JP2000037578A - Cushion material and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a light cushion maternal which is excellent in ventilation property and is less deformable, and its manufacturing method. SOLUTION: A felt mat is formed in such a manner that thermoplastic resin or thermosetting resin is further added to a generally horizontally piled fiber, waves are formed on the fiber and the fiber is cured in heat. A plurality of the felt mats is attached polymerizing, and cut into slim width pieces 5 at a predetermined width. A direction of the slim width pieces 5 is changed 90 deg. at an axis of longitudinal direction. A cushion member 6 of a predetermined size has a width and a thickness of cut pieces in such a way that contacting surfaces of a plurality of the slim width pieces are bonded to each other in a state that a horizontal direction of the fiber is changed to a vertical direction. The cushion member has the fiber disposed to the vertical direction to a cushion surface.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cushioning material having good air permeability, little sag and lightness, and a method for producing the same.

[0002]

2. Description of the Related Art A cushion material is used inside a bed (mat). A spring material is used for the cushion material, and a synthetic resin elastic foam or wood dust is generally used as a binder inside a springless mat. There is a three-layer structure in which the upper and lower sides of a synthetic resin foam are sandwiched between solidified insulation boards. The multi-layer structure with an insulation board inside has a tatami appearance.
Tatami mats (called tatami mats) are used because they have an appropriate degree of hardness, but often cause mold generation due to moisture, body temperature, binder starch and the like trapped inside.

For the purpose of resolving such difficulties, springless mats having good air permeability, such as polyester compressed cotton mats and palm fiber mats, have already been made, but polyester compressed cotton mats have a moderate hardness such as tatami mats. It is not suitable for persons with low back pain or the like, because it has a depression along the body shape at bedtime, and it is difficult to turn over.

On the other hand, palm fiber mats must be finished in a somewhat bulky state in order to maintain cushioning and air permeability, so that sagging occurs. In addition, natural materials have the advantage that they absorb moisture easily, As a result, there is a problem that a significant sag occurs, and it cannot withstand long-term use.

[0005]

In order to improve the sag of such a natural fiber mat (cushion material), the density becomes high, and the cushioning property and the air permeability are impaired.
At present, it is difficult to spread because it becomes heavy and costly. The present invention has studied a manufacturing method for solving the difficulties of cushioning materials made of natural materials.

[0006]

The cushioning material of the present invention is characterized in that the fibers are oriented substantially perpendicular to the plane of the cushion. Orienting the fibers in a direction substantially perpendicular to the cushion plane includes that the two-dimensionally randomly oriented surface of the fibers laminated in the horizontal direction is substantially perpendicular. Further, an embossed or netted surface is formed on the upper surface or the bottom surface of the cushion plane. The cushioning material of the present invention may be used not only when the cushioning material is used as a core material with a bead, but also when the surface is simply covered with a cover or the like.

In the method of manufacturing a cushion material according to the present invention, a web is formed by laminating in a substantially horizontal direction while mixing thermoplastic fibers or a thermosetting resin with a fiber to form a web, and heating the resulting web to form a felt mat. A plurality of felt mats are polymerized and adhered, cut into a predetermined width to form a narrow piece, and the fiber is oriented approximately 90 ° from the horizontal direction to the vertical direction by changing the orientation by approximately 90 ° around the longitudinal direction of the narrow piece. In this state, the contact surfaces of the plurality of narrow pieces are united to form a cushion material of a predetermined size in which the width of the cut piece is thick. To unite the contact surfaces of the narrow strips here means to bond the narrow strips using an adhesive, or to arrange the narrow strips in a heating press and heat and heat to weld the fibers. It includes a method such as integration.

Further, the predetermined width of the narrow piece is cut in two directions, that is, in the width direction and the lengthwise direction of the felt mat.
° A cushioning material manufacturing method characterized by being arranged so as to intersect to form a mosaic-shaped cushioning material of a predetermined size. In addition, after bonding the contact surfaces of the narrow pieces,
An embossed or netted surface is provided directly on the surface or on the surface felt layer.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A cushion material according to the present invention and a method for manufacturing the cushion material will be described with reference to FIGS. All the fibers used were natural materials, and fibers such as palm coconut fiber, hemp fiber, and cotton fiber were used. These can be collected from waste such as hemp bags. The fibers are formed into a web using a binder resin (thermosetting or thermoplastic) as is usually done.
The web is formed by a carding machine and a fleece machine so that each fiber is uniformly laminated in the horizontal direction. A web obtained by laminating the fibers in a substantially horizontal direction is heated and cut into a fixed size (25 × 1000 × 2000 mm) as shown in FIG. The use of thick fibers such as palm coconut fibers is very effective in maintaining elasticity.

The felt mat 1 is fed to the gluing machine 2 from the cutting width direction as shown in (b), and an adhesive (aqueous emulsion emulsion or the like) is uniformly applied to the upper surface at about 100 g / m. Twenty sheets (500 mm in height) are aligned and stacked properly, and then left under pressure for several hours using a compression molding machine (may be dried in a dryer until they are completely bonded). To obtain a laminate 3.

As shown in FIG. 2, a plurality of the felt mats 1 are polymerized and bonded, and are cut into a predetermined width by a cutting machine 4 to form narrow pieces 5. In addition, a thin material polymerized and bonded may be cut by a punching cutter or the like. Next, as shown in FIG. 3 (a), the fiber is turned from the horizontal direction to the almost vertical direction by changing the direction by approximately 90 ° about the longitudinal direction of the narrow piece 5 as an axis. In this manner, a plurality of narrow pieces 5 are arranged, and an adhesive is applied and adhered to the contact surface to form a cushion material 6 having a predetermined size.

The embossed or netted surface can be provided directly on the surface of the cushion material 6 after the contact surfaces of the narrow pieces are adhered to each other or on the surface felt layer. FIG. 4 shows a state in which a felt layer for a surface layer is provided on the cushion material 6. send. The surface felt 7 is subjected to a netting process in a separate step, and the roll coater 9,
In step 9, an adhesive such as an emulsion adhesive is applied evenly.

The netting process is a process in which a synthetic resin is applied to the surface of the cushion material 6 directly or to the surface felt layer like a mesh pattern. As shown in FIG. This is a structure in which the cushion material is sent below the resin application device 10 to be used. The resin application device 10 discharges the resin while moving left and right in synchronization with the movement of the cushion material.

The embossing is performed by a surface embossing machine 12 provided with a mold 11, either directly on the surface of the cushion material 6 as shown in the lower part of FIG. 6 or on the surface felt 7 as shown above. Even embossing can be performed.

[0015]

According to the present invention, the fibers are used by changing the direction from the horizontal direction to the vertical direction with respect to the load.
It has become possible to improve sag in natural fiber mats (cushion material) and the like. In addition, since it does not become high-density at the time of load, air permeability was secured, generation of mold and the like was prevented, and lightening and cushioning were also very good. The cushion material can be made of natural materials such as wastes, and the cost of the cushion material has been reduced. The cushion material integrated by superposing and bonding a plurality of sheets can be subjected to insect repellent and fungicide treatment by giving characteristics to each of the superposed and bonded sheets, and the partial strength can be adjusted by changing the fiber density.

[Brief description of the drawings]

FIG. 1 is a schematic view showing a process of sending a felt mat to a gluing machine and polymerizing and bonding to form a laminate.

FIG. 2 is a perspective view showing a state in which a laminate is cut into a predetermined width by a cutting machine to form narrow pieces.

FIG. 3 is a perspective view showing a state in which fibers are directed from a horizontal direction to a substantially vertical direction by changing the direction of a narrow strip, and are arranged and bonded to form a cushion material.

FIG. 4 is a schematic view illustrating a step of providing a surface felt layer on a cushion material.

FIG. 5 is a perspective view showing a state of a netting process.

FIG. 6 is a schematic view showing a state of embossing.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Felt mat 2 Glue machine 3 Laminate 4 Cutting machine 5 Narrow piece 6 Cushion material 7 Surface felt 8 Crimping machine 9 Roll coater 10 Resin coating device 11 Mold

 ──────────────────────────────────────────────────続 き Continuing on the front page F term (reference) 4F100 AJ02 AK01A AK01B BA01 BA02 BA03 BA06 BA22 DC16B DD01B DG01A DG06A DG15A DG15B DJ00 EC182 EH46B EJ082 EJ172 EJ322 EJ39B EJ402 EJ422 HB21B03A03 JB13A03 J03A03 EA03

Claims (5)

[Claims] 1. A cushioning material in which fibers are oriented in a direction substantially perpendicular to a cushion surface. 2. An embossed or netted surface is formed on an upper surface or a bottom surface of a cushion surface.
The cushion material described. 3. A web is formed by laminating in a substantially horizontal direction while mixing a thermoplastic fiber or a thermosetting resin with a fiber, and forming a web by heating the web to form a felt mat. Then, it is cut into a predetermined width to form a narrow strip, and by changing the orientation of the narrow strip by approximately 90 ° with respect to the longitudinal direction thereof, the plurality of narrow strips are oriented in a state where the fibers are directed substantially vertically from the horizontal direction. A method for manufacturing a cushion material, comprising: abutting surfaces of each other are united to form a cushion material of a predetermined size having a thickness of a cut piece as a thickness. 4. A predetermined width cut of the narrow piece according to claim 3 is a two-way cut of a felt mat in a width direction cut and a longitudinal direction cut, and the fibers are mutually cut in a state where the fibers are directed substantially horizontally from a horizontal direction. A method for manufacturing a cushion material, wherein the cushion material is arranged so as to intersect at 90 degrees to form a cushion material of a predetermined size. 5. A cushion material comprising an embossed or netted surface provided directly on a surface or a felt layer for a surface layer after bonding of contact surfaces of narrow pieces according to claim 3 or 4. Manufacturing method.