、実開昭５８−１
０５７１４号公報には硬い構造と推測される網状体を用
いたもの記載されているが、耐熱耐久性や寝心地及び軽
量化や洗濯性などの取扱性には何ら配慮されていない。
特開昭５８−１０９６７０号公報には、片面に凹凸を有
する網状体が提案されているが、細い繊維から構成した
クッションとは異なり表面が凸凹でタッチが悪く、耐熱
耐久性や寝心地及び軽量化や洗濯性などの取扱性には何
ら配慮されていない。特開平６−３２７７２３号公報に
は、洗浄パイプや通気管等を装着可能な孔部を有する網
状体が開示されているが、素材がオレフィンのため耐熱
耐久性が著しく劣り、軽量化や洗濯性などの取扱性にも
何ら配慮されておらずワディング層やクッション材には
使用ができないものである。また、特公平３−１７６６
６号公報には繊度の異なる吐出線条を互いに融着してモ
−ル状物を作る方法も開示されているがクッション材に
は適さない網状構造体である。特公平３−５５５８３号
公報には、ごく表面のみ冷却前に回転体等の細化装置で
細くする方法が記載されている。この方法では表面をフ
ラット化できず、厚みのある細い線条層を作ることでき
ない。したがって座り心地の良好なクッション材にはな
らない。特開平１−２０７４６２号公報では、塩化ビニ
−ル製のフロアマットの開示があるが、室温での圧縮回
復性が悪く、耐熱性は著しく悪いので、クッション材と
しては好ましくないものである。なお、上述構造体はベ
ットマットに関する配慮が全くなされていない。A thermoplastic olefin network used for civil engineering work is disclosed in JP-A-47-44839. As a cushion body using them, Shokai 58
No. 93270 discloses a laminated structure of a hard structure and a soft structure. No. 58-95760 discloses a structure having an air conditioning unit inside a net having a hard structure.
Although Japanese Patent Laid-Open No. 05714 describes that a net-like body that is assumed to have a hard structure is used, no consideration is given to heat resistance and durability, comfortableness to sleep, handleability such as weight reduction and washability.
Japanese Unexamined Patent Publication (Kokai) No. 58-109670 proposes a mesh body having irregularities on one side, but unlike a cushion made of thin fibers, the surface is uneven and the touch is bad, and heat resistance durability, sleeping comfort and weight reduction are achieved. No consideration was given to handling such as washing and washing. Japanese Unexamined Patent Publication No. 6-327723 discloses a reticulated body having a hole portion into which a cleaning pipe, a ventilation pipe, etc. can be mounted. However, since the material is olefin, the heat resistance and durability are remarkably inferior, and the weight reduction and the washability are achieved. It is not possible to use it as a wadding layer or cushioning material because it is not considered in handling. In addition, Japanese Patent Publication No. 3-1766
Japanese Patent Laid-Open No. 6-61 also discloses a method in which ejection filaments having different fineness are fused to each other to form a mole, but a net-like structure which is not suitable as a cushion material. Japanese Examined Patent Publication No. 3-55583 describes a method of thinning only a very surface with a thinning device such as a rotating body before cooling. With this method, the surface cannot be flattened and a thick thin linear layer cannot be formed. Therefore, it does not provide a comfortable cushioning material. Japanese Unexamined Patent Publication No. 1-207462 discloses a vinyl chloride floor mat, but it is not preferable as a cushioning material because it has poor compression recovery at room temperature and remarkably poor heat resistance. Note that no consideration is given to the bed mat in the above structure.
【０００７】[0007]
【発明が解決しようとする課題】上記問題点を解決し、
耐熱耐久性、形態保持性、クッション性に優れ、蒸れ難
く、折り曲げ性も良好で使い易く、火災時に有毒ガスの
発生が少なく、難燃性で、ＭＲＳＡ等の雑菌を除去する
ための洗濯ができて水切り性の良好な、更には、リサイ
クルも可能なベット用に最適なクッション体及び敷布団
や家具用にも適するクッション体を提供することを目的
とする。To solve the above problems,
It has excellent heat resistance and durability, shape retention and cushioning properties, it does not easily get damp, and it has good bendability, is easy to use, has little toxic gas generation in the event of fire, is flame retardant, and can be washed to remove miscellaneous bacteria such as MRSA. It is an object of the present invention to provide a cushion body having good drainage property, which is also suitable for beds that can be recycled, and a cushion body suitable for bed sheets and furniture.
【０００８】[0008]
【課題を解決するための手段】上記課題を解決するため
の手段、即ち、本発明は、クッション層の少なくとも上
面にワディング層が積層され、且つ、全体面が側地で被
われたベットマットであり、クッション層は、熱可塑性
弾性樹脂からなる線径が５ｍｍ以下の連続した線条を曲
がりくねらせランダムループを形成し、それぞれのルー
プの接触部の大部分が融着されてなる三次元立体構造網
状体で形成され、該三次元立体構造網状体は上、下両面
が実質的にフラット化されており、見掛密度が０．０５
〜０．１ｇ／cm3 、厚みが５ｍｍ以上であり、ワディン
グ層は、熱可塑性樹脂からなる繊維を用いたダブルラッ
セルニットからなり、該ワディング層の見掛密度が０．
２ｇ／cm3 以下であることを特徴とするベットマットで
ある。更には、クッション層を構成する熱可塑性弾性樹
脂が、室温での３００％伸長後の回復率（室温伸長回復
率）が２０％以上、７０℃での１０％伸長を２４時間保
持した後の回復率（７０℃伸長回復率）が３０％以上で
あるベットマットであり、クッション層を構成する網状
体の線径が０．０１mm以上、見掛けの密度が０．０１ｇ
／cm3 から０．０８ｇ／cm3 、厚みが１０mm以上である
ベットマットであり、クッション層を構成する網状体の
線径が０．０５mm以上２mm以下、見掛けの密度が０．０
２ｇ／cm3 から０．０６ｇ／cm3 、厚みが２０mm以上５
００mm以下であるベットマットであり、ワディング層の
空隙率が９０％以上で厚みが２ｍｍ以上１０ｍｍ以下で
あるベットマットであり、クッション層とワディング層
が熱可塑性樹脂で熱融着により接合一体化したベットマ
ットであり、クッション層に熱可塑性弾性樹脂からなる
成分を示差走査型熱量計で測定した融解曲線に室温以上
融点以下の温度に吸熱ピ−クを持つ網状体を用いたベッ
トマットであり、クッション層を構成する網状体の該線
条の断面形状が中空断面又は及び異形断面であるベット
マットであり、通気度が５０cc／cm2 秒以上であるベッ
トマットであり、クッション層を構成する熱可塑性弾性
樹脂及びワディング層を構成する熱可塑性樹脂がポリエ
ステルであるベットマットであり、熱可塑性樹脂からな
る繊維で形成された側地を被せて構成したベットマット
であり、複数のオリフィスを持つ多列ノズルより熱可塑
性弾性樹脂をその融点より２０〜８０℃高い溶融温度
で、該ノズルより下方に向けて吐出させ、溶融状態で連
続線条のループを形成し、それぞれのループを互いに接
触し、融着させ３次元構造を形成しつつ、引取り装置で
挟み込み冷却槽で冷却せしめた後、得られた三次元構造
体の上、下両面又は片面に熱可塑性樹脂からなるダブル
ラッセルニットを積層し、側地を被せるベットマットの
製法であり、網状体を形成する時、引取ネットにダブル
ラッセルニットを同時に供給して該網状体表面に溶融接
着させてクッション体を形成するベットマットの製法で
あり、製品化に至る任意の工程で網状体を構成する熱可
塑性弾性樹脂の融点より少なくとも１０℃以下の温度で
アニ−リングよる疑似結晶化処理を行うベットマットの
製法である。[Means for Solving the Problems] Means for solving the above problems, that is, the present invention is a bed mat in which a wadding layer is laminated on at least the upper surface of a cushion layer, and the entire surface is covered with a lateral layer. The cushion layer is a three-dimensional solid formed by winding continuous filaments made of thermoplastic elastic resin with a diameter of 5 mm or less to form a random loop, and most of the contact portions of each loop are fused. The three-dimensional three-dimensional structure network is substantially flat on both upper and lower surfaces and has an apparent density of 0.05.
To 0.1 g / cm 3, the thickness is not less 5mm or more, wadding layer comprises double raschel knit using fibers made of a thermoplastic resin, the apparent density of the wadding layer is 0.
The bed mat is characterized in that it is 2 g / cm 3 or less. Furthermore, the thermoplastic elastic resin forming the cushion layer has a recovery rate after room temperature elongation of 300% (room temperature elongation recovery rate) of 20% or more, and recovery after holding 10% elongation at 70 ° C. for 24 hours. Rate (70 ° C elongation recovery rate) is 30% or more, the bed mat has a wire diameter of 0.01 mm or more and an apparent density of 0.01 g.
/ Cm 3 to 0.08 g / cm 3 , a bed mat having a thickness of 10 mm or more, the mesh diameter of the mesh layer forming the cushion layer is 0.05 mm or more and 2 mm or less, and the apparent density is 0.0
2g / cm 3 to 0.06g / cm 3 , thickness 20mm or more 5
A bed mat having a diameter of 00 mm or less, a porosity of a wadding layer of 90% or more, and a thickness of 2 mm or more and 10 mm or less. The cushion layer and the wadding layer are joined and integrated by thermal fusion with a thermoplastic resin. A bed mat, which is a bed mat using a net having an endothermic peak at a temperature of room temperature or higher and a melting point or lower in a melting curve measured by a differential scanning calorimeter for a component made of a thermoplastic elastic resin in a cushion layer, A bed mat in which the cross-sectional shape of the filaments of the reticulate body composing the cushion layer is a hollow cross section and / or a modified cross section, and the air permeability is 50 cc / cm 2 seconds or more. The plastic elastic resin and the thermoplastic resin forming the wadding layer are bed mats made of polyester, and are formed of fibers made of the thermoplastic resin. It is a bed mat formed by covering the ground, and the thermoplastic elastic resin is discharged downward from the nozzle at a melting temperature 20 to 80 ° C. higher than the melting point of the multi-row nozzle having a plurality of orifices in a molten state. After forming loops of continuous filaments, contacting the loops with each other and fusing them to form a three-dimensional structure, sandwiched by a take-up device and cooled in a cooling tank, and then on the obtained three-dimensional structure , A method of producing a bed mat in which a double Russell knit made of a thermoplastic resin is laminated on the lower both sides or one side and covered with a side material. It is a method of producing a bed mat which is melt-bonded to the surface to form a cushion body, and is at least 10 ° C. higher than the melting point of the thermoplastic elastic resin constituting the reticulate body in any process leading to commercialization. This is a method for producing a bed mat in which a pseudo crystallization treatment by annealing is performed at the following temperature.
【０００９】本発明に於ける熱可塑性樹脂とは、加熱に
より可塑性が現れて自由に変形できるようになり、また
冷却すれば再び固くなり、しかも此の間にほとんど化学
変化を起こさないような性質を有する高分子からなる樹
脂をいう。本発明に用いる熱可塑性樹脂の例は、以下に
詳述する熱可塑性弾性樹脂及び熱可塑性非弾性樹脂が好
ましい。The thermoplastic resin in the present invention has a property that plasticity appears by heating so that it can be freely deformed, and it becomes solid again when cooled, and that it hardly causes a chemical change in the meantime. A polymer resin. As examples of the thermoplastic resin used in the present invention, a thermoplastic elastic resin and a thermoplastic non-elastic resin described in detail below are preferable.
【００１０】本発明における熱可塑性弾性樹脂とは、ソ
フトセグメントとして分子量３００〜５０００のポリエ
−テル系グリコ−ル、ポリエステル系グリコ−ル、ポリ
カ−ボネ−ト系グリコ−ルまたは長鎖の炭化水素末端を
カルボン酸または水酸基にしたオレフィン系化合物等を
ブロック共重合したポリエステル系エラストマ−、ポリ
アミド系エラストマ−、ポリウレタン系エラストマ−、
ポリオレフィン系エラストマ−などが挙げられる。熱可
塑性弾性樹脂とすることで、再溶融により再生が可能と
なるため、リサイクルが容易となる。例えば、ポリエス
テル系エラストマ−としては、熱可塑性ポリエステルを
ハ−ドセグメントとし、ポリアルキレンジオ−ルをソフ
トセグメントとするポリエステルエ−テルブロック共重
合体、または、脂肪族ポリエステルをソフトセグメント
とするポリエステルエステルブロック共重合体が例示で
きる。ポリエステルエ−テルブロック共重合体のより具
体的な事例としては、テレフタル酸、イソフタル酸、ナ
フタレン２・６ジカルボン酸、ナフタレン２・７ジカル
ボン酸、ジフェニル４・４’ジカルボン酸等の芳香族ジ
カルボン酸、１・４シクロヘキサンジカルボン酸等の脂
環族ジカルボン酸、琥珀酸、アジピン酸、セバチン酸ダ
イマ−酸等の脂肪族ジカルボン酸または、これらのエス
テル形成性誘導体などから選ばれたジカルボン酸の少な
くとも１種と、１・４ブタンジオ−ル、エチレングリコ
−ル、トリメチレングリコ−ル、テトレメチレングリコ
−ル、ペンタメチレングリコ−ル、ヘキサメチレングリ
コ−ル等の脂肪族ジオ−ル、１・１シクロヘキサンジメ
タノ−ル、１・４シクロヘキサンジメタノ−ル等の脂環
族ジオ−ル、またはこれらのエステル形成性誘導体など
から選ばれたジオ−ル成分の少なくとも１種、および平
均分子量が約３００〜５０００のポリエチレングリコ−
ル、ポリプロピレングリコ−ル、ポリテトラメチレング
リコ−ル、エチレンオキシド−プロピレンオキシド共重
合体からなるグリコ−ル等のポリアルキレンジオ−ルの
うち少なくとも１種から構成される三元ブロック共重合
体である。ポリエステルエステルブロック共重合体とし
ては、上記ジカルボン酸とジオ−ル及び平均分子量が約
３００〜５０００のポリラクトン等のポリエステルジオ
−ルのうち少なくとも各１種から構成される三元ブロッ
ク共重合体である。熱接着性、耐加水分解性、伸縮性、
耐熱性等を考慮すると、ジカルボン酸としてはテレフタ
ル酸、または、及びナフタレン２・６ジカルボン酸、ジ
オ−ル成分としては１・４ブタンジオ−ル、ポリアルキ
レンジオ−ルとしてはポリテトラメチレングリコ−ルの
３元ブロック共重合体または、ポリエステルジオ−ルと
してポリラクトンの３元ブロック共重合体が特に好まし
い。特殊な例では、ポリシロキサン系のソフトセグメン
トを導入したものも使うこたができる。また、上記エラ
ストマ−に非エラストマ−成分をブレンドされたもの、
共重合したもの、ポリオレフィン系成分をソフトセグメ
ントにしたもの等も本発明の熱可塑性弾性樹脂に包含さ
れる。ポリアミド系エラストマ−としては、ハ−ドセグ
メントにナイロン６、ナイロン６６、ナイロン６１０、
ナイロン６１２、ナイロン１１、ナイロン１２等及びそ
れらの共重合ナイロンを骨格とし、ソフトセグメントに
は、平均分子量が約３００〜５０００のポリエチレング
リコ−ル、ポリプロピレングリコ−ル、ポリテトラメチ
レングリコ−ル、エチレンオキシド−プロピレンオキシ
ド共重合体からなるグリコ−ル等のポリアルキレンジオ
−ルのうち少なくとも１種から構成されるブロック共重
合体を単独または２種類以上混合して用いてもよい。更
には、非エラストマ−成分をブレンドされたもの、共重
合したもの等も本発明に使用できる。ポリウレタン系エ
ラストマ−としては、通常の溶媒（ジメチルホルムアミ
ド、ジメチルアセトアミド等）の存在または不存在下
に、（Ａ）数平均分子量１０００〜６０００の末端に水
酸基を有するポリエ−テル及び又はポリエステルと
（Ｂ）有機ジイソシアネ−トを主成分とするポリイソシ
アネ−トを反応させた両末端がイソシアネ−ト基である
プレポリマ−に、（Ｃ）ジアミンを主成分とするポリア
ミンにより鎖延長したポリウレタンエラストマ−を代表
例として例示できる。（Ａ）のポリエステル、ポリエ−
テル類としては、平均分子量が約１０００〜６０００、
好ましくは１３００〜５０００のポリブチレンアジペ−
ト共重合ポリエステルやポリエチレングリコ−ル、ポリ
プロピレングリコ−ル、ポリテトラメチレングリコ−
ル、エチレンオキシド−プロピレンオキシド共重合体か
らなるグリコ−ル等のポリアルキレンジオ−ルが好まし
く、（Ｂ）のポリイソシアネ−トとしては、従来公知の
ポリイソシアネ−トを用いることができるが、ジフェニ
ルメタン４・４’ジイソシアネ−トを主体としたイソシ
アネ−トを用い、必要に応じ従来公知のトリイソシアネ
−ト等を微量添加使用してもよい。（Ｃ）のポリアミン
としては、エチレンジアミン、１・２プロピレンジアミ
ン等公知のジアミンを主体とし、必要に応じて微量のト
リアミン、テトラアミンを併用してもよい。これらのポ
リウレタン系エラストマ−は単独又は２種類以上混合し
て用いてもよい。なお、本発明の熱可塑性弾性樹脂の融
点は耐熱耐久性が保持できる１４０℃以上が好ましく、
１６０℃以上のものを用いると耐熱耐久性が向上するの
でより好ましい。なお、本発明のベットマットを構成す
る網状体は好ましい実施形態として難燃性を付与するた
め燐系化合物を含有させるので、熱安定性が難燃剤を含
有しないものよりやや劣るので、必要に応じ、抗酸化剤
等を添加して耐熱性や耐久性を向上させるのが特に好ま
しい。抗酸化剤は、好ましくはヒンダ−ド系抗酸化剤と
しては、ヒンダ−ドフェノ−ル系とヒンダ−ドアミン系
があり、窒素を含有しないヒンダ−ドフェノ−ル系抗酸
化剤を１％〜５％添加して熱分解を抑制すると燃焼時の
致死量が少ない有毒ガスの発生を抑えられるので特に好
ましい。本発明の目的である好ましい耐久性とクッショ
ン性を兼備できるベットマットになるクッション層を構
成する熱可塑性弾性樹脂の後述する方法で測定した伸長
回復性は、室温での３００％伸長後の回復率（室温伸長
回復率）は２０％以上、７０℃での１０％伸長を２４時
間保持した後の回復率（７０℃伸長回復率）は３０％以
上であり、より好ましくは、室温伸長回復率が３０％以
上、７０℃伸長回復率が４０％以上であり、最も好まし
くは、室温伸長回復率が４０％以上、７０℃伸長回復率
が５０％以上とする。このような伸長回復性を付与する
成分を構成する熱可塑性弾性樹脂のソフトセグメント含
有量は好ましくは１５重量％以上、より好ましくは３０
重量％以上であり、耐熱耐へたり性からは８０重量％以
下が好ましく、より好ましくは７０重量％以下である。
即ち、本発明の弾性網状体の振動や応力の吸収機能をも
たせる成分のソフトセグメント含有量は好ましくは１５
重量％以上８０重量％以下であり、より好ましくは３０
重量％以上７０重量％以下である。The thermoplastic elastic resin in the present invention means, as the soft segment, an ether type glycol, a polyester type glycol, a polycarbonate type glycol or a long chain hydrocarbon having a molecular weight of 300 to 5,000. Polyester elastomer obtained by block-copolymerizing an olefinic compound having a carboxylic acid or a hydroxyl group at the terminal, a polyamide elastomer, a polyurethane elastomer,
Examples include polyolefin elastomers. By using a thermoplastic elastic resin, it becomes possible to regenerate by remelting, and thus recycling becomes easy. For example, as the polyester elastomer, a polyester ether block copolymer having a thermoplastic polyester as a hard segment and a polyalkylenediol as a soft segment, or a polyester ester having an aliphatic polyester as a soft segment A block copolymer can be illustrated. More specific examples of the polyester ether block copolymer include aromatic dicarboxylic acids such as terephthalic acid, isophthalic acid, naphthalene 2.6 dicarboxylic acid, naphthalene 2.7 dicarboxylic acid, and diphenyl 4.4'dicarboxylic acid. At least one of alicyclic dicarboxylic acids such as 1,4-cyclohexanedicarboxylic acid, aliphatic dicarboxylic acids such as succinic acid, adipic acid, sebacic acid dimer acid, and dicarboxylic acids selected from ester-forming derivatives thereof Seeds and aliphatic diols such as 1.4 butanediol, ethylene glycol, trimethylene glycol, tetremethylene glycol, pentamethylene glycol and hexamethylene glycol, 1.1 cyclohexane Alicyclic diols such as dimethanol and 1,4-cyclohexane dimethanol, or these Of at least one diole component selected from the ester-forming derivatives thereof and polyethylene glycol having an average molecular weight of about 300 to 5,000.
It is a ternary block copolymer composed of at least one of polyalkylenediol such as glycol, polypropylene glycol, polytetramethylene glycol, glycol made of ethylene oxide-propylene oxide copolymer and the like. . The polyester ester block copolymer is a ternary block copolymer composed of at least one of the above dicarboxylic acids, diol, and polyester diol such as polylactone having an average molecular weight of about 300 to 5,000. . Thermal adhesion, hydrolysis resistance, stretchability,
Considering heat resistance and the like, terephthalic acid as dicarboxylic acid, or naphthalene 2.6 dicarboxylic acid, 1.4 butanediol as diole component, and polytetramethylene glycol as polyalkylenediol. The terpolymer block copolymer or the terpolymer block copolymer of polylactone as the polyester diol is particularly preferable. In a special case, it is possible to use the one in which a polysiloxane-based soft segment is introduced. In addition, the above elastomer is blended with a non-elastomer component,
Those obtained by copolymerization and those obtained by softening the polyolefin component are also included in the thermoplastic elastic resin of the present invention. As a polyamide elastomer, the hard segment is nylon 6, nylon 66, nylon 610,
Polyethylene glycol, polypropylene glycol, polytetramethylene glycol, ethylene oxide having an average molecular weight of about 300 to 5000 is used as the soft segment in the skeleton of nylon 612, nylon 11, nylon 12, etc. and their copolymerized nylon. -A block copolymer composed of at least one kind of polyalkylenediol such as glycol composed of a propylene oxide copolymer may be used alone or in combination of two or more kinds. Furthermore, blends of non-elastomer components and copolymers thereof can be used in the present invention. Examples of the polyurethane elastomer include (A) a polyester and / or a polyester having a hydroxyl group at the terminal and having a number average molecular weight of 1,000 to 6000 in the presence or absence of a usual solvent (dimethylformamide, dimethylacetamide, etc.). ) A typical example is a polyurethane elastomer obtained by reacting a polyisocyanate containing an organic diisocyanate as a main component with a prepolymer having isocyanate groups at both ends and (C) extending the chain with a polyamine containing a diamine as a main component. Can be illustrated as (A) Polyester, Polyester
The tellers have an average molecular weight of about 1000 to 6000,
Preferably from 1300 to 5000 polybutylene adipates
Copolyester, polyethylene glycol, polypropylene glycol, polytetramethylene glycol
Polyalkylenediol such as glycol and ethylene oxide-propylene oxide copolymer glycol is preferable, and as the polyisocyanate of (B), a conventionally known polyisocyanate can be used. An isocyanate mainly composed of 4'diisocyanate may be used, and if necessary, a trace amount of conventionally known triisocyanate may be added and used. As the polyamine (C), known diamines such as ethylenediamine and 1.2-propylenediamine are mainly used, and if necessary, trace amounts of triamine and tetraamine may be used in combination. These polyurethane elastomers may be used alone or in combination of two or more. The melting point of the thermoplastic elastic resin of the present invention is preferably 140 ° C. or higher at which heat resistance and durability can be maintained,
It is more preferable to use a material having a temperature of 160 ° C. or higher because the heat resistance and durability are improved. In addition, since the reticulate body constituting the bed mat of the present invention contains a phosphorus compound for imparting flame retardancy as a preferred embodiment, the thermal stability is slightly inferior to that not containing a flame retardant. It is particularly preferable to add an antioxidant or the like to improve heat resistance and durability. The antioxidant is preferably a hindered phenol-based antioxidant and a hindered amine-based antioxidant, and a nitrogen-free hindered phenol-based antioxidant is 1% to 5%. It is particularly preferable to suppress the thermal decomposition by adding it, because the generation of toxic gas with a small lethal amount at the time of combustion can be suppressed. The elongation recovery measured by the method described below of the thermoplastic elastic resin forming the cushion layer which becomes the bed mat capable of having both the preferable durability and the cushioning property which is the object of the present invention is the recovery after 300% elongation at room temperature. (Room temperature elongation recovery rate) is 20% or more, and the recovery rate after holding 10% elongation at 70 ° C. for 24 hours (70 ° C. elongation recovery rate) is 30% or more, more preferably room temperature elongation recovery rate. 30% or more and 70 ° C extension recovery rate is 40% or more, and most preferably, room temperature extension recovery rate is 40% or more and 70 ° C extension recovery rate is 50% or more. The soft segment content of the thermoplastic elastic resin constituting the component imparting such elongation recovery is preferably 15% by weight or more, more preferably 30% by weight.
It is preferably not less than 80% by weight, more preferably not more than 70% by weight from the viewpoint of heat and fatigue resistance.
That is, the soft segment content of the component having the function of absorbing vibration and stress of the elastic network of the present invention is preferably 15
% To 80% by weight, more preferably 30%
It is not less than 70% by weight and not more than 70% by weight.
【００１１】本発明ベットマットの好ましい実施形態と
して難燃性を付与する必要から、熱可塑性弾性樹脂中に
燐含有量（Ｂｐｐｍ）がソフトセグメント含有量（Ａ重
量％）に対し、６０Ａ＋２００≦Ｂ≦１０００００の関
係を満足するのが良い。満足しない場合は難燃性が劣る
の場合がある。１０００００ｐｐｍを越えると可塑化効
果による塑性変形が大きくなり熱可塑性弾性樹脂の耐熱
性が劣るので好ましくない。好ましい燐含有量（Ｂｐｐ
ｍ）はソフトセグメント含有量（Ａ重量％）に対し、３
０Ａ＋１８００≦Ｂ≦１０００００であり、より好まし
い燐含有量（Ｂｐｐｍ）はソフトセグメント含有量（Ａ
重量％）に対し、１６Ａ＋２６００≦Ｂ≦５００００で
ある。難燃性は多量のハロゲン化物と無機物を添加して
高度の難燃性を付与する方法があるが、燃焼時に致死量
の少ない有毒なハロゲンガスを多量に発生し、火災時の
中毒の問題があり、焼却時には、焼却炉の損傷が大きく
なるので、本発明では、好ましいハロゲン化物の含有量
は１０重量％以下、より好ましいハロゲン化物の含有量
は５重量％以下、最も好ましくはハロゲン化物を含有し
ないものである。本発明の燐系難燃剤としては、例え
ば、ポリエステル系熱可塑性弾性樹脂の場合、樹脂重合
時に、ハ−ドセグメント部分に難燃剤として、例えば特
開昭５１−８２３９２号公報等に記載された１０〔２・
３・ジ（２・ヒドロキシエトキシ）−カルボニルプロピ
ル〕９・１０・ジヒドロ・９・オキサ・１０ホスファフ
ェナレンス・１０オキシロ等のカルボン酸をハ−ドセグ
メントの酸成分の一部として共重合したポリエステル系
熱可塑性弾性樹脂とする方法や、熱可塑性弾性樹脂に後
工程で、例えば、トリス（２・４−ジ−ｔ−ブチルフェ
ニル）フスファイト等の燐系化合物を添加して難燃性を
付与することができる。その他、難燃性を付与できる難
燃剤としては、各種燐酸エステル、亜燐酸エステル、ホ
スホン酸エステル（必要に応じハロゲン元素を含有する
上記燐酸エステル類）、もしくはこれら燐化合物から誘
導される重合物が例示できる。本発明は、熱可塑性弾性
樹脂中に各種改質剤、添加剤、着色剤等を必要に応じて
添加できる。本発明ベットマットを構成するクッション
層の網状体やワディング層の接着成分に難燃性を付与す
るために燐を含有させており、この理由は、上記してい
る如く、安全性の観点から、火災時に発生するシアンガ
ス、ハロゲンガス等の致死量の少ない有毒ガスをできる
だけ少なくすることにある。このため、本発明ベットマ
ットを構成する網状体やワディング層及び補強層の燃焼
ガスの毒性指数は好ましくは６以下、より好ましくは
５．５以下である。また、側地又は補強層にポリエステ
ル繊維を使用する場合、好ましくはポリエステル系熱可
塑性弾性樹脂とすることで分別せずに再生リサイクルが
できる。Since it is necessary to impart flame retardancy as a preferred embodiment of the bed mat of the present invention, the phosphorus content (Bppm) in the thermoplastic elastic resin is 60A + 200 ≦ B ≦ with respect to the soft segment content (A weight%). It is good to satisfy the relationship of 100,000. If not satisfied, flame retardancy may be inferior. If it exceeds 100,000 ppm, the plastic deformation due to the plasticizing effect becomes large and the heat resistance of the thermoplastic elastic resin becomes poor, which is not preferable. Preferable phosphorus content (Bpp
m) is 3 with respect to the soft segment content (A% by weight)
0A + 1800 ≦ B ≦ 100,000, and more preferable phosphorus content (Bppm) is soft segment content (A
(% By weight), 16A + 2600 ≦ B ≦ 50000. For flame retardancy, there is a method to add a high level of flame retardancy by adding a large amount of halides and inorganic substances, but when burning, a large amount of toxic halogen gas with a small lethal amount is generated, and there is a problem of poisoning during fire. Therefore, in the incineration, the damage of the incinerator becomes large, so that in the present invention, the preferable halide content is 10% by weight or less, the more preferable halide content is 5% by weight or less, and the most preferable halide content is It does not. As the phosphorus-based flame retardant of the present invention, for example, in the case of a polyester-based thermoplastic elastic resin, a flame-retardant in the hard segment portion during resin polymerization is described, for example, in JP-A-51-82392. [2 ...
Carboxylic acid such as 3-di (2-hydroxyethoxy) -carbonylpropyl] 9,10, dihydro, 9, oxa, 10 phosphaphenalene, 10 oxylo was copolymerized as a part of the acid component of the hard segment. A flame-retardant property is imparted by adding a phosphorus-based compound such as tris (2.4-di-t-butylphenyl) -fusphite in a subsequent step to the thermoplastic thermoplastic resin or in the thermoplastic elastic resin. can do. Other flame retardants capable of imparting flame retardancy include various phosphoric acid esters, phosphorous acid esters, phosphonic acid esters (the above phosphoric acid esters containing a halogen element as necessary), or polymers derived from these phosphorus compounds. It can be illustrated. In the present invention, various modifiers, additives, colorants and the like can be added to the thermoplastic elastic resin as needed. Phosphorus is added to the flame-retardant adhesive component of the cushion layer netting or wadding layer constituting the bed mat of the present invention in order to provide flame retardancy. The reason is, as described above, from the viewpoint of safety. The goal is to minimize the use of toxic gases, such as cyanogen gas and halogen gas, which are produced in the event of fire and have a low lethal dose. For this reason, the toxicity index of the combustion gas of the net, the wadding layer and the reinforcing layer constituting the bed mat of the present invention is preferably 6 or less, more preferably 5.5 or less. Further, when polyester fibers are used for the side material or the reinforcing layer, it is preferable to use a polyester-based thermoplastic elastic resin so that the material can be recycled without being separated.
【００１２】本発明のベットマットを構成する熱可塑性
弾性樹脂からなる成分は、示差走査型熱量計にて測定し
た融解曲線において、融点以下に吸熱ピ−クを有するの
が好ましい。融点以下に吸熱ピ−クを有するものは、耐
熱耐へたり性が吸熱ピ−クを有しないものより著しく向
上する。例えば、本発明の好ましいポリエステル系熱可
塑性樹脂として、ハ−ドセグメントの酸成分に剛直性の
あるテレフタル酸やナフタレン２・６ジカルボン酸など
を９０モル％以上含有するもの、より好ましくはテレフ
タル酸やナフタレン２・６ジカルボン酸の含有量は９５
モル％以上、特に好ましくは１００モル％とグリコ−ル
成分をエステル交換後、必要な重合度まで重合し、次い
で、ポリアルキレンジオ−ルとして、好ましくは平均分
子量が５００以上５０００以下、特に好ましくは１００
０以上３０００以下のポリテトラメチレングリコ−ルを
１５重量％以上７０重量％以下、より好ましくは３０重
量％以上６０重量％以下共重合量させた場合、ハ−ドセ
グメントの酸成分に剛直性のあるテレフタル酸やナフタ
レン２・６ジカルボン酸の含有量が多いとハ−ドセグメ
ントの結晶性が向上し、塑性変形しにくく、かつ、耐熱
抗へたり性が向上するが、溶融熱接着後更に融点より少
なくとも１０℃以上低い温度でアニ−リング処理すると
より耐熱抗へたり性が向上する。圧縮歪みを付与してか
らアニ−リングすると更に耐熱抗へたり性が向上する。
このような処理をした網状体を示差走査型熱量計で測定
した融解曲線に室温以上融点以下の温度で吸熱ピークを
より明確に発現する。なおアニ−リングしない場合は融
解曲線に室温以上融点以下に吸熱ピ−クを発現しない。
このことから類推するに、アニ−リングにより、ハ−ド
セグメントが再配列され、疑似結晶化様の架橋点が形成
され、耐熱抗へたり性が向上しているのではないかとも
考えられる。（この処理を疑似結晶化処理と定義する）
この疑似結晶化処理効果は、ポリアミド系弾性樹脂やポ
リウレタン系弾性樹脂にも有効である。The component comprising the thermoplastic elastic resin constituting the bed mat of the present invention preferably has an endothermic peak below the melting point in the melting curve measured by a differential scanning calorimeter. Those having an endothermic peak below the melting point have significantly improved heat resistance and sag resistance than those having no endothermic peak. For example, a preferable polyester-based thermoplastic resin of the present invention contains 90 mol% or more of terephthalic acid or naphthalene 2.6 dicarboxylic acid having rigidity in the acid component of the hard segment, more preferably terephthalic acid or The content of naphthalene 2.6 dicarboxylic acid is 95
After transesterification of the glycol component with mol% or more, particularly preferably 100 mol%, polymerization is carried out to a required degree of polymerization, and then, as the polyalkylene diol, the average molecular weight is preferably 500 or more and 5000 or less, particularly preferably 100
When the polytetramethylene glycol of 0 or more and 3000 or less is copolymerized in an amount of 15% by weight or more and 70% by weight or less, more preferably 30% by weight or more and 60% by weight or less, the acid component of the hard segment has rigidity. When the content of a certain terephthalic acid or naphthalene 2.6 dicarboxylic acid is high, the crystallinity of the hard segment is improved, the plastic deformation is less likely to occur, and the heat resistance and sag resistance are improved. When the annealing treatment is performed at a temperature lower by at least 10 ° C. or more, the heat resistance and sag resistance is further improved. If annealing is performed after applying compressive strain, heat resistance and sag resistance are further improved.
The reticulated body treated in this way has a melting curve measured by a differential scanning calorimeter, and more clearly shows an endothermic peak at a temperature of room temperature or higher and melting point or lower. If annealing is not performed, no endothermic peak appears in the melting curve above room temperature and below the melting point.
By analogy with this, it is considered that the annealing causes rearrangement of the hard segments and formation of pseudo-crystallization-like cross-linking points to improve the heat resistance and sag resistance. (This process is defined as pseudo crystallization process)
This pseudo-crystallization treatment effect is also effective for polyamide-based elastic resins and polyurethane-based elastic resins.
【００１３】本発明における熱可塑性非弾性樹脂とは、
ポリエステル、ポリアミド、ポリオレフィン等が例示で
きる。なお、本発明ではガラス転移点温度が少なくとも
４０℃以上のものを使用するのが好ましい。例えば、ポ
リエステルでは、ポリエチレンテレフタレ−ト（ＰＥ
Ｔ）、ポリエチレンナフタレ−ト（ＰＥＮ）、ポリシク
ロヘキシレンジメチレンテレフタレ−ト（ＰＣＨＤ
Ｔ）、ポリシクロヘキシレンジメチレンナフタレ−ト
（ＰＣＨＤＮ）、ポリブチレンテレフタレ−ト（ＰＢ
Ｔ）、ポリブチレンナフタレ−ト（ＰＢＮ）、ポリアリ
レ−ト等、及びそれらの共重合ポリエステル等が例示で
きる。ポリアミドでは、ポリカプロラクタム（ＮＹ
６）、ポリヘキサメチレンアジパミド（ＮＹ６６）、ポ
リヘキサメチレンセバカミド（ＮＹ６−１０）等が例示
できる。ポリオレフィンとしては、ポリプロピレン（Ｐ
Ｐ）、ポリブテン・１（ＰＢ・１）等が例示できる。本
発明に用いる熱可塑性非弾性樹脂としては、クッション
材の側地にポリエステルを用いる場合が多いので、廃棄
する場合に分離せずにリサイクルが可能なクッション素
材として、耐熱性も良好なＰＥＴ、ＰＥＮ、ＰＢＮ、Ｐ
ＣＨＤＴ等のポリエステルが特に好ましい。更には、Ｐ
ＥＴ、ＰＥＮ、ＰＢＮ、ＰＣＨＤＴ等と重縮合して燐含
有エステル形成性化合物を共重合または燐含有難燃剤を
含有してなる難燃性ポリエステル（以下難燃性ポリエス
テルと略す）が好ましく、例えば、特開昭５１−８２３
９２号公報、特開昭５５−７８８８号公報、特公昭５５
−４１６１０号公報等に例示されたものが挙げられる。
なお、塩化ビニ−ルは自己消火性を有するが燃焼すると
有毒ガスを多く発生すること、及び耐熱耐久性が劣るの
で本発明に用いるのは好ましくない。The thermoplastic non-elastic resin in the present invention means
Examples thereof include polyester, polyamide and polyolefin. In the present invention, it is preferable to use one having a glass transition temperature of 40 ° C. or higher. For example, for polyester, polyethylene terephthalate (PE
T), polyethylene naphthalate (PEN), polycyclohexylene dimethylene terephthalate (PCHD
T), polycyclohexylene dimethylene naphthalate (PCHDN), polybutylene terephthalate (PB)
Examples thereof include T), polybutylene naphthalate (PBN), polyarylate, and copolymerized polyesters thereof. For polyamide, polycaprolactam (NY
6), polyhexamethylene adipamide (NY66), polyhexamethylene sebacamide (NY6-10) and the like. As polyolefin, polypropylene (P
P), polybutene-1 (PB-1) and the like can be exemplified. As the thermoplastic non-elastic resin used in the present invention, polyester is often used for the side material of the cushion material, and therefore PET and PEN having good heat resistance can be used as a cushion material that can be recycled without being separated when discarded. , PBN, P
Polyesters such as CHDT are particularly preferred. Furthermore, P
A flame-retardant polyester (hereinafter abbreviated as flame-retardant polyester) formed by polycondensation with ET, PEN, PBN, PCHDT or the like to copolymerize a phosphorus-containing ester-forming compound or containing a phosphorus-containing flame retardant is preferable. JP-A-51-823
92, JP-A-55-7888, JP-B-55
-41610 and the like are exemplified.
Although vinyl chloride has self-extinguishing properties, it produces a large amount of toxic gas when burned, and its heat resistance and durability are poor, so it is not preferable to use it in the present invention.
【００１４】本発明ベットマットの基本のクッション層
は、繊径が５mm以下の熱可塑性弾性樹脂からなる連続し
た線条を曲がりくねらせ互いに接触させて該接触部の大
部分が融着一体化された３次元立体構造体を形成し、両
面が実質的にフラット化された網状体のため、ワディン
グ層を介して外部から与えられた変形、特には局部的に
大きい変形応力が与えられた場合でも、フラット化され
た網状体の面で変形応力を受け止め変形応力を分散さ
せ、熱可塑性弾性樹脂からなる線条が３次元立体構造体
を形成し融着一体化されているので、構造体全体が変形
してエネルギ−変換により変形応力を吸収させることに
よりゴム弾性による低い反発力で変形応力を受け止める
ので、極端な局部的沈み込みを防止し、人体に対し柔ら
かな把持力で体型を支えることができる好ましい体型保
持機能を発現する。ベットマットでは振動吸収機能も要
求される。本発明の網状体からなるクッション層は、ベ
ットイン時や寝返り時に外部から与えられた振動を熱可
塑性弾性樹脂の振動吸収機能で大部分の振動を吸収減衰
し、好ましい振動吸収機能も発現する。変形応力が解除
されると熱可塑性弾性樹脂のゴム弾性で容易に元の形態
に回復する機能があるので耐へたり性も良好である。更
に、空隙率が高く、通気孔径が著しく大きいので通気抵
抗が低く通気性が著しく良好であり、寝返り等による変
形応力の変化を受けると熱可塑性弾性樹脂のゴム弾性を
有する線条が３次元立体構造体を形成し融着一体化され
ているので、構造体全体が変形により圧縮回復してワデ
ィング層を介して透過したクッション層中に溜まった蒸
気や熱を含む空気を圧縮時排出し、回復時新鮮な外気と
入替えるポンプ機能を有するため、ワディング層とクッ
ション層間の熱及び蒸気の移動が容易となり蒸れ難くい
快適な寝心地を提供できるベットマットである。この目
的から、本発明の網状体を形成する振動吸収性と弾性回
復性の良い熱可塑性弾性樹脂からなる線条の線径は５mm
以下である。見掛け密度を０．２ｇ／cm2 以下にした場
合、５mmを越えると構成本数が少なくなり、密度斑を生
じて部分的に耐久性の悪い構造ができ、応力集中による
疲労が大きくなり耐久性が低下するので好ましくない。
本発明の熱可塑性弾性樹脂からなる線条の線径が細すぎ
ると抗圧縮性が低くなり過ぎて変形による応力吸収性が
低下するので０．０１mm以上であり、構成本数の低下に
よる構造面の緻密性を損なわない３mm以下である。より
好ましくは０．０５mm以上、２mm以下である。本発明の
網状体を形成する連続線条のランダムループの平均直径
は好ましくは５０mm以下、特に２〜２５mmとするのが目
的を達成するためには好ましい。本発明の網状体の見掛
け密度は、０．００５ｇ／cm3 では反発力が失われ、変
形応力吸収能力や振動吸収能力が不充分となりクッショ
ン機能を発現させにくくなる場合があり、０．２５ｇ／
cm3 以上では反発力が高すぎて座り心地が悪くなる場合
があるが、本発明では軽量化して取扱性を向上させる目
的で０．１０ｇ／cm3 以下である。振動吸収能力や変形
応力吸収機能が生かせてクッション体としての機能が発
現されやすい０．０１ｇ／cm3 以上０．０８ｇ／cm3 以
下が好ましく、より好ましくは０．０２ｇ／cm3 以上
０．０６ｇ／cm3 以下である。本発明における網状体は
線径の異なる線状を見掛け密度との組合せで最適な構成
とする異繊度積層構造とする方法も好ましい実施形態と
して選択できる。本発明の網状体の厚みは５mm以上が必
要である。厚みが５mm未満では応力吸収機能と応力分散
機能が低下するので好ましくない。好ましい厚みは力の
分散をする面機能と振動や変形応力吸収機能が発現でき
る厚みとして１０mm以上であり、より好ましくは２０mm
以上５００mm以下である。単板で厚みが５００mm以上に
なると後述する折り曲げ性が低下するので、より厚いク
ッション層を所望する場合は、所望に応じて５００mm以
下、好ましくは２００mm以下の薄い厚みのクッション層
を非接合の状態で積層することで折り曲げ性を損なうこ
とを抑えることができる。厚みが５００mm以下となるよ
うに積層する場合、界面を接合しても良く、非接合でも
面がフラットなので応力の伝達が面で伝達されるので変
形対応性に支障はない。網状体の表面が実質的にフラッ
ト化されてない場合、ワディング層から伝達される局部
的な外力は、変形応力を面で受けることが出来ず、表面
の線条及び接着点部分までに選択的に伝達され、変形応
力を分散させる機能が低下するので、応力集中が発生す
る場合があり、このような外力に対しては応力集中によ
る疲労が発生して耐へたり性が低下する場合がある。な
お、該線条が熱可塑性弾性樹脂からなる場合は３次元構
造部分で構造全体が変形するので応力集中は緩和される
が、へたりが進行するに伴い体型保持機能も低下する。
非弾性樹脂では、そのまま応力が接着点に集中して構造
破壊を生じ回復しなくなる。更には、表面が実質的にフ
ラット化されてなく凸凹があると寝た時背部や臀部等に
異物感を与えるため寝心地が悪くなり好ましくない。な
お、線状が連続していない場合は、線条の接着点が応力
の伝達点となるため接着点に著しい応力集中が起こり構
造破壊を生じ耐熱耐久性が劣り好ましくない。構造破壊
しない段階でも抗圧縮性が劣り、体型保持性が劣る問題
があり、この問題を解決するため密度を高くすると、空
隙率の低下と共に通気性も低下して快適性が低下し、重
量も重くなり取扱性が著しく劣る。融着していない場合
は、形態保持が出来ず、構造体が一体で変形しないた
め、応力集中による疲労現象が起こり耐久性が劣ると同
時に、形態が変形して体型保持ができなくなるので好ま
しくない。本発明クッション層のより好ましい融着の程
度は、線条が接触している部分の大半が融着した状態で
あり、もっとも好ましくは接触部分が全て融着した状態
である。公知の非弾性樹脂のみからなる線条で構成した
網状体では、表面層で吸収できない大きい変形応力を受
けるとゴム弾性を持たないので変形しにくく大きい反発
力を示すため、適度の沈み込みが起こらず、強い反発力
を示すので不快な体型支持感を与え好ましくない体型保
持機能を発現する。更に、圧縮変形により塑性変形を生
じて回復しなくなり耐久性も劣る。更に、圧縮回復によ
るポンプ機能が殆ど有しないので蒸れ低減化機能が劣
る。架橋性発泡ポリウレタンでは、振動吸収機能や耐へ
たり性は弾性樹脂のため良好であるが、応力伝達が容易
な構造のため、局部的な変形に容易に追随して極端な局
部的沈み込みを発生し、体型保持機能が劣る。又、発泡
ポリウレタンは通気性が極めて劣るため蒸れ易く、快適
な寝心地が得られないベットマットとなるクッション層
である。本発明ベットマットは通気性をより高め、鬱血
を防止し、クッション材をそのまま溶融再生してリサイ
クルも可能とする目的で、ワディング層に熱可塑性樹脂
からなる繊維を使用したのダブルラッセルニットをクッ
ション層の両面又は表面側の片面に積層する。積層され
るダブルラッセルニットは、表面がル−プで構成され、
織物のように緻密な構造ではないので、変形圧力に追随
できる自由度が大きく、僅かな変化でも圧縮力を支える
接触点の移動がおこり、体表の圧縮点が変化し鬱血しに
くいワディング機能と、中間層が低密度化されており、
通気性が極めて良好であり、熱と蒸気の移動が容易にな
り蒸れ難くなる。前記クッション層との積層構造は構造
全体で圧縮応力を受け止め変形するが、人体と接する局
所的な高圧縮応力点をクッション層が網状構造の荒い梁
でしか受け止めないので、体表の高圧縮応力点がダブル
ラッセルニットのみより更に低減し、より鬱血しにくい
ワディング機能を発現できる。更に、クッション層が新
鮮な空気を入れ換えるポンプ機能を持つので、ベットマ
ット表面の熱と蒸気の移動が著しく早く起こる相乗効果
で非常に蒸れにくいベットマットとなる。それらの機能
は蒸れを抑え、鬱血を低減化し、側地を介して新鮮な空
気を皮膚面に送ることにより、相乗効果として床擦れ防
止に有効に作用する。特に顕著なこの様な効果を付与す
るには側地を介してクッション層側面から排気される空
気の通気度を５０cc／cm2 秒以上とできる構成にするの
が望ましい。この事は、外気の温度や湿度が高くなる夏
にも涼しいベットマットを提供することができる。本発
明のワディング層を構成するダブルラッセルニットの密
度は込み過ぎると高圧縮応力支持面積の増加による鬱血
防止機能の低下と通気性が劣り蒸れ防止効果も低下する
ので見掛け密度が０．２ｇ／cm3 以下が必要である。見
掛け密度が低すぎると抗圧縮性が低下してワディング層
の機能が低下するので、好ましい見掛け密度は０．０１
ｇ／cm3 以上０．１ｇ／cm3 以下で空隙率が９０％以
上、より好ましくは見掛け密度は０．０４ｇ／cm3 以上
０．０６ｇ／cm3 以下で空隙率が９５％以上である。ダ
ブルラッセルニットの厚みは、２mm未満ではワディング
層機能が低下する。２０mm以上ではクッション層の有用
な適度の沈み込みと柔らかい把持力で体を支える体型保
持機能や振動吸収機能を低下させる。好ましい厚みは３
mm以上１５mm以下、より好ましくは５mm以上１０mm以下
である。ダブルラッセルニットをクッション層の両面に
積層すると裏表の両面で鬱血防止機能と蒸れ防止機能を
得ることができる。片面にのみ積層し、他の面に別の機
能、例えば保温性の優れた機能を持つワディング層を積
層して夏冬使い分ける等の使用形態もとれる。積層クッ
ション体のクッション層とワヂィング層の界面は界面を
接合しても良く、非接合でも面がフラットなので応力の
伝達が面で伝達されるので変形対応性に支障はない。接
合する場合は、後述するベットマットの折り畳み性との
関係で伸縮性を有する熱可塑性弾性樹脂を接着成分とし
て使用するのが好ましい。接着成分としては融点又は流
動介し温度が１００℃未満では耐熱性が劣り、２００℃
以上では熱接着がしにくいので、１００℃以上２００℃
以下のものが好ましい。かくして、積層されたクッショ
ン体は側地に包まれて本発明のベットマットになる。本
発明のベットマットは、前記特徴と共に、折り曲げ性や
洗濯性に優れた特徴を有する。即ち、クッション材に伸
縮性が有るため折り曲げ性に優れ、頭部や上半身を起こ
す必要がある介護用等のベットに使用することができ
る。敷布団として使用する場合は、折り畳んで収納する
ことも可能である。クッション層が非弾性樹脂で構成さ
れるものは折り曲げが困難である。硬い素材で構成され
たものは無理に折り曲げると折り曲げ部が破壊する場合
があり、柔らかい素材で構成されたものは塑性変形して
クッションが折り曲げ部付近が凹み、繰り返し折り曲げ
ると屈曲疲労で破断するが、弾性樹脂からなる本発明の
クッション層と変形に対する自由度の高いダブルラッセ
ルニットの積層構造のため、折り曲げが容易で、繰り返
し折り曲げに対しても塑性変形しにくく耐久性に優れる
点が本発明と大きく異なる点である。折り曲げ性を改良
するために、折り曲げ構造とするものが提案されている
が、本発明のクッション層と異なりクッション層に非弾
性樹脂が使用されているため耐久性が劣るものである。
洗濯性の良い点は、通常の繊維からなるクッション層の
繊維径０．００１mm以下のもの較べ、本発明のクッショ
ン体の大部分を構成するクッション層の線径が０．０１
mm以上であり、ワディング層のダブルラッセルニットも
低密度で構成本数が少ないため、線条の表面積が著しく
少ないため線条表面の付着水分が少なくできるので、特
に水切り性に優れる。水切り性が良いので乾燥時間を短
縮できる。この為、本発明のベットマットは頻繁に洗濯
でき、結果として、清潔なベットマットを常に使用でき
る。本発明のベットマットの洗濯は、側地とクッション
体を別々にして洗濯することもできるし、丸洗いも可能
である。業務用ベットでは、必要に応じて殺菌する場合
がある。殺菌は１００℃未満のエチレンオキサイドガス
又は１３０℃の蒸気を用いるのが一般的である。本発明
のベットマットでは、圧縮応力を付与しないで１５分未
満で殺菌することで変形させずに殺菌することが可能で
あるが、公知のオレフィン系や塩化ビニ−ル系素材を用
いた場合は、耐熱性が劣り殺菌時の加熱で塑性変形し嵩
減りを生じる点が本発明と異なる点である。なお、網状
体及び積層クッション形成段階から製品化される任意の
段階で上述の疑似結晶化処理を施すことにより、網状体
中の熱可塑性弾性樹脂からなる成分を示差走査型熱量計
で測定した融解曲線に室温以上融点以下の温度に吸熱ピ
ークを持つようにすると熱可塑性弾性樹脂の伸縮性と耐
熱性が著しく向上し、製品の耐熱耐久性も格段に向上す
るのでより好ましい。In the basic cushion layer of the bed mat of the present invention, continuous filaments made of a thermoplastic elastic resin having a fiber diameter of 5 mm or less are bent and brought into contact with each other, and most of the contact portions are fused and integrated. 3D three-dimensional structure is formed, and both sides are substantially flattened. Therefore, even when external deformation is applied through the wadding layer, especially when a large deformation stress is locally applied. , The flattened mesh surface receives the deformation stress and disperses the deformation stress, and the filaments made of the thermoplastic elastic resin form a three-dimensional three-dimensional structure and are fused and integrated. By deforming and absorbing the deforming stress by energy conversion, it receives the deforming stress with a low repulsive force due to rubber elasticity, so it prevents extreme local subsidence and gives the human body a soft grasping force against the human body. Expressing preferred type retaining function can be obtained. The bed mat also requires a vibration absorbing function. The cushion layer made of the net-like body of the present invention absorbs and attenuates most of the vibration applied from the outside at the time of bed-in or turning over by the vibration absorbing function of the thermoplastic elastic resin, and also exhibits a preferable vibration absorbing function. When the deformation stress is released, the rubber elasticity of the thermoplastic elastic resin has a function of easily recovering the original shape, and therefore the sag resistance is also good. Furthermore, since the porosity is high and the ventilation hole diameter is extremely large, the ventilation resistance is low and the ventilation is extremely good, and when the deformation stress is changed due to rolling over, etc., the linear line having the rubber elasticity of the thermoplastic elastic resin has a three-dimensional shape. As the structure is formed and fused and integrated, the entire structure is compressed and recovered by deformation, and the air containing steam and heat accumulated in the cushion layer that has permeated through the wadding layer is discharged during compression and recovered. Since the bed mat has a pump function of replacing with fresh air at the time, heat and steam can be easily transferred between the wadding layer and the cushion layer, and the bed mat can provide a comfortable sleep that is hard to be stuffy. For this purpose, the wire diameter of the filament made of thermoplastic elastic resin having good vibration absorption and elastic recovery forming the reticulated body of the present invention is 5 mm.
It is the following. When the apparent density is 0.2 g / cm 2 or less, if the thickness exceeds 5 mm, the number of components will be small, density unevenness will occur, and a structure with poor durability can be partially formed, and fatigue due to stress concentration will increase and durability will increase. It is not preferable because it decreases.
If the wire diameter of the filament made of the thermoplastic elastic resin of the present invention is too small, the anti-compression property becomes too low and the stress absorbability due to deformation decreases, so it is 0.01 mm or more. It is 3 mm or less so as not to impair compactness. More preferably, it is 0.05 mm or more and 2 mm or less. The average diameter of the continuous loop random loops forming the reticulated body of the present invention is preferably 50 mm or less, and particularly preferably 2 to 25 mm in order to achieve the object. When the apparent density of the reticulate body of the present invention is 0.005 g / cm 3 , the repulsive force is lost, the deforming stress absorbing ability and the vibration absorbing ability are insufficient, and the cushioning function may not be easily expressed.
If it is cm 3 or more, the repulsive force may be too high and the sitting comfort may be poor, but in the present invention, it is 0.10 g / cm 3 or less for the purpose of reducing the weight and improving the handleability. 0.01 g / cm 3 or more and 0.08 g / cm 3 or less are preferable, and more preferably 0.02 g / cm 3 or more and 0.06 g, in which the function as a cushion body is easily expressed by utilizing the vibration absorbing ability and the deformation stress absorbing function. / Cm 3 or less. As a preferred embodiment, a method in which the reticulate body in the present invention has a different fineness laminated structure in which linear shapes having different wire diameters are combined with an apparent density to have an optimum configuration can be selected. The thickness of the mesh body of the present invention is required to be 5 mm or more. If the thickness is less than 5 mm, the stress absorbing function and the stress dispersing function are deteriorated, which is not preferable. A preferable thickness is 10 mm or more, more preferably 20 mm, as a surface function for dispersing force and a function for absorbing vibration and deformation stress.
It is not less than 500 mm. If the thickness of a single plate is 500 mm or more, the bendability described below deteriorates. Therefore, when a thicker cushion layer is desired, a cushion layer having a thin thickness of 500 mm or less, preferably 200 mm or less is not bonded as desired. By stacking with, it is possible to prevent the bending property from being impaired. In the case of stacking so as to have a thickness of 500 mm or less, the interface may be joined, and even if it is not joined, since the surface is flat, the transmission of stress is transmitted by the surface, so there is no problem in deformability. If the surface of the mesh body is not substantially flattened, the local external force transmitted from the wadding layer cannot receive the deformation stress on the surface, and the surface line and the bonding point are selectively exposed. The stress concentration may occur because the function to disperse the deformation stress is reduced, and the stress concentration may occur against such external force, which may cause fatigue due to stress concentration. . When the filaments are made of thermoplastic elastic resin, the entire structure is deformed in the three-dimensional structure portion, so stress concentration is relieved, but the body shape retention function is also deteriorated as the fatigue is advanced.
In the case of non-elastic resin, stress concentrates on the bonding point as it is, causing structural destruction and cannot be recovered. Furthermore, if the surface is not substantially flattened and has irregularities, it gives a feeling of foreign matter to the back, buttocks, etc. when the person sleeps, which is unfavorable because it makes the sleeping comfort worse. When the linear shape is not continuous, the adhesive point of the filament becomes a stress transmitting point, so that remarkable stress concentration occurs at the adhesive point and structural destruction occurs, resulting in poor heat resistance and durability, which is not preferable. There is a problem that the compression resistance is inferior even at the stage where the structure is not destroyed, and the body shape retention property is inferior.If the density is increased to solve this problem, the porosity decreases, the air permeability decreases and the comfort decreases, and the weight also decreases. It becomes heavy and the handling is extremely poor. If they are not fused, the shape cannot be maintained and the structure does not deform integrally, resulting in a fatigue phenomenon due to stress concentration and poor durability, and at the same time deforming the shape and making it impossible to maintain the body shape, which is not preferable. . The more preferable degree of fusion bonding of the cushion layer of the present invention is a state in which most of the portions in contact with the filaments are fused, and most preferably all the contact portions are fused. In a net-like body composed of known filaments made only of non-elastic resin, when it receives a large deformation stress that cannot be absorbed by the surface layer, it does not have rubber elasticity and it does not easily deform and shows a large repulsive force. In addition, since it exhibits a strong repulsive force, it gives an unpleasant body-supporting feeling and exhibits an unfavorable body-shape holding function. Further, due to the compressive deformation, plastic deformation occurs and the recovery is lost, and the durability is poor. Further, since it has almost no pump function by compression recovery, the function of reducing stuffiness is inferior. The cross-linkable polyurethane has excellent vibration absorption function and sag resistance because it is an elastic resin, but it has a structure that facilitates stress transmission, so it can easily follow local deformation to prevent extreme local subsidence. Occurs, and the function of maintaining body shape is poor. Further, the foamed polyurethane is a cushion layer which becomes a bed mat which is apt to get damp because it has extremely poor air permeability and does not provide comfortable sleeping comfort. The bed mat of the present invention is a double russel knit cushion made of a fiber made of a thermoplastic resin in the wadding layer for the purpose of further improving breathability, preventing congestion, and allowing the cushion material to be directly melted and recycled for recycling. Laminate on both sides of the layer or on one side on the front side. The surface of the double Russell knit to be laminated is composed of loops,
Since it is not a dense structure like woven fabric, it has a large degree of freedom to follow the deformation pressure, and even a slight change causes the movement of the contact point that supports the compression force, and the compression point of the body surface changes and the wadding function that is less likely to cause congestion. , The intermediate layer has a low density,
It has extremely good air permeability, makes it easy for heat and steam to move, and makes it difficult to steam. The laminated structure with the cushion layer receives compressive stress in the entire structure and is deformed, but since the cushion layer only receives the local high compressive stress point in contact with the human body with the rough beam of the net structure, the high compressive stress on the body surface is high. The number of points is further reduced compared to the double Russell knit only, and the wadding function that is less likely to cause congestion can be expressed. Further, since the cushion layer has a pumping function for replacing fresh air, the bed mat is extremely resistant to stuffiness due to the synergistic effect that heat and steam on the surface of the bed mat move remarkably quickly. Their functions are to suppress stuffiness, reduce congestion, and send fresh air to the skin surface through the lateral area, thereby effectively acting as a synergistic effect for preventing floor rubs. In order to give a particularly remarkable effect as described above, it is desirable that the air exhausted from the side surface of the cushion layer through the side fabric has a permeability of 50 cc / cm 2 seconds or more. This can provide a bed mat that is cool even in the summer when the temperature and humidity of the outside air are high. If the density of the double russel knit constituting the wadding layer of the present invention is too high, the apparent density is 0.2 g / cm because the congestion prevention function is decreased due to the increase of the high compression stress supporting area, the air permeability is poor, and the stuffiness preventing effect is decreased. 3 or less is required. When the apparent density is too low, the anti-compression property is lowered and the function of the wadding layer is deteriorated.
g / cm 3 or more 0.1 g / cm 3 or less porosity of 90% or more, more preferably an apparent density of 0.04 g / cm 3 or more 0.06 g / cm 3 or less in porosity is 95% or more. If the thickness of the double Russell knit is less than 2 mm, the function of the wadding layer is deteriorated. When the thickness is 20 mm or more, the cushioning layer has a useful moderate depression and the soft gripping force lowers the figure-holding function and vibration-absorbing function of supporting the body. Preferred thickness is 3
It is not less than mm and not more than 15 mm, more preferably not less than 5 mm and not more than 10 mm. When double Raschel knit is laminated on both sides of the cushion layer, it is possible to obtain the function of preventing congestion and the stuffiness on both sides. It can be used in such a manner that it is laminated only on one side and a wadding layer having another function, for example, a function of excellent heat retention, is laminated on the other side and used properly in summer and winter. The interface between the cushion layer and the wading layer of the laminated cushion body may be joined to each other, and even if they are not joined, since the surface is flat, the transmission of stress is transmitted by the surface, so there is no problem in the deformation adaptability. In the case of joining, it is preferable to use a thermoplastic elastic resin having stretchability as an adhesive component in relation to the foldability of the bed mat described later. If the temperature of the adhesive component is less than 100 ° C through the melting point or flow, the heat resistance is inferior.
Since heat adhesion is difficult with the above, 100 ℃ or more 200 ℃
The following are preferred. Thus, the laminated cushion body is wrapped in the side cloth to form the bed mat of the present invention. The bed mat of the present invention has, in addition to the above-mentioned features, excellent bendability and washability. That is, since the cushioning material has elasticity, it has excellent bendability and can be used for a bed for nursing care or the like that requires raising the head or upper body. When used as a mattress, it can be folded and stored. If the cushion layer is made of non-elastic resin, it is difficult to bend. If a material made of a hard material is bent forcibly, the bent part may be destroyed, and if a material made of a soft material is plastically deformed, the cushion is dented near the bent part, and if repeatedly bent, it breaks due to bending fatigue. Since the cushion layer of the present invention is made of an elastic resin and the laminated structure of the double Rassel knit having a high degree of freedom in deformation, it is easy to fold and is resistant to plastic deformation even with repeated folds and excellent in durability. This is a big difference. In order to improve the bending property, a structure having a bending structure has been proposed. However, unlike the cushion layer of the present invention, the non-elastic resin is used for the cushion layer, so that the durability is poor.
The good washability is that the cushion layer of the present invention has a wire diameter of 0.01, as compared with a cushion layer made of normal fibers having a fiber diameter of 0.001 mm or less.
Since the double russell knit of the wadding layer has a low density and a small number of constituents, the surface area of the filaments is extremely small and the moisture adhering to the filament surface can be reduced, so that the drainage property is particularly excellent. Since it has good draining property, the drying time can be shortened. Therefore, the bed mat of the present invention can be washed frequently, and as a result, a clean bed mat can always be used. For washing the bed mat of the present invention, the side ground and the cushion body can be washed separately, or can be washed in a circle. Commercial beds may be sterilized as needed. For sterilization, ethylene oxide gas below 100 ° C or steam at 130 ° C is generally used. The bed mat of the present invention can be sterilized without being deformed by sterilizing it in less than 15 minutes without applying compressive stress. However, in the case of using a known olefin-based or vinyl chloride-based material, The difference from the present invention is that the heat resistance is poor and plastic deformation is caused by heating during sterilization, resulting in loss of bulk. In addition, by performing the above-mentioned pseudo crystallization treatment at any stage from the step of forming the net body and the laminated cushion to the product, the component made of the thermoplastic elastic resin in the net body is melted by a differential scanning calorimeter. It is more preferable that the curve has an endothermic peak at a temperature of room temperature or higher and melting point or lower, because the stretchability and heat resistance of the thermoplastic elastic resin are remarkably improved, and the heat resistance and durability of the product are remarkably improved.
【００１５】本発明のクッション層を構成する網状体の
線条の断面形状は特には限定されないが、中空断面や異
形断面にすることで好ましい抗圧縮性（反発力）やタッ
チを付与することができるので特に好ましい。抗圧縮性
は繊度や用いる素材のモジュラスにより調整して、線径
を細くしたり、柔らかい素材では中空率や異形度を高く
し初期圧縮応力の勾配を調整できるし、線径をやや太く
したり、ややモジュラスの高い素材では中空率や異形度
を低くして寝心地が良好な抗圧縮性を付与する。中空断
面や異形断面の他の効果として中空率や異形度を高くす
ることで、同一の抗圧縮性を付与した場合、より軽量化
が可能となり、ベットマットの交換や布団などの場合
は、上げ下ろし時の取扱性が向上する。好ましい抗圧縮
性（反発力）やタッチを付与することができる他の好ま
しい方法として、本発明の網状体の線条を複合構造とす
る方法がある。複合構造としては、シ−スコア構造また
はサイドバイサイド構造及びそれらの組合せ構造などが
挙げられる。が、特にはクッション層が大変形してもエ
ネルギ−変換できない振動や変形応力をエネルギ−変換
して回復できる立体３次元構造とするために線状の表面
の５０％以上を柔らかい熱可塑性弾性樹脂が占めるシ−
スコア構造またはサイドバイサイド構造及びそれらの組
合せ構造などが挙げられる。シ−スコア構造ではシ−ス
成分は振動や変形応力をエネルギ−変換が容易なソフト
セグメント含有量が多い熱可塑性弾性樹脂とし、コア成
分は抗圧縮性を示すソフトセグメント含有量が少ない熱
可塑性弾性樹脂で構成し適度の沈み込みによる背部や臀
部等の接触部への快適なタッチを与えることができる。
サイドバイサイド構造では振動や変形応力をエネルギ−
変換が容易なソフトセグメント含有量が多い熱可塑性弾
性樹脂の溶融粘度をソフトセグメント含有量が少ない抗
圧縮性を示す熱可塑性弾性樹脂の溶融粘度より低くして
線状の表面を占めるソフトセグメント含有量が多い熱可
塑性弾性樹脂の割合を多くした構造（比喩的には偏芯シ
−ス・コア構造のシ−スに熱可塑性弾性樹脂を配した様
な構造）として線状の表面を占めるソフトセグメント含
有量が多い熱可塑性弾性樹脂の割合を８０％以上とした
ものが特に好ましく、最も好ましくは線状の表面を占め
るソフトセグメント含有量が多い熱可塑性弾性樹脂の割
合を１００％としたシ−スコアである。ソフトセグメン
ト含有量が多い熱可塑性弾性樹脂の線状の表面を占める
割合が多くなると、溶融して融着するときの流動性が高
いので接着が強固になる効果があり、構造が一体で変形
する場合、接着点の応力集中に対する耐疲労性が向上
し、耐熱性や耐久性がより向上する。本発明のクッショ
ン体を構成する網状体の線条を複合構造とした場合、熱
接着機能も付与でき、ダブルラッセルニットとの熱接着
一体構造化ができる。例えば、網状体の線条構造がシ−
スコア構造として、シ−ス成分は振動や変形応力をエネ
ルギ−変換が容易なソフトセグメント含有量が多い熱可
塑性弾性樹脂を熱接着成分とし、コア成分の抗圧縮性を
示すソフトセグメント含有量が少ない熱可塑性弾性樹脂
を網状形態の保持機能をもたせるための高融点成分とす
る構成で、熱接着成分の融点を高融点樹脂の融点より１
０℃以上低くしたものを用いることにより熱接着層の機
能も付与できる。また、片面のみダブルラッセルニット
との熱接着一体化し、他面に短繊維ウエッブ、不織布、
布帛類等を熱接着一体化してクッション体又は製品化す
ることができる。クッション層とワディング層を積層
し、非接合又は接着剤等を用いて接合したクッション体
は、車両用座席、船舶用座席、車両用、船舶用、病院用
等の業務用及び家庭用ベット、家具用椅子、事務用椅
子、布団類等のクッション体としても有用である。The cross-sectional shape of the filaments of the net-like body that constitutes the cushion layer of the present invention is not particularly limited, but a preferable anti-compression property (repulsive force) and touch can be imparted by forming a hollow cross section or a modified cross section. It is particularly preferable because it is possible. The compression resistance can be adjusted according to the fineness and the modulus of the material used to make the wire diameter thin, and for soft materials the hollow ratio and the degree of irregularity can be increased to adjust the gradient of the initial compression stress, and the wire diameter can be made slightly thicker. For materials with a slightly high modulus, the hollowness and the degree of irregularity are reduced to provide good anti-compression properties with good sleeping comfort. As another effect of the hollow cross section and the irregular cross section, by increasing the hollow ratio and the irregularity, it is possible to reduce the weight when the same anti-compression property is given, and when changing the bed mat or futon, raise and lower it. The handling property at the time is improved. As another preferable method for imparting preferable anti-compression property (repulsive force) and touch, there is a method of forming the filament of the reticulated body of the present invention into a composite structure. Examples of the composite structure include a score core structure, a side-by-side structure, and a combination structure thereof. However, in particular, 50% or more of the linear surface is made of a soft thermoplastic elastic resin in order to form a three-dimensional three-dimensional structure capable of energy-converting and recovering vibration and deformation stress that cannot be energy-converted even if the cushion layer is largely deformed. Occupied by
Examples thereof include a score structure, a side-by-side structure and a combination structure thereof. In the sheath core structure, the sheath component is a thermoplastic elastic resin with a large content of soft segments that can easily convert energy into vibration and deformation stress, and the core component is a thermoplastic elastic resin with a small content of soft segments that exhibits anti-compression properties. It is made of resin and can give a comfortable touch to contact parts such as the back and buttocks due to an appropriate degree of depression.
With the side-by-side structure, vibration and deformation stress
Soft segment content that can be easily converted Soft segment content that occupies a linear surface by lowering the melt viscosity of the thermoplastic elastic resin that has low soft segment content and thermoplastic resin that exhibits anti-compression property A soft segment occupying a linear surface as a structure with a large proportion of thermoplastic elastic resin (metaphorically, a structure in which a thermoplastic elastic resin is arranged in an eccentric sheath-core structure) It is particularly preferable that the proportion of the thermoplastic elastic resin having a large content is 80% or more, and most preferably the sheath core having the proportion of the thermoplastic elastic resin having a large content of the soft segment occupying the linear surface as 100%. Is. When the proportion of the thermoplastic elastic resin with a large soft segment content that occupies the linear surface is large, the flowability when melting and fusing is high, so there is the effect of strengthening the adhesion, and the structure deforms as a unit. In this case, the fatigue resistance against stress concentration at the bonding points is improved, and the heat resistance and durability are further improved. When the filaments of the net-like body forming the cushion body of the present invention have a composite structure, a heat-bonding function can be imparted, and a heat-bonding integral structure with a double Russell knit can be realized. For example, the linear structure of the mesh is
As a score structure, the sheath component has a large soft segment content that makes it easy to energy-convert vibrations and deformation stresses. The thermoplastic elastic resin is used as a thermal adhesive component, and the soft segment content showing the anti-compressibility of the core component is small. The thermoplastic elastic resin is used as a high-melting-point component for providing a net-like shape-holding function, and the melting point of the heat-adhesive component is 1 from the melting point of the high-melting-point resin.
The function of the heat-bonding layer can be imparted by using the one whose temperature is lowered by 0 ° C. or more. In addition, only one side is integrated with double raschel knit by heat bonding, and the other side is short fiber web, non-woven fabric,
A cloth body or the like can be heat-bonded and integrated into a cushion body or a product. The cushion body obtained by laminating the cushion layer and the wadding layer and joining them by using non-bonding or using an adhesive or the like is used for vehicle seats, ship seats, vehicle seats, ship seats, hospital beds and other commercial and household beds and furniture. It is also useful as a cushion body for office chairs, office chairs, duvets, and the like.
【００１６】次に本発明の製法を述べる。複数のオリフ
ィスを持つ多列ノズルより熱可塑性弾性樹脂をその融点
より２０℃以上高く、８０℃未満高い溶融温度で、該ノ
ズルより下方に向けて吐出させ、溶融状態で互いに接触
させて融着させ３次元構造を形成しつつ、引取り装置で
挟み込み冷却槽で冷却せしめた後、両面又は片面に熱可
塑性樹脂からなるダブルラッセルニットを積層して、側
地を被せるベットマットの製法である。網状体は、熱可
塑性弾性樹脂を一般的な溶融押出機を用いて溶融し、複
数のオリフィスを持つ多列ノズルに供給し、オリフィス
より下方へ吐出する。この時の溶融温度は、熱可塑性弾
性樹脂の融点より２０℃〜８０℃高い温度である。熱可
塑性弾性樹脂の融点より８０℃を越える高い溶融温度に
すると熱分解が著しくなり熱可塑性弾性樹脂のゴム弾性
特性が低下するので好ましくない。他方、熱可塑性弾性
樹脂の融点より１０℃以上高くしないとメルトフラクチ
ャ−を発生し正常な線条形成が出来なくなり、また、吐
出後ル−プ形成しつつ接触させ融着させる際、線条の温
度が低下して線条同士が融着しなくなり接着が不充分な
網状体となる場合があり好ましくない。好ましい溶融温
度は融点より２０℃から６０℃高い温度、より好ましく
は融点より２５℃から４０℃高い温度である。オリフィ
スの形状は特に限定されないが、中空断面（例えば三角
中空、丸型中空、突起つきの中空等となるよう形状）及
び、又は異形断面（例えば三角形、Ｙ型、星型等の断面
二次モ−メントが高くなる形状）とすることで前記効果
以外に溶融状態の吐出線条が形成する３次元構造が流動
緩和し難くし、逆に接触点での流動時間を長く保持して
接着点を強固にできるので特に好ましい。特開平１−２
０７５号公報に記載の接着のための加熱をする場合、３
次元構造が緩和し易くなり平面的構造化し、３次元立体
構造化が困難となるので好ましくない。網状体の特性向
上効果としては、見掛けの嵩を高くでき軽量化になり、
また抗圧縮性が向上し、弾発性も改良できへたり難くな
る。中空断面では中空率が８０％を越えると断面が潰れ
易くなるので、好ましくは軽量化の効果が発現できる１
０％以上７０％以下、より好ましくは２０％以上６０％
以下である。オリフィスの孔間ピッチは線状が形成する
ル−プが充分接触できるピッチとする必要がある。緻密
な構造にするには孔間ピッチを短くし、粗密な構造にす
るには孔間ピッチを長くする。本発明の孔間ピッチは好
ましくは３mm〜２０mm、より好ましくは５mm〜１０mmで
ある。本発明では所望に応じ異密度化や異繊度化もでき
る。列間のピッチ又は孔間のピッチも変えた構成、及び
列間と孔間の両方のピッチも変える方法などで異密度層
を形成できる。また、オリフィスの断面積を変えて吐出
時の圧力損失差を付与すると、溶融した熱可塑性弾性樹
脂を同一ノズルから一定の圧力で押し出される吐出量が
圧力損失の大きいオリフィスほど少なくなる原理を使っ
て長手方向の区間でオリフィスの断面積が異なる列を少
なくとも複数有するノズルを用い異繊度線条からなる網
状構造体を製造することができる。次いで、該ノズルよ
り下方に向けて吐出させ、ル−プを形成させつつ溶融状
態で互いに接触させて融着させ３次元構造を形成しつ
つ、引取りネットで挟み込み、網状体の表面の溶融状態
の曲がりくねった吐出線条を４５°以上折り曲げて変形
させて表面をフラット化すると同時に曲げられていない
吐出線条との接触点を接着して構造を形成後、連続して
冷却媒体（通常は室温の水を用いるのが冷却速度を早く
でき、コスト面でも安くなるので好ましい）で急冷して
本発明の３次元立体網状構造体化した網状体を得る。ノ
ズル面と引取り点の距離は少なくとも４０cm以下にする
ことで吐出線条が冷却され接触部が融着しなくなること
を防ぐのが好ましい。吐出線条の吐出量５ｇ／分孔以上
と多い場合は１０cm〜４０cmが好ましく、吐出線条の吐
出量５ｇ／分孔未満と少ない場合は５cm〜２０cmが好ま
しい。網状体の厚みは溶融状態の３次元立体構造体両面
を挟み込む引取りネットの開口幅（引取りネット間の間
隔）で決まる。本発明では上述の理由から引取りネット
の開口幅は５mm以上とする。次いで水切り乾燥するが冷
却媒体中に界面活性剤等を添加すると、水切りや乾燥が
しにくくなったり、熱可塑性弾性樹脂が膨潤することも
あり好ましくない。尚、ノズル面と樹脂を固化させる冷
却媒体上に設置した引取りコンベアとの距離、樹脂の溶
融粘度（網状体形成時の溶融粘度は好ましくは５００ポ
イズから１００００ポイズであり、２００００ポイズを
越えるとル−プ形成速度が遅くなり、緻密な網状構造を
形成しにくくなるので好ましくない。）、オリフィスの
孔径と吐出量などにより所望のループ径や線径をきめら
れる。冷却媒体上に設置した間隔が調整可能な一対の引
取りコンベアで溶融状態の吐出線条を挟み込み停留させ
ることで互いに接触した部分を融着させつつ、連続して
冷却媒体中に引込み固化させ網状体を形成する時、上記
コンベアの間隔を調整することで、融着した網状体が溶
融状態でいる間で厚み調節が可能となり、所望の厚みの
ものが得られる。コンベア速度も速すぎると、接触点の
形成が不充分になったり、融着点が充分に形成されるま
でに冷却され、接触部の融着が不充分になる場合があ
る。また、速度が遅過ぎると溶融物が滞留し過ぎ、密度
が高くなるので、所望の見掛け密度に適したコンベア速
度を設定する必要がある。次いで本発明では、該網状体
とワディング層となるダブルラッセルニットと積層して
クッション体とする。ダブルラッセルニットと該網状体
を接合一体化することもできる。この場合、熱接着層又
は接着剤を別途該網状体とダブルラッセルニット間に使
用して接合一体化してもよく、該網状体の熱接着機能を
使ってダブルラッセルニットと接合一体化してもよい。
本発明の好ましい一体化方法としては、溶融状態の吐出
線条を挟み込み停留させることで互いに接触した部分を
融着させつつ、連続して冷却媒体中に引込み固化させ網
状体を形成する時、引取ネットにダブルラッセルニット
を同時に供給して該網状体表面に溶融接着させる方法が
選択できる。該網状体を一旦冷却後、又はダブルラッセ
ルニットと積層して一体成形したクッション体にした後
等、製品化に至る任意の工程で網状体を構成する熱可塑
性弾性樹脂の融点より少なくとも１０℃以下の温度でア
ニ−リングよる疑似結晶化処理を行うのがより好ましい
製法である。疑似結晶化処理温度は、少なくとも融点
（Ｔｍ）より１０℃以上低く、Ｔａｎδのα分散立ち上
がり温度（Ｔαｃｒ）以上で行う。この処理で、融点以
下に吸熱ピ−クを持ち、疑似結晶化処理しないもの（吸
熱ピ−クを有しないもの）より該網状体の耐熱耐へたり
性が著しく向上する。本発明の好ましい該網状体の疑似
結晶化処理温度は（Ｔαｃｒ＋１０℃）から（Ｔｍ−２
０℃）である。単なる熱処理により疑似結晶化させても
耐熱耐へたり性が向上するが、更には、１０％以上の圧
縮変形を付与してアニ−リングすることで耐熱耐へたり
性が著しく向上するのでより好ましい。また、該網状体
を一旦冷却後、乾燥工程を経する場合、乾燥温度をアニ
−リング温度とすることで同時に疑似結晶化処理を行う
ができる。また、製品化する工程で別途疑似結晶化処理
を行うができる。次いで所望の長さまたは形状に切断し
てクッション材に用いる。本発明では次いで側地でクッ
ション体を被い縫製して、又は縫製した側地を被せてベ
ットマットを得る。Next, the manufacturing method of the present invention will be described. A thermoplastic elastic resin is discharged downward from the nozzle at a melting temperature higher than its melting point by 20 ° C. or more and less than 80 ° C. from a multi-row nozzle having a plurality of orifices, and they are brought into contact with each other in a molten state to be fused. This is a method of producing a bed mat in which a three-dimensional structure is formed, sandwiched by a take-up device, cooled in a cooling tank, and then double Russell knit made of a thermoplastic resin is laminated on both sides or one side to cover a side material. The reticulate body is obtained by melting a thermoplastic elastic resin by using a general melt extruder, supplying the multi-row nozzle having a plurality of orifices, and discharging the resin downward from the orifices. The melting temperature at this time is 20 ° C. to 80 ° C. higher than the melting point of the thermoplastic elastic resin. If the melting temperature is higher than 80 ° C. higher than the melting point of the thermoplastic elastic resin, thermal decomposition becomes remarkable and the rubber elastic properties of the thermoplastic elastic resin deteriorate, which is not preferable. On the other hand, unless the temperature is higher than the melting point of the thermoplastic elastic resin by 10 ° C. or more, melt fracture occurs and normal filament formation cannot be performed. Further, when the filament is formed by looping after discharge and is brought into contact and fused. The temperature may be lowered and the filaments may not be fused to each other, resulting in a network having insufficient adhesion, which is not preferable. The preferred melting temperature is 20 ° C to 60 ° C above the melting point, more preferably 25 ° C to 40 ° C above the melting point. The shape of the orifice is not particularly limited, but may be a hollow cross section (for example, a triangular hollow, a round hollow, a shape with a projection, etc.) and / or an irregular cross section (for example, a triangular, Y-shaped, star-shaped cross-section secondary mode). In addition to the above effects, it is difficult for the three-dimensional structure formed by the discharge filaments in the molten state to relax the flow, and on the contrary, the flow time at the contact point is maintained for a long time to strengthen the adhesion point. It is particularly preferable because it can be JP-A 1-2
When heating for adhesion as described in Japanese Patent No. 075,
It is not preferable because the three-dimensional structure is easily relaxed, the two-dimensional structure becomes a planar structure, and the three-dimensional three-dimensional structure becomes difficult. As the effect of improving the properties of the mesh body, the apparent bulk can be increased and the weight can be reduced,
In addition, the anti-compression property is improved, and the elasticity is also improved, which makes it difficult to reach the end. In the case of a hollow cross section, if the hollow ratio exceeds 80%, the cross section tends to be crushed.
0% to 70%, more preferably 20% to 60%
It is the following. The pitch between the holes of the orifice needs to be a pitch with which the loop formed by the line can sufficiently contact. The pitch between holes is shortened for a dense structure, and the pitch between holes is lengthened for a coarse structure. The pitch between the holes of the present invention is preferably 3 mm to 20 mm, more preferably 5 mm to 10 mm. In the present invention, different densities and different fineness can be obtained as desired. The different density layer can be formed by a configuration in which the pitch between rows or the pitch between holes is also changed, or a method in which the pitch between both rows and holes is also changed. Also, if the pressure loss difference at the time of discharge is given by changing the cross-sectional area of the orifice, the principle that the discharged amount of molten thermoplastic elastic resin extruded from the same nozzle at a constant pressure becomes smaller for the orifice with larger pressure loss, is used. It is possible to manufacture a reticulated structure composed of filaments of different fineness by using a nozzle having at least a plurality of rows having different cross-sectional areas of orifices in a section in the longitudinal direction. Then, the liquid is discharged downward from the nozzle, and while forming a loop, they are brought into contact with each other in a molten state to be fused to form a three-dimensional structure, and are sandwiched by a take-up net to melt the surface of the net-like body. Bending the twisted discharge line of 45 degrees or more to deform it to flatten the surface and at the same time bond the contact points with the unbent discharge line to form a structure, and then continuously cool the medium (usually at room temperature). It is preferable to use the water of (1) because the cooling rate can be increased and the cost can be reduced). The distance between the nozzle surface and the take-off point is preferably at least 40 cm or less to prevent the discharge filament from being cooled and the contact portion not being fused. When the discharge amount of the discharge line is as large as 5 g / min or more, 10 cm to 40 cm is preferable, and when the discharge amount of the discharge line is less than 5 g / min hole, 5 cm to 20 cm is preferable. The thickness of the net-like body is determined by the opening width (interval between the take-up nets) of the take-up net sandwiching both surfaces of the three-dimensional structure in the molten state. In the present invention, the opening width of the take-up net is set to 5 mm or more for the above reason. Next, it is drained and dried, but if a surfactant or the like is added to the cooling medium, draining and drying may be difficult, or the thermoplastic elastic resin may swell, which is not preferable. In addition, the distance between the nozzle surface and the take-up conveyor installed on the cooling medium for solidifying the resin, the melt viscosity of the resin (the melt viscosity at the time of forming the mesh body is preferably 500 poises to 10000 poises, and above 20000 poises). It is not preferable because the loop forming speed becomes slower and it becomes difficult to form a dense net-like structure.), And the desired loop diameter and wire diameter can be determined by the orifice hole diameter and the discharge amount. A pair of take-up conveyors with adjustable intervals installed on the cooling medium sandwich and hold the molten discharge filaments to fuse the parts that are in contact with each other and continuously draw in the cooling medium to solidify them. By adjusting the distance between the conveyors when forming the body, the thickness can be adjusted while the fused net-like body is in a molten state, and a desired thickness can be obtained. If the conveyor speed is too high, the formation of contact points may be insufficient, or the contact point may be cooled until the fusion point is sufficiently formed, resulting in insufficient fusion of the contact portion. Further, if the speed is too slow, the melt will stay too much and the density will increase, so it is necessary to set the conveyor speed suitable for the desired apparent density. Next, in the present invention, the mesh body and a double Russell knit to be a wadding layer are laminated to form a cushion body. The double Russell knit and the mesh can also be joined and integrated. In this case, a heat-bonding layer or an adhesive may be separately used between the reticulated body and the double Russell knit to bond and integrate them, or the heat-bonding function of the reticulated body may be used to bond and integrate the double Russell knit. .
As a preferred integration method of the present invention, when the molten discharge filaments are sandwiched and held to fuse the portions that are in contact with each other, they are continuously drawn into a cooling medium to solidify and form a net-like body. A method can be selected in which the double Russell knit is simultaneously supplied to the net and melt-bonded to the surface of the net. At least 10 ° C. or lower than the melting point of the thermoplastic elastic resin forming the reticulated body in any process leading to commercialization, such as after the reticulated body is once cooled or after being laminated with a double Russell knit to form an integrally molded cushion body. The more preferable manufacturing method is to perform the pseudo-crystallization treatment by annealing at the temperature of. The pseudo-crystallization treatment temperature is at least 10 ° C. lower than the melting point (Tm), and is higher than the α dispersion rising temperature (Tαcr) of Tan δ. By this treatment, the heat resistance and sag resistance of the reticulate body is remarkably improved as compared with a material having an endothermic peak at a temperature equal to or lower than the melting point and having no pseudo-crystallization treatment (one having no endothermic peak). The preferred pseudo-crystallization treatment temperature of the network of the present invention is from (Tαcr + 10 ° C) to (Tm-2
0 ° C). The heat-settling resistance is improved even if it is pseudo-crystallized by a simple heat treatment, and further, the heat-settling resistance is remarkably improved by applying a compressive deformation of 10% or more and annealing is more preferable. . Further, when the reticulate body is once cooled and then subjected to a drying step, the pseudo crystallization treatment can be simultaneously performed by setting the drying temperature to the annealing temperature. Also, a pseudo crystallization treatment can be separately performed in the process of commercialization. Then, it is cut into a desired length or shape and used as a cushion material. In the present invention, the cushion mat is then sewn on the side cloth or the sewn side cloth is covered to obtain a bed mat.
【００１７】本発明のベットマットを用いる場合、その
使用目的により、該網状体に使用する樹脂、線径、ル−
プ径、見掛け密度、厚み等を、及びダブルラッセルニッ
トに使用する樹脂、線径、編み構造、見掛け密度、厚み
等を適切に選択する必要がある。例えば、ソフトなタッ
チと適度の沈み込みと張りのある膨らみを付与するため
には、該網状体をやや高密度で細い繊径の緻密な構造が
好ましく、適度の硬さと圧縮時のヒステリシスを直線的
に変化させて体型保持性を良くし、耐久性を保持させる
ために、該網状体を中密度で太い繊径、やや大きいル−
プ径の層と低密度で細い繊径、細かいル−プ径の層を積
層一体化した構造にするのが好ましい。また、樹脂製造
過程以外でも性能を低下させない範囲で製造過程から網
状体又は、及びダブルラッセルニットに加工し、製品化
する任意の段階で難燃化、防虫抗菌化、耐熱化、撥水撥
油化、着色、芳香等の機能付与を薬剤添加等の処理加工
ができる。本発明のベットマットに用いるクッション層
は、３次元構造を損なわない程度に成形型等を用いて使
用目的にあった形状に成形して側地を被せるのみで車両
用座席、船舶用座席、ベット、椅子、家具等に用いるこ
ともできる。勿論、用途との関係で要求性能に合うべき
他の素材、例えば、異なる網状体、短繊維集合体や硬綿
クッション材、不織布等と組合せて用いることも可能で
ある。When the bed mat of the present invention is used, depending on the purpose of use, the resin, the wire diameter, and the rule used for the net-like body are used.
It is necessary to appropriately select the diameter, apparent density, thickness, etc., and the resin, wire diameter, knitting structure, apparent density, thickness, etc. used for the double Russell knit. For example, in order to impart a soft touch, an appropriate depression and a bulge with tension, it is preferable that the mesh is a dense structure with a slightly high density and a fine fiber diameter, and the appropriate hardness and hysteresis during compression are linear. In order to improve the body shape retention and durability, the mesh is made of medium density, thick fiber diameter and slightly large rule.
It is preferable to have a structure in which a layer having a loop diameter and a layer having a low density, a fine fiber diameter, and a fine loop diameter are laminated and integrated. In addition, other than the resin manufacturing process, it is processed into a mesh or double Russell knit from the manufacturing process within a range that does not deteriorate the performance, and at any stage of commercialization, it becomes flame retardant, insect repellent antibacterial, heat resistant, water and oil repellent. It is possible to add functions such as chemicalization, coloring, and aroma, and perform processing such as adding chemicals. The cushion layer used in the bed mat of the present invention is formed into a shape suitable for the purpose of use by using a molding die or the like to the extent that the three-dimensional structure is not impaired, and only the side cloth is covered. It can also be used for chairs, furniture, etc. Of course, it is also possible to use it in combination with another material that should meet the required performance in relation to the application, for example, different mesh bodies, short fiber aggregates, hard cotton cushion materials, non-woven fabrics and the like.
【００１８】[0018]
【実施例】以下に実施例で本発明を詳述する。EXAMPLES The present invention will be described in detail below with reference to examples.
【００１９】なお、実施例中の評価は以下の方法で行っ
た。 1. 融点（Ｔｍ）および融点以下の吸熱ピ−ク 島津製作所製ＴＡ５０，ＤＳＣ５０型示差熱分析計を使
用し、昇温速度２０℃／分で測定した吸発熱曲線から吸
熱ピ−ク（融解ピ−ク）温度を求めた。 2. Ｔαｃｒ ポリマ−を融点＋１０℃に加熱して、厚み約３００μm
のフイルムを作成して、オリエンテック社製バイブロン
ＤＤＶII型を用い、１１０Ｈｚ、昇温速度１℃／分で測
定したＴａｎδ（虚数弾性率Ｍ”と弾性率の実数部分
Ｍ’との比Ｍ”／Ｍ’）のゴム弾性領域から融解領域へ
の転移点温度に相当するα分散の立ち上がり温度。 3. 室温伸長回復率 ポリマ−を融点＋１０℃に加熱して、厚み約３００μm
のフイルムを作成して、オリエンテック社製テンシロン
ＵＴＭ４型を用い、伸長速度１００％にて３００％伸長
後歪みを０％に戻し、２分間放置後再度破断まで伸長さ
せた時の、再度伸長時に応力が発現する伸長率を３００
％から差し引いた伸長率を３００％で除した値を％で示
す。（ｎ＝３） 4. ７０℃伸長回復率 ポリマ−を融点＋１０℃に加熱して、厚み約３００μm
のフイルムを作成して、オリエンテック社製テンシロン
ＵＴＭ４型を用い、７０℃雰囲気にした加熱オーブン中
で伸長速度１００％にて１０％伸長歪みを付与して２４
時間保持した後、歪みを０％に戻し、５分間放置後再度
破断まで伸長させた時の、再度伸長時に応力が発現する
伸長率を１０％から差し引いた伸長率を１０％で除した
値を％で示す。（ｎ＝３） 5. 見掛け密度 試料を１５cm×１５cmの大きさに切断し、４か所の高さ
を測定し、体積を求め試料の重さを体積で徐した値で示
す。（ｎ＝４の平均値） 6. 線条の繊径 試料を１０箇所から各線条部分を切り出し、アクリル樹
脂で包埋して断面を削り出し切片を作成して断面写真を
得る。拡大した断面写真より線径を求め、拡大倍率で叙
した値（ｎ＝１０の平均値） 7. 融着 試料を目視判断で融着しているか否かを接着している繊
維同士を手で引っ張って外れないか否かで外れないもの
を融着していると判断する。 8. 耐熱耐久性（７０℃残留歪） 試料を１５cm×１５cmの大きさに切断し、５０％圧縮し
て７０℃乾熱中２２時間放置後冷却して圧縮歪みを除き
１日放置後の厚みと処理前の厚みの差と処理前の厚みと
の比を％で示す（ｎ＝３の平均値） 9. 繰返し圧縮歪 試料を１５cm×１５cmの大きさに切断し、側地、ワディ
ング層、クッション層がずれたり外れないように、界面
の四隅を縫い糸で接合したものを、島津製作所製サ−ボ
パルサ−にて、２５℃６５％ＲＨ室内にて５０％の厚み
まで１Ｈｚのサイクルで圧縮回復を繰り返し２万回後の
試料を１日放置後の厚みと処理前の厚みの差と処理前の
厚みとの比を％で示す。（ｎ＝３の平均値） 10.通気度 試料を直径１０cmの円筒状に打ち抜き、側面をシ−ルで
きる試料厚みに相当する高さの内径１０cmの金属筒に５
％圧縮した状態で入れ、上下を５％圧縮厚み分のパッキ
ンでシ−ルして横漏れしないようにしたサンプルを作成
し、株式会社テクノワ−ルド社製（コスモ計器設計品）
通気量測定器、高圧タイプを用い測定した通気量（cc／
cm2 秒）を通気度として示す。 11.折り曲げ性 クッション層とワディング層を積層して作成したクッシ
ョン体に所定のサイズに縫製された東洋紡績製ハイムか
らなるポリエステル織物の側地を被って作成したベット
マットを水平面から片端を抑えて押し出し、４５°に切
り欠いた勾配面に接するまでの長さを以下の基準で示
す。５０cm未満：◎、１００cm未満：○、１５０cm未
満：△、１５０cm以上：× 12.水切り性 ベットマットの重量を測定後に水槽に浸して１０分後に
取り出し、出来るだけ水切りしない状態での重量を測定
した後、水切りして、３０℃ＲＨ６５％の雰囲気の室内
で壁に立てかけ１２時間放置後の重量を測定して残留水
分の量を求め、以下の基準で評価した。残留水分が２％
以下：◎、残留水分が３％以下：○、残留水分が５％以
下：△、残留水分が５％以上：× 13.寝心地 クッション層とワディング層を積層して作成したクッシ
ョン体に所定のサイズに縫製された東洋紡績製ハイムか
らなるポリエステル織物の側地を被って作成したベット
マットをベットフレ−ムにセットして、２８℃ＲＨ７５
％室内でパネラ−を寝かせて以下の評価をおこなった。
（ｎ＝５）なお、ベットマット上にはシ−ツを敷き、掛
け布団にはダウン／フェザ−：９０／１０混合羽毛１．
８kg入り、枕は自宅で使用中のものを使用させた。 (1) 違和感：寝たときの「背中に感じる違和感」の程度
を感覚的に定性評価した。感じない；◎、殆ど感じな
い；○、やや感じる；△、感じる；× (2) 沈み込み：寝たときの体型保持状況の程度を感覚的
に定性評価した。適度の沈み込みで非常に心地よい；
◎、沈み込みやや少又はやや大で心地良い；○、沈み込
み小又は大で心地よさにやや欠ける；△、沈み込み過ぎ
又は沈み込まないで心地よさを感じない；× (3) 蒸れ感：２時間寝ていて、臀部や背中等のベットマ
ットと接する部分に感じる蒸れ感を感覚的に定性評価し
た。殆ど感じない：◎、僅かに蒸れを感じる；○、やや
蒸れを感じる；△、蒸れを著しく感じる；× (4) 体圧の圧迫感：寝てから動かないでどの程度我慢し
ていられるか：３０分以内；×、１時間以内；△、２時
間以内；○、２時間以上；◎ (5) 総合評価： (1)から(5) までの評価の◎を４点、○
を３点、△を２点、×を１点として１２点以上で△を含
まないもの；非常に良い（◎）、１２点以上で△を含む
もの；良い（○）、１０点以上で×を含まないもの；や
や悪い（△）、×を含むもの；悪い（×）として評価し
た。The evaluations in the examples were carried out by the following methods. 1. Melting point (Tm) and endothermic peak below melting point The endothermic peak (melting peak) is measured from the endothermic curve measured using a Shimadzu TA50, DSC50 type differential thermal analyzer at a heating rate of 20 ° C / min. -H) The temperature was determined. 2. Tαcr polymer is heated to a melting point of + 10 ° C to a thickness of about 300 μm.
Film was prepared and measured using a Vibron DDVII type manufactured by Orientec Co., Ltd. at a rate of 110 Hz and a heating rate of 1 ° C./min. Tan δ (the ratio of the imaginary elastic modulus M ″ to the real part M ′ of the elastic modulus M ″ / The rising temperature of α dispersion corresponding to the transition temperature from the rubber elastic region to the melting region of M ′). 3. Room temperature elongation recovery rate Polymer is heated to melting point + 10 ° C and thickness is about 300μm.
Of the film, using Tensilon UTM4 type manufactured by Orientec Co., Ltd., the strain was returned to 0% after stretching 300% at a stretching speed of 100%, and was allowed to stand for 2 minutes and then stretched to break again. Elongation rate at which stress develops is 300
The value obtained by dividing the elongation rate subtracted from% by 300% is shown in%. (N = 3) 4. 70 ° C. elongation recovery rate Polymer is heated to a melting point + 10 ° C. to have a thickness of about 300 μm.
24 film was prepared by using Tensilon UTM4 type manufactured by Orientec Co., Ltd. and applying a 10% elongation strain at a elongation rate of 100% in a heating oven in an atmosphere of 70 ° C.
After holding for a period of time, the strain is returned to 0%, and after being left for 5 minutes and then stretched to break again, the value obtained by subtracting the stretch rate at which stress develops again at 10% from the stretch rate at 10% is divided by 10%. Shown in%. (N = 3) 5. Apparent Density The sample is cut into a size of 15 cm × 15 cm, the heights at four locations are measured, the volume is calculated, and the weight of the sample is divided by the volume. (Average value of n = 4) 6. Fiber diameter of filaments Each filament portion is cut out from 10 locations, embedded with acrylic resin, the cross section is cut out to make a section, and a cross-section photograph is obtained. The value obtained by obtaining the wire diameter from the enlarged cross-sectional photograph and enlarging it with the magnifying power (n = 10 average value) 7. Fusing By hand, check the fibers that are adhered to each other to see if the sample is fused or not. It is judged whether or not something that cannot be removed is fused by pulling. 8. Heat resistance and durability (residual strain at 70 ° C) Cut the sample into a size of 15 cm x 15 cm, compress it by 50%, leave it in dry heat at 70 ° C for 22 hours, cool it to remove the compression strain, and leave it for one day after leaving it. The ratio of the difference in thickness before treatment to the thickness before treatment is shown in% (n = 3 average value) 9. Cyclic compression strain The sample was cut into a size of 15 cm x 15 cm, and the lateral side, wadding layer, and cushion were cut. In order to prevent the layers from slipping and coming off, the four corners of the interface were joined with sewing thread, and compression recovery was performed at a cycle of 1 Hz to a thickness of 50% in a room at 25 ° C and 65% RH with a Servo pulsar manufactured by Shimadzu Corporation. The ratio of the difference between the thickness after standing for 1 day and the thickness before the treatment and the thickness before the treatment of the sample after repeating 20,000 times is shown in%. (Average value of n = 3) 10. Air permeability The sample was punched out into a cylindrical shape with a diameter of 10 cm, and a metal cylinder with an inside diameter of 10 cm having a height corresponding to the thickness of the sample that can seal the side surface was used.
% Compressed, and sealed with packing of 5% compression thickness on the top and bottom to create a sample that does not leak sideways, manufactured by Techno World Co., Ltd. (Cosmo instrument design product)
Airflow measured using an airflow meter, high pressure type (cc /
cm 2 sec) is shown as the air permeability. 11. Bendability A cushion mat made by laminating a cushioning layer and a wadding layer is covered with a side cloth of polyester fabric made of Toyobo Co., Ltd. made by Toyobo Co. The length until extrusion and contact with a sloped surface notched at 45 ° is shown below. Less than 50 cm: ◎, less than 100 cm: ○, less than 150 cm: △, more than 150 cm: × 12. Drainability After wetting the bed mat, it was immersed in a water tank and taken out 10 minutes later, and the weight was measured without draining as much as possible. After that, the water was drained off, and after standing for 12 hours on a wall in a room with an atmosphere of 30 ° C. and RH of 65%, the weight was measured and the amount of residual water was determined, and evaluated according to the following criteria. 2% residual water
Below: ◎, residual water content is 3% or less: ○, residual water content is 5% or less: △, residual water content is 5% or more: × 13. Comfortable sleep A cushion body made by laminating a cushion layer and a wadding layer has a predetermined size. The bed mat made by covering the side fabric of the polyester woven fabric made of Toyobo Co., Ltd., which is sewn on, is set on the bed frame at 28 ° C RH75.
% The paneler was laid down in the room and the following evaluation was performed.
(N = 5) Sheets are laid on the bed mat, and down / feather: 90/10 mixed feathers are used for the comforter.
The pillow weighed 8kg and was the same as the one used at home. (1) Feeling uncomfortable: The degree of "feeling uncomfortable on the back" when sleeping was qualitatively and qualitatively evaluated. No feeling; ◎, almost no feeling; ○, slightly felt; △, felt; × (2) Depression: The degree of body retention when sleeping was sensitized qualitatively. Very comfortable with moderate subduction;
◎, slightly depressed or slightly large, comfortable; ○, slightly depressed or large, slightly lacking in comfort; △, too deep or not submerging and does not feel comfortable; × (3) Feeling of stuffiness: A qualitative qualitative evaluation was performed on the stuffiness felt on the buttocks, the back, and the like in contact with the bed mat after sleeping for 2 hours. Almost no feeling: ◎, slightly stuffy; ○, slightly stuffy; △, remarkably stuffy; × (4) Pressure of body pressure: how much you can endure without moving after sleeping: 30 minutes or less; ×, 1 hour or less; △, 2 hours or less; ○, 2 hours or more; ◎ (5) Comprehensive evaluation: 4 points out of ◎ from (1) to (5)
3 points, △ is 2 points, × is 1 point and does not include Δ with 12 points or more; very good (⊚), that with 12 points or more; Good (○), 10 points or more is x It was evaluated as those which did not contain; those which were somewhat bad (Δ) and those which contained x; bad (x).
【００２０】実施例１ ポリエステル系エラストマ−として、ジメチルテレフタ
レ−ト（ＤＭＴ）又は、ジメチルナフタレ−ト（ＤＭ
Ｎ）と１・４ブタンジオ−ル（１・４ＢＤ）を少量の触
媒と仕込み、常法によりエステル交換後、ポリテトラメ
チレングリコ−ル（ＰＴＭＧ）を添加して昇温減圧しつ
つ重縮合せしめポリエ−テルエステルブロック共重合エ
ラストマ−を生成させ、次いで抗酸化剤１％及び難燃剤
１０％（燐含有量５０００〜１００００ｐｐｍ）を添加
混合後ペレット化し、５０℃４８時間真空乾燥して得ら
れた熱可塑性弾性樹脂原料の処方を表１に示す。Example 1 As a polyester elastomer, dimethyl terephthalate (DMT) or dimethyl naphthalate (DM) was used.
N) and 1.4 butanediol (1.4 BD) were charged with a small amount of a catalyst, and after transesterification by a conventional method, polytetramethylene glycol (PTMG) was added and polycondensation was performed while heating and depressurizing. -The heat obtained by forming a terester block copolymer elastomer, then adding and mixing 1% of an antioxidant and 10% of a flame retardant (phosphorus content: 5000 to 10000 ppm), pelletizing, and vacuum drying at 50 ° C for 48 hours. Table 1 shows the formulation of the plastic elastic resin raw material.
【００２１】[0021]
【表１】 [Table 1]
【００２２】幅１２０cm、長さ１０cmのノズル有効面に
幅方向の孔間ピッチ５mm、長さ方向の孔間ピッチ１０mm
の千鳥配列としたオリフィス形状は外径２mm、内径１．
６mmでトリプルブリッジの中空形成性断面としたノズル
に、得られた熱可塑性弾性樹脂原料を別々の押出機にて
溶融し、Ａ−１をシ−ス成分に、Ａ−２をコア成分とな
るようにオリフィス直前で分配し、溶融温度２４５℃に
て単孔当たりの吐出量２．０ｇ／分（Ａ−１：１ｇ／
分、Ａ−２：１ｇ／分）にてノズル下方に吐出させ、ノ
ズル面１２cm下に冷却水を配し、幅１４０cmのステンレ
ス製エンドレスネットを平行に１０cm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、該溶融状
態の吐出線状を曲がりくねらせル−プを形成して接触部
分を融着させつつ３次元網状構造を形成し、該溶融状態
の網状体の両面を引取りコンベア−で挟み込みつつ毎分
１ｍの速度で２５℃の冷却水中へ引込み固化させ両面を
フラット化した後引取り、水切り後、連続して１２０℃
の加熱空気を循環させたセッタ−中を１５分間通過させ
冷却後、所定の大きさに切断して得た網状体は断面形状
がシ−スコア構造の三角おむすび型の中空断面で中空率
が４０％、線径が１．２mmの融点以外に１２６℃に吸熱
ピープをもつ線条が、形成するル−プの互いの接触点は
殆ど融着により接合され、両面は実質的にフラット化さ
れ、平均の見掛け密度が０．０４６ｇ／cm2 、厚み９．
５cm、繰返し圧縮歪み２．８％、耐熱耐久性１１．２％
であった。別途、地糸に５０デニ−ル／３６フィラメン
トのポリエステル繊維、パイル糸に線径０．０５mmのポ
リエステルエラストマ−（Ａ−２）繊維を用い、常法に
より、亀甲形格子となる厚み５mm、見かけ密度が０．０
６ｇ／cm2 、空隙率９６％のダブルラッセルニットを作
成した。次いで、１２０℃の加熱空気を循環させたセッ
タ−中で１５分間熱処理し、冷却後所定の大きさに切断
して、２枚の該網状体の両面に積層した。次いで、所定
の大きさに縫製された東洋紡績製ハイムからなるポリエ
ステル繊維からなる側地に挿入して本発明のベットマッ
トを得た。得られたベットマットの評価結果を表２に示
す。表２で明らかごとく、耐熱性、耐久性、通気性、折
り曲げ性、水切り性に優れ、寝心地の良好なベットマッ
トである。なお、このベットマットは難燃性を示し、燃
焼ガスの毒性指数は５．１であった。このことから、火
災時の安全性も高いベットマットであることが分かる。On the effective surface of the nozzle having a width of 120 cm and a length of 10 cm, the pitch between the holes in the width direction is 5 mm and the pitch between the holes in the length direction is 10 mm.
The zigzag array of orifices has an outer diameter of 2 mm and an inner diameter of 1.
The obtained thermoplastic elastic resin raw material is melted in a separate extruder into a nozzle having a hollow-forming cross section of a triple bridge of 6 mm, and A-1 is used as a sheath component and A-2 is used as a core component. Dispensing just before the orifice, the discharge rate per single hole is 2.0 g / min (A-1: 1 g /
Min., A-2: 1 g / min), the cooling water is placed 12 cm below the nozzle surface, and a pair of take-up conveyors are placed parallel to each other with an endless net made of stainless steel having a width of 140 cm at intervals of 10 cm. The melted discharge line is bent to form a loop and the contact portions are fused together to form a three-dimensional network structure. While sandwiching both sides with a take-up conveyor, it is drawn into cooling water at 25 ° C. at a speed of 1 m / min to solidify and flatten both sides, then taken off, drained, and continuously 120 ° C.
After passing through a setter in which heated air is circulated for 15 minutes to cool and then cutting to a predetermined size, the reticulated body has a triangular cross-sectional hollow cross-section with a cis core structure and a hollow ratio of 40. %, The filament having an endothermic peep at 126 ° C. in addition to the melting point of 1.2 mm is almost joined by fusion bonding at the contact points of the formed loops, and both sides are substantially flattened. Average apparent density 0.046 g / cm 2 , thickness 9.
5 cm, cyclic compression strain 2.8%, heat resistance durability 11.2%
Met. Separately, a polyester fiber of 50 denier / 36 filament is used for the ground yarn, and a polyester elastomer (A-2) fiber of 0.05 mm wire diameter is used for the pile yarn. Density is 0.0
A double Russell knit having 6 g / cm 2 and a porosity of 96% was prepared. Then, heat treatment was carried out for 15 minutes in a setter in which heated air of 120 ° C. was circulated, and after cooling, cut into a predetermined size and laminated on both surfaces of the two mesh bodies. Next, the bed mat of the present invention was obtained by inserting it into a side fabric made of polyester fiber made of Heim made by Toyobo, which was sewn to a predetermined size. Table 2 shows the evaluation results of the obtained bet mats. As is clear from Table 2, the bed mat is excellent in heat resistance, durability, breathability, bending property, and water draining property, and has good sleeping comfort. The bed mat exhibited flame retardancy and the combustion gas toxicity index was 5.1. From this, it can be seen that the bed mat has high safety in case of fire.
【００２３】[0023]
【表２】 [Table 2]
【００２４】実施例２ 幅１２０cm、長さ５cmのノズル有効面に幅方向の孔間ピ
ッチ５mm、長さ方向の孔間ピッチ１０mmの千鳥配列とし
たオリフィス形状は外径１mm丸断面としたノズルに、得
られた熱可塑性弾性樹脂原料Ａ−５を押出機にて溶融
し、溶融温度２４５℃にて単孔当たりの吐出量２．０ｇ
／分にてノズル下方に吐出させ、ノズル面１５cm下に冷
却水を配し、幅１４０cmのステンレス製エンドレスネッ
トを平行に平行に４．５cm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、該溶融状態の吐出線
状を曲がりくねらせル−プを形成して接触部分を融着さ
せつつ３次元網状構造を形成し、該溶融状態の網状体の
両面を引取りコンベア−で挟み込みつつ毎分１ｍの速度
で２５℃の冷却水中へ引込み固化させ両面をフラット化
した後引取り、水切り後、連続して１２０℃の加熱空気
を循環させたセッタ−中を１５分間通過させ冷却後、所
定の大きさに切断して得た網状体は、断面形状が丸断面
で、線径が０．９mmの融点以外に１２６℃に吸熱ピーク
をもつ線条が、形成するル−プの互いの接触点は殆ど融
着により接合され、両面が実質的にフラット化され、平
均の見掛け密度が０．０４８ｇ／cm2 、厚み４．５cm、
繰返し圧縮歪み７．５％、耐熱耐久性１８．４％であっ
た。次いで、実施例１で使用したダブルラッセルニット
を１２０℃の加熱空気を循環させたセッタ−中で１５分
間熱処理し、冷却後所定の大きさに切断して、２枚の該
網状体の両面に積層した。次いで、所定の大きさに縫製
された東洋紡績製ハイムからなるポリエステル繊維から
なる側地に挿入して本発明のベットマットを得た。得ら
れたベットマットの評価結果を表２に示す。表２で明ら
かごとく、耐熱性、耐久性、通気性、折り曲げ性、水切
り性に優れ、寝心地の良好なベットマットである。な
お、このベットマットは難燃性を示し、燃焼ガスの毒性
指数は５．１であった。このことから、火災時の安全性
も高いベットマットであることが分かる。Example 2 A nozzle having a width of 120 cm and a length of 5 cm and having a staggered arrangement with a hole-to-hole pitch of 5 mm in the width direction and a hole-to-hole pitch of 10 mm in the length direction on a nozzle effective surface has an outer diameter of 1 mm and a round cross section. The obtained thermoplastic elastic resin raw material A-5 was melted by an extruder, and the discharge amount per single hole was 2.0 g at a melting temperature of 245 ° C.
Discharge at the bottom of the nozzle at a rate of 1 / min, place cooling water 15 cm below the nozzle surface, and put a pair of take-up conveyors on the water surface in parallel with the stainless endless net with a width of 140 cm at intervals of 4.5 cm. The melted discharge line is bent to form a loop and the contact portions are fused to form a three-dimensional network structure, and both sides of the melted network are drawn. While sandwiching it with a conveyor, it is drawn into cooling water at 25 ° C at a speed of 1 m / min to be solidified and flattened on both sides, then taken off, drained, and then in a setter in which heated air at 120 ° C is continuously circulated for 15 minutes. The reticulate body obtained by passing and cooling and then cutting it into a predetermined size has a round cross-section, and a linear line having an endothermic peak at 126 ° C is formed in addition to the melting point of the wire diameter of 0.9 mm. -The contact points of the Surface is substantially flattened, the apparent density of the average 0.048 g / cm 2, thickness 4.5 cm,
The cyclic compression strain was 7.5%, and the heat resistance durability was 18.4%. Then, the double Russell knit used in Example 1 was heat-treated in a setter in which heated air at 120 ° C. was circulated for 15 minutes, cooled, and cut into a predetermined size, and the both sides of the two reticulated bodies were cut. Laminated. Next, the bed mat of the present invention was obtained by inserting it into a side fabric made of polyester fiber made of Heim made by Toyobo, which was sewn to a predetermined size. Table 2 shows the evaluation results of the obtained bet mats. As is clear from Table 2, the bed mat is excellent in heat resistance, durability, breathability, bending property, and water draining property, and has good sleeping comfort. The bed mat exhibited flame retardancy and the combustion gas toxicity index was 5.1. From this, it can be seen that the bed mat has high safety in case of fire.
【００２５】実施例３ 幅１２０cm、長さ５cmのノズル有効面に幅方向の孔間ピ
ッチ５mm、長さ方向の孔間ピッチ１０mmの千鳥配列とし
たオリフィス形状は外径２mm、内径１．６mmでトリプル
ブリッジの中空形成性断面としたノズルに、得られた熱
可塑性弾性樹脂Ａ−３を押出機にて溶融し、溶融温度２
３５℃にて単孔当たりの吐出量２．０ｇ／分にてノズル
下方に吐出させ、ノズル面１２cm下に冷却水を配し、幅
１４０cmのステンレス製エンドレスネットを平行に６cm
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、実施例１で用いたダブルラッセルニットをコン
ベアの両側から供給しつつ、該溶融状態の吐出線状を曲
がりくねらせル−プを形成して接触部分を融着させつつ
３次元網状構造を形成し、該溶融状態の網状体の両面を
ダブルラッセルニットで挟み込みつつダブルラッセルニ
ットとも融着させつつ、毎分１ｍの速度で２５℃の冷却
水中へ引込み固化させた後引取り、水切り後、連続して
１２０℃の加熱空気を循環させたセッタ−中を１５分間
通過させ冷却後、所定の大きさに切断して得た網状体の
両面は実質的にフラット化された状態で両面をダブルラ
ッセルニットと接合されたクッション体を得た。クッシ
ョン体中の網状体は、断面形状は中空おむすび型断面
で、線径が１．２mmの融点以外に１２６℃に吸熱ピーク
をもつ線条が、形成するル−プの互いの接触点は殆ど融
着により接合され、平均の見掛け密度が０．０４８ｇ／
cm2 、厚み４．５cm、繰返し圧縮歪み５．８％、耐熱耐
久性１０．８％であった。次いで、所定の大きさに縫製
された東洋紡績製ハイムからなるポリエステル繊維から
なる側地に挿入して本発明のベットマットを得た。得ら
れたベットマットの評価結果を表２に示す。表２で明ら
かごとく、耐熱性、耐久性、通気性、折り曲げ性、水切
り性に優れ、寝心地の良好なベットマットである。な
お、このベットマットは難燃性を示し、燃焼ガスの毒性
指数は５．１であった。このことから、火災時の安全性
も高いベットマットであることが分かる。Example 3 A staggered array of orifices having an outer diameter of 2 mm and an inner diameter of 1.6 mm was formed on a nozzle effective surface having a width of 120 cm and a length of 5 cm with a hole-to-hole pitch of 5 mm in the width direction and a hole-to-hole pitch of 10 mm in the length direction. The obtained thermoplastic elastic resin A-3 was melted in an extruder with a nozzle having a triple bridge hollow forming cross section, and the melting temperature was 2
Discharge at a discharge rate of 2.0 g / min per single hole at 35 ° C. below the nozzle, place cooling water below the nozzle surface 12 cm, and make a stainless endless net of width 140 cm 6 cm in parallel.
A pair of take-up conveyors are arranged at intervals so that they partially come out on the water surface, and while supplying the double Russell knit used in Example 1 from both sides of the conveyor, the discharge line in the molten state is bent. -Forming a three-dimensional network structure while forming a lump and fusing the contact portion, and sandwiching both sides of the network in the molten state with a double Russell knit and fusing with a double Russell knit, a speed of 1 m / min. After being drawn into cooling water at 25 ° C for solidification, removed, drained, continuously passed through a setter in which heated air at 120 ° C is circulated for 15 minutes to cool, and then cut into a predetermined size to obtain A cushion body was obtained in which both sides of the reticulated body were substantially flattened, and both sides were joined with a double Russell knit. The net-like body in the cushion body has a hollow rice ball-shaped cross-section, and the filaments having an endothermic peak at 126 ° C in addition to the melting point of the wire diameter of 1.2 mm form almost no contact points of the loops. Bonded by fusion and the average apparent density is 0.048g /
cm 2 , thickness 4.5 cm, cyclic compression strain 5.8%, heat resistance durability 10.8%. Next, the bed mat of the present invention was obtained by inserting it into a side fabric made of polyester fiber made of Heim made by Toyobo, which was sewn to a predetermined size. Table 2 shows the evaluation results of the obtained bet mats. As is clear from Table 2, the bed mat is excellent in heat resistance, durability, breathability, bending property, and water draining property, and has good sleeping comfort. The bed mat exhibited flame retardancy and the combustion gas toxicity index was 5.1. From this, it can be seen that the bed mat has high safety in case of fire.
【００２６】実施例４ ポリウレタン系エラストマ−として、４・４’ジフェニ
ルメタンジイソシアネ−ト（ＭＤＩ）とＰＴＭＧ及び鎖
延長剤として１・４ＢＤを添加して重合し次いで抗酸化
剤２％を添加混合練込み後ペレット化し真空乾燥してポ
リエ−テル系ウレタンポリマ−の処方を表３に示す。Example 4 As a polyurethane elastomer, 4,4'-diphenylmethane diisocyanate (MDI), PTMG and 1.4BD as a chain extender were added and polymerized, and then 2% of an antioxidant was added and mixed. Table 3 shows the formulation of the polyether urethane polymer after kneading, pelletizing and vacuum drying.
【００２７】[0027]
【表３】 [Table 3]
【００２８】得られた熱可塑性弾性樹脂（シ−ス成分：
Ｂ−１、コア成分：Ｂ−２）を溶融温度２２０℃とした
以外実施例１と同様にして得た網状体の線条のシ−スコ
ア構造の断面形状が三角おむすび型の中空断面で中空率
４０％、線径が１．１mmの融点以外に１２６℃に吸熱ピ
ークをもつ線条が、形成するル−プの互いの接触点は殆
ど融着により接合され、両面が実質的にフラット化さ
れ、平均の見掛け密度が０．０４７ｇ／cm 2 、厚み９．
５cm、繰返し圧縮歪み３．６％、耐熱耐久性７．５％で
あった。次いで、実施例１で使用したダブルラッセルニ
ットを１２０℃の加熱空気を循環させたセッタ−中で１
５分間熱処理し、冷却後所定の大きさに切断して、４枚
の該網状体の両面に積層した。次いで、所定の大きさに
縫製された東洋紡績製ハイムからなるポリエステル繊維
からなる側地に挿入して本発明のベットマットを得た。
得られたベットマットの評価結果を表２に示す。表２で
明らかごとく、耐熱性、耐久性、通気性、折り曲げ性、
水切り性に優れ、寝心地の良好なベットマットである。The thermoplastic elastic resin thus obtained (seed component:
B-1 and core component: B-2) had a melting temperature of 220 ° C.
Except for the reticulated filament strips obtained in the same manner as in Example 1.
(A) The cross-sectional shape of the structure is a triangular rice ball type hollow cross-section
40%, melting point of wire diameter 1.1 mm and endothermic pi
The loops formed by the ark have almost no contact points with each other.
It is joined by fusing and is substantially flat on both sides.
And the average apparent density is 0.047 g / cm 2, Thickness 9.
5 cm, cyclic compressive strain 3.6%, heat resistance durability 7.5%
there were. Then, the double Rasselni used in Example 1
1 in a setter in which heated air at 120 ° C is circulated.
Heat treatment for 5 minutes, cool and cut into a predetermined size, then 4 pieces
Was laminated on both sides of the mesh body. Then to a predetermined size
Polyester fiber made from sewn heiyo made heim
A bed mat of the present invention was obtained by inserting the bed mat of the present invention.
Table 2 shows the evaluation results of the obtained bet mats. In Table 2
Obviously, heat resistance, durability, breathability, bendability,
It is a bed mat with excellent drainability and good sleeping comfort.
【００２９】比較例１ メルトインデックス１２のポリプロピレン（ＰＰ）単成
分のみを溶融温度を２５０℃とした以外、実施例２と同
様にして得た網状体は、中実丸断面で、線径が１．８m
m、の融点以外に１２６℃に吸熱ピークをもつ線条が、
形成するル−プの互いの接触点は殆ど融着により接合さ
れ、両面が実質的にフラット化され、平均の見掛け密度
が０．０４７ｇ／cm2 、厚み４．５cm、繰返し圧縮歪み
３０．２％、耐熱耐久性４９．５％であった。次いで、
実施例１で使用したダブルラッセルニットを１２０℃の
加熱空気を循環させたセッタ−中で１５分間熱処理し、
冷却後所定の大きさに切断して、１枚の該網状体の両面
に積層した。次いで、所定の大きさに縫製された東洋紡
績製ハイムからなるポリエステル繊維からなる側地に挿
入して本発明のベットマットを得た。得られたベットマ
ットの評価結果を表２に示す。表２で明らかごとく、非
弾性オレフィンからなる網状体のため、通気性、水切り
性には優れるが、耐熱性、耐久性、折り曲げ性、寝心地
が著しく劣るベットマットであり、難燃性も不合格にな
り火災時には問題がでるベットマットである。Comparative Example 1 A reticulate body obtained in the same manner as in Example 2 except that only the polypropylene (PP) single component having a melt index of 12 had a melting temperature of 250 ° C. has a solid round cross section and a wire diameter of 1 .8m
In addition to the melting points of m and m, the filaments that have an endothermic peak at 126 ° C
Almost all the contact points of the loops to be formed are joined by fusion bonding and both sides are substantially flattened, and the average apparent density is 0.047 g / cm 2 , thickness 4.5 cm, and cyclic compression strain 30.2. % And heat resistance durability was 49.5%. Then
The double Russell knit used in Example 1 was heat treated for 15 minutes in a setter in which heated air at 120 ° C. was circulated,
After cooling, it was cut into a predetermined size and laminated on both sides of one sheet of the mesh body. Next, the bed mat of the present invention was obtained by inserting it into a side fabric made of polyester fiber made of Heim made by Toyobo, which was sewn to a predetermined size. Table 2 shows the evaluation results of the obtained bet mats. As is clear from Table 2, since it is a reticulated body made of non-elastic olefin, it is a bed mat that is excellent in breathability and drainability, but is extremely inferior in heat resistance, durability, bendability, and sleeping comfort, and it also fails in flame retardancy. It is a bed mat that causes problems in case of fire.
【００３０】比較例２ 幅１２０cm、長さ１０cmのノズル有効面に幅方向の孔間
ピッチ５mm、長さ方向の孔間ピッチ１０mmの千鳥配列と
したオリフィス形状は外径１mm丸断面としたノズルに、
得られた熱可塑性弾性樹脂原料Ａ−５を押出機にて溶融
し、溶融温度２３５℃にて単孔当たりの吐出量３．０ｇ
／分にてノズル下方に吐出させ、ノズル面５cm下に冷却
水を配し、幅１４０cmのステンレス製エンドレスネット
を平行に平行に９．５cm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、該溶融状態の吐出線状
を曲がりくねらせル−プを形成して接触部分を融着させ
つつ３次元網状構造を形成し、該溶融状態の網状体の両
面を引取りコンベア−で挟み込みつつ毎分１ｍの速度で
２５℃の冷却水中へ引込み固化させ両面をフラット化し
た後引取り、水切り後、所定の大きさに切断して得た網
状体は、断面形状が丸断面で、線径が５．９mmの融点以
外に吸熱ピークをもたない線条が、形成するル−プの互
いの接触点は殆ど融着により接合され、両面が実質的に
フラット化され、平均の見掛け密度が０．０７４ｇ／cm
2 、厚み９．５cm、繰返し圧縮歪み１８．３％、耐熱耐
久性２８．４％であった。次いで、実施例１で使用した
ダブルラッセルニットを２枚の該網状体の両面に積層し
た。次いで、所定の大きさに縫製された東洋紡績製ハイ
ムからなるポリエステル繊維からなる側地に挿入して得
られたベットマットの評価結果を表２に示す。表２で明
らかごとく、通気性、水切り性、蒸れ感の少ない点に優
れるが、耐熱性、耐久性、折り曲げ性、蒸れ感以外の寝
心地が劣るベットマットである。なお、このベットマッ
トは難燃性を示し、燃焼ガスの毒性指数は５．１であっ
た。このことから、火災時の安全性は高いベットマット
であることが分かる。Comparative Example 2 A nozzle having a width of 120 cm and a length of 10 cm and having a staggered arrangement with a hole-to-hole pitch of 5 mm in the width direction and a hole-to-hole pitch of 10 mm in the length direction on a nozzle having a circular cross section with an outer diameter of 1 mm. ,
The obtained thermoplastic elastic resin raw material A-5 was melted with an extruder, and the melting amount was 235 ° C., and the discharge amount per single hole was 3.0 g.
/ Min, and the cooling water is placed under the nozzle surface 5 cm, and a pair of take-up conveyors are partially projected on the water surface in parallel with the stainless endless net of width 140 cm at intervals of 9.5 cm. The melted discharge line is bent to form a loop and the contact portions are fused to form a three-dimensional network structure, and both sides of the melted network are drawn. While being sandwiched by a conveyor, it is drawn into cooling water at 25 ° C. at a speed of 1 m / min to be solidified and flattened on both sides, then taken out, drained, and cut into a predetermined size. In the cross section, the filaments having no endothermic peak other than the melting point of 5.9 mm in diameter are formed by joining most of the contact points of the loops formed by fusion bonding and substantially flattening both sides. Average apparent density is 0.074g / cm
2 , the thickness was 9.5 cm, the cyclic compression strain was 18.3%, and the heat resistance was 28.4%. Next, the double Russell knit used in Example 1 was laminated on both surfaces of the two mesh bodies. Next, Table 2 shows the evaluation results of the bed mat obtained by inserting the bed mat into a side fabric made of polyester fiber made of Toyobo Heim sewn to a predetermined size. As is clear from Table 2, the bed mat is excellent in breathability, drainability, and less dampness, but inferior in sleep comfort other than heat resistance, durability, bendability, and dampness. The bed mat exhibited flame retardancy and the combustion gas toxicity index was 5.1. From this, it can be seen that the bed mat has high safety in case of fire.
【００３１】比較例３ 溶融温度２４５℃にて、ノズル面３０cm下に引取りコン
ベアネットを配し、引き取り速度を０．３ｍ／分とした
以外、比較例２と同様の方法で得た網状体は、断面形状
が丸断面で、線径が１．９mmの融点以外に吸熱ピークを
もたない線条が、形成するル−プの互いの接触点は殆ど
融着により接合され、両面が実質的にフラット化され、
平均の見掛け密度が０．２４ｇ／cm2 、厚み９．５cm、
繰返し圧縮歪み１９．８％、耐熱耐久性２９．４％であ
った。次いで、比較例２と同様にして得たベットマット
の評価結果を表２に示す。表２で明らかごとく、通気
性、水切り性、蒸れ感の少ない点に優れるが、耐熱性、
耐久性、折り曲げ性、蒸れ感以外の寝心地が劣るベット
マットである。なお、このベットマットは難燃性を示
し、燃焼ガスの毒性指数は５．１であり、火災時の安全
性は高いベットマットである。Comparative Example 3 A reticulate body obtained in the same manner as in Comparative Example 2 except that a take-up conveyor net was placed 30 cm below the nozzle surface at a melting temperature of 245 ° C. and the take-up speed was 0.3 m / min. Is a round cross-section with a wire diameter of 1.9 mm, which has no endothermic peak other than the melting point, and the contact points of the loops formed are almost joined by fusion, and both sides are substantially Is flattened,
Average apparent density is 0.24 g / cm 2 , thickness is 9.5 cm,
The cyclic compression strain was 19.8% and the heat resistance durability was 29.4%. Then, Table 2 shows the evaluation results of the bet mats obtained in the same manner as in Comparative Example 2. As is clear from Table 2, it is excellent in breathability, drainability, and less dampness, but heat resistance,
It is a bed mat that is inferior in sleep comfort other than durability, bendability, and dampness. In addition, this bed mat shows flame retardancy, the toxicity index of combustion gas is 5.1, and the bed mat is highly safe in case of fire.
【００３２】比較例４ 単孔当たりの吐出量０．３ｇ／分とし、ノズル面５cm下
に引取りコンベアネットを配し、引き取り速度を１．９
ｍ／分とした以外、比較例３と同様の方法で得た網状体
は、断面形状が丸断面で、線径が０．４mmの融点以外に
吸熱ピークをもたない線条が、形成するル−プの互いの
接触点は殆ど融着により接合され、両面が実質的にフラ
ット化され、平均の見掛け密度が０．００４ｇ／cm2 、
厚み９．５cm、繰返し圧縮歪み１３．６％、耐熱耐久性
２２．４％であった。次いで、比較例２と同様にして得
たベットマットの評価結果を表２に示す。表２で明らか
ごとく、通気性、折り曲げ性、水切り性に優れるが、耐
熱性、耐久性、寝心地が劣るベットマットである。Comparative Example 4 A discharge rate per single hole was 0.3 g / min, a take-up conveyor net was placed 5 cm below the nozzle surface, and a take-up speed was 1.9.
The reticulate body obtained by the same method as in Comparative Example 3 except that m / min was a cross section having a round cross section, and a line having no endothermic peak other than the melting point of 0.4 mm was formed. Almost all contact points of the loops are joined by fusion bonding, both sides are substantially flattened, and the average apparent density is 0.004 g / cm 2 ,
The thickness was 9.5 cm, the cyclic compression strain was 13.6%, and the heat resistance durability was 22.4%. Then, Table 2 shows the evaluation results of the bet mats obtained in the same manner as in Comparative Example 2. As is clear from Table 2, the bed mat is excellent in breathability, bending property and drainage property, but inferior in heat resistance, durability and sleeping comfort.
【００３３】比較例５ 溶融温度２３０℃にて、単孔当たりの吐出量１．５ｇ／
分とし、ノズル面６０cm下に引取りコンベアネットを配
し、引き取り速度を１ｍ／分とした以外、比較例２と同
様の方法で得た網状体は、断面形状が丸断面で、線径が
１．９mmの融点以外に吸熱ピークをもたない線条となる
が、線条がル−プを形成しないで接触点が殆どできず、
網状体を形成しなかった。この線条を無理に見掛け密度
が０．０５ｇ／cm2 、厚み９．５cmのウエッブ状とし、
次いで、比較例２と同様にして得たベットマットの評価
結果を表２に示す。表２で明らかごとく、接触点が接合
されない場合は、寝心地が劣るベットマットになる。な
お、このベットマットは寝心地が劣悪なため他の評価を
していない。Comparative Example 5 At a melting temperature of 230 ° C., the discharge amount per single hole was 1.5 g /
Minutes, a take-up conveyor net was placed 60 cm below the nozzle surface, and the take-up speed was set to 1 m / min. The filament has no endothermic peak other than the melting point of 1.9 mm, but the filament does not form a loop and almost no contact point is formed.
No reticulate was formed. Forcing this wire into a web with an apparent density of 0.05 g / cm 2 and a thickness of 9.5 cm,
Then, Table 2 shows the evaluation results of the bet mats obtained in the same manner as in Comparative Example 2. As is clear from Table 2, when the contact points are not joined, the bed mat is inferior in sleeping comfort. Since this bed mat has poor sleeping comfort, no other evaluation was made.
【００３４】比較例６ 溶融温度２４５℃にて、単孔当たりの吐出量１．５ｇ／
分とし、ノズル面２０cm下に引取りコンベアネットを配
し、片側のコンベアネットの表面に５mmの凹凸を付けた
ものとし、引き取り速度を１ｍ／分とした以外、比較例
２と同様の方法で得た網状体は、断面形状が丸断面で、
線径が０．９mmの融点以外に吸熱ピークをもたない線条
が、形成するル−プの互いの接触点は殆ど融着により接
合され、片面は実質的にフラット化されているが、他面
は凹凸を有する、平均の見掛け密度が０．０３５ｇ／cm
2 、最も厚い場所の厚み９．５cm、繰返し圧縮歪み１
９．５％、耐熱耐久性２９．２％であった。次いで、比
較例２と同様にして得たベットマットの評価結果を表２
に示す。表２で明らかごとく、通気性、折り曲げ性、水
切り性、蒸れ感の少ない点に優れるが、耐熱性、耐久性
がやや劣り、凸凹側を使った寝心地では違和感があり、
蒸れ感以外の寝心地がやや劣るベットマットである。な
お、このベットマットは難燃性を示し、燃焼ガスの毒性
指数は５．１であり、火災時の安全性は高いベットマッ
トである。Comparative Example 6 At a melting temperature of 245 ° C., the discharge amount per single hole was 1.5 g /
In the same manner as in Comparative Example 2, except that a take-up conveyor net was placed 20 cm below the nozzle surface and the surface of one side of the conveyor net had irregularities of 5 mm, and the take-up speed was 1 m / min. The obtained reticulate body has a round cross section,
Wires having no endothermic peak other than the melting point of the wire diameter of 0.9 mm, the contact points of the loops to be formed are almost joined by fusion, and one side is substantially flattened. The other surface has irregularities, the average apparent density is 0.035 g / cm
2 , thickness of the thickest place 9.5cm, repeated compressive strain 1
The heat resistance and durability were 9.5% and 29.2%, respectively. Then, the evaluation results of the bet mat obtained in the same manner as in Comparative Example 2 are shown in Table 2.
Shown in As is clear from Table 2, although it is excellent in breathability, bending property, drainability, and less dampness, it is slightly inferior in heat resistance and durability, and there is a feeling of discomfort when sleeping on the uneven side.
It is a bed mat with a slightly inferior sleeping comfort other than a damp feeling. In addition, this bed mat shows flame retardancy, the toxicity index of combustion gas is 5.1, and the bed mat is highly safe in case of fire.
【００３５】比較例７ 幅１２０cm、長さ１cmのノズル有効面に幅方向の孔間ピ
ッチ５mm、長さ方向の孔間ピッチ５mmの千鳥配列とした
オリフィス形状は外径１mm丸断面としたノズルを用い、
単孔当たりの吐出量０．３ｇ／分とし、ノズル面５cm下
に引取りコンベアネットを配し、０．４cm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、引き
取り速度を１．０ｍ／分とした以外、比較例３と同様の
方法で得た網状体は、断面形状が丸断面で、線径が０．
４mmの融点以外に吸熱ピークをもたない線条が、形成す
るル−プの互いの接触点は殆ど融着により接合され、両
面が実質的にフラット化され、平均の見掛け密度が０．
０６４ｇ／cm2 、厚み０．４cm、繰返し圧縮歪み１８．
６％、耐熱耐久性２９．８％であった。次いで、比較例
２と同様にして得たベットマットの評価結果を表２に示
す。表２で明らかごとく、通気性、折り曲げ性、水切り
性に優れるが、耐熱性、耐久性が劣り、クッション層が
薄すぎて寝心地が著しく劣るベットマットである。COMPARATIVE EXAMPLE 7 A nozzle having a width of 120 cm and a length of 1 cm and a staggered arrangement with a hole-to-hole pitch of 5 mm in the width direction and a hole-to-hole pitch of 5 mm in the length direction was used as the orifice shape. Used,
The discharge rate per single hole is 0.3 g / min, a take-up conveyor net is placed 5 cm below the nozzle surface, and a pair of take-up conveyors are placed at 0.4 cm intervals so that they partially come out on the water surface. The reticulate body obtained in the same manner as in Comparative Example 3 except that the speed was 1.0 m / min had a round cross section and a wire diameter of 0.
The filaments having no endothermic peak other than the melting point of 4 mm are formed by almost fusion-bonding the contact points of the formed loops, substantially flattening both surfaces, and an average apparent density of 0.
064 g / cm 2 , thickness 0.4 cm, cyclic compressive strain 18.
It was 6% and the heat resistance durability was 29.8%. Then, Table 2 shows the evaluation results of the bet mats obtained in the same manner as in Comparative Example 2. As is clear from Table 2, the bed mat is excellent in breathability, bending property, and water draining property, but inferior in heat resistance and durability, and the cushion layer is too thin to remarkably sleep.
【００３６】比較例８ 水切り後、連続して熱処理しない以外、実施例２と同様
にして得た網状体は、断面形状が丸断面で、線径が０．
９mmの融点以外に吸熱ピークをもたない線条が、形成す
るル−プの互いの接触点は殆ど融着により接合され、両
面が実質的にフラット化され、平均の見掛け密度が０．
０４８ｇ／cm2 、厚み４．５cm、繰返し圧縮歪み７．５
％、耐熱耐久性１８．４％であった。次いで、見掛け密
度が０．０５ｇ／cm3 の市販のポリエステル硬綿を厚み
５mmにスライスし、所定の大きさに切断して、１枚の該
網状体の両面に市販のゴム系接着接着剤を塗布して積層
した硬綿を網状体と接着し、所定の大きさに縫製された
ポリエステル繊維からなる側地に挿入して得られたベッ
トマットの評価結果を表２に示す。表２で明らかごと
く、寝心地はやや良いが、耐熱性、耐久性、通気性、折
り曲げ性、水切り性が劣るベットマットである。Comparative Example 8 A reticulate body obtained in the same manner as in Example 2 except that the heat treatment was not continuously performed after the water was drained had a circular cross section and a wire diameter of 0.
The filaments having no endothermic peak other than the melting point of 9 mm are joined by fusion bonding at the contact points of the formed loops, the both surfaces are substantially flattened, and the average apparent density is 0.
048 g / cm 2 , thickness 4.5 cm, cyclic compressive strain 7.5
%, And the heat resistance durability was 18.4%. Next, a commercially available polyester hard cotton having an apparent density of 0.05 g / cm 3 is sliced to a thickness of 5 mm, cut into a predetermined size, and a commercially available rubber-based adhesive is applied to both sides of one reticulated body. Table 2 shows the evaluation results of the bed mat obtained by bonding the coated and laminated hard cotton to the net and inserting it into the side fabric made of polyester fiber sewn to a predetermined size. As is clear from Table 2, the bed mat is slightly comfortable to sleep, but inferior in heat resistance, durability, breathability, bending property, and drainage property.
【００３７】比較例９ 厚み１０cm、見掛け密度０．０５ｇ／cm3 の市販のポリ
エステル硬綿をクッション材とし、実施例１で使用した
ダブルラッセルニットをワディング層として積層し、所
定の大きさに縫製されたポリエステル繊維からなる側地
に挿入して得られたベットマットの評価結果を表２に示
す。表２で明らかごとく、寝心地はやや良いが沈み込み
が少なく、耐熱性、耐久性、通気性、折り曲げ性、水切
り性は劣るベットマットである。Comparative Example 9 A commercially available polyester hard cotton having a thickness of 10 cm and an apparent density of 0.05 g / cm 3 was used as a cushion material, and the double Russell knit used in Example 1 was laminated as a wadding layer and sewn to a predetermined size. Table 2 shows the evaluation results of the bed mat obtained by inserting it into the side material made of the polyester fiber. As is clear from Table 2, this bed mat is comfortable to sleep in, but has little sinking, and is inferior in heat resistance, durability, breathability, bendability and drainability.
【００３８】比較例１０ 厚み１０cm、見掛け密度０．０５ｇ／cm3 の市販の発泡
ポリウレタンをクッション材とし、実施例１で使用した
ダブルラッセルニットをワディング層として積層し、所
定の大きさに縫製されたポリエステル繊維からなる側地
に挿入して得られたベットマットの評価結果を表２に示
す。表２で明らかごとく、耐熱性、耐久性は優れている
が、通気性、折り曲げ性、水切り性、寝心地が劣るベッ
トマットである。Comparative Example 10 A commercially available foamed polyurethane having a thickness of 10 cm and an apparent density of 0.05 g / cm 3 was used as a cushioning material, and the double Russell knit used in Example 1 was laminated as a wadding layer and sewn to a predetermined size. Table 2 shows the evaluation results of the bed mat obtained by inserting the mat into a side material made of polyester fiber. As is clear from Table 2, this bed mat is excellent in heat resistance and durability, but inferior in breathability, bendability, drainability and sleeping comfort.
【００３９】実施例５ 実施例２で得た網状体の両面に実施例１で用いたワディ
ング層を積層して、所定の大きさに縫製された側地に挿
入して敷布団を得た。得られた敷布団の評価結果では、
耐熱耐久性、通気性、折り曲げ性、水切り性、寝心地が
共に優れた敷布団であった。Example 5 A quilt was obtained by laminating the wadding layers used in Example 1 on both sides of the mesh body obtained in Example 2 and inserting the wadding layers in the side fabric sewn to a predetermined size. In the evaluation results of the obtained mattress,
The mattress was excellent in heat resistance and durability, breathability, bendability, drainability, and sleeping comfort.
【００４０】実施例６ 実施例２で得た網状体の両面に実施例１で用いたワディ
ング層を積層して、所定の大きさに縫製された側地に挿
入して座布団を得た。得られた敷布団の評価結果では、
耐熱耐久性、通気性、折り曲げ性、水切り性、座り心地
が共に優れた座布団であった。Example 6 A cushion was obtained by laminating the wadding layers used in Example 1 on both sides of the mesh body obtained in Example 2 and inserting the wadding layer into a side cloth sewn to a predetermined size. In the evaluation results of the obtained mattress,
It was a cushion with excellent heat resistance and durability, breathability, bendability, drainability, and sitting comfort.
【００４１】[0041]
【発明の効果】伸長回復性の良い熱可塑性弾性樹脂から
なる線条が融着一体化され表面をフラット化した網状体
をクッション層にし、熱可塑性樹脂からなる繊維を使用
したダブルラッセルニットをワディング層に積層された
ベットマットであるので、蒸れ難く寝心地が良好で、耐
熱耐久性、形態保持性、クッション性に優れ、折り曲げ
性も良好で使い易く、火災時に有毒ガスの発生が少な
く、難燃性で、ＭＲＳＡ等の雑菌を除去するための洗濯
ができて水切り性の良好な、更には、リサイクルも可能
な一般家庭用、病院用及びホテル用等のベットに最適な
ベットマットを提供できる。更に敷布団や家具用にも適
するクッション体として使用できる有用なベットマット
を提供できる。EFFECTS OF THE INVENTION A double Russell knit using fibers made of a thermoplastic resin is used as a cushion layer made of a net-like body having a flattened surface in which filaments made of a thermoplastic elastic resin having good elongation recovery are fused and integrated to form a wadding. Since it is a bed mat laminated in layers, it does not get stuffy easily and it has a good sleeping comfort. It also has excellent heat resistance and durability, shape retention and cushioning properties, and it has good bendability and is easy to use. It is possible to provide a bed mat which is suitable for general household use, hospital use, hotel use, etc., which can be washed to remove miscellaneous bacteria such as MRSA and has good drainability, and which is also recyclable. Further, it is possible to provide a useful bed mat that can be used as a cushion body suitable for a futon and furniture.
Claims (14)
ング層が積層され、且つ、全体面が側地で被われたベッ
トマットであり、クッション層は、熱可塑性弾性樹脂か
らなる線径が５ｍｍ以下の連続した線条を曲がりくねら
せランダムループを形成し、それぞれのループの接触部
の大部分が融着されてなる三次元立体構造網状体で形成
され、該三次元立体構造網状体は上、下両面が実質的に
フラット化されており、見掛密度が０．０５〜０．１ｇ
／cm3 、厚みが５ｍｍ以上であり、ワディング層は、熱
可塑性樹脂からなる繊維を用いたダブルラッセルニット
からなり、該ワディング層の見掛密度が０．２ｇ／cm3
以下であることを特徴とするベットマット。1. A bed mat in which a wadding layer is laminated on at least the upper surface of a cushion layer and the entire surface is covered with a side material, and the cushion layer is made of a thermoplastic elastic resin and has a continuous wire diameter of 5 mm or less. The three-dimensional three-dimensional network is formed by winding the formed filaments into a random loop, and most of the contact portions of the respective loops are fused, and the three-dimensional three-dimensional network has upper and lower surfaces. Is substantially flattened, and the apparent density is 0.05 to 0.1 g
/ Cm 3 , the thickness is 5 mm or more, the wadding layer is made of a double Russell knit using fibers made of a thermoplastic resin, and the apparent density of the wadding layer is 0.2 g / cm 3.
A bet mat characterized by the following:
脂が、室温での３００％伸長後の回復率（室温伸長回復
率）が２０％以上、７０℃での１０％伸長を２４時間保
持した後の回復率（７０℃伸長回復率）が３０％以上で
ある請求項１記載のベットマット。2. The thermoplastic elastic resin constituting the cushion layer has a recovery rate after room temperature elongation of 300% (room temperature elongation recovery rate) of 20% or more and after holding 10% elongation at 70 ° C. for 24 hours. 2. The bed mat according to claim 1, wherein the recovery rate (extension recovery rate at 70 ° C.) is 30% or more.
０．０１mm以上、見掛けの密度が０．０１ｇ／cm3 から
０．０８ｇ／cm3 、厚みが１０mm以上である請求項１記
載のベットマット。3. The reticulate body constituting the cushion layer has a wire diameter of 0.01 mm or more, an apparent density of 0.01 g / cm 3 to 0.08 g / cm 3 , and a thickness of 10 mm or more. Bet mat.
０．１mm以上２mm以下、見掛けの密度が０．０２ｇ／cm
3 から０．０６ｇ／cm3 、厚みが２０mm以上５００mm以
下である請求項１記載のベットマット。4. The wire diameter of the net-like body constituting the cushion layer is 0.1 mm or more and 2 mm or less, and the apparent density is 0.02 g / cm.
The bed mat according to claim 1, which has a thickness of 3 to 0.06 g / cm 3 and a thickness of 20 mm or more and 500 mm or less.
みが２ｍｍ以上１０ｍｍ以下である請求項１記載のベッ
トマット。5. The bed mat according to claim 1, wherein the wadding layer has a porosity of 90% or more and a thickness of 2 mm or more and 10 mm or less.
樹脂で熱融着により接合一体化した請求項１記載のベッ
トマット。6. The bed mat according to claim 1, wherein the cushion layer and the wadding layer are joined and integrated with each other by heat fusion with a thermoplastic resin.
る成分を示差走査型熱量計で測定した融解曲線に室温以
上融点以下の温度に吸熱ピ−クを持つ網状体を用いた請
求項１記載のベットマット。7. A reticulated body having an endothermic peak at a temperature above room temperature and below its melting point in a melting curve of a component comprising a thermoplastic elastic resin measured by a differential scanning calorimeter in the cushion layer. Bet mat.
の断面形状が中空断面又は及び異形断面である請求項１
記載のベットマット。8. The cross-sectional shape of the filaments of the net-like body forming the cushion layer is a hollow cross section or an irregular cross section.
Bed mat described.
項１記載のベットマット。9. The bed mat according to claim 1, which has an air permeability of 50 cc / cm 2 seconds or more.
樹脂及びワディング層を構成する熱可塑性樹脂がポリエ
ステルである請求項記載のベットマット。10. A bed mat according to claim 1, wherein the thermoplastic elastic resin forming the cushion layer and the thermoplastic resin forming the wadding layer are polyesters.
た側地を被せて構成した請求項１記載のベットマット。11. The bed mat according to claim 1, wherein the bed mat is covered with a side material formed of fibers made of a thermoplastic resin.
り熱可塑性弾性樹脂をその融点より２０〜８０℃高い溶
融温度で、該ノズルより下方に向けて吐出させ、溶融状
態で連続線条のループを形成し、それぞれのループを互
いに接触し、融着させ３次元構造を形成しつつ、引取り
装置で挟み込み冷却槽で冷却せしめた後、得られた三次
元構造体の上、下両面又は片面に熱可塑性樹脂からなる
ダブルラッセルニットを積層し、側地を被せることを特
徴とするベットマットの製法。12. A thermoplastic elastic resin is discharged downward from the nozzle at a melting temperature 20 to 80 ° C. higher than the melting point of the multi-row nozzle having a plurality of orifices, and a continuous linear loop is formed in a molten state. After forming and contacting the loops with each other and fusing them to form a three-dimensional structure, the loops are sandwiched by a take-up device and cooled in a cooling tank, and then the obtained three-dimensional structure is placed on both upper and lower surfaces or one side. A method for producing a bed mat, which comprises laminating double Russell knits made of a thermoplastic resin and covering the side cloth.
ブルラッセルニットを同時に供給して該網状体表面に溶
融接着させてクッション体を形成する請求項１２記載の
ベットマットの製法。13. The method for producing a bed mat according to claim 12, wherein a double raschel knit is simultaneously supplied to the take-up net and melt-bonded to the surface of the net when forming the net.
成する熱可塑性弾性樹脂の融点より少なくとも１０℃以
下の温度でアニ−リングよる疑似結晶化処理を行う請求
項１２記載のベットマットの製法。14. The bed mat according to claim 12, wherein pseudo-crystallization treatment by annealing is performed at a temperature of at least 10 ° C. or lower than the melting point of the thermoplastic elastic resin forming the reticulate body in any step leading to commercialization. Manufacturing method.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP14357995A JP3585003B2 (en) | 1995-06-09 | 1995-06-09 | Bed mat and its manufacturing method |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP14357995A JP3585003B2 (en) | 1995-06-09 | 1995-06-09 | Bed mat and its manufacturing method |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH08336443A true JPH08336443A (en) | 1996-12-24 |
| JP3585003B2 JP3585003B2 (en) | 2004-11-04 |
Family
ID=15342025
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP14357995A Expired - Lifetime JP3585003B2 (en) | 1995-06-09 | 1995-06-09 | Bed mat and its manufacturing method |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3585003B2 (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP5602934B1 (en) * | 2013-12-28 | 2014-10-08 | 株式会社カズマ | Mattress for bedding |
| US9615670B2 (en) | 2014-02-23 | 2017-04-11 | C-Eng Co., Ltd. | Core material for cushion, and cushion |
| WO2023190964A1 (en) * | 2022-03-31 | 2023-10-05 | 東洋紡エムシー株式会社 | Three-dimensional net-like structure and manufacturing method for same |
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| JPH04215710A (en) * | 1990-12-13 | 1992-08-06 | Mitsubishi Motors Corp | Air-permeable seat |
| JPH05311559A (en) * | 1992-05-01 | 1993-11-22 | Teijin Ltd | Novel high performance cushion structure and its production |
| JPH06296535A (en) * | 1993-04-13 | 1994-10-25 | Toray Ind Inc | Sterically interlaced textile substrate |
| JPH0723834A (en) * | 1993-07-07 | 1995-01-27 | Toyobo Co Ltd | Laminate |
| JPH0768061A (en) * | 1993-02-26 | 1995-03-14 | Toyobo Co Ltd | Net-work structure for cushion and its manufacture |
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1995
- 1995-06-09 JP JP14357995A patent/JP3585003B2/en not_active Expired - Lifetime
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH04215710A (en) * | 1990-12-13 | 1992-08-06 | Mitsubishi Motors Corp | Air-permeable seat |
| JPH05311559A (en) * | 1992-05-01 | 1993-11-22 | Teijin Ltd | Novel high performance cushion structure and its production |
| JPH0768061A (en) * | 1993-02-26 | 1995-03-14 | Toyobo Co Ltd | Net-work structure for cushion and its manufacture |
| JPH06296535A (en) * | 1993-04-13 | 1994-10-25 | Toray Ind Inc | Sterically interlaced textile substrate |
| JPH0723834A (en) * | 1993-07-07 | 1995-01-27 | Toyobo Co Ltd | Laminate |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP5602934B1 (en) * | 2013-12-28 | 2014-10-08 | 株式会社カズマ | Mattress for bedding |
| US9615670B2 (en) | 2014-02-23 | 2017-04-11 | C-Eng Co., Ltd. | Core material for cushion, and cushion |
| WO2023190964A1 (en) * | 2022-03-31 | 2023-10-05 | 東洋紡エムシー株式会社 | Three-dimensional net-like structure and manufacturing method for same |
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