JPH091708A - Mat and manufacture thereof - Google Patents
Mat and manufacture thereofInfo
- Publication number
- JPH091708A JPH091708A JP7153308A JP15330895A JPH091708A JP H091708 A JPH091708 A JP H091708A JP 7153308 A JP7153308 A JP 7153308A JP 15330895 A JP15330895 A JP 15330895A JP H091708 A JPH091708 A JP H091708A
- Authority
- JP
- Japan
- Prior art keywords
- mat
- cushion layer
- elastic resin
- polyester
- thermoplastic elastic
- 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)
- Laminated Bodies (AREA)
- Nonwoven Fabrics (AREA)
Abstract
Description
【０００１】[0001]
【産業上の利用分野】本発明は、蒸れ難く、保温性、体
型保持性に優れ寝心地が良好で、耐久性、折り曲げ性に
も優れ洗濯が可能で、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、座蒲団、家具等のクッション材にも適
したマット及びその製法に関する。BACKGROUND OF THE INVENTION The present invention is suitable for general household use, which is difficult to get stuffy, has excellent heat retention and body shape retention, is comfortable to sleep, has excellent durability and bendability, can be washed, and can always maintain cleanliness. The present invention relates to a bed mat most suitable for beds for hospitals and hotels, a mat also suitable for cushioning materials such as bedding, cushions and furniture, and a manufacturing method thereof.
【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, it is necessary to wash the bed mat due to the problem that hospital beds become hot beds such as MRSA, but urethane, which has poor water permeability, has become a social problem because it cannot be washed.
【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
No. publication. 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、水切り性が悪く殺菌できな
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−９１／１９０
３２号公報、特開平５−１５６５６１号公報、特開平５
−１６３６５４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２−１４２
５１３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
−２８５０３１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 that it is not drainable and cannot be sterilized. 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-bonding fiber using a polyester elastomer that is soft and recovers even if it is deformed to some extent and uses non-elastic polyester as a core component is disclosed in Japanese Patent Laid-Open No. 4-240219 and a cushion using the fiber. Body is WO-91 / 190
32, JP-A-5-155651, JP-A-5
It is proposed in Japanese Patent Publication No. 163654. 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 for further improving the durability, JP-A-5-163654 is available.
Japanese Patent Laid-Open Publication No. 9-242242 proposes a structure consisting of a polyester elastomer containing isophthalic acid as a sheath component and a heat-bonding composite fiber using an inelastic polyester as a core component. Deformation becomes remarkable, heat resistance and compression resistance deteriorate, and there is a problem in using it for a 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 bendability, a method of forming a folded structure is disclosed in JP-A-55-36373 and JP-A-2-142.
Although proposed in Japanese Patent Laid-Open No. 513 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. In addition, as a structure in which a cavity is formed in the bent portion to improve the bendability, for example, Japanese Patent Laid-Open No. Hei.
Although there is a publication such as -285031, it has not been able to solve the problem of foams such as urethane or the problem of hard cotton.
【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、殺菌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、洗濯性、殺菌性な
どの取扱性には何ら配慮されていない。特開平６−３２
７７２３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３−１７６６６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 the use of a mesh body which is presumed to have a hard structure is described in Japanese Patent Publication No. 05714, no consideration is given to heat resistance and durability, sleeping comfort, weight reduction, washability and sterilization. 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 handleability such as washability and sterilization. JP-A-6-32
Japanese Patent No. 7723 discloses a reticulated body having a hole through which a cleaning pipe, a ventilation pipe and the like can be mounted, but since the material is olefin, the heat resistance and durability are remarkably inferior, and the handleability such as weight reduction and washing property is improved. No consideration was given to it, and it cannot be used as a wadding layer or cushioning material. Further, Japanese Patent Publication No. 3-17666 discloses a method of fusing discharge filaments having different fineness to each other to form a mold, but it is a mesh structure not suitable for 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】特開平６−２６９３４５号公報には、遠赤
外線輻射機能を持つ不織布等の寝具用部材を被う、綿材
をシ−トで挟みキルトした布団用パッドが開示されてい
るが、体型保持機能や蒸れ防止機能等の寝心地改良、耐
熱耐久性、水切り性や乾燥性等の洗濯性、及び折り曲げ
性に関する配慮がなされていない問題がある。実開平６
−４８４５３号公報には、折り目をつけた硬綿をキルテ
ィングを施した詰綿充填包布に包まれた敷布団が開示さ
れている。敷布団としては、折り畳み性と保温性は良い
が、通気性に劣り蒸れ易く、体型保持性が不充分で、耐
熱耐久性、水切り性や乾燥性等の洗濯性と殺菌性の配慮
がなされていない問題がある。Japanese Unexamined Patent Publication (Kokai) No. 6-269345 discloses a pad for a futon in which a cotton material is sandwiched between sheets and quilted, which covers a bedding member such as a non-woven fabric having a far infrared radiation function. There is a problem that attention is not paid to improvement of sleeping comfort such as a holding function and a stuffiness preventing function, heat resistance and durability, washability such as draining property and drying property, and bending property. Actual Kaihei 6
Japanese Patent No. 48453 discloses a comforter wrapped in a quilted stuffed cotton-filled wrapping cloth made of hard cotton with folds. As a mattress, it has good foldability and heat retention, but it is inferior in breathability and easily stuffy, has insufficient body retention, and has not been considered for washability and sterilization such as heat resistance and durability, draining and drying. There's a problem.
【０００８】[0008]
【発明が解決しようとする課題】上記問題点を解決し、
蒸れ難く、保温性、形態保持性等の寝心地を良くし、耐
熱耐久性、折り曲げ性も良好で使い易く、ＭＲＳＡ等の
雑菌を除去するための洗濯や殺菌が可能な構造とし、更
には、リサイクルし易いベット、敷布団、座蒲団、家具
用クッションに最適なマット及びその製法を提供するこ
とを目的とする。To solve the above problems,
It has a structure that makes it difficult to get stuffy, keeps it warm and keeps its shape, and has good heat resistance and bending properties, and is easy to use. An object of the present invention is to provide a bed, a mattress, a seat cushion, an optimal mat for a cushion for furniture, and a manufacturing method thereof, which are easy to do.
【０００９】[0009]
【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、本発明は編織物からなる側地でクッショ
ン層を包み込んだマットであり、クッション層の少なく
とも片面の側地の構造が２枚の編織物シートの間にワデ
ィング層が挟み込まれてキルティング縫製された構造に
なっており、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、見掛け密度が０．００５〜０．１０ｇ
／cm3 、厚みが５mm以上であり、ワディング層は、ポリ
エステル繊維ウェブからなり、見掛け密度が０．１ｇ／
cm3 以下であることを特徴とするマットである。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０．０
１mm以上、見掛けの密度が０．０１ｇ／cm3 から０．０
８ｇ／cm3 、厚みが１０mm以上であるマットであり、ク
ッション層を構成する網状体の線径が０．１mm以上２mm
以下、見掛けの密度が０．０２ｇ／cm3 から０．０６ｇ
／cm3 、厚みが２０mm以上５００mm以下であるマットで
あり、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マットであり、クッション体を構成
する熱可塑性弾性樹脂がポリエステルであるマットであ
り、ワディング層の両面を編織物で被われ、縫製された
側地の通気度が２０cc／cm2 秒以上であるマットであ
り、熱可塑性弾性樹脂がポリエステルであるマットであ
り、繊維表面にポリエチレングリコ−ル成分を０．０５
重量％以上含有するポリエステル繊維を主たるマトリッ
クスとするウエッブであるマットであり、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、得られた３次元構造体の上、下両面又は
片面にポリエステル繊維を主たるマトリックスとしたウ
ェッブの両面を編織物で被いキルチィング縫製した側地
を被せるマットの製造法であり、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
処理を行うマットの製法であり、ポリエチレングリコ−
ルを１重量％以上、１０重量％混合して繊維化したポリ
エステル繊維を主たるマトリックスとして用いるマット
の製造法である。[Means for Solving the Problems] Means for solving the above problems, that is, the present invention is a mat in which a cushion layer is wrapped with a side material made of knitted fabric, and the structure of the side material on at least one side of the cushion layer is The wading layer is sandwiched between two knitted fabric sheets and quilted and sewn. The cushion layer is made of thermoplastic elastic resin and has a linear diameter of 5 mm or less. A loop is formed, and most of the contact portions of each loop are fused and formed of a three-dimensional three-dimensional structure network,
The three-dimensional three-dimensional structure network is substantially flattened on both upper and lower surfaces and has an apparent density of 0.005 to 0.10 g.
/ Cm 3 , the thickness is 5 mm or more, the wadding layer is made of polyester fiber web, and the apparent density is 0.1 g /
The mat is characterized by having a size of not more than cm 3 . 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, a mat having a recovery rate (70 ° C. elongation recovery rate) of 30% or more after holding 10% elongation at 70 ° C. for 24 hours, and the wire diameter of the mesh body constituting the cushion layer is 0.0.
1mm or more, apparent density 0.01g / cm 3 to 0.0
It is a mat having a thickness of 8 g / cm 3 and a thickness of 10 mm or more, and the wire diameter of the mesh body forming the cushion layer is 0.1 mm or more and 2 mm.
Below, apparent density is 0.02g / cm 3 to 0.06g
/ Cm 3 and a thickness of 20 mm or more and 500 mm or less, and a reticulate body having an endothermic peak at a temperature of room temperature or more and melting point or less in a melting curve measured by a differential scanning calorimeter of a component made of a thermoplastic elastic resin. A mat in which the cross-sectional shape of the filaments of the reticulate body forming the cushion layer is a hollow cross section and / or a modified cross section, and the thermoplastic elastic resin forming the cushion body is polyester. , A mat having both sides of a wadding layer covered with a knitted fabric and a sewn side material having an air permeability of 20 cc / cm 2 seconds or more, a thermoplastic elastic resin made of polyester, and a polyethylene glycol on the fiber surface. − 0.05 component
A mat, which is a web whose main matrix is polyester fiber containing at least wt.%, Is a thermoplastic elastic resin having a melting temperature 20 to 80 ° C. higher than its melting point, at a melting temperature higher than that of a multi-row nozzle having a plurality of orifices, below the nozzle. Discharge toward and form a continuous linear loop in the molten state, and the loops are brought into contact with each other and fused to form a three-dimensional structure, sandwiched by a take-up device and cooled in a cooling tank, and then obtained. It is a method for producing a mat in which the upper and lower surfaces of the three-dimensional structure are covered with a knitted fabric on both sides of one side or the other side of a web whose main matrix is polyester fiber, and a side material quilted and sewn is covered. In the mat, 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 reticulated body in the step. It is a law, polyethylene glycol -
This is a method for producing a mat using polyester fibers fibrillated by mixing 1% by weight or more and 10% by weight as a main matrix.
【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８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
ン性を兼備できるマット類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 8 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 1 of an alicyclic dicarboxylic acid such as 1,4-cyclohexanedicarboxylic acid, an aliphatic dicarboxylic acid such as succinic acid, adipic acid, and sebacic acid dimer acid, or a dicarboxylic acid selected from these ester-forming derivatives 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 with a number average molecular weight of 1000 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 later of the thermoplastic elastic resin forming the cushion layer, which is a mat that can have both favorable durability and cushioning property, which is the object of the present invention, is the recovery rate 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,
The 70 ° C extension recovery rate is 40% or more, and most preferably, the room temperature extension recovery rate is 40% or more, and the 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 or more, and 80% by weight from the viewpoint of heat and fatigue resistance. The following is preferable, and 70% by weight or less is more preferable. That is, the soft segment content of the component having the function of absorbing vibrations and stress of the elastic network of the present invention is preferably 15% by weight or more and 80% by weight or less, more preferably 30% by weight or more and 70% by weight or less. .
【００１１】本発明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（Ｂｐｐｍ）はソ
フトセグメント含有量（Ａ重量％）に対して、３０Ａ＋
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
層の網状体は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、本発明マットを構成する網状体の燃焼ガ
スの毒性指数は、好ましくは５．５以下、より好ましく
は５．０以下である。ポリエステル繊維からなるワディ
ング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、最も好ましくは５以下である。
また、側地にもポリエステル繊維を使用するのが好まし
い。クッション層の網状体を構成する熱可塑性弾性樹脂
は、同一種類に統一するのが好ましい。例えばポリエス
テル系熱可塑性弾性樹脂とすることで、クッション層と
ワディング層は個々に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 mat of the present invention, the phosphorus content (Bppm) in the thermoplastic elastic resin is the soft segment content (A% by weight).
On the other hand, it is preferable to satisfy the relationship of 60A + 200 ≦ B ≦ 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. A preferable phosphorus content (Bppm) is 30A + with respect to the soft segment content (A weight%).
1800 ≦ B ≦ 100,000, and more preferable phosphorus content (Bppm) is 16A + 2600 ≦ B ≦ 50000 with respect to the soft segment content (A weight%). 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. Examples of the phosphorus-based flame retardant of the present invention include:
In the case of a polyester-based thermoplastic elastic resin, as a flame retardant in the hard segment portion at the time of resin polymerization, for example, as described in JP-A-51-82392, 10 [2.3]
・ Di (2-hydroxyethoxy) -carbonylpropyl] 9,10 ・ dihydro ・ 9 ・ oxa ・ 10 phosphaphenalene ・ 10 Polyester obtained by copolymerizing a carboxylic acid such as oxylo 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 to the thermoplastic elastic resin in a later step or a method of forming the thermoplastic elastic resin. be able to. 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. The reticulate body of the cushion layer constituting the bed mat of the present invention contains phosphorus for imparting flame retardancy. The reason is, as described above, from the viewpoint of safety, cyan gas generated at the time of fire, The aim is to minimize the amount of toxic gas such as halogen gas that has a low lethal dose. Therefore, the toxicity index of the combustion gas of the reticulate body constituting the mat of the present invention is preferably 5.5 or less, more preferably 5.0 or less. The toxic index of the combustion gas of the wadding layer made of polyester fiber is preferably 6 or less, more preferably 5.5 or less, and most preferably 5 or less.
Also, it is preferable to use polyester fibers for the side material. It is preferable that the thermoplastic elastic resins forming the mesh body of the cushion layer are of the same type. For example, when the polyester-based thermoplastic elastic resin is used, the cushion layer and the wadding layer can be recycled without being separately separated.
【００１２】本発明の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９
０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１０００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 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, as a preferable polyester-based thermoplastic resin of the present invention, terephthalic acid or naphthalene 2.6 dicarboxylic acid having rigidity in the acid component of the hard segment is used.
The content of 0 mol% or more, more preferably the content of terephthalic acid or naphthalene 2.6 dicarboxylic acid is 95 mol% or more, and particularly preferably 100 mol% to the required degree of polymerization after transesterification of the glycol component. Polymerize, then
As the polyalkylene diol, 15 polytetramethylene glycol having an average molecular weight of 500 or more and 5000 or less, particularly preferably 1000 or more and 3000 or less is preferably used.
% To 70% by weight, more preferably 30% by weight
When the amount of copolymerization is 60% by weight or more, the crystallinity of the hard segment is improved if the content of terephthalic acid or naphthalene 2.6 dicarboxylic acid having rigidity in the acid component of the hard segment is large. Although it is less likely to undergo plastic deformation and the heat resistance and sag resistance are improved, the heat resistance and sag resistance is further improved by performing an annealing treatment at a temperature lower than the melting point by at least 10 ° C. or more after melt heat bonding. If annealing is performed after applying compressive strain, heat resistance and sag resistance are further improved. The endothermic peak is more clearly expressed in the melting curve measured by a differential scanning calorimeter of the reticulated body thus treated 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 treatment is defined as pseudo crystallization treatment.) This pseudo crystallization treatment effect is also effective for polyamide elastic resin and polyurethane elastic resin.
【００１３】本発明におけるポリエステル繊維は、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、ポリエチレンテレフタレ−ト
（ＰＥＴ）、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（ＰＣＨ
ＤＴ）、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。クッション層及び側地にポリエステル繊維を用い
る場合は、廃棄する場合に分離すればリサイクルが可能
で、耐熱性も良好なＰＥＴ、ＰＥＮ、ＰＢＮ、ＰＣＨＤ
Ｔ等のポリエステルが特に好ましい。更には、ＰＥＴ、
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５１−８２３９２号
公報、特開昭５５−７８８８号公報、特公昭５５−４１
６１０号公報等に例示されたものが挙げられる。本発明
では、ポリエステル繊維を用いる他の目的の一つは、繊
維の水分率を低下させるためであるが、発汗した水分は
速やかに皮膚面より移動させる必要から繊維表面は親水
化して放水性を高めるのが好ましく、例えば、ポリエチ
レンオキサイド（ＰＥＯ）やポリエチレングリコ−ル
（ＰＥＧ）、ポリプロピレングリコ−ル（ＰＰＧ）、ポ
リブチレングリコ−ル（ＰＢＧ）等のポリエ−テル類及
びそれらの共重合体や燐化合物との反応物を少なくとも
０．０５重量％以上繊維表面に存在することが好まし
い。より好ましくは０．１重量％以上１重量％以下であ
る。２重量％以上存在させると繊維の摩擦係数が高くな
り、開繊性が劣るので好ましくない。後加工で付与して
もよいが、洗濯耐久性を保持するためには、ポリエステ
ルに混合するのが好ましい。混合方法は、重合時に添加
する方法やポリマ−ブレンドして練り込む方法、紡糸時
に溶融ブレンドして練り込む方法が使える。混合する場
合の添加量は、ＰＥＧでは、分子量５０００以上２００
００以下のものを１重量％以上１０重量％以下添加する
のが好ましい。１重量％未満では充分な放水性が付与で
きず、１５重量％以上では、繊維のモジュラスが低下す
るので好ましくない。更には、繊維断面を異形断面又は
中空異形断面にしてサイホン効果でより効率的に放水性
を付与するのがより好ましい。異形断面の場合は後加工
でも耐久性が付与できるので好ましい実施形態である。The polyester fiber used in the present invention preferably has a glass transition temperature of at least 40 ° C. or higher. For example, polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polycyclohexylene dimethylene terephthalate (PCH)
DT), polycyclohexylene dimethylene naphthalate (PCHDN), polybutylene terephthalate (PB)
Examples thereof include T), polybutylene naphthalate (PBN), polyarylate, and copolymerized polyesters thereof. When polyester fiber is used for the cushion layer and the side material, it can be recycled if it is separated when discarded, and PET, PEN, PBN, PCHD with good heat resistance.
Polyesters such as T are particularly preferred. Furthermore, PET,
A flame-retardant polyester (hereinafter abbreviated as flame-retardant polyester) obtained by polycondensing 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-51-82392, JP-A-55-7888, JP-B-55-41
Examples thereof include those disclosed in Japanese Patent No. 610. In the present invention, one of the other purposes of using the polyester fiber is to reduce the moisture content of the fiber, but since the sweated water needs to be quickly transferred from the skin surface, the fiber surface is hydrophilized to release water. It is preferable to increase it. For example, polyethylene oxide (PEO), polyethylene glycol (PEG), polypropylene glycol (PPG), polybutylene glycol (PBG) and other polyethers and their copolymers, It is preferable that at least 0.05% by weight or more of the reaction product with the phosphorus compound is present on the fiber surface. It is more preferably 0.1% by weight or more and 1% by weight or less. When it is present in an amount of 2% by weight or more, the friction coefficient of the fiber becomes high and the openability is deteriorated, which is not preferable. Although it may be applied by post-processing, it is preferably mixed with polyester in order to maintain durability against washing. As a mixing method, a method of adding at the time of polymerization, a method of kneading with a polymer blend, and a method of melt kneading with kneading at the time of spinning can be used. In the case of PEG, the addition amount is 5,000 or more and 200 or less.
It is preferable to add 1 or more and less than or equal to 0% by weight and 10 or less by weight. If it is less than 1% by weight, sufficient water discharge cannot be imparted, and if it is 15% by weight or more, the modulus of the fiber decreases, which is not preferable. Furthermore, it is more preferable that the cross section of the fiber is a modified cross section or a hollow modified cross section to more efficiently give water discharge by the siphon effect. A modified cross-section is a preferred embodiment because durability can be imparted even in post-processing.
【００１４】本発明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。ベット用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マット類である。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０．０
６ｇ／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５
００mm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、編織物を介して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マットとなるクッション
層である。本発明のマットは、見掛け密度が０．１０ｇ
／cm3 以下のポリエステル繊維のウェブからなるワディ
ング層を表面側又は、及び裏面側に両面を編織物で被い
キルチィング縫製した側地で包まれたマットである。ウ
エッブからなるワディング層の両面を編織物で被いキル
ティング縫製した側地でクッション層を包むことで、洗
濯時にクッション層を単独で取り出し洗濯できる。又、
所望に応じて特性の異なるクッション層（例えば、夏用
と冬用の入替え、やや硬めとやや柔かめの入替え等）を
入替えて個人的な好みも満足し易くしている。逆に、後
述するワディング層を変えてその好みを満足させること
もできるし、その両方を変えることもできる。好ましい
フィット感で体型を保持するためのワディング層に用い
るポリエステル繊維のウェッブは特には限定されない
が、汗や湿気をできるだけ早く皮膚面からワディング層
を介して移動させ蒸れ感を与えず、適正な保温性と好ま
しいフィット感で体型を保持して快適な眠りを永続的に
提供するため、本発明の望ましい実施形態としては、好
ましくは繊維表面を親水化し、より好ましくは異形断面
化、又は中空化した繊維表面を親水化して放水性を高め
たポリエステル繊維を主たるマトリックスとしたウェッ
ブを用いる。ワディング層に放水性を高めたポリエステ
ル繊維を用いることで、皮膚面の体温になった汗や水蒸
気は、編織物を介して皮膚面からワディング層へ移動
し、ワディング層から編織物を介してただちにクッショ
ン層表面に移動する。次いでクッション層が新鮮な空気
と入れ換えるポンプ機能を持つので、クッション層表面
に移動した熱と水分はクッション層を介して外部に放出
される相乗効果で皮膚面が乾燥すると、水分蒸発による
皮膚面の温度低下も伴い蒸れ感を低減させる。なお、ポ
リエステル繊維は、天然繊維と異なり吸湿吸水性が著し
くすくないので、水蒸気は側地の透湿性に依存し、吸湿
による皮膚面の著しい水分蒸発による冷え過ぎを防止し
て一定の湿度を保持するので保温性が保持される。ま
た、ワディング層中に水分が殆ど留まらないため黴など
の温床になりにくい。ワディング層を構成するウエッブ
中のポリエステル繊維は、親水化したポリエステル繊維
の混合率は好ましくは少なくとも５０重量％以上であ
り、より好ましくは７５重量％、最も好ましくは１００
重量％である。見掛け密度は、０．１ｇ／cm3 を越える
とワディング層は通気性が低下し透湿性が低下するの
で、透湿性からの見掛け密度は、好ましくは０．０６ｇ
／cm3 以下、より好ましくは０．０４ｇ／cm3 以下であ
る。かくして、ワディング層とクッション層の相乗効果
で蒸れにくく、且つ保温性も優れたマット機能を発現で
きる。ポリエステル繊維のウェッブからなるワディング
層の他の機能として、ポリエステル繊維間をキルティン
グにより側地と接合一体化した構造体を形成しているの
で、繊維の変形応力に対する自由度が大きく、局部的な
変形応力を受けると繊維の移動が起こり、構造体全体が
変形して側地に伝達された応力が、熱可塑性弾性樹脂か
らなるクッション層でエネルギ−変換により変形応力を
吸収されることによりゴム弾性による低い反発力で変形
応力を受け止められるので、人体に対し柔らかな把持力
で体型を支えられる相乗効果で人体と接する局所的な高
圧縮応力点が形成されにくくなり、より鬱血しにくいワ
ディング機能を発現できる。この機能は側地を介して新
鮮な空気を皮膚面に送ることにより、更なる相乗効果と
して床擦れ防止にも有効に作用する。特に顕著なこの様
な効果を付与するには、両面を編織物で被われたワディ
ング層表面からクッション層側面へ排気される空気の通
気度を１０cc／cm2 秒以上となる構成にするのが望まし
い。なお、本発明のワディング層を被う編織物の通気度
は特には制限されないが、床擦れ防止効果を付与するに
は、ワディング層とクッション層を隔てる編織物の通気
度は、好ましくは３０cc／cm2 秒以上である。また、表
面側の編織物の通気度も３０cc／cm2秒以上とするのが
好ましい。本発明のマットを構成する側地は、マットの
側面を、編織物のみで構成し、クッション層と外気間の
通気性を向上させることで、クッション層のポンプ機能
をより効果的に活用できるので好ましい。本発明のワデ
ィング層を構成するウエッブの見掛け密度は高過ぎると
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
０．１ｇ／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０．０１ｇ／cm3 以上０．
０６ｇ／cm3 以下、より好ましくは見掛け密度は０．０
３ｇ／cm3以上０．０５ｇ／cm3 以下である。ワディン
グ層の厚みは、２mm未満ではワディング層機能が低下す
る。３０mm以上ではクッション層との相乗効果の有用な
前記機能や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３mm以上１５mm以下、より好ましくは５mm以上１
０mm以下である。本発明マットのワディング層に用いる
ポリエステル繊維の繊度は所望に応じて選択されるが、
通常のカ−ド開繊で使用できる繊度としては、０．５デ
ニ−ルから１００デニ−ルであるが、好ましくは２デニ
−ルから３０デニ−ル、より好ましくは４デニ−ルから
１５デニ−ルである。特別な場合は５００デニ−ルまで
の繊度が選択できる。また、本発明マットのワディング
層に用いるポリエステル繊維の断面形状は特に限定され
ないが、異形断面で異形度が１．２以上や中空断面で中
空率が１０％以上、または中空異形断面で異形度１．２
以上、中空率５％以上とすることで、嵩高性、保温性、
抗圧縮性が向上するので好ましい。巻縮形態は開繊ウエ
ッブとなり絡合性が保持できれば機械巻縮でも立体巻縮
でも特には限定されないが、立体巻縮で巻縮度が５％以
上３０％以下で巻縮数が５個／インチ以上１５個／イン
チ以下とすることで柔らかな嵩高性が向上するので好ま
しく、立体巻縮で巻縮度が５％以上２０％以下で巻縮数
が１６個／インチ以上３０個／インチ以下とすることで
抗圧縮性が向上できるので好ましい。繊維長は１５mm以
上１５０mm以下であればカ−ド開繊またはエア−開繊で
き、特には制限されないが、好ましくは開繊しやすく絡
合状態が良い３０mm以上１００mm以下を用いる。やや柔
らかい風合いとするには２デニ−ルから８デニ−ルの細
い繊度を用い、やや硬い風合いとするには６デニ−ルか
ら３０デニ−ルの太い繊度を用いるのが好ましい。腰が
ありタッチが柔らかな風合いとするには、０．５デニ−
ルから５デニ−ルの繊度のものと、６デニ−ルから１５
デニ−ルの繊度のものを１／９から５／５を混繊して用
いるのが好ましい。巻縮形態が機械巻縮で易滑処理した
ものと立体巻縮で親水加工したものを混繊して嵩高性を
抑制しつつ柔らかさと耐へたり性および放水性を付与で
きる。ワディング層に他の特性を付加するために、例え
ば、防ダニ剤、抗菌剤、消臭剤、難燃剤、芳香剤等を親
水化と同時に付与したポリエステル繊維を用いる又は、
別途にそれらを含有するポリエステル繊維を混繊して機
能を高めたり、撥水性、疎水性等の特性を利用して水切
り乾燥性を改善して欠点のカバ−や特徴を倍加する等の
機能付与できる繊維を混繊するのが望ましい。好みに応
じてポリエステル繊維からなる所望の異なるワディング
層をクッション層面に積層して夏冬使い分ける等の使用
形態もとれる。又、本発明の基本機能を失わない範囲に
おいて、クッション層及び、又はワディング層に他の素
材が積層されてもかまわない。本発明マットは洗濯性が
良い。即ち、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０．０１mm以上
であり、ワディング層のウェッブは繊維の表面せきは大
きいが、クッション体全体での平均の構成本数が少ない
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、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。また、本発明のワデ
ィング層を構成するウェッブが、キルティングされてい
るので、側地ごとの洗濯でもウェッブの偏りや絡みつき
によるフェルト化が生じにくい。キルティングの細かさ
は特には限定されないが、好ましくは３cm以上１５cm以
下のピッチ、より好ましくは５cm以上１０cm以下のキル
トピッチである。この為、本発明のマットは頻繁に洗濯
でき、結果として、清潔なマットを常に使用できる。本
発明マットの洗濯は、丸洗いも可能であるが、洗濯後の
水切り性がワディング層は少し劣るので丸洗いした場合
は乾燥時間が長く掛かるので、クッション層と側地に分
割してワディング層の厚みを薄くすることで、水切り性
と乾燥速度を早くできる洗濯方法を採用するのが好まし
い。本発明の好ましい実施形態としては、クッション層
の取り出し、挿入が容易なように、側地に閉鎖できる開
閉口を有するものが良い。また、本発明のマットは、ク
ッション層に熱可塑性弾性樹脂を用いているので、その
伸縮性があるので折り曲げが向上する。さらに、本発明
では、クッション層と変形自由度の高いウェッブからな
るワディング層が分離され、キルティングされているの
で、折り曲げ性をより向上させている。即ち、クッショ
ン層面にワディング層を接合すると面剛性を高める機能
をして、接合しないものより折り曲げ性が低下すること
防止すると共に、キルティング部分が折り曲げ点になる
機能をはたし、折り曲げ性が向上している。この機能
は、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。厚みが薄い敷布団として使用
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、熱可塑性弾性樹脂からなる本発明のクッション層
とウェッブをキルティングされているので変形に対する
自由度の高いワディング層の積層構造のため、折り曲げ
が可能で、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硬綿類と大きく異なる点
である。硬綿の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。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。本発明マットは、圧縮応力を付与しな
いで１３０℃の蒸気で９０分未満の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１３０℃以下の素材を熱接着成分に用いたマット
の場合は、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
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 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. Since the three-dimensional three-dimensional structure is formed and the mesh body is substantially flat on both sides, even when externally applied deformation 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 thermoplastic elastic resin form a three-dimensional three-dimensional structure and are fused and integrated, so that the entire structure is deformed. By absorbing the deformation stress by energy conversion and receiving the deformation stress with a low repulsive force due to rubber elasticity, it prevents extreme local depression and supports the body with a soft gripping force against the human body. DOO expresses preferred type holding function possible. The betting mat is also required to have 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. The mats have a pump function of replacing fresh air with time, so that heat and steam can be easily transferred between the wadding layer and the cushion layer, and the mats can provide comfortable sleeping that is hard to stuff. For this purpose, the wire diameter of the filament made of thermoplastic elastic resin having good vibration absorption and elastic recovery forming the mesh body of the present invention is 5 mm or less. 5 mm when the apparent density is 0.2 g / cm 2 or less
If it exceeds, the number of constituents decreases, a density unevenness is generated, and a structure having poor durability is partially formed, and fatigue due to stress concentration increases and durability deteriorates, which is not preferable. 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 reticulate 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. It is preferably 0.01 g / cm 3 or more and 0.08 g / cm 3 or less, more preferably 0.02 g / cm 3 or more 0.0, in which the function as a cushion body is easily expressed by utilizing the vibration absorbing ability and the deformation stress absorbing function.
It is 6 g / 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 or more, as a surface function for dispersing force and a function of absorbing vibration and deformation stress.
It is less than 00 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 is not substantially flattened, the local external force transmitted from the wadding layer through the knitted fabric cannot receive the deformation stress on the surface, and the lines and bonding points on the surface. Since the function to disperse the deformation stress is selectively transmitted up to the part, stress concentration may occur, and fatigue due to stress concentration may occur against such external force, resulting in sag resistance. It may decrease. 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 person feel uncomfortable. 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. No
Since it has 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 cushioning layer which becomes a mat which is apt to be stuffy and does not provide comfortable sleeping because the air permeability is extremely poor. The mat of the present invention has an apparent density of 0.10 g.
A mat having a wadding layer made of a polyester fiber web of less than 1 cm 3 / cm 3 on the front surface side and / or the back surface side covered with knitting fabric and quilted and sewn. By covering both sides of the wading layer made of a web with a knitted fabric and wrapping the cushion layer with the quilted side, the cushion layer can be individually taken out and washed at the time of washing. or,
Cushion layers having different characteristics (for example, replacement for summer and winter, replacement for slightly harder and slightly softer, etc.) are replaced as desired to facilitate personal satisfaction. On the contrary, the wadding layer described below can be changed to satisfy the taste, or both of them can be changed. The web of polyester fiber used for the wadding layer for holding the body shape with a favorable fit is not particularly limited, but sweat and moisture are transferred from the skin surface through the wadding layer as quickly as possible, and a proper heat retention is not given. In order to maintain the body shape and to provide a comfortable sleep lasting with a good fit and a favorable fit, the preferred embodiment of the present invention is that the fiber surface is preferably hydrophilic, more preferably a modified cross-section or hollow. A web having a main matrix of polyester fibers whose surface is made hydrophilic to enhance water discharge is used. By using polyester fiber with increased water release in the wadding layer, sweat and water vapor that have reached the skin temperature move from the skin surface to the wading layer through the knitted fabric, and immediately from the wadding layer through the knitted fabric. Move to the surface of the cushion layer. Next, since the cushion layer has a pump function of replacing with fresh air, the heat and water transferred to the surface of the cushion layer are released to the outside through the cushion layer. With the decrease in temperature, the stuffiness is reduced. Unlike natural fibers, polyester fibers do not significantly absorb moisture and absorb water, so water vapor depends on the moisture permeability of the side material, and prevents excessive cooling due to significant moisture evaporation of the skin surface due to moisture absorption and maintains a constant humidity. Therefore, heat retention is maintained. In addition, since water hardly stays in the wadding layer, it is hard to become a hotbed such as mold. Regarding the polyester fibers in the web constituting the wadding layer, the mixing ratio of the hydrophilic polyester fibers is preferably at least 50% by weight, more preferably 75% by weight, and most preferably 100% by weight.
% By weight. If the apparent density exceeds 0.1 g / cm 3 , the wadding layer has reduced air permeability and moisture permeability, so the apparent density from the moisture permeability is preferably 0.06 g.
/ Cm 3 or less, more preferably 0.04 g / cm 3 or less. Thus, the synergistic effect of the wadding layer and the cushion layer makes it possible to develop a mat function that is resistant to stuffiness and has excellent heat retention. As another function of the wadding layer consisting of a web of polyester fibers, the polyester fiber is quilted to form a structure that is joined and integrated with the lateral side, so there is a large degree of freedom with respect to the deformation stress of the fibers and local deformation. When stress is applied, the fibers move and the entire structure is deformed and the stress transmitted to the side ground is absorbed by the deformation stress by energy conversion in the cushion layer made of thermoplastic elastic resin. Since it can receive the deformation stress with a low repulsive force, the synergistic effect of supporting the body shape with a soft gripping force against the human body makes it difficult for local high compressive stress points that come into contact with the human body to be formed, and a wadding function that further prevents congestion is expressed. it can. This function sends fresh air to the surface of the skin through the lateral side, and as a further synergistic effect, effectively works to prevent floor rubs. In order to impart such a particularly remarkable effect, it is preferable that the air permeability of the air exhausted from the surface of the wadding layer covered with the knitted fabric to the side surface of the cushion layer is 10 cc / cm 2 seconds or more. desirable. Although the air permeability of the knitted fabric covering the wadding layer of the present invention is not particularly limited, the air permeability of the knitted fabric separating the wadding layer and the cushion layer is preferably 30 cc / cm in order to impart a floor rubbing prevention effect. 2 seconds or more. The air permeability of the knitted fabric on the surface side is preferably 30 cc / cm 2 seconds or more. In the side material that constitutes the mat of the present invention, the side surface of the mat is constituted only by the knitted fabric, and by improving the air permeability between the cushion layer and the outside air, the pump function of the cushion layer can be more effectively utilized. preferable. If the apparent density of the web constituting the wadding layer of the present invention is too high, the congestion-preventing function is deteriorated due to an increase in the high-compression-stress supporting area, the breathability is poor, and the stuffiness preventing effect is also deteriorated, so the apparent density is 0.1 g / cm 3 You need the following: When the apparent density is too low, the anti-compression property is lowered and the function of the wadding layer is lowered, so that the preferable apparent density is 0.01 g / cm 3 or more.
06 g / cm 3 or less, more preferably an apparent density of 0.0
3 g / cm 3 or more 0.05 g / cm 3 or less. If the thickness of the wadding layer is less than 2 mm, the function of the wading layer will deteriorate. When the thickness is 30 mm or more, the useful function described above, which has a synergistic effect with the cushion layer, and a proper sinking and a soft gripping force for supporting the body are reduced. The preferred thickness is 3 mm or more and 15 mm or less, more preferably 5 mm or more 1.
0 mm or less. The fineness of the polyester fiber used in the wadding layer of the mat of the present invention is selected as desired,
The fineness that can be used for ordinary card opening is 0.5 denier to 100 denier, preferably 2 denier to 30 denier, more preferably 4 denier to 15 denier. Denier. In special cases, fineness up to 500 denier can be selected. Further, the cross-sectional shape of the polyester fiber used in the wadding layer of the mat of the present invention is not particularly limited, but the irregularity of the modified cross-section is 1.2 or more, the hollow ratio of the hollow cross-section is 10% or more, or the irregularity of the hollow modified cross-section is 1 or more. .2
As described above, by setting the hollow rate to be 5% or more, the bulkiness, heat retention,
It is preferable because the anti-compression property is improved. The crimping form is not particularly limited to mechanical crimping or three-dimensional crimping as long as the web is an open web and the entanglement can be maintained, but in three-dimensional crimping, the crimping degree is 5% or more and 30% or less, and the number of crimping is 5 / It is preferable that the number of inches is 15 or more / inch or less because the soft bulkiness is improved, and the degree of crimp is 3% or more and 20% or less, and the number of crimps is 16 / inch or more and 30 / inch or less. It is preferable since the anti-compression property can be improved by adjusting the above. The fiber length can be card-opened or air-opened as long as it is 15 mm or more and 150 mm or less, and is not particularly limited, but preferably 30 mm or more and 100 mm or less, which is easy to open and entangled. It is preferable to use a fineness of 2 to 8 denier for a slightly soft texture, and a thick fineness of 6 to 30 denier for a slightly hard texture. For a soft texture with a waist and a soft touch, 0.5 deniers
From 5 to 10 denier and 6 to 15 denier
It is preferable to use denier having a fineness of 1/9 to 5/5. It is possible to impart softness, sag resistance, and water discharge while suppressing bulkiness by mixing fibers having a crimped form that is easily crimped by mechanical crimping and one that is hydrophilically processed by three-dimensional crimping. In order to add other properties to the wadding layer, for example, an anti-mite agent, an antibacterial agent, a deodorant, a flame retardant, a polyester fiber to which a hydrophilic agent and the like have been added at the same time, or,
Addition of functions such as mixing the polyester fibers containing them separately to enhance the function, improving the draining and drying properties by utilizing the characteristics such as water repellency and hydrophobicity, and doubling the coverage and characteristics of defects It is desirable to mix possible fibers. Depending on the taste, desired different wadding layers made of polyester fibers may be laminated on the cushion layer surface to be used properly in summer and winter. Further, other materials may be laminated on the cushion layer and / or the wadding layer as long as the basic function of the present invention is not lost. The mat of the present invention has good washability. That is, compared with a cushion layer made of ordinary fibers having a fiber diameter of 0.001 mm or less, the wire diameter of the cushion layer constituting most of the cushion body of the present invention is 0.01 mm or more, and the web of the wadding layer is made of fibers. However, since the average number of constituents in the entire cushion body is small, the surface area of the filaments is extremely small and the moisture adhering to the surface of the filaments can be reduced, resulting in excellent drainage. Since it has good draining property, the drying time can be shortened. In addition, since the web constituting the wadding layer of the present invention is quilted, even if the side cloth is washed, the felt is less likely to be formed due to the unevenness or entanglement of the web. The fineness of the quilting is not particularly limited, but the pitch is preferably 3 cm or more and 15 cm or less, and more preferably 5 cm or more and 10 cm or less. Therefore, the mat of the present invention can be washed frequently and, as a result, a clean mat can always be used. The mat of the present invention can be washed by washing with a circle, but since the draining property after washing is a little inferior to the wadding layer, it takes a long time to dry it when washed with a circle. It is preferable to adopt a washing method capable of increasing the drainage property and the drying speed by making the thickness thin. As a preferred embodiment of the present invention, it is preferable that the cushion layer has an opening / closing port that can be closed at the side so that the cushion layer can be easily taken out and inserted. Further, since the mat of the present invention uses the thermoplastic elastic resin for the cushion layer, the mat has elasticity, so that the bending is improved. Further, in the present invention, since the cushion layer and the wadding layer made of a web having a high degree of freedom of deformation are separated and quilted, the bendability is further improved. That is, when the wadding layer is joined to the cushion layer surface, it has the function of enhancing the surface rigidity, preventing the bending property from being deteriorated as compared with the one not joined, and at the same time providing the function of the quilting part serving as a bending point to improve the bending property. doing. This function can be used for a bed for care or the like that requires the user to raise the head or upper body. When used as a thin mattress, it can be folded and stored. If the cushion layer is made of non-elastic resin, it is difficult to bend. If the material made of a hard material is bent forcibly, the bent part may be destroyed, and if the 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 cushioning layer of the present invention made of a thermoplastic elastic resin and the web are quilted, the laminated structure of the wadding layer has a high degree of freedom with respect to deformation, so that it can be folded and is resistant to plastic deformation even when repeatedly folded The excellent property is a point that is greatly different from the present invention and the hard cotton. In order to improve the foldability of hard cotton, a fold structure has been proposed, but unlike the cushion layer of the present invention, a non-elastic resin is used for the cushion layer, so that the durability is poor. Commercial beds may be sterilized as needed. For sterilization, ethylene oxide gas below 100 ° C or steam at 130 ° C is generally used. The mat of the present invention can be sterilized without being deformed by sterilizing with steam at 130 ° C. for less than 90 minutes without applying compressive stress. However, known olefins and materials at 130 ° C. or lower are heat-bonded. The mat used as an ingredient is inferior in heat resistance and plastically deforms by heating during sterilization to cause bulk reduction, which is a difference from the present invention. By performing the above-mentioned pseudo-crystallization treatment at any stage from the reticulated body forming step to a commercialized product, the components composed of the thermoplastic elastic resin in the reticulated body are measured at room temperature on a melting curve measured by a differential scanning calorimeter. Stretching and heat resistance of the thermoplastic elastic resin are remarkably improved by having an endothermic peak at a temperature equal to or higher than the melting point,
It is more preferable because 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
は繊径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、ベット用マットの交換や布団、座布団な
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
性樹脂の割合が１００％のシ−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。本発明のマッ
ト類は、クッション層の片面にポリエステル繊維のウェ
ッブを編織物で被いキルティングした、好ましくは親水
化したポリエステル繊維を主たるマトリックスとしたウ
ェッブを編織物で被いキルティングしたワディング層を
設置し、他面に硬綿、天然繊維ウエッブ、不織布、編み
物、布帛類等を設置し、キルティングにより一体化した
側地でクッション層を包むこともできる。本発明マット
は、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、布団、座蒲団、家具用マット類等に特
に有用であるが、車両用座席、家具用椅子、事務用椅子
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 by adjusting the fiber diameter and the modulus of the material used to make the wire diameter thinner, and for soft materials, the hollowness and irregularity can be increased to adjust the gradient of the initial compression stress, and the wire diameter can be made slightly thicker. Or, if the material has a slightly high modulus, the hollowness and the degree of irregularity are lowered to give the good anti-compression property with good sleeping comfort. As another effect of the hollow cross section and irregular cross section, by increasing the hollow ratio and the degree of irregularity, it is possible to reduce the weight even if the same anti-compression property is given, and in the case of replacing the mat for the bed, the duvet, the cushion, etc. Improves the handleability when raising and lowering. 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 obtain a three-dimensional structure in which vibration and deformation stress that cannot be energy-converted even if the cushion layer is largely deformed can be energy-converted and recovered. And a side-by-side structure and a combination 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, the melt viscosity of a thermoplastic elastic resin with a high soft segment content that facilitates energy conversion of vibration and deformation stress is lower than the melt viscosity of a thermoplastic elastic resin with a low soft segment content that exhibits anti-compression properties. A structure in which the proportion of thermoplastic elastic resin occupying a linear surface and having a large amount of soft segment is increased (metaphorically, a structure in which a thermoplastic elastic resin is arranged in an eccentric sheath-core structure) ), The proportion of the thermoplastic elastic resin occupying the linear surface and having a large soft segment content is 80%.
The above-mentioned ones are particularly preferable, and most preferable is a sheath core in which the proportion of the thermoplastic elastic resin occupying the linear surface and having a large soft segment content is 100%. 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. The mats of the present invention have a wadding layer in which a web of polyester fibers is quilted with a knitted fabric on one side of the cushion layer, preferably a web with a main matrix of hydrophilicized polyester fibers is quilted with a knitted fabric. However, it is also possible to lay a hard cotton, a natural fiber web, a non-woven fabric, a knitted fabric, a cloth, etc. on the other surface and wrap the cushion layer with the integrated side fabric by quilting. The mat of the present invention is particularly useful for commercial seats such as ships' seats, vehicles, ships, hospitals, and hospital beds, futons, cushions, furniture mats, etc., but also seats for vehicles, chairs for furniture, It is also useful as a cushion for office chairs.
【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℃から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、両面又は片面に天然繊維をマト
リックスとしたウェッブの両面を編織物で被いキルチィ
ング縫製した側地で包まれた側地を被せるマットの製法
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１−２０７５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８
０％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１０％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〜４０
cm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、該網状体を一旦冷却後、連続し
て、又は、非連続に疑似結晶化処理を行い所定の大きさ
に切断して、又は、切断後疑似結晶化処理される。他
方、ワディング層のポリエステル繊維は公知の方法で得
られるステープルなら良いが、本発明では、親水化剤と
してポリエ−テル等を繊維表面に付与したポリエステル
繊維を用いるのが好ましく、親水化剤としてポリエ−テ
ル等を練り込まれたポリエステルを用いた繊維が特に好
ましい。本発明の特に好ましい実施形態である親水化剤
を練り込む方法としては、重合時に混合する方法、ポリ
エステル樹脂に混練り機能を有する押出機を用いて練り
込んだレジンを作成して使用する方法及び、溶融紡糸時
に直接混合練り込みする方法がある。本発明での、例え
ば、紡糸時直接混合練り込みする方法では、押出機のス
クリュ−のコンプレッション部や先端メタ−リング部に
ダルメ−ジやクロスソ−等の混練り機能をもつ二軸押出
機または単軸押出機を用いて、ポリエステルと共に所定
量を定量供給しつつポリエステルの融点より１０℃以上
３０℃未満の温度で溶融混練りする方法や、ポリエステ
ル樹脂をその融点より２０℃以上５０℃未満の温度で溶
融し、次いで押出機のコンプレッション部から先端メタ
−リング部の間で、該ポリエステルの溶融温度で溶融し
て親水化剤のポリエチレングリコ−ルを定量供給して練
り込む方法（直接メルトブレンド法）があり、本発明で
は後者がより望ましい。親水化剤の練り込み量は１重量
％以上１０重量％添加し、例えばポリエチレングリコ−
ルでは溶融混合ができる粘度を保持できる数平均分子量
５０００以上５００００未満が好ましく、８０００以上
２００００未満がより好ましい。混練り状態はポリエス
テルを主たるマトリックスとした非相溶混合になる。か
くして親水化剤を混練りされた溶融ポリエステル樹脂
は、定量ポンプで計量しつつノズルよりポリエステルの
融点より１０℃以上５０℃未満の温度で紡糸しポリエス
テル繊維を得る。本発明では、繊維断面を好ましくは異
形断面又は中空断面とできるノズルのオリフィス形状を
選択する。より好ましくは、異形中空断面となるノズル
のオリフィス形状を選択する。ポリエステル繊維は非対
象冷却法又は複合紡糸法により潜在捲縮能を付与し、延
伸後熱処理により立体捲縮を発現させて切断または、切
断後熱処理して立体捲縮を発現させて得るのが好まし
い。該ポリエステル繊維は耐へたり性と耐熱性も要求さ
れるので、初期引張り抵抗度が少なくとも３５ｇ／デニ
−ル以上で、７０℃での初期引張り抵抗度が少なくとも
１０ｇ／デニ−ル以上にしたものが好ましい。嵩高性と
抗圧縮性からの立体捲縮の捲縮度は１５％以上、捲縮数
は１０〜２５個／インチが好ましい。かくして得られた
親水化したポリエステル繊維はワディング層の主たるマ
トリックスとして他のポリエステル繊維と所望の配合量
にて混合開繊する。親水化ポリエステル繊維と他のポリ
エステル繊維の混合比率を１００／０〜５０／５０重量
比として、オ−プナ−等で予備開繊混合した後カ−ド等
で開繊し、３次元化構造とした開繊ウエッブを形成し、
厚みが３mmから１０mmとした時、見掛け密度が０．１ｇ
／cm3 以下、好ましくは、見掛け密度が０．０１ｇ／cm
3 から０．０６ｇ／cm3 となるように積層したウェッブ
を所定の大きさに切断してワディング層を得る。好まし
くは、次いで常法により厚みが３mmから１０mmとした時
見掛け密度が０．０１ｇ／cm3 から０．０６ｇ／cm3 と
なるようにウェッブを積層して所定の大きさに切断して
ワディング層を得る。次いで、該ワディング層の両面を
編織物で被いキルティングして挿入するクッション層の
両面又は片面に設置されるよう構成し、クッション層の
挿入、取り出しを行う開閉口をつけた所定の大きさの側
地に縫製される。本発明マットの側地は、マットの側面
は編織物のみが設置されるように構成することで、側面
の通気性を高めると、新鮮な外気を入替えるクッション
層のポンプ機能をより高められるので好ましい。次い
で、該側地にクッション層を挿入して本発明のマットを
得る。本発明における結晶化処理は、製品化に至る任意
の工程で熱可塑性弾性樹脂の少なくとも融点（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）より耐熱耐へたり性が著しく向上す
る。本発明の好ましい疑似結晶化処理温度は（Ｔαｃｒ
＋１０℃）から（Ｔｍ−２０℃）である。単なる熱処理
により疑似結晶化させると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。Next, the manufacturing method of the present invention will be described. A three-dimensional structure in which a thermoplastic elastic resin is discharged downward from the nozzle at a melting temperature 20 ° C. to 80 ° C. higher than its melting point from a multi-row nozzle having a plurality of orifices, and is brought into contact with each other in a molten state to be fused. After forming it, it is sandwiched by a take-up device and cooled in a cooling tank, then both sides or one side of a web with a matrix of natural fibers is covered with a knitted fabric, and a side ground wrapped with a side ground quilted is covered. This is a method for producing a mat, and a method for producing a mat in which a pseudo crystallization treatment is performed by annealing at a temperature of at least 10 ° C. or lower than a melting point of a thermoplastic elastic resin forming a reticulate body in an arbitrary step leading to commercialization. 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. from the melting point of the thermoplastic elastic resin.
℃ higher temperature. 80 ° C from the melting point of the thermoplastic elastic resin
If the melting temperature is higher than this, thermal decomposition will be remarkable and the rubber elasticity of the thermoplastic elastic resin will be deteriorated, 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
Higher temperatures, 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 When heating for adhesion as described in Japanese Patent Application Laid-Open No. 1-2075, the three-dimensional structure is easily relaxed, a planar structure is formed, and a three-dimensional three-dimensional structure becomes difficult, which is not preferable. As an effect of improving the properties of the reticulate body, the apparent bulk can be increased, the weight can be reduced, the anti-compression property can be improved, and the elasticity can be improved, which is difficult to obtain. The hollow section has a hollow ratio of 8
If it exceeds 0%, the cross section tends to be crushed, so that it is preferably 10% or more and 70% or less, more preferably 20% or more and 60% or less so that the effect of weight reduction can be exhibited. 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, discharge downward from the nozzle,
While forming a loop, they are brought into contact with each other in a molten state and fused to form a three-dimensional structure, and are sandwiched by a take-up net, and the winding winding filaments in the molten state on the surface of the mesh body are bent by 45 ° or more. After deforming to flatten the surface and at the same time form a structure by adhering the contact points with the discharge line that is not bent, a cooling medium (usually using room temperature water can increase the cooling rate, It is preferable because it is cheap in terms of cost), and is rapidly cooled to obtain the three-dimensional three-dimensional net-structured net-like body of the present invention. 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. If the discharge amount of the discharge line is 5g / hole or more, 10cm-40
cm is preferable, and 5 cm to 20 cm is preferable when the discharge amount of the discharge filament is less than 5 g / hole. 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. still,
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 reticulate body is preferably 500 poises to 10000 poises, and when it exceeds 20000 poise, It is not preferable because the forming speed becomes slow and it becomes difficult to form a dense network 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 reticulated body is once cooled and then continuously or discontinuously pseudo-crystallized to be cut into a predetermined size, or after being cut, pseudo-crystallized. On the other hand, the polyester fiber of the wadding layer may be staple obtained by a known method, but in the present invention, it is preferable to use a polyester fiber having a fiber surface provided with a polyether or the like as the hydrophilizing agent, and the polyester fiber as the hydrophilizing agent is used. Fibers made of polyester in which tel etc. are kneaded are particularly preferable. As a method of kneading a hydrophilizing agent which is a particularly preferred embodiment of the present invention, a method of mixing at the time of polymerization, a method of preparing and using a resin kneaded using an extruder having a kneading function to a polyester resin, and Alternatively, there is a method of directly mixing and kneading at the time of melt spinning. In the present invention, for example, in the method of directly mixing and kneading at the time of spinning, a twin-screw extruder having a kneading function such as a dullage or a cross saw at a compression portion or a tip metal ring portion of a screw of an extruder or A method of melt kneading at a temperature of 10 ° C or higher and lower than 30 ° C higher than the melting point of the polyester while supplying a predetermined amount together with the polyester using a single-screw extruder, or a polyester resin having a temperature of 20 ° C or higher and lower than 50 ° C higher than the melting point A method of melting at a temperature and then kneading between the compression section and the tip metalling section of the extruder by melting at the melting temperature of the polyester and quantitatively supplying a polyethylene glycol as a hydrophilizing agent (direct melt blending). Method), and the latter is more desirable in the present invention. The kneading amount of the hydrophilizing agent is 1% by weight or more and 10% by weight, for example, polyethylene glycol-
In this case, the number average molecular weight of 5,000 or more and less than 50,000 is preferable, and the number average molecular weight of 8,000 or more and less than 20,000 is more preferable. The kneaded state is an incompatible mixture with polyester as the main matrix. The molten polyester resin thus kneaded with the hydrophilizing agent is spun at a temperature of 10 ° C. or higher and lower than 50 ° C. higher than the melting point of polyester through a nozzle while being metered by a metering pump to obtain a polyester fiber. In the present invention, the orifice shape of the nozzle is selected so that the fiber cross section is preferably a modified cross section or a hollow cross section. More preferably, the orifice shape of the nozzle having a modified hollow cross section is selected. It is preferable that the polyester fiber is obtained by imparting a latent crimping ability by an asymmetric cooling method or a composite spinning method, and by causing the three-dimensional crimp to develop by cutting and heat treatment after stretching, or by performing a heat treatment after cutting to develop the three-dimensional crimp. . Since the polyester fiber is also required to have sag resistance and heat resistance, the initial tensile resistance is at least 35 g / denier and the initial tensile resistance at 70 ° C. is at least 10 g / denier or more. Is preferred. The crimp degree of the three-dimensional crimp is preferably 15% or more, and the number of crimps is preferably 10 to 25 crimps / inch from the viewpoint of bulkiness and anti-compression property. The hydrophilized polyester fiber thus obtained is mixed and opened with other polyester fibers as a main matrix of the wadding layer in a desired blending amount. With the mixing ratio of the hydrophilic polyester fiber and the other polyester fiber being 100/0 to 50/50 weight ratio, pre-opening and mixing with an opener or the like and then opening with a card or the like to give a three-dimensional structure. Forming an open fiber web,
When the thickness is changed from 3mm to 10mm, the apparent density is 0.1g
/ Cm 3 or less, preferably an apparent density of 0.01 g / cm
The webs laminated so as to have a weight of 3 to 0.06 g / cm 3 are cut into a predetermined size to obtain a wadding layer. Preferably, then by an ordinary method by laminating web as apparent density when thickness was 10mm from 3mm is 0.06 g / cm 3 from 0.01 g / cm 3 was cut into a predetermined size wadding layer To get Then, both sides of the wadding layer are covered with a knitted fabric and quilted, and the cushion layer is inserted on both sides or one side of the cushion layer, and the cushion layer is inserted and taken out. Sewn on the side ground. The side material of the mat of the present invention is configured such that only the knitted fabric is installed on the side surface of the mat, and if the air permeability of the side surface is increased, the pump function of the cushion layer for replacing fresh outside air can be further improved. preferable. Then, a cushion layer is inserted into the side ground to obtain the mat of the present invention. The crystallization treatment in the present invention is performed at a temperature lower than at least the melting point (Tm) of the thermoplastic elastic resin by 10 ° C. or more and an Tan dispersion α dispersion rising temperature (Tαcr) or higher in any step leading to commercialization. With this treatment, the heat resistance and sag resistance are remarkably improved as compared with those having a heat absorption peak below the melting point and having no pseudo-crystallization treatment (those having no heat absorption peak). The preferred pseudo-crystallization treatment temperature of the present invention is (Tαcr
+ 10 ° C) to (Tm-20 ° C). If it is pseudo-crystallized by simple heat treatment, heat resistance and sag resistance are improved.
However, it is more preferable to impart compressive deformation of 10% or more and anneal to significantly improve the heat resistance and sag resistance. 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.
【００１７】本発明のマットは、ベット、敷布団、座蒲
団、家具用マット等以外に、その機能を利用して用いる
ことが出来る。例えば、クッション層を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、又は、マットを構造を
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、車両用座席、船舶用座席、椅子、家具等
に用いることができる。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
合体からなる硬綿クッション材、不織布等と組合せて用
いることも可能である。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成形体に加工し、
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。The mat of the present invention can be used by utilizing its function in addition to a bed, a mattress, a seat cushion, a furniture mat and the like. For example, the cushion layer is simply molded 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 the mat is simply covered with the molding material. It can be molded into a shape suitable for the purpose of use and used for vehicle seats, boat seats, chairs, furniture and the like. 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, a different mesh body, a hard cotton cushion material composed of a short fiber aggregate, a non-woven fabric, or the like. In addition, other than the resin manufacturing process, it is processed into a molded product from the manufacturing process within a range that does not deteriorate the performance,
Flame retardant, insect repellent antibacterial, heat resistant, at any stage of commercialization
Water and oil repellency, coloring, aroma and other functions can be processed by adding chemicals.
【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。 9. 耐熱耐久性（７０℃残留歪） 試料を１５cm×１５cmの大きさに切断し、マットは側地
（編織物を両面に挟んでキルチングしたワディング層）
と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、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、マットは側地
（編織物を両面に挟んでキルチングしたワディング層）
と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１Ｈ
ｚ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 ワディング層の両面を編織物で被われた側地を直径１０
cm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 作成したマットを水平面から片端を抑えて押し出し、４
５°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。１００cm未満：◎、１３０cm未満：○、１５
０cm未満：△、１５０cm以上：× 12.水切り性 作成した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、できるだけ水切りして、３０℃ＲＨ６５％
の雰囲気の室内で壁に立てかけ２４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５％以下：◎、残留水分が７％以下：○、残
留水分が１０％以下：△、残留水分が１０％以上：× 13.寝心地 作成した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；◎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 being stretched for 300% at a stretching rate of 100%, and was allowed to stand for 2 minutes. 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 the value obtained by subtracting the elongation rate obtained by subtracting the elongation rate at which stress develops again from 10% when it is allowed to elongate to fracture again after leaving it for 5 minutes, 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 places, embedded with acrylic resin, the cross section is cut out, and a section is prepared to obtain a cross-section photograph. 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. 9. Heat resistance and durability (residual strain at 70 ° C) The sample is cut into a size of 15 cm x 15 cm, and the mat is a side fabric (wadding layer quilted with knitted fabric on both sides).
And the cushion layer is bonded to the four corners of the interface with sewing threads so that it does not slip or come off. Compress it by 50%, leave it in dry heat at 70 ° C for 22 hours, cool it to remove compression strain, and leave it for 1 day. The ratio of the difference in thickness between the thickness before treatment and the thickness before treatment is expressed in% (n = 3 average value) 9. Repeated compressive strain The sample was cut into a size of 15 cm × 15 cm, and the mat was used as a side fabric Wadding layer quilted by sandwiching between
To prevent the cushion layer from slipping or coming off, join the four corners of the interface with sewing threads and use a Shimadzu servo pulsar
At 25 ° C, 65% RH, 1H up to 50% thickness
The compression recovery was repeated in the cycle of z and the sample after 20,000 times was 1
The ratio of the difference between the thickness after standing for a day and the thickness before treatment and the thickness before treatment is shown in%. (Average value of n = 3) 10. Air permeability The diameter of the side material covered with knitted fabric on both sides of the wadding layer is 10
It is punched out into a cylindrical shape of cm and put in a metal tube with an inner diameter of 10 cm at a height corresponding to the thickness of the side that can be sealed in a state of 5% compression, and the top and bottom are sealed with a packing of 5% compression thickness. A sample was created to prevent side leakage, and an air flow rate measurement device manufactured by Techno World Co., Ltd. (Cosmo instrument design product),
The air permeability (cc / cm 2 sec) measured using the high pressure type is shown as the air permeability. 11. Bendability Extrude the created mat from the horizontal surface with one end suppressed, 4
The length until contacting the sloped surface cut out at 5 ° is shown by the following criteria. Less than 100 cm: ◎, less than 130 cm: ○, 15
Less than 0 cm: △, 150 cm or more: × 12. Drainability After measuring the weight of the prepared mat, immerse it in a water tank after 10 minutes, remove it as much as possible, and drain at 30 ° C RH 65%
After standing for 24 hours in a room with the atmosphere described above, the weight was measured after standing for 24 hours, and the amount of residual water was determined and evaluated according to the following criteria.
Residual water content is 5% or less: ◎, Residual water content is 7% or less: ◯, Residual water content is 10% or less: △, Residual water content is 10% or more: × 13. Comfortable sleep Set the created mat on the bed frame, 28 ° C
The following evaluation was performed with the paneller laid down in a RH 75% room. (N = 5) Sheets were laid on the bed mats, 1.8 / kg down / feather: 90/10 mixed feathers were put in the comforter, and pillows used at home were used. (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 deeply felt; × (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 while 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: Within 30 minutes; × within 1 hour; △ within 2 hours; ○, over 2 hours; ◎
【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、ポリエステル繊維は、コンプレッショ
ン部及びメタ−リング部先端にダルメ−ジを持つ２台の
押出機にて、極限粘度０．６３と０．５６の酸成分とし
て１０〔２・３・ジ（２・ヒドロキシエチキシ）−カル
ボニルプロピル〕９・１０・ジヒドロ・９・オキサ・１
０ホスファフェナレンス・１０・オキシロを燐含有量で
１２００ｐｐｍとなるように共重合したＰＥＴをそれぞ
れ供給し、２８０℃にて溶融し、コンプレッション部よ
り２７０℃に溶融したＰＥＧを添加量５重量％となるよ
うにプランジャーポンプにて供給して２８０℃で直接メ
ルトブレンド法にて溶融混練りした各ポリエステルを重
量比５０／５０に分配して単孔当たり３．０ｇ／分孔
（１．５ｇ／分：１．５ｇ／分）として紡糸温度２８０
℃にてオリフィス形状が中空で３つの突起ができる形状
の繊維となるノズルより、紡糸速度１３００ｍ／分で複
合紡糸し、次いで、７０℃及び１８０℃にて２段延伸し
て得た延伸糸を６４mmに切断し１７０℃にてフリ−熱処
理して立体捲縮を発現させ、突起を３つもつ異形中空断
面で異形度（外接円面積／断面積）が２．０で中空率１
６％のサイドバイサイド構造の繊度６デニ−ル、初期引
張り抵抗度３５ｇ／デニ−ル、捲縮度２３％、捲縮数１
６個／インチのポリエステル繊維を得た。次いで、該ポ
リエステル繊維をオ−プナ−にて予備開繊した後カ−ド
で開繊して得たウエッブを厚みが８mmとなったときの見
掛け密度が０．０５ｇ／cm2 となるように積層し、所定
の大きさに切断して得たワディング層に東洋紡績製ハイ
ムのポリエステル繊維からなる通気度３０cc/cm2秒のブ
ロードを被せて１０cm間隔の菱形格子状にキルトし、ク
ッション層の表面と裏面にワディング層が設置され、側
面はワディング層がなく、クッション層を挿入取り出し
ができる開閉口を持つ構造に縫製された側地に、該クッ
ション層を挿入して本発明のベット用マットを得た。得
られたベット用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、折り曲げ性、水切り性
に優れ、側地の通気性も良く、寝心地の良好なベット用
マットである。なお、このベット用マットは難燃性を示
し、燃焼ガスの毒性指数は５．０であった。このことか
ら、火災時の安全性も高いベット用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 for cooling, the reticulate body obtained by cutting into a predetermined size has a triangular cross-sectional hollow cross section with a hollow core having 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, polyester fiber was used as an acid component having an intrinsic viscosity of 0.63 and 0.56 in 10 extruders (2, 3・ Hydroxyethoxy) -carbonylpropyl] 9 / 10-dihydro-9-oxa-1
PET, which was copolymerized with 0 phosphaphenalence-10 oxylo so as to have a phosphorus content of 1200 ppm, was supplied, melted at 280 ° C., and PEG melted at 270 ° C. from the compression part was added in an amount of 5% by weight. Each of the polyesters melted and kneaded by a direct melt blending method at 280 ° C. by a plunger pump is distributed in a weight ratio of 50/50 to obtain 3.0 g / min. / Min: 1.5 g / min) spinning temperature 280
At 0 ° C., a composite yarn is spun at a spinning speed of 1300 m / min from a nozzle that is a fiber having a hollow orifice shape and three protrusions, and then drawn at two stages at 70 ° C. and 180 ° C. It is cut into 64 mm and free-heat-treated at 170 ° C to develop a three-dimensional crimp, and in a deformed hollow section with three protrusions, the degree of deformation (circumscribed circle area / section area) is 2.0 and the hollow ratio is 1
6% side-by-side structure fineness 6 denier, initial tensile resistance 35 g / denier, crimp 23%, crimp number 1
Six polyester fibers per inch were obtained. Then, the polyester fiber was pre-opened with an opener and then opened with a card so that the apparent density when the thickness of the web was 8 mm was 0.05 g / cm 2. The wadding layer obtained by laminating and cutting to a predetermined size was covered with a broad cloth made of TOYOBO HEIM polyester fiber with an air permeability of 30 cc / cm 2 seconds and quilted in a rhombic lattice pattern at 10 cm intervals to form a cushion layer. A mat for betting according to the present invention, in which the cushion layer is inserted into the side material sewn in a structure in which a wadding layer is provided on the front surface and the back surface, and there is no wadding layer on the side surface and an opening / closing opening through which the cushion layer can be inserted and removed. Got Table 2 shows the evaluation results of the obtained mat for betting. As is clear from Table 2, the mat for betting is excellent in heat resistance, durability, bending property, drainability, breathability of the side material, and comfortable to sleep. The mat for bet showed flame retardancy, and the combustion gas toxicity index was 5.0. From this, it can be seen that the mat for betting is highly safe 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、極限粘度０．６３のＰＥＴを用い、常法に
よりオリフィス形状がＣ型の中空断面を形成するノズル
より２８５℃にて単孔吐出量３．０ｇ／分孔にて紡出
し、ノズル直下より非対称冷却法にて潜在巻縮能を付与
した以外実施例１と同様にして得た立体巻縮をもち、中
空断面で中空率が３６％、繊度６デニ−ル、初期引張り
抵抗度３８ｇ／デニ−ル、捲縮度２５％、捲縮数１４個
／インチのポリエステル繊維を得た。このポリエステル
繊維を用い、オ−プナ−にて予備開繊した後カ−ドで開
繊して得たウエッブを見掛け密度が０．０５ｇ／cm2 と
なるように積層し、東洋紡績製ハイムのポリエステル繊
維からなる通気度３０cc/cm2秒のブロードを被せて８cm
間隔の菱形格子状にキルトし、クッション層の表面と裏
面にワディング層が設置され、側面はワディング層がな
く、クッション層を挿入取り出しができる開閉口を持つ
構造に縫製された側地に、該クッション層を挿入して本
発明のベット用マットを得た。得られたベット用マット
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、折り曲げ性、水切り性に優れ、側地の通気
性も良く寝心地の良好なベットマットである。なお、こ
のマットは燃焼ガスの毒性指数は５．０であった。この
ことから、火災時の安全性が良い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 15 minutes / min., Cooling water is placed 15 cm below the nozzle surface, and a pair of take-up conveyors partially exit above the water surface in parallel with stainless endless nets with a width of 140 cm at intervals of 4.5 cm. The melted discharge line is bent to form a loop to fuse the contact portions to form a three-dimensional network structure, and both sides of the molten 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 to a predetermined size has a round cross-section, and a linear filament having an endothermic peak at 126 ° C is formed in addition to a melting point 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, using PET having an intrinsic viscosity of 0.63, a single-hole discharge rate of 3.0 g / min was spun at 285 ° C. from a nozzle that forms a hollow cross section with a C-shaped orifice by a conventional method. The three-dimensional crimp obtained in the same manner as in Example 1 except that the latent crimping ability was imparted by the asymmetric cooling method, the hollow section had a hollow ratio of 36%, a fineness of 6 denier, and an initial tensile resistance of 38 g / denier. A polyester fiber having a crimp degree of 25% and a crimp number of 14 / inch was obtained. Using this polyester fiber, the web obtained by pre-opening with an opener and then opening with a card was laminated so as to have an apparent density of 0.05 g / cm 2 . 8 cm with a broadness of 30 cc / cm 2 seconds made of polyester fiber
Quilted in the shape of a rhombus lattice, the wadding layer is installed on the front and back of the cushion layer, the side surface has no wadding layer, and the side layer sewn into a structure having an opening / closing opening through which the cushion layer can be inserted and removed, The cushion layer was inserted to obtain the bed mat of the present invention. Table 2 shows the evaluation results of the obtained mat for betting. As is clear from Table 2, the bed mat is excellent in heat resistance, durability, bending property, drainability, breathability of the side material and comfortable to sleep. The matte had a combustion gas toxicity index of 5.0. From this, it can be seen that the mat has good 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、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両面が実質的にフラッ
ト化された網状体は、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、実施例１で得たポリ
エステル繊維と実施例２で得たポリエステル繊維を７０
／３０重量比で混合し、実施例１と同様にして得たワデ
ィング層となるウェッブを東洋紡績製ハイムのポリエス
テル繊維からなる通気度３０cc/cm2秒のブロードを被せ
て実施例２と同様のキルトし、クッション層の表面と裏
面にワディング層が設置され、側面はワディング層がな
く、クッション層を挿入取り出しができる開閉口を持つ
構造に縫製された側地に、該クッション層を挿入して得
た本発明のベット用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、折り曲げ性、水切
り性に優れ、側地の通気性も良く寝心地の良好なベット
マットである。なお、このベット用マットは燃焼ガスの
毒性指数は５．０であった。このことから、火災時の安
全性も良いベット用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
3. Discharge at a discharge rate of 2.0 g / min per single hole at 35 ° C. below the nozzle, arrange cooling water 12 cm below the nozzle surface, and make stainless endless nets 140 cm wide in parallel.
A pair of take-up conveyors are arranged at intervals of 5 cm so as to partially protrude above the water surface, and the discharge line in the molten state is bent to form loops to fuse the contact portions and to form a three-dimensional mesh structure. Was formed, and was drawn into cooling water at 25 ° C. at a rate of 1 m / min for solidification, then taken off, drained, and then passed through a setter in which heated air at 120 ° C. was continuously circulated for 15 minutes to cool, The net-like body obtained by cutting into a predetermined size and having both sides substantially flat is a hollow rice ball-shaped cross section, and a wire having a heat absorption peak at 126 ° C in addition to a melting point of 1.2 mm. The contact points of the loops formed by the stripes are almost joined by fusion bonding, and the average apparent density is 0.048 g /
cm 2 , thickness 4.5 cm, cyclic compression strain 5.8%, heat resistance durability 10.8%. Then, the polyester fiber obtained in Example 1 and the polyester fiber obtained in Example 2 were mixed with 70
The mixture was mixed at a weight ratio of 30/30 and the web as the wadding layer obtained in the same manner as in Example 1 was covered with a broad cloth having a permeability of 30 cc / cm 2 seconds and made of polyester fiber manufactured by Toyobo Co., Ltd. Heim. Quilting, the wadding layer is installed on the front and back of the cushion layer, the side surface does not have a wading layer, and the cushion layer is inserted into the side fabric sewn into the structure that has an opening for inserting and removing the cushion layer. Table 2 shows the evaluation results of the obtained mat for betting of the present invention. As is clear from Table 2, the bed mat is excellent in heat resistance, durability, bending property, drainability, breathability of the side material and comfortable to sleep. The bed gas mat had a combustion gas toxicity index of 5.0. From this, it is understood that the mat for betting has good 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／cm2 、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２で使用した側地に、該クッシ
ョン層を挿入して得た本発明のベット用マットの評価結
果を表２に示す。表２で明らかごとく、耐熱性、耐久
性、折り曲げ性、水切り性に優れ、側地の通気性も良く
寝心地の良好なベット用マットである。The thermoplastic elastic resin thus obtained (seed component:
B-1 and core component: B-2) except that the melting temperature was 220 ° C., and the cross-sectional shape of the cis-core structure of the filaments of the reticulate body obtained in the same manner as in Example 1 was a hollow in the shape of a triangular rice ball. In addition to the melting point with a rate of 40% and a wire diameter of 1.1 mm, the filaments that have an endothermic peak at 126 ° C are joined by fusion bonding at the contact points of the loops formed, and both sides are substantially flattened. The average apparent density is 0.047 g / cm 2 , and the thickness is 9.
5 cm, cyclic compression strain 3.6%, heat resistance durability 7.5%. Next, Table 2 shows the evaluation results of the betting mat of the present invention obtained by inserting the cushion layer into the side material used in Example 2. As is clear from Table 2, this bet mat is excellent in heat resistance, durability, bendability and drainability, and has good breathability on the side fabric 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．
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で得たポリエステル繊維をオ−プナ−にて予備開繊し
た後カ−ドで開繊して得たウエッブを厚み６mmとなると
きの見掛け密度が０．０５ｇ／cm2 となるように積層し
たワディング層を所定の大きさに切断し、東洋紡績製ハ
イムのポリエステル繊維からなる通気度３０cc/cm2秒の
ブロードを被せて１２cmの菱形格子状にキルトし、クッ
ション層の表面と裏面にワディング層が設置され、側面
はワディング層がなく、クッション層を挿入取り出しが
できる開閉口を持つ構造に縫製された側地に、該クッシ
ョン層を挿入して得た本発明のベット用マットの評価結
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、水切り性には優れるが、耐熱
性、耐久性、折り曲げ性、側地の通気性は良いが蒸れ感
以外の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
The filaments having no endothermic peak other than the melting points of m and m 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.
047 g / cm 2 , thickness 4.5 cm, repeated compressive strain 30.
It was 2% and the heat resistance durability was 49.5%. The polyester fiber obtained in Example 1 was pre-opened with an opener and then opened with a card to give a web having an apparent density of 0.05 g / cm 2 at a thickness of 6 mm. The wadding layer laminated so that it is cut into a predetermined size, covered with a broad air permeability of 30 cc / cm 2 seconds made of TOYOBO HEIM polyester fiber, and quilted into a 12 cm rhombus lattice, the surface of the cushion layer. And a backing with a wadding layer, the side surface has no wading layer, and the cushion layer is inserted into and removed from the side fabric sewn into a structure having an opening and closing opening through which the cushion layer can be inserted and removed. The evaluation results of the mat are shown in Table 2. As is clear from Table 2, since it is a reticulated body made of non-elastic olefin, it is excellent in drainability, but has good heat resistance, durability, bendability, and breathability of the side material, but it is inferior in sleeping comfort other than stuffiness. It is a bed mat that also fails flame retardancy and has problems during a 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、比較例１で使用した
側地に該クッション層を挿入して得たベット用マットの
評価結果を表２に示す。表２で明らかごとく、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用マットで
ある。なお、このベット用マットの燃焼ガスの毒性指数
は５．１であった。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, Table 2 shows the evaluation results of the mat for betting obtained by inserting the cushion layer into the side material used in Comparative Example 1. As is clear from Table 2, the mat for betting is excellent in drainage and less dampness, but inferior in sleep comfort other than heat resistance, durability, bendability and dampness. The combustion gas toxicity index of this bed mat was 5.1.
【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用マッ
トの評価結果を表２に示す。表２で明らかごとく、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用マット
である。なお、このベット用マットは燃焼ガスの毒性指
数は５．１であった。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%. Next, Table 2 shows the evaluation results of the betting mats obtained in the same manner as in Comparative Example 2. As is clear from Table 2, although excellent in drainage and less dampness, heat resistance, durability,
It is a mat for betting that is inferior in sleeping comfort other than bendability and dampness. The bed gas mat had a combustion gas toxicity index of 5.1.
【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
たベット用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用マットである。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%. Next, Table 2 shows the evaluation results of the betting mats obtained in the same manner as in Comparative Example 2. As is clear from Table 2, it has excellent breathability, bendability, and drainability,
It is a bed mat that has poor 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用マットの評
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 /
And the take-up conveyor net was placed under the nozzle surface 60 cm and the take-up speed was 1 m / min. The net-like body obtained in the same manner as in Comparative Example 2 had a round cross-section and a wire diameter of 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,
Next, Table 2 shows the evaluation results of the betting 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用マットの評価結果を表
２に示す。表２で明らかごとく、折り曲げ性、水切り
性、蒸れ感、圧迫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、寝心地がやや劣るベット用マットである。なお、こ
のベット用マットの燃焼ガスの毒性指数は５．１であっ
た。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. Next, Table 2 shows the evaluation results of the betting mats obtained in the same manner as in Comparative Example 2. As is clear from Table 2, it is excellent in terms of bendability, drainability, stuffiness, and pressure but it is slightly inferior in heat resistance and durability. It's Matt. The combustion gas toxicity index of this bed mat was 5.1.
【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、側地側
面の厚みを１．５cmとしたものを用いた以外、比較例２
と同様にして得たベット用マットの評価結果を表２に示
す。表２で明らかごとく、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, Comparative Example 2 was used except that the thickness of the lateral side surface was 1.5 cm.
Table 2 shows the evaluation results of the betting mat obtained in the same manner as in. As is clear from Table 2, the bed mat is excellent in bendability and drainability, but inferior in heat resistance and durability, and the cushion layer is too thin, resulting in remarkably inferior sleeping comfort.
【００３６】比較例８ 疑似結晶化処理しなかった以外実施例２と同様にして得
た網状体の特性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
１６．５％、耐熱耐久性２６．４％であった。別途、実
施例２で使用したポリエステル繊維をオ−プナ−にて予
備開繊した後カ−ドで開繊して得たウエッブを見掛け密
度が０．１２ｇ／cm2 となるようにして積層以外実施例
２と同様にして得たベット用マットの評価結果を表２に
示す。表２より明らかなごとく、ワディング層の密度が
高すぎるため、側地の通気性、折り曲げ性が悪く、寝心
地も劣るベット用マットであった。Comparative Example 8 The characteristics of the reticulate body obtained in the same manner as in Example 2 except that the pseudo crystallization treatment was not carried out were that the cross-sectional shape was a round cross section and the wire diameter was 0.9 mm.
Other than the melting point of
Almost all the contact points of the loops to be formed are joined by fusion bonding and both sides are substantially flattened, the average apparent density is 0.048 g / cm 2 , the thickness is 4.5 cm, and the cyclic compression strain is 16.5. %, And the heat resistance durability was 26.4%. Separately, the polyester fiber used in Example 2 was pre-opened with an opener and then opened with a card to obtain a web having an apparent density of 0.12 g / cm 2 and other than lamination. Table 2 shows the evaluation results of the betting mats obtained in the same manner as in Example 2. As is clear from Table 2, since the density of the wadding layer was too high, the mat for a bed was poor in breathability and bendability of the side material and inferior in sleeping comfort.
【００３７】比較例９ 実施例２で使用したポリエステル繊維をオ−プナ−にて
予備開繊した後カ−ドで開繊して得たウエッブを見掛け
密度が０．０５ｇ／cm2 となるように積層したウェッブ
に東洋紡績製ハイムのポリエステル繊維からなる通気度
３０cc/cm2秒のブロードを被せて、キルトせずに、比較
例８で使用したクッション層の表面と裏面にワディング
層が設置され、側面はワディング層がなく、クッション
層を挿入取り出しができる開閉口を持つ構造に縫製され
た側地に、比較例８で得た該クッション層を挿入して得
たベット用マットの評価結果を表２に示す。表２より明
らかなごとく、折り曲げ性と寝心地は良いが、耐熱耐久
性が劣り、キルトされていないので洗濯後のワディング
層がフェルト化する問題点もあるベット用マットであっ
た。COMPARATIVE EXAMPLE 9 The polyester fiber used in Example 2 was pre-opened with an opener and then opened with a card so that the web had an apparent density of 0.05 g / cm 2. The web laminated on was covered with a broad air permeability of 30 cm / cm 2 seconds made of Heim polyester fiber manufactured by Toyobo Co., Ltd., and wadding layers were provided on the front and back surfaces of the cushion layer used in Comparative Example 8 without quilting. The side face has no wadding layer, and the cushion layer obtained in Comparative Example 8 is inserted into the side fabric sewn in a structure having an opening / closing opening through which the cushion layer can be inserted and taken out. It shows in Table 2. As is clear from Table 2, it was a mat for betting which had good bending properties and comfortable to sleep, but was poor in heat resistance and durability, and had a problem that the wadding layer after washing became felt because it was not quilted.
【００３８】比較例１０ 精練したインド綿と実施例２で使用したポリエステル繊
維を７０／３０重量比で混合し、オ−プナ−にて予備開
繊した後カ−ドで開繊して得たウエッブを見掛け密度が
０．０５ｇ／cm2 となるようにパンチ密度１０本／cm2
でニ−ドルパンチして所定の大きさに切断したワディン
グ層を比較例８で得た該クッション層の表裏に積層し
て、比較例８と同様にして得た側地に挿入して得たベッ
ト用マットの評価結果を表２に示す。表２より明らかな
ごとく、寝心地は良いが、ワディング層がポリエステル
繊維以外を含有するため水切り性が劣るベット用マット
であった。なお、実施例１のマット及び比較例９のマッ
トを粗砕して乾燥し、再度繊維化しようとしたが、実施
例１のマットは繊維形成ができたが、比較例９のマット
は紡糸時の糸切れが著しく繊維化できなかった。このこ
とから、ポリエステル以外の素材を含むマットは直接プ
ロダクトリサイクルが困難なことがわかる。Comparative Example 10 Scoured Indian cotton and the polyester fiber used in Example 2 were mixed in a weight ratio of 70/30, pre-opened with an opener and then opened with a card. as apparent density web is 0.05 g / cm 2 punch density of ten / cm 2
Beds obtained by laminating the cushioning layers obtained in Comparative Example 8 on the front and back of the cushioning layer obtained by Comparative Example 8 by needle punching with Table 2 shows the evaluation results of the mat. As is clear from Table 2, the mat for a bed had good sleeping comfort, but was poor in drainability because the wadding layer contained other than polyester fibers. The mat of Example 1 and the mat of Comparative Example 9 were coarsely crushed, dried, and re-fiberized. The mat of Example 1 was able to form fibers, but the mat of Comparative Example 9 was spun. The yarn was severely broken and could not be formed into fibers. From this, it can be seen that it is difficult to directly product-recycle mats containing materials other than polyester.
【００３９】比較例１１ 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たも
のをワディング層にした以外、比較例２と同様にして得
た側地に、比較例８で得た該網状体を挿入して得たベッ
ト用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、折り曲げ
性、水切り性が劣るベット用マットである。Comparative Example 11 Comparative Example 2 was repeated except that a commercially available polyester hard cotton having an apparent density of 0.05 g / cm 3 was sliced into a thickness of 5 mm and cut into a predetermined size to form a wadding layer. Table 2 shows the evaluation results of the betting mat obtained by inserting the net-like body obtained in Comparative Example 8 into the obtained side fabric. As is clear from Table 2, the mat for bed is slightly comfortable to sleep but inferior in heat resistance, durability, bendability and drainability.
【００４０】比較例１２ 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、
比較例８で用いた２枚の積層網状体の両面に市販のゴム
系接着接着剤を塗布して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用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、折り曲げ性、水切り性が劣るベット用マッ
トである。Comparative Example 12 Commercially available polyester hard cotton having an apparent density of 0.05 g / cm 3 was sliced to a thickness of 5 mm and cut into a predetermined size.
A commercially available rubber adhesive was applied to both surfaces of the two laminated reticulated bodies used in Comparative Example 8 to bond hard cotton to the reticulated body, and a polyester fiber sewn to a predetermined size was applied to the side fabric. Table 2 shows the evaluation results of the mat for betting obtained by inserting. As is clear from Table 2, the mat for bed is slightly comfortable to sleep but inferior in heat resistance, durability, bendability and drainability.
【００４１】比較例１３ 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、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
たベット用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、折り曲げ性、水切り性は劣るベット用マッ
トである。Comparative Example 13 A bed obtained by using a commercially available polyester hard cotton having a thickness of 10 cm and an apparent density of 0.05 g / cm 3 as a cushioning material and inserting it into a side cloth made of polyester fiber sewn to a predetermined size. Table 2 shows the evaluation results of the mat. As is clear from Table 2, the mat for betting is a bed mat which is slightly comfortable but has little sinking and is inferior in heat resistance, durability, bendability and drainability.
【００４２】比較例１４ 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、比較例２で使用した
ワディング層を用いた側地に挿入して得られたベット用
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、折り曲げ性、水切り
性、側地の通気性は良いが寝心地が劣るベットマットで
ある。Comparative Example 14 A mat for betting obtained by using a commercially available foamed polyurethane having a thickness of 10 cm and an apparent density of 0.05 g / cm 3 as a cushioning material and inserting it into a lateral side using the wadding layer used in Comparative Example 2. The evaluation results of are shown in Table 2. As is clear from Table 2,
A bed mat that has excellent heat resistance and durability, but has good bendability, drainability, and breathability on the side, but is inferior in sleeping comfort.
【００４３】実施例５ 実施例２で得た網状体を厚みを変えた以外実施例１と同
様にして得た側地に挿入して得られた敷布団の評価結果
では、耐熱性、耐久性、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 The mattress obtained by inserting the reticulate body obtained in Example 2 into a lateral fabric obtained in the same manner as in Example 1 except that the thickness was changed shows heat resistance, durability, and It was a mattress with excellent foldability, drainability, and sleeping comfort.
【００４４】実施例６ 実施例２で得た網状体を厚みを変えた以外実施例１と同
様にして得た側地に挿入して座蒲団を得た。得られた座
蒲団の評価結果では、耐熱性、耐久性、水切り性、座り
心地共に優れた座蒲団であった。Example 6 A dentition was obtained by inserting the reticulate body obtained in Example 2 into the lateral ground obtained in the same manner as in Example 1 except that the thickness was changed. According to the evaluation results of the obtained zakka, the zakka was excellent in heat resistance, durability, drainability and sitting comfort.
【００４５】[0045]
【発明の効果】ポリエステル繊維の特性を生かしたウェ
ッブからなるワディング層をキルティングにより固定し
て縫製した側地に、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
状体からなるクッション層を挿入したマット及び、製法
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、
火災時に有毒ガスの発生が少なく、ＭＲＳＡ等の雑菌を
除去するための洗濯や殺菌ができ、リサイクルし易い一
般家庭用、病院用及びホテル用等のベット、敷布団、座
蒲団及び、家具用に最適なマット、及び、製造法を提供
できる。EFFECTS OF THE INVENTION A wadding layer made of a web utilizing the characteristics of polyester fibers is fixed by quilting and sewn to a side fabric, and a filament made of a thermoplastic elastic resin having good elongation recovery is fused and integrated to form a surface. A mat in which a cushion layer made of a flattened mesh is inserted, and a manufacturing method, so that it is difficult to get stuffy and has good sleeping comfort, heat resistance durability, shape retention, excellent cushioning property, and good bending property.
Suitable for general household, hospital and hotel beds, mattresses, cushions, and furniture that can be easily washed and sterilized to remove miscellaneous bacteria such as MRSA, etc. A mat and a manufacturing method can be provided.
Claims (13)
み込んだマットであり、クッション層の少なくとも片面
の側地の構造が２枚の編織物シートの間にワディング層
が挟み込まれてキルティング縫製された構造になってお
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、見掛け密度が０．００５〜０．１０ｇ／cm3 、
厚みが５mm以上であり、ワディング層は、ポリエステル
繊維ウェブからなり、見掛け密度が０．１ｇ／cm3 以下
であることを特徴とするマット。1. A mat in which a cushion layer is wrapped with a side fabric made of a knitted fabric, and the structure of the side fabric on at least one side of the cushion layer is quilted and sewn with a wadding layer sandwiched between two knitted fabric sheets. The cushion layer has a structure in which a continuous line made of a thermoplastic elastic resin and having a diameter of 5 mm or less is bent to form a random loop, and most of the contact portions of each loop are fused. The three-dimensional three-dimensional network has a substantially flat upper and lower surfaces, and has an apparent density of 0.005 to 0.10 g / cm 3 ,
A mat having a thickness of 5 mm or more, a wadding layer made of a polyester fiber web, and an apparent density of 0.1 g / cm 3 or less.
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. The mat according to claim 1, which has a recovery rate (70 ° C extension recovery rate) of 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
載のマット。3. The net-like 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. 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 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.
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記載のマット。5. A reticulated body having an endothermic peak at a temperature above room temperature and below the melting point in a melting curve of a component comprising a thermoplastic elastic resin measured by a differential scanning calorimeter in the cushion layer. 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
記載のマット。6. The cross-sectional shape of the filaments of the net-like body that constitutes the cushion layer is a hollow cross section or an irregular cross section.
The listed mat.
性弾性樹脂がポリエステルである請求項１記載のマッ
ト。7. The mat according to claim 1, wherein the thermoplastic elastic resin forming the mesh-like body of the cushion layer is polyester.
キルティング縫製された側地の通気度が２０cc／cm2 秒
以上である請求項１記載のマット。8. A woven fabric on both sides of the wadding layer,
The mat according to claim 1, wherein the quilted sewn side fabric has an air permeability of 20 cc / cm 2 seconds or more.
請求項１記載のマット。9. The mat according to claim 1, wherein the thermoplastic elastic resin is polyester.
リエチレングリコ−ル成分を０．０５重量％以上含有す
るポリエステル繊維を主たるマトリックスとしたウエッ
ブである請求項１記載のマット。10. The mat according to claim 1, wherein the composition of the wadding layer is a web mainly composed of a polyester fiber containing 0.05% by weight or more of a polyethylene glycol component on the surface of the fiber.
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、得られた三
次元構造体の上、下両面又は片面にポリエステル繊維を
主たるマトリックスとしたウェッブの両面を編織物で被
いキルティング縫製した側地を被せるマットの製造法。11. A thermoplastic elastic resin is discharged downward from a multi-row nozzle having a plurality of orifices at a melting temperature 20 to 80 ° C. higher than its melting point to form a continuous linear loop in a molten state. After forming and looping the loops in contact with each other to form a three-dimensional structure, the loops are sandwiched by a take-off 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 of manufacturing a mat in which both sides of a web mainly composed of polyester fibers are covered with a knitted fabric and covered with a quilted side.
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１１記載のマットの製造法。12. The production of a mat according to claim 11, wherein the pseudo-crystallization treatment by annealing is carried out at a temperature of at least 10 ° C. or lower than the melting point of the thermoplastic elastic resin constituting the reticulated body in any step leading to commercialization. Law.
上、１０重量％混合して繊維化したポリエステル繊維を
主たるマトリックスとして用いる請求項１１記載のマッ
トの製造法。13. The method for producing a mat according to claim 11, wherein a polyester fiber obtained by mixing polyethylene glycol in an amount of 1% by weight or more and 10% by weight is used as a main matrix.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP15330895A JP3627827B2 (en) | 1995-06-20 | 1995-06-20 | Mat and manufacturing method thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP15330895A JP3627827B2 (en) | 1995-06-20 | 1995-06-20 | Mat and manufacturing method thereof |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH091708A true JPH091708A (en) | 1997-01-07 |
| JP3627827B2 JP3627827B2 (en) | 2005-03-09 |
Family
ID=15559652
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP15330895A Expired - Lifetime JP3627827B2 (en) | 1995-06-20 | 1995-06-20 | Mat and manufacturing method thereof |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3627827B2 (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2020502377A (en) * | 2016-12-23 | 2020-01-23 | 東レ株式会社 | Polyester hollow filament and method for producing the same |
| CN114872360A (en) * | 2022-05-06 | 2022-08-09 | 常州市永丰新材料科技有限公司 | Preparation method of environment-friendly waterproof XPE (crosslinked polyethylene) pad |
Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH0648453U (en) * | 1992-09-29 | 1994-07-05 | 東洋興業株式会社 | Easy-to-fold floor mat |
| JPH0768061A (en) * | 1993-02-26 | 1995-03-14 | Toyobo Co Ltd | Net-work structure for cushion and its manufacture |
-
1995
- 1995-06-20 JP JP15330895A patent/JP3627827B2/en not_active Expired - Lifetime
Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH0648453U (en) * | 1992-09-29 | 1994-07-05 | 東洋興業株式会社 | Easy-to-fold floor mat |
| JPH0768061A (en) * | 1993-02-26 | 1995-03-14 | Toyobo Co Ltd | Net-work structure for cushion and its manufacture |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2020502377A (en) * | 2016-12-23 | 2020-01-23 | 東レ株式会社 | Polyester hollow filament and method for producing the same |
| CN114872360A (en) * | 2022-05-06 | 2022-08-09 | 常州市永丰新材料科技有限公司 | Preparation method of environment-friendly waterproof XPE (crosslinked polyethylene) pad |
Also Published As
| Publication number | Publication date |
|---|---|
| JP3627827B2 (en) | 2005-03-09 |
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