WO2000047807A1 - Cushion material - Google Patents

Abstract

A cushion material manufactured by laminating sheets of the non-woven fabric comprising matrix fibers and binder fibers, characterized in that said matrix fibers have a fineness of 6.7 dtex or more and the fiber direction in the non-woven fabric is parallel with the thickness direction of the cushion material.

Description

 Description Cushion material Technical field

 The present invention relates to a cushion material made of a nonwoven fabric, and particularly to a material suitably used for a cushion material for a bed mat. Background art

 Conventionally, nonwoven fabrics made of synthetic fibers have been often used as cushioning materials for Bedmat furniture. In these nonwoven fabrics, for example, fibers having a relatively high melting point, such as polyester fibers, and fibers having a lower melting point are opened, mixed, then carded to form a web, and the web is laminated by cross lay. In this state, it is produced by performing a heat treatment with infrared rays or far-infrared rays continuously, and heat-fusing the fibers. However, in the manufacturing process as described above, the web formed by carding is laminated along the thickness direction of the nonwoven fabric. Therefore, the fiber direction in the nonwoven fabric is perpendicular to the thickness direction. In other words, since the fibers are lying in the nonwoven fabric, the inherent elastic properties of the fibers cannot be used, and as a cushioning material, when a compressive load is applied in the thickness direction, the resilience is small and the set is large. Existed.

In addition, since the fibers are lying in the nonwoven fabric, water permeability and air permeability in the thickness direction of the nonwoven fabric are low. If the water permeability is low, there is a problem that drainage of washing water becomes slower when washing bed mats and the like, and it takes time. Also, if the air permeability is low, there is a problem that it takes a long time since evaporation of water is suppressed by drying after washing. Furthermore, after laminating the webs, a cushion material is produced by heat-sealing the fibers with infrared rays or far-infrared rays continuously. However, in this case, the surface part to which the infrared or far-infrared rays are directly irradiated has a high degree of thermal fusion, but if the density is high or the thickness is large, the thermal fusion proceeds from the surface part to the central part. Is reduced. For this reason, the degree of heat fusion in the nonwoven fabric becomes non-uniform, and an appropriate texture as a cushion material cannot be obtained. For this reason, there is a problem that it is difficult to manufacture a device having a very high density or a large thickness.

 An object of the present invention is to provide a cushioning material which is excellent in water permeability and air permeability because a compressive load is applied in the thickness direction and the sag is small, and the bending rigidity is small, so that it is easy to impart flexibility. To supply. Disclosure of the invention

 The present inventors have studied the selection, blending, and manufacturing method of the materials constituting the absorber, and have completed the present invention. That is, the cushioning material is a cushioning material in which a nonwoven fabric composed of a matrix fiber and a binder fiber is laminated, and the matrix fiber is 6.7 dtex or more, and the fiber direction in the nonwoven fabric is the same as the thickness direction of the cushioning material. It is a cushion material characterized by being parallel. BEST MODE FOR CARRYING OUT THE INVENTION

When a synthetic fiber is used as the matrix fiber of the present invention, the type of the polymer is not particularly limited. For example, aromatic polyesters such as polyethylene terephthalate-polybutylene terephthalate, aliphatic polyesters such as polylactic acid and polyproprolactone, polyolefins such as polypropylene-polyethylene, nylon 6 and nylon 66 Polyamides and copolymers thereof can be used. Also, these A mixture of two or more fibers may be used.

 Natural fibers can also be used for the matrix fibers. In this case, cellulose, wool, cotton, silk, etc. can be used. Further, a mixture of two or more of these fibers may be used. Of course, the above synthetic fibers and natural fibers may be used in combination.

 The fineness of the matrix fiber needs to be 6.7 dtex or more, preferably 6.7 to 55 dtex—x, and more preferably 6.7 to 22 dtex. If it is 6.7 dtex or more, the porosity of the nonwoven fabric increases, so that appropriate water permeability and air permeability can be obtained. For this reason, after using a bed mat or the like, when washing is performed, drainage of water at the time of washing becomes faster, so that time can be reduced. In addition, the washing water can be quickly evaporated in the drying step after the washing.

 If the fineness of the matrix fiber is less than 6.7 dtex, the water permeability and air permeability of the nonwoven fabric will decrease. For this reason, the drainage of washing water during washing is slow, and it takes time. In addition, if the air permeability decreases, it takes time because the evaporation of the washing water is suppressed by drying after washing, which is also inappropriate.

 The binder fiber used in the present invention is usually made of synthetic fiber, and has a lower melting point or softening point than that of the matrix fiber. After mixing the matrix fiber and binder fiber, heat treatment is performed at a temperature at which only the binder fiber melts (softens), stabilizing the fibers in the non-woven fabric and cushioning properties of the cushioning material. And stability.

The kind of the polymer used for the binder fiber is not particularly limited as long as a part or the whole thereof has a lower melting point (softening point) than that of the polymer used for the matrix fiber. For example, aromatic polyesters such as polyethylene terephthalate and polybutylene terephthalate, polylactic acid, and polypropyla Aliphatic polyesters such as croton, polyolefins such as polypropylene and polyethylene, polyamides such as nylon 6 and nylon 66, and copolymers thereof can be used. Further, a mixture of two or more of these fibers may be used.

 The binder fiber may be a single component fiber made of the above polymer, but if a sheath-core type conjugate fiber having a low melting point polymer in the sheath component and a higher melting point polymer in the core component is used, the core component is supported. This is more preferable because the heat fusion function can be achieved while maintaining the function. As such heat-fused fibers, Belcombi of Kanebo Synthetic Co., Ltd., which has ordinary polyethylene terephthalate polymer as the core component and low melting point copolymerized polyethylene terephthalate polymer as the sheath component, is already commercially available. Power is not limited to these.

 The mixing ratio of the binder fiber is preferably 5 to 70%. It is preferable that the content is within this range, since sufficient formability can be maintained during the forming process and cushioning with a soft touch as a cushion material can be obtained.

 These matrix fibers and binder fibers are subjected to primary heat treatment of a web obtained by opening, blending, and carding to form a nonwoven fabric.

 In the cushion material made of the nonwoven fabric of the present invention, the fiber direction needs to be parallel to the thickness direction of the cushion material. By being parallel to the thickness direction, even if a compressive load is applied to the cushion, resilience is large, so that it is possible to reduce sag.

 In addition, there is an advantage that the time required for washing can be shortened because water is quickly drained during washing.

Furthermore, since the fiber direction in the nonwoven fabric is parallel to the thickness direction, the bending rigidity is reduced. Therefore, when used as cushioning material, it is easy to impart flexibility to the body line during molding. There is a point.

 To make the fiber direction in the nonwoven fabric parallel to the thickness direction, for example, the following method is used.

 First, the matrix fiber and the binder fiber are spread, mixed, and then the web obtained by forcing is subjected to primary heat treatment to form a nonwoven fabric. This heat treatment is usually performed with dry heat such as far-infrared rays or hot air to temporarily fuse the fibers in the nonwoven fabric. The temperature and time conditions are determined appropriately according to the type of matrix fiber and binder fiber used.

 Further, the non-woven fabrics are laminated under a desired condition and subjected to a second heat treatment in a compressed state, whereby the respective non-woven fabric layers are mutually fused. Thereafter, the nonwoven fabric in the block state is sliced to obtain a nonwoven fabric in which the fiber direction in the nonwoven fabric is parallel to the thickness direction of the cushion material.

 At this time, in the secondary heat treatment, the laminated nonwoven fabric is compressed and held parallel to the laminating direction, and wet heat treatment with steam is performed. Moist heat treatment conditions such as temperature and time may be appropriately determined. According to this method, the entire nonwoven fabric is uniformly heated, and a cushion material having an arbitrary density can be obtained. For example, a high-density cushioning material can be obtained by increasing the number of layers even if the nonwoven fabric has the same basis weight.

 Also, unlike the case where the heat treatment is performed continuously after the conventional carding process, the thickness of the cushion material can be freely controlled by the thickness at which the nonwoven fabric in the block state is sliced. For this reason, it becomes easy to produce a cushion material having a large thickness, which was difficult in the conventional continuous manufacturing process.

In the cushion material of the present invention, it is preferable that the average thickness of the main body portion excluding a special portion of an end portion and a mounting portion in use is 5 mm or more. If the average thickness is 5 mm or more, sufficient cushioning properties as cushioning material Can be maintained, and a fixed feeling and a stable feeling can be obtained.

Further, the average density is preferably 5 to 200 kg Zm ³ . It is preferable that the content is in this range, since a sufficient cushioning property as a cushion material can be maintained, and a fixed feeling and a stable feeling can be obtained.

 The cushion material of the present invention can be entirely or partially force-barried with a woven or knitted mesh material. The effect of force balling can be expected to not only reinforce the strength of the cushioning material surface, but also prevent peeling and fluff. In addition, the reduction of surface friction is expected to make it easier to pack cushion material into the side lands. Here, the side land is a plain sheet or a bag-like sheet on which makeup such as dyeing or printing is applied, and is a part that directly contacts the skin.

 The material of the woven or knitted material used for force balling is not particularly limited. As a covering method, for example, there is a method of sewing on a cushion material surface by sewing.

 The cushioning material of the present invention may be subjected to processing such as forming irregularities on the surface or making cuts if necessary. Example

 (Method of measuring set and evaluation)

 Cut the sample to a width of 10 O mmx length 10 — O mmx thickness 8 O mm, compress this sample from the top surface with a 20 O mm ^ disk to compress 10% of the initial thickness, and hysteresis loss The rate was measured.

 When the hysteresis loss rate was less than 40%, ◎ was given, when 40% or more and less than 60%, 〇, when 60% or more and less than 80%, △, and 80% or more was X.

(Method of measuring and evaluating bending stiffness) Cut the sample to a width of 100 mm x length of 100 mm x thickness of 8 mm. The test was performed by the cantilever method according to JISL 1085. The sample was slid in the direction of a 45 ° slope, and the movement distance when the center of one end touched the slope was measured.

 The evaluation is ◎ if the moving distance is less than 600 mm, △ if it is 600 mm or more and less than 800 mm, △ if it is 800 mm or more and less than 100 mm, 100 O When the center-center of one end did not touch the slope even after being moved by mm, it was designated as X. (Method of measuring and evaluating water permeability)

 Cut the sample to a width of 1000 mm x length 180 mm x mm and a thickness of 8 mm. Measure the sample weight before measurement, and use it as the weight before immersion.

 After immersing this sample in water for 10 minutes, slowly pull it up and let it stand on a wire mesh for 5 minutes. After this, measure the sample weight and use it as the weight after immersion. From the weight before immersion and the weight after immersion, calculate the amount of water retained in the sample by the following formula.

Amount of water held by sample (kg) = Weight after immersion (kg) — Weight before immersion (kg)

 The evaluation is ◎ if the amount of water held by the sample is less than 7 5.O kg, 〇 if it is 7 5.O kg or more and less than 77.5 kg, and 77.5 kg or more and less than 80.O kg Then, △, and 80. O kg or more was defined as X.

 (Method of measuring and evaluating air permeability)

 Cut the sample to a width of 6 O mmx length of 6 O mm X thickness of 8 O mm. The air permeability was measured using a KES-F8AP1 Frazier air permeability meter manufactured by Kato Tech.

The evaluation is ◎ if the air permeability is 60 cm ³ / cm ² Z s or more, 〇 if the air permeability is 40 cm ³ / cm ² Z s or more and less than 60 cm ³ / cm ² Z s, 20 cm ³ / If cm ² Z s or more and less than 40 cm ³ Z cm ² Z s, △, 20 cm ³ / cm X is defined as ² Z s or less.

 (Method of measuring and evaluating flaking and fluff)

 A sensory test for visually observing the sample surface was performed. The evaluation was ◎ when there was no peeling and fluff on the surface, ま っ た く when some were observed, and X when considerably observed.

 (Method of measuring and evaluating surface friction)

 A sensory test was performed according to the difficulty in packing the sample in the side ground. In the evaluation, ◎ indicates a state where the sample can be easily packed in the side ground, 若 indicates a state where there is a young resistance, and X indicates a state where there is considerable resistance.

 Example 1

 A web was prepared by blending and forcing with the composition shown in Table 1, and was temporarily fused by far infrared rays. Next, these were laminated, compressed and held between two plates, put in a steam kettle and subjected to steam setting for 120 to 5 minutes to produce a non-woven fabric in a blocked state. This was further inverted 90 degrees and sliced to produce a cushion material in which the fiber direction in the nonwoven fabric was parallel to the thickness direction.

Hysteresis loss rate of sag of manufactured cushion material is 33.6%, travel distance of flexural rigidity is 595 mm, retained water quantity of permeability is 75.8 kg, ventilation Once again 7 2. was ^{4 cm 3 / cm 2 Z s} . In addition, peeling and fluff were observed in some places on the surface, and there was a slight resistance when the sample was packed in the side ground. Table 2 shows the results of these evaluations.

 Example 2

A web was prepared by blending and carding with the composition shown in Table 1 and was provisionally fused by far infrared rays. Next, these were laminated, compressed and held between two plates, put in a steam pot, and steam-set for 5 minutes at 120 to produce a non-woven fabric in a blocked state. Flip it 90 degrees and slice Then, a cushion material in which the fiber direction in the nonwoven fabric was parallel to the thickness direction was manufactured. In addition, a mesh fabric was sewn on the entire surface of the cushioning material by a sewing machine as a force-balancing material.

The hysteresis loss rate when measuring the sag of the manufactured cushioning material is 34.2%, the moving distance when measuring the bending stiffness is 595 mm, the retained water amount when measuring the water permeability is 78.2 kg, The air permeability was 58.8 cm ³ Z cm ² / s.

 In addition, there was no peeling or fluff on the surface, and the sample could be easily packed in the side. Table 2 shows the results of these evaluations.

 Comparative Example 1

 A web was prepared by blending and carding with the composition shown in Table 1 and was provisionally fused by far infrared rays. Next, these were laminated, compressed and held between two plates, put in a steam kettle, and steam-set for 5 minutes at 120 to produce a non-woven fabric in a blocked state. Slicing was performed as it was to produce a cushion material in which the fiber direction in the nonwoven fabric was perpendicular to the thickness direction.

The hysteresis loss ratio of the manufactured cushion material was 84.9% when measuring set, and the center of one end did not touch the slope even when moved by 100 mm when measuring bending stiffness. The amount of retained water at the time of water permeability measurement was 79.4 kg "7. The air permeability was 39.2 cm ³ / cm ² / s.

 In addition, peeling and fluff were observed in some places on the surface, and there was a slight resistance when the sample was packed in the side ground. Table 2 shows the results of these evaluations.

 Comparative Example 2

A web was prepared by blending and carding with the composition shown in Table 1 and was provisionally fused by far infrared rays. Next, these were laminated, compressed and held between two plates, put in a steam pot, and steam-set at 120 T: for 5 minutes to produce a non-woven fabric in a blocked state. Flip it 90 degrees and slice O 00/47807

Then, a cushion material in which the fiber direction in the nonwoven fabric was parallel to the thickness direction was manufactured.

Hysteresis loss rate of sag of manufactured cushion material is 58.1%, travel distance of flexural rigidity is 71.2 mm, water retention is 79.1 kg for water permeability measurement, ventilation time was ^{3 5. lcm 3 / cm 2 Z} s.

 In addition, peeling and fluff were observed in some places on the surface, and there was a slight resistance when the sample was packed in the side ground. Table 2 shows the results of these evaluations.

 Comparative Example 3

 A web was prepared by blending and forcing with the composition shown in Table 1, and was provisionally fused by far infrared rays. Next, these were laminated, compressed and held between two plates, put in a steam kettle, and steam-set for 5 minutes at 120 to produce a non-woven fabric in a blocked state. Slicing was performed as it was to produce a cushion material in which the fiber direction in the nonwoven fabric was perpendicular to the thickness direction.

The hysteresis loss ratio of the manufactured cushion material was 88.2% when measuring set, and the center of one end did not touch the slope even if the movement distance when measuring bending stiffness was 100 mm. The amount of retained water at the time of water permeability measurement was 82.7 kg, and the air permeability was 18.6 cm ³ cm ² Z s.

In addition, flaking and fluff were observed in some places on the surface, and there was wakasen resistance when the sample was packed in the side ground. Table 2 shows the results of these evaluations. 【table 1】

[Table 2]

産業上の利用可能性

Industrial applicability

 INDUSTRIAL APPLICABILITY The present invention is a cushioning material which has a small sag even when a compressive load is applied and has a low bending rigidity so that it is easy to impart flexibility, and is excellent in water permeability and air permeability. It is suitably used for cushioning materials.

Claims

The scope of the claims 1. A cushioning material in which a nonwoven fabric composed of a matrix fiber and a binder fiber is laminated, wherein the matrix fiber is 6.7 dte X or more, and the fiber direction in the nonwoven fabric is the thickness of the cushioning material. Cushioning material characterized by being parallel to the direction.