JP2009112548A - Bedding apparatus excellent in cushion characteristic and silence property, and method for manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a bedding apparatus including resilient mesh structure which has durable cushioning properties and silence property. <P>SOLUTION: On the surface of a random loop of a three-dimensional random loop joint structure obtained by causing a continuous linear object having fineness of 300d tex or more which is formed of a polyester copolymer to wind to form the random loop, and bringing respective loops into contact with each other in a melted condition to make most of contact portions be subjected to fusion bonding to each other, polyester-based resin is stuck. A polyester-based reticulated structure obtained like this is used for at least a part of the bedding. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a bedding using at least a part of an elastic network structure having durable cushioning properties and quietness.

  Currently, foamed urethane, inelastic crimped fiber-filled cotton, and resin cotton or hard cotton bonded with inelastic crimped fibers are used as cushion materials for bedding.

  However, although foam-crosslinked urethane has good durability as a cushioning material, it is easy to steam because it has poor moisture permeability and heat storage, and it is not thermoplastic. The damage of the gas is large, and the toxic gas removal is expensive. As a result, landfills are often used. However, since it is difficult to stabilize the ground, there is a problem that the landfill site is limited and the cost increases. In addition, the processability is excellent, but there is a problem of pollution of chemicals used during production. In addition, since the fibers are not fixed in thermoplastic polyester adhesive-filled cotton, the form of use collapses, the fibers move, and there is a problem of reduced sublimation and elasticity due to crimping. become.

  Resin cotton in which polyester fibers are bonded with an adhesive, such as those using a rubber system as an adhesive (for example, Patent Documents 1, 2, and 3), and those using a crosslinkable urethane (for example, Patent Document 4) is there. These cushion materials are inferior in durability and have problems such as being unable to be recycled because they are not thermoplastic and not having a single composition, and there are problems such as complexity of workability and pollution of chemicals used during production. .

  There are some that use polyester hard cotton (for example, Patent Documents 5 and 6). However, since the non-crystalline polymer with brittle fiber component of the thermal bonding fiber is used, the bonded part is fragile, and the bonded part can be easily used during use. There is a problem inferior in durability, such as being destroyed and its form and elasticity being lowered.

  Further, as an improved method, a method of entanglement processing (for example, Patent Document 7) has been proposed, but there is a problem that the brittleness of the bonded portion is not solved and the elasticity is greatly reduced. Moreover, there is also complexity during processing. Furthermore, there is also a problem that it is difficult to impart a soft cushioning property to the bonded portion that is difficult to deform. For this reason, the cushioning material using the heat-bonding fiber using the polyester elastomer which is soft even if an adhesion part changes and it changes is proposed (for example, patent documents 8). In order to lower the melting point, the polyester elastomer of the adhesive component used in this fiber structure contains 50 to 80 mol% of terephthalic acid in the acid component of the hard segment, and the content of polyalkylene glycol as the soft segment is 30 to 30%. 50% by weight, isophthalic acid or the like as other acid component composition is increased, the amorphous property is increased, the melting point is 180 ° C. or less, and the low melt viscosity improves the formation of the heat-bonded portion, thereby improving the amoeba-like shape. Although an adhesive part is formed, it is a core-sheath type composite fiber using polyethylene terephthalate for the core part, so there is a problem that the texture is hard and it is difficult to fit the body shape, and composite spun fiber is used In addition, there is a problem that the cost increases because a process of reheating and melt bonding is required.

  As an alternative to urethane, a cushioning material made of a mixture of a polyolefin resin and a vinyl acetate resin, a vinyl acetate copolymer, or styrene butadiene styrene has been studied (for example, Patent Document 9). However, it has less sinking than urethane, has a high stress at 25% compression, a small difference in stress between compression and decompression, so rebound is too high, and light resistance is poor because it is mixed with other components. There are problems such as poor thickness retention during repeated compression, high specific gravity and high weight. Furthermore, since this cushion material is a combination of different materials, there is a problem that recycling is difficult.

  A three-dimensional random structure in which a continuous linear body made of polyester copolymer thermoplastic elastic resin is twisted to form a random loop, and the respective loops are brought into contact with each other in a molten state, and most of the contact portion is fused. A loop joint structure has been proposed, but there is a problem that it is noisy and difficult to sleep when used for bedding because it makes a squeaking noise during compression and recovery.

JP 60-11352 A JP 61-141388 A Japanese Patent Laid-Open No. 61-141391 JP-A 61-137732 JP 58-136828 A JP-A-3-249213 JP-A-4-245965 International Publication No. 91/19032 Pamphlet JP 2003-250667 A

  The present invention has been made against the background of the problems of the prior art, and provides a bedding that uses at least a part of an elastic net-like structure that has excellent durability and cushioning properties and is less susceptible to stuffiness, and particularly has reduced sound during compression and recovery. The purpose is to do.

As a result of intensive studies to solve the above problems, the present inventors have finally completed the present invention. That is, the present invention is as follows.
1. A tertiary formed by twisting continuous linear bodies of polyester copolymer having a fineness of 300 dtex or more to form a random loop, bringing the respective loops into contact with each other in a molten state, and fusing most of the contact portions. A bedding using a polyester-based elastic network structure, which is an original random-loop bonded structure, in which a polyester-based resin is attached to the surface of a random loop, at least in part.
2. The bedding according to 1 above, wherein the thickness retention before and after the repeated compression test of 80,000 times is 90% or more.
3. 2. The bedding according to 1 above, wherein the polyester resin containing 0.01 to 10% of pigment is adhered to the surface of the random loop in an amount of 2 to 15% by weight.
4). 4. The method for producing a bedding according to any one of the above items 1 to 3, wherein the polyester-based resin is attached to the elastic network structure as a water-based emulsion and dried at 0 to 150 ° C.

  Since the elastic network structure according to the present invention reduces noise during compression and recovery, it is possible to provide a bedding using at least a part of the elastic network structure having durable cushioning and quietness.

Hereinafter, the present invention will be described in detail.
The polyester copolymer in the present invention is a polyester ether block copolymer having a thermoplastic polyester as a hard segment and a polyalkylene diol as a soft segment, or a polyester ether block copolymer having an aliphatic polyester as a soft segment. It can be illustrated. More specific examples of polyester ether block copolymers include aromatic dicarboxylic acids such as terephthalic acid, isophthalic acid, naphthalene 2,6 dicarboxylic acid, naphthalene 2,7 dicarboxylic acid, diphenyl 4,4 'dicarboxylic acid, -At least one dicarboxylic acid selected from alicyclic dicarboxylic acids such as 4-cyclohexanedicarboxylic acid, aliphatic dicarboxylic acids such as oxalic acid, adipic acid, sebacic acid, dimer acid, or ester-forming derivatives thereof Aliphatic diols such as 1,4 butanediol, ethylene glycol, tremethylene glycol, tetremethylene glycol, pentamethylene glycol, hexamethylene glycol and the like, and alicyclics such as 1,1 cyclohexanedimethanol and 1,4 cyclooxane dimethanol Diol or this At least one diol component selected from these ester-forming derivatives and the like, and polyalkylene diols such as polyethylene glycol, polypropylene glycol, polytetramethylene glycol, ethylene oxide-propylene oxide copolymer having an average molecular weight of about 300 to 5,000 Among these, a ternary block copolymer composed of at least one kind. The polyester ester block copolymer is a ternary block copolymer composed of at least one of the dicarboxylic acid, diol, and polyester diol such as polylactone having an average molecular weight of about 300 to 3000. Considering thermal adhesiveness, hydrolysis resistance, stretchability, heat resistance, etc., dicarboxylic acid is terephthalic acid or naphthalene 2,6 dicarboxylic acid, diol component is 1,4 butanediol, polyalkylenediol Is particularly preferably a polytetramethylene glycol ternary block copolymer or a polyester diol polylactone ternary block copolymer. As a special example, a polysiloxane-based soft segment can be used. Moreover, the said polyester elastomer can be used individually or in mixture of 2 or more types. Furthermore, a polyester elastomer blended with a non-elastomeric component or a copolymerized one can be used in the present invention.

  The elastic net-like structure used for a part of the bedding of the present invention winds a continuous linear body having a fineness of 300 dtex or more to form a random loop, and each loop is brought into contact with each other in a molten state, so that a large contact portion is formed. A three-dimensional random loop bonded structure formed by fusing portions is preferable.

  If the fineness is less than 300 dtex, the strength is lowered and the repulsive force is lowered, which is not preferable. The preferred fineness of the continuous linear body of the present invention is 500 dtex or more and 100000 dtex or less where excellent repulsive force can be obtained, and if it is 100,000 dtex or more, the number of linear bodies is reduced and the compression characteristics are deteriorated, so the use part is limited. May be. More preferably, it is 500-50000 dtex. The cross-sectional shape of the continuous linear body is not particularly limited. However, when the continuous linear body has a fine fineness, a modified cross-section or a hollow cross-section is preferable because the repulsive force is improved.

  In addition, when it is not a continuous linear three-dimensional random loop bonded structure, for example, a cotton structure composed of a short fiber mixed with a composite fiber or an adhesive fiber using a low-melting polymer in the sheath portion is heat-treated and bonded. In this case, it is joined in the shape of an amoeba and has a two-dimensionally balanced spread and fiber directionality, but there are almost no fibers lined up in the thickness direction, and only the recovery force in the shear direction is used. Since the axial recovery force cannot be used, the elasticity of the planar object is exhibited, and the resilience becomes large like spring deformation proportional to the square of the displacement, which is not preferable.

  The continuous linear body made of the thermoplastic resin forming the elastic network structure of the present invention may be a composite form combined with other thermoplastic resins within a range not impairing the object of the present invention. Examples of the composite form include linear bodies such as a sheath / core type, a side-by-side type, and an eccentric sheath / core type when the linear body itself is combined.

  As a composite (integrated adhesion structure) of elastic network structure layer, sandwich structure of elastomer layer / non-elastomeric layer / elastomeric layer, two-layer structure of elastomer layer / non-elastomeric layer, partially inside the elastomer layer of matrix And a composite structure in which a non-elastomeric layer is arranged.

  The elastic network structure of the present invention is appropriately selected from the respective network structures such as those having different loop sizes, different decitex, different compositions, different densities, etc. in relation to the required performance. You may laminate or mix.

  Furthermore, it may be a composite structure in which a hard cushion (preferably made of a heat-bonding fiber using an elastomer) is disposed as the second layer on the surface of the laminated structure as necessary.

  In the elastic network structure used in at least a part of the bedding of the present invention, it is preferable that 2 to 15% by weight of a polyester resin is adhered to the random loop surface. It was found that the durability of the cushioning property is remarkably improved by setting the resin amount within this range. In addition, the inventors have surprisingly found that the noise during compression and recovery is significantly reduced. If it is less than 2% by weight, the bonding between the loops becomes insufficient, so that the durability of the cushioning property becomes insufficient, and the sound noise is not improved. Furthermore, resin adhesion spots are likely to occur and the quality tends to be inferior. On the other hand, if it exceeds 15% by weight, not only the elastic network structure becomes heavier, but also a problem that a resin film is formed in the loop and the texture becomes hard is likely to occur. In addition, since the movement of the loop is limited, there is a problem that cushioning and texture become hard. More preferably, it is 3 to 10% by weight.

  The elastic network structure used for at least a part of the bedding of the present invention preferably has a thickness retention of 90% or more before and after the repeated compression test of 80,000 times in the repeated compression test. Bedding is often used for a long time and for a long time, and sag is likely to occur due to repeated deformation due to the load of the human body. It is not preferable that the thickness retention before and after the repeated compression test of 80,000 times is less than 90% because the load concentration portion is particularly liable to bend at the heel portion or the shoulder portion, which tends to impair sleeping comfort. Preferably it is 93% or more, more preferably 95% or more.

  It is preferable that the elastic network structure used for at least a part of the bedding of the present invention has a compression hardness reduction ratio of 10% or less at 50% compression before and after repeated compression tests of 80,000 times. As for the sag of the cushion body caused by repeated use, the compression hardness first decreases, and then the thickness decreases. The elastic network structure without the resin has almost no apparent change in thickness, but actually the compression hardness decreases and the cushion body becomes soft. That is, when actually used, there is a problem that a feeling of bottoming occurs. The present inventors investigated the cause, and the loop members who were bonded as the reason were repeatedly unbonded due to compression, and although there was no appearance, the resistance to compression was lost. I found. As a measure for improvement, it has been found that adhesion between loops is strengthened and compression hardness is maintained by applying resin. If the reduction ratio of the compression hardness exceeds 10%, it is not preferable because a feeling of sag due to use tends to be felt. More preferably, it is 6% or less.

The elastic network structure used for at least a part of the bedding of the present invention preferably contains 0.01 to 15% by weight of a pigment in a polyester resin. The purpose of adding the pigment to the resin is to visually confirm that the adhesion state of the resin is uniform, and to improve the design by coloring. When a dye is used instead of a pigment, if the side surface and the elastic network structure are in contact with and rubbed with moisture such as sweat, and the dye is present on the surface of the elastic network structure, the side surface This is not preferable because color transfer occurs. In contrast, pigments are preferred because they do not dissolve in moisture such as sweat and do not cause such problems.
If the pigment is less than 0.01% by weight, it is difficult to determine the state where the resin is adhered, and quality control becomes difficult, which is not preferable. On the other hand, if it exceeds 15% by weight, not only the cost is increased, but also the adhesive strength of the resin is lowered. More preferably, it is 0.03 to 10 weight%, More preferably, it is 0.05 to 5 weight%.

  The polyester resin to be attached to the elastic network used for at least a part of the bedding of the present invention has an aromatic dicarboxylic acid whose polycarboxylic acid component does not contain a sulfonic acid metal base in an amount of 40 to 99.5 mol%, aliphatic or fatty It is composed of 59.5 to 0 mol% of a cyclic dicarboxylic acid and 0.5 to 10 mol% of a sulfonic acid metal base-containing aromatic dicarboxylic acid, and the polyol component is an aliphatic glycol having 2 to 8 carbon atoms and / or a carbon number. It is preferable that it is a polyester-type resin which consists of 6-12 alicyclic glycol. Examples of the aromatic dicarboxylic acid that does not contain a sulfonic acid metal base include terephthalic acid, isophthalic acid, orthophthalic acid, and 2,6-naphthalenedicarboxylic acid. These aromatic dicarboxylic acids not containing a sulfonic acid metal base are preferably 40 to 99.5 mol% of the polycarboxylic acid component. In the case of less than 40 mol%, the mechanical strength and weather resistance of the polyester resin are inferior, which is not preferable. If it exceeds 99.5 mol%, the polyester resin will not be dispersed in the system.

  Examples of the aliphatic or alicyclic dicarboxylic acid include succinic acid, adipic acid, azelaic acid, sepacic acid, dodecanedioic acid, dimer acid, tetrahydrophthalic acid, hexahydrophthalic acid, hexahydroisophthalic acid, hexahydroterephthalic acid. Etc. The aliphatic or alicyclic dicarboxylic acid is preferably 59.5 to 0 mol% of the polycarboxylic acid component. When it exceeds 59.5 mol%, the water resistance and the coating film strength are lowered, and the tackiness is exhibited. Furthermore, p-hydroxybenzoic acid, p- (2-hydroxyethoxy) benzoic acid, hydroxypivalic acid, γ-butyrolactone, ε-caprolactone, or the like can be used as necessary. Moreover, if necessary, polycarboxylic acids having 8 or more functional groups such as trimellitic acid and pyromellitic acid can be used as long as they are 10 mol% or less based on the total polycarboxylic acid component.

  Examples of the aliphatic glycol having 2 to 8 carbon atoms include ethylene glycol, 1,2-propylene glycol, 1,3-propanediol, 1,4-butanediol, neopentyl glycol, 1,5-pentanediol, 1,6- Examples include hexanediol. The aliphatic glycol having 2 to 8 carbon atoms and / or the alicyclic glycol having 6 to 12 carbon atoms is preferably 90 to 100 mol% based on the total polyol component. Further, if necessary, an 8-functional or higher functional polyol such as trimethylolpropane, trimethylolethane, glycerin, pentaerythritol may be 5% by weight or less based on the total polyol component. Furthermore, polyalkylene glycol, particularly polyethylene glycol having a molecular weight of 100 to 10,000, may be used as long as it is 5% by weight or less based on the total polyol component. If the amount of polyalkylene glycol, particularly polyethylene glycol, exceeds 10 mol%, the water resistance and weather resistance of the polyester resin are extremely lowered, which is not preferable.

  Examples of the aromatic dicarboxylic acid containing a sulfonic acid metal base include metals such as sulfoterephthalic acid, 5-sulfoisophthalic acid, 4-sulfophthalic acid, 4-sulfonaphthalene-2,7-dicarboxylic acid, and 5 [4-sulfophenoxy] isophthalic acid. Mention may be made of salts. Examples of the metal salt include salts such as Li, Na, K, Mg, Ca, Cu, and Fe. Particularly preferred is 5-sodium sulfoisophthalic acid. The sulfonic acid metal base-containing dicarboxylic acid is 0.5 to 10 mol% with respect to the total polycarboxylic acid component, and preferably 1.0 to 6 mol% with respect to the total polycarboxylic acid component. When no sulfonic acid metal base-containing aromatic dicarboxylic acid is used, the dispersibility of the polyester resin in water is very poor. As the amount of the metal base-containing aromatic dicarboxylic acid increases, good dispersibility is exhibited. However, when the amount exceeds 10 mol%, the dispersibility of the obtained polyester resin in water is good, but this is not preferable because the water resistance of the film obtained after coating and drying tends to be very poor.

  The polyester resin to be attached to the elastic network used for at least a part of the bedding of the present invention preferably has a breaking elongation of 500 to 1000%. If it is less than 500%, the cushioning property tends to be too hard, which is not preferable. On the other hand, if it exceeds 1000%, a sticky feeling tends to appear, which is not preferable. More preferably, it is 600 to 900%.

  The polyester resin attached to the elastic network used for at least a part of the bedding of the present invention preferably has a Shore hardness of 20 to 60. If the Shore hardness is less than 20, it is not preferable because the durability of the cushion tends to deteriorate, and if it exceeds 60, the texture tends to become hard. More preferably, it is 30-50.

  The polyester resin adhered to the elastic network used in at least a part of the bedding of the present invention preferably has a glass transition temperature of -40 to 50 ° C. If it is less than −40 ° C., the sticky feeling is likely to occur, which is not preferable. More preferably, it is 0-40 degreeC.

  The polyester resin to be attached to the elastic network used for at least a part of the bedding of the present invention is essentially amorphous and preferably has a softening point of 90 to 150 ° C. In the case of a crystalline polyester having a clear crystal melting point, the obtained aqueous dispersion has poor storage stability and easily causes phase separation, and a stable aqueous dispersion cannot be obtained. When the softening point of the polyester resin does not reach 90 ° C., the obtained film is not preferable because it has strong adhesiveness and poor water resistance. On the other hand, when the softening point exceeds 150 ° C., the dispersibility in water is deteriorated, which is not preferable. More preferably, it is 100-140 degreeC.

  The polyester resin to be attached to the elastic network used for at least a part of the bedding of the present invention preferably has a number average molecular weight of 10,000 to 30,000. When the molecular weight does not reach 10,000, it is not preferable because the mechanical properties, particularly flexibility, of the obtained film is inferior. Furthermore, when the molecular weight exceeds 30000, the viscosity of the aqueous dispersion increases, and it becomes difficult to increase the content of the polyester resin, which is not preferable. More preferably, it is 12000-25000.

  The polyester resin to be attached to the elastic network used in at least a part of the bedding of the present invention preferably has a hydroxyl value (KOHmg / g) of 1.5 to 5. If it is less than 1.5, it is not preferable because the resin is easily peeled off, and if it exceeds 5, it is not preferable because it tends to give a sticky feeling. More preferably, it is 2.5-4.

  The polyester resin to be attached to the elastic network used for at least a part of the bedding of the present invention preferably has an acid value (KOHmg / g) of 2 to 4. If it is less than 2, it is not preferable because the resin is likely to be discolored, and if it exceeds 4, it is difficult to control the amount of adhesion of the resin. More preferably, it is 2.5-3.5.

  The polyester resin to be adhered to the elastic network structure used in at least a part of the bedding of the present invention can be used alone or in combination of two or more if necessary.

  In addition to the pigment, the polyester resin to be attached to the elastic network structure used for at least a part of the bedding of the present invention does not significantly deteriorate the characteristics of the bedding of the present invention. ) Repellent, anti-allergen (allergy calming agent), hygroscopic agent, hygroscopic exothermic agent, phase change type temperature regulator (MCP), fragrance, water absorbent, water repellent, water and oil repellent, antifouling An agent, a light resistance agent, a weather resistance agent, a photocatalytic processing agent, a softening agent, a curing agent, a crosslinking agent, a dull agent, and the like may be mixed. In that case as well, the total amount including those components is defined as the amount of the polyester resin adhered.

  Moreover, any method such as a spray method, a dipping method, or a shower method may be used as a resin application method. In addition, in order to remove the excessively adhered resin, it can be appropriately selected and employed, such as squeezing with a pressure roller, vibration, shaking, and blowing of pressurized air.

  It is preferable that the polyester resin is attached to the elastic network as a water-based emulsion and dried at 0 to 150 ° C. It is possible to manufacture by dissolving a polyester resin in an organic solvent and attaching it to an elastic network structure, but it is not preferable in consideration of the influence on the human body and the release of the system to pollute the environment. . Drying at less than 0 ° C. is not preferable because the moisture contained in the resin solidifies and does not dry. Drying at a temperature exceeding 150 ° C. is not preferable because the elastic network structure tends to be deformed. More preferably, it is 30-130 degreeC, Furthermore, 60-110 degreeC is still more preferable.

  Hereinafter, the present invention will be specifically described with reference to examples, but the present invention is not limited thereto. In addition, the measurement and evaluation of the characteristic value in an Example were performed as follows.

(1) Fineness A sample is cut into a size of 20 cm × 20 cm, and linear bodies are collected from 10 locations. The specific gravity at 40 ° C. of the linear bodies collected at 10 locations is measured using a density gradient tube. Furthermore, the cross-sectional area of the linear body collected at the 10 locations is determined from a photograph magnified 30 times with a microscope, and the volume of the linear body having a length of 10,000 m is determined from the photograph. The value obtained by multiplying the obtained specific gravity and volume is defined as the fineness (weight of linear body 10,000 m) (average value of n = 10).

(2) Thickness retention ratio before and after repeated compression test of 80,000 times A sample was cut into a size of 30 cm × 30 cm, and 1 Hz up to a thickness of 50% in a 25 ° C. 65% RH room with a servo pulsar manufactured by Shimadzu Corporation The thickness (b) after leaving the sample for 80,000 times after repeating compression recovery in a cycle for 1 day is determined, and the thickness (a) before treatment is calculated from the following formula, (b / a) × 100: unit% (Average value of n = 3).

(3) Reduction ratio of compression hardness at the time of 50% compression before and after repeated compression tests of 80,000 times The sample was cut into a size of 30 cm × 30 cm, left unloaded for 24 hours, and then placed in an environment at 25 ° C. The sample was left for 1 hour, pre-compressed to 75% at a speed of 50 mm / min with a φ200 mm compression plate with an orientex Tensilon in an environment of 25 ° C., and immediately returned to its original thickness at a speed of 50 mm / min. Leave for 3 minutes. Thereafter, it was again compressed by 50% at a speed of 50 mm / min, and the load at that time was measured (c). After returning to the original thickness, the sample was taken out, and the sample after 80,000 times was repeatedly compressed with a Shimadzu servo pulsar until the thickness reached 50% in a 25 ° C. 65% RH chamber at a cycle of 1 Hz. Leave for days.
Pre-compressed to 75% of the thickness before compression repeatedly at a speed of 50 mm / min with a φ200 mm compression plate using a Tensilon manufactured by Orientex in an environment of 25 ° C., and immediately the original thickness at a speed of 50 mm / min. Let stand for 3 minutes. Then, it is compressed again to a thickness of 50% of the thickness before compression repeatedly at a speed of 50 mm / min, and the load at that time is measured (d), calculated from the following formula, (cd) / (c) × 100 Yes: unit% (average value of n = 3).

(4) Adhesion amount of polyester resin The weight (e) of the elastic network structure before processing and the weight (f) after processing were measured and calculated by the following formula. That is, it is calculated from {(fe) / (e)} × 100: unit%.

<Example 1>
Dimethyl terephthalate (DMT) and 1,4 butanediol (1,4BD) are charged with a small amount of catalyst, transesterified by a conventional method, polytetramethylene glycol (PTMG) is added, and polycondensation is carried out while heating and reducing pressure. An ether ester block copolymer elastomer was produced, and then 1% antioxidant was added, kneaded, pelletized, and vacuum dried at 50 ° C. for 48 hours to obtain a thermoplastic elastic resin raw material.

The obtained thermoplastic elastic resin raw material is at a temperature 40 ° C. higher than the melting point of the thermoplastic elastic resin from a nozzle in which orifices having a hole diameter of 1.5 mm are arranged on a nozzle effective surface having a width of 70 cm and a length of 7 cm at intervals of 5 mm between holes. Melt, dispose cooling water 30cm below the nozzle surface, and take a 60cm wide stainless steel endless net in parallel with a spacing of 5cm between the pair of take-up conveyors so that they partially come out on the water surface. The surface obtained by cutting into a length of 1 m after performing pseudo-crystallization treatment while fusing into the cooling water heated to 70 ° C. at a rate of 1 m per minute while sandwiching both sides and solidifying. An elastic network structure having a flattened density of 0.05 g / cm ³ was obtained. The fineness of the linear body of the elastic network structure was 2000 dtex. When the elastic network structure was repeatedly compressed and released, a squeaking sound was heard.

  As post-processing, a polyester-based softening agent “EX200A” manufactured by Takamatsu Yushi Co., Ltd. was added to an aqueous emulsion obtained by diluting “Vainal (registered trademark) MD1480” manufactured by Toyobo Co., Ltd. with water so that the solid content concentration was 21%. The mixture was mixed so that the mixing ratio was 9: 1, and 0.1% by weight of SA Blue XG manufactured by Mikuni Dye Co., Ltd. was added as a blue pigment and stirred. Table 1 shows the components and characteristics of “Vaironal (registered trademark) MD1480”. The mixed solution was filled into a bath, and the elastic network structure was dipped, and then placed on a vibrating metal mesh to remove excess aqueous emulsion. And it was made to dry for 30 minutes with an 80 degreeC dryer, and the resin-processed elastic network structure colored blue was obtained. The obtained resin-processed elastic network has a thickness retention rate of 99% before and after the 80,000 repeated compression test, and the compression hardness reduction rate at 50% compression before and after the 80,000 repeated compression test is 2%. Met. From the weight comparison, the adhesion amount of the resin was 4%.

  The texture of the obtained resin-processed elastic network structure was soft, did not feel sticky, and the colored spots were inconspicuous. A polyester nonwoven fabric (thickness 3 cm) was combined on the lower side of the elastic network structure and inserted into the futon side fabric to form a mattress. I lay down on the mattress, and I didn't squeak as I moved.

<Example 2>
A resin-processed elastic network structure was prepared in the same manner as in Example 1 except that the solid content concentration of “Vylonal (registered trademark) MD1480” was 25%. The obtained resin-processed elastic network has a thickness retention ratio of 98% before and after 80,000 repeated compression tests, and a reduction rate of compression hardness at 50% compression before and after 80,000 repeated compression tests is 5%. Met. From the weight comparison, the adhesion amount of the resin was 12%. The appearance was excellent with no spots, but the texture was slightly hard. Moreover, the quietness of the mattress was very excellent.

<Example 3>
A resin-processed elastic network structure was prepared in the same manner as in Example 1 except that the solid content concentration of “Vylonal (registered trademark) MD1480” was 15%. The obtained resin-processed elastic network has a thickness retention ratio of 96% before and after the repeated compression test of 80,000 times, and a reduction rate of the compression hardness at the time of 50% compression before and after the repeated compression test of 80,000 times is 5%. Met. From the weight comparison, the adhesion amount of the resin was 2%. The appearance was slightly conspicuous, but the texture was soft and good. Also, the mattress did not make a loud noise.

<Example 4>
An elastic network structure having a density of 0.045 g / cm ³ was obtained in the same manner as in Example 1 except that the shape of the hole on the nozzle surface was horseshoe-shaped and the fiber cross section was hollow (7000 dtex).

  Continuously, polyester softener “EX200A” manufactured by Takamatsu Yushi Co., Ltd. is mixed with water-based emulsion diluted with water so that the solid content concentration becomes “20%” by “Vaironal (registered trademark) MD1985” manufactured by Toyobo Co., Ltd. The mixture was mixed so that the ratio was 9: 1, and 8% by weight of PSM black 14522 manufactured by Mikuni Dye Co., Ltd. was added as a black pigment and stirred. Table 1 shows the components and characteristics of “Vaironal (registered trademark) MD1985”. The mixed solution was applied to the elastic network structure by a shower method, and then pressurized air was blown to remove excess aqueous emulsion. And it was made to dry with an 80 degreeC drying machine for 30 minutes, and the resin-processed elastic network structure colored black was obtained. The obtained resin-processed elastic network has a thickness retention ratio of 97% before and after 80,000 repeated compression tests, and a reduction rate of compression hardness at 50% compression before and after 80,000 repeated compression tests is 5%. Met. From the weight comparison, the adhesion amount of the resin was 5%.

  The texture of the obtained elastic network structure was soft, non-sticky, and colored spots were not noticeable. A bed mattress was formed by combining three elastic net-like structures in a 21-cm sheet. I lay down on the mattress and did not itch when I moved.

<Example 5>
To a water-based emulsion obtained by diluting “Vaironal (registered trademark) MD1985” manufactured by Toyobo Co., Ltd. with water so that the solid content concentration becomes 27%, PSM Red FGR manufactured by Mikuni Dye Co., Ltd. as a red pigment is 0.005. Weight% was added and stirred. The mixture was applied to the elastic network obtained in the same manner as in Example 1 by the dipping method, and then squeezed with a pressure roller to remove excess aqueous emulsion. And it was made to dry for 30 minutes with an 80 degreeC dryer, and the resin-processed elastic network structure colored in red was obtained. The obtained resin-processed elastic network has a thickness retention ratio of 98% before and after repeated compression tests of 80,000 times, and a reduction rate of compression hardness at 50% compression before and after repeated tests of 80,000 times is 3%. Met. From the weight comparison, the adhesion amount of the resin was 6%.

  Since the polyester-based softener was not added, the texture of the obtained resin-processed elastic network structure was slightly hard, but there was no stickiness and the colored spots were not noticeable. Only the elastic network structure was inserted into the pillow cover to obtain a pillow. When I put my head on it and moved it, there was no itch.

<Comparative Example 1>
The “vironal (registered trademark) MD1480”, the polyester softener “EX200A” and the pigment were not applied to the elastic network, and the raw elastic network obtained in Example 1 was inserted into the pillowcase. It was a pillow. When I put my head on it and moved it, I heard a creaking sound. The thickness retention before and after the 80,000 repeated compression test of the raw elastic network structure was 96%, and the reduction ratio of the compression hardness at the time of 50% compression before and after the 80,000 repeated compression test was 13%. .

<Comparative example 2>
Hexane, hexene, and ethylene are polymerized by a known method using a metallocene compound as a catalyst, and the obtained ethylene / α-olefin copolymer (specific gravity 0.923 g / cm ³ ) is applied to a nozzle effective surface having a width of 50 cm and a length of 5 cm. Made of stainless steel with a width of 60 cm, melted at a temperature 40 ° C. higher than the melting point of the thermoplastic elastic resin from a nozzle in which orifices with a hole diameter of 1.5 mm are arranged at an interval of 5 mm between holes, and cooling water is arranged 30 cm below the nozzle surface. A pair of take-up conveyors are arranged parallel to each other on the surface of the water at intervals of 5 cm in parallel with an endless net, and the contact part is fused and the both sides are sandwiched between both sides, and the temperature is 25 ° C. at a speed of 1 m / min. The elastic network structure having a density of 0.03 g / cm ³ obtained by flattening the surface obtained by drawing into water and solidifying and cutting to a length of 1 m was obtained. The fineness of the linear body of the elastic network structure was 1600 dtex. The obtained elastic network structure was subjected to post-processing similar to that in Example 1. However, the drying temperature was 40 ° C. Before and after the repeated compression test of 80,000 times, the reduction rate of compression hardness at 50% compression was as high as 15%, and the resin applied in the post-processing was peeled off and peeled off when compression and release were repeated.

<Comparative Example 3>
The raw elastic network structure obtained in Example 1 was similarly dipped using a urethane-based emulsion adhesive, and then the excess drug was shaken off from the network structure, heat-treated at 150 ° C. for 30 minutes, and dried. At the same time, it was cured. In drying, the odor that seems to be of urethane resin was strong, which hindered work. At this time, the thickness retention ratio of the obtained resin-processed elastic network structure before and after the 80,000 repeated compression test was 98%, and the reduction ratio of the compression hardness at the time of 50% compression before and after the 80,000 repeated compression test. Was 3%. From the weight comparison, the adhesion amount of the resin was 5.6%.

  The resulting resin-processed elastic network structure was soft, but also had a sticky feeling. When evaluated as a mattress, a slight squeaking sound was heard.

<Comparative example 4>
The raw elastic network structure obtained in Example 1 was dipped in the same manner using a solution obtained by diluting a vinyl acetate emulsion adhesive (woodwork bond) with water twice, and then naturally dried. At this time, the obtained resin-processed elastic network structure has a thickness retention ratio of 96% before and after repeated compression tests of 80,000 times, and a reduction ratio of compression hardness when compressed by 50% before and after repeated tests of 80,000 times. Was 8%. The adhesion amount of the resin was 4.6%.

  The adhesive applied to the surface of the obtained resin-processed elastic network structure had noticeable uneven spots and was damped, and was easily peeled off to give a poor finish. The mute effect could not be confirmed.

<Comparative Example 5>
The raw elastic network structure obtained in Example 1 was subjected to resin processing using a chloroprene rubber-based adhesive, but the viscosity of the drug was high and a solution diluted twice with toluene was used. However, since the odor of the solvent was too strong and the operation was extremely difficult, the elastic network structure was cut into 30 cm square, dipped in a draft, and naturally dried. At this time, the thickness retention ratio of the obtained resin-processed elastic network structure before and after the 80,000 repeated compression test was 98%, and the reduction ratio of the compression hardness at the time of 50% compression before and after the 80,000 repeated compression test. Was 3%. The adhesion amount of the resin was 3.8%.

It can be suitably used for bedding including an elastic net-like structure that has excellent durability and cushioning properties and is less likely to be stuffy, and particularly has reduced sound during compression and recovery.

Claims (4)

  A tertiary formed by twisting continuous linear bodies of polyester copolymer having a fineness of 300 dtex or more to form a random loop, bringing the respective loops into contact with each other in a molten state, and fusing most of the contact portions. A bedding using a polyester-based elastic network structure, which is an original random-loop bonded structure, in which a polyester-based resin is attached to the surface of a random loop, at least in part.   The bedding according to claim 1, wherein the thickness retention before and after the repeated compression test of 80,000 times is 90% or more.   The bedding according to claim 1, wherein the polyester-based resin containing 0.01 to 10% of pigment is adhered to the surface of the random loop in an amount of 2 to 15% by weight. The method for producing a bedding according to any one of claims 1 to 3, wherein the polyester-based resin is attached to the elastic network structure as a water-based emulsion and dried at 0 to 150 ° C.