KR101415920B1 - High elastic cushion and method of fabricating the same - Google Patents

Abstract

The present invention relates to a hollow polyester fiber having a hollow ratio of 10 to 40%, an elastic composite fiber comprising a polyester-based elastomer or a polyurethane-based elastomer and a polyester-based polymer, a low-melting-point polyester-based elastomer having a melting point of 120 to 180 캜, And a non-woven fabric made of a low-melting-point elastic composite fiber made of a high-molecular-weight polymer. The present invention also relates to a method for producing the same.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a high elastic cushion material,

The present invention relates to an environmentally friendly elastic cushioning material and a method for producing the same, and more particularly, to an elastic cushioning material having excellent shape stability and durability using a conjugate fiber and a method for producing the same.

Generally, polyurethane foam (commonly referred to as "sponge ") is the most widely used material for cushioning materials used in daily life, and is widely used because of its lightness, elasticity and cost. However, the polyurethane foam foamed with the polyurethane resin spontaneously has a peculiar smell, yellowing occurs with time, deterioration of elasticity due to corrosion of the foamed cell itself, generation of dust, and difficulty in recycling there was.

Therefore, although much attention has been paid to the material to replace the polyurethane foam, a material showing a satisfactory effect has not been presented yet.

Korean Patent Laid-Open Publication No. 1990-8073 discloses a fiber-forming polymer having a melting point of 100 ° C to 220 ° C and having at least one hollow continuous with the fiber axis, wherein the hollow fiber has a hollow ratio of 5-80% A thermally adhesive fiber having a single fiber fineness of 0.5-30 denier and having a number of crimps of 3 to 40 fibers per inch and a fiber length of 10 to 150 mm has been proposed. However, the fiber is insufficient in elasticity, .

Korean Patent No. 908340 discloses that 10 to 70% by weight of a polyester conjugate fiber, 10 to 70% by weight of a polyester conjugate fiber surface-treated with an oil added with silicone, 10 to 70% by weight of a low-melting-point heat-sealable binder fiber and 10 to 70% by weight of a core-sheath type composite fused fiber of polyester or polystyrene, wherein the respective materials are mixed and carded to form a web Next, the laminated web is joined by a method of needle punching using a needle having a barb to form a sheet, the sheet is passed through a dry box and a heating roller, The present invention relates to a high-elasticity nonwoven fabric which is produced by mixing two types of conjugate fibers and heat-sealable binder fibers, Adjuster repeat durability of the elastic structure is dropped when using large and the possibility of the elastic recovery and resilience depression, sense of touch of the surface there is a risk that large differences in the polyurethane foam.

Korean Patent Laid-Open Publication No. 2008-80144 discloses a molded product obtained by thermoforming a fiber spherical body in a mold, wherein the fiber spherical body has a melting point lower than the melting point of the non-elastic polyester and the inelastic polyester by 40 占 폚 or more , Wherein the inelastic polyester is exposed so as to occupy 25 to 49% of the surface of the composite staple fiber, and (b) a staple fiber comprising a polytrimethylene terephthalate staple fiber and an elastic thermoplastic elastomer And a part of its fiber inter-woven points is thermally adhered at a flexible open / close place. However, since a special equipment for forming a spherical body is required, an increase in manufacturing cost is incurred do.

In addition, when the nonwoven fabric is simply laminated with the existing single-fiber fibers and heat-treated and then taken out of the molding frame, there is a disadvantage that the surface touch of the nonwoven fabric is hard.

In addition, Korean Patent No. 896214 discloses a process for producing a multi-layer nonwoven fabric comprising a single-spun nonwoven fabric and a long-spun nonwoven fabric; Attaching the multi-layer nonwoven fabric composed of the single-fiber nonwoven fabric and the long-fiber nonwoven fabric to the adhered portion of the upper body, attaching the single-fiber nonwoven fabric to the adhesive portion and positioning the long-fiber nonwoven fabric downward; Supplying a foamed liquid to a lower body that is downwardly separated from the upper body; And the foaming liquid supplied to the lower body is foamed to produce a sheet foam pad, wherein the foaming liquid is not impregnated with the multi-layer nonwoven fabric due to the long fibrous nonwoven fabric when foaming the foaming liquid. However, the long fiber nonwoven fabric constituting the multi-layer nonwoven fabric should have a smaller fiber diameter and a smaller unit weight (weight per unit area) than the short fiber nonwoven fabric.

Therefore, in order to improve the applicability and economical efficiency as a cushion cover pad, an inner skin material of a vehicle interior material, a mattress of a bedding material, a pad for a cushion, a padding material of a ski suit or a winter clothing, It is required to develop a material having a high softness and high durability while exhibiting a soft touch with a light weight per unit weight.

In order to solve the above problems, it is an object of the present invention to provide a high-elastic cushioning material which is light in weight and soft, yet excellent in rebound resilience, shape stability and durability, and a method for manufacturing the same.

Further, the present invention provides a highly elastic cushioning material in which the elasticity of the cushioning material is maintained not only at the initial elasticity of the cushioning material due to the rigidity of the polyester but also at the time of long-term use, and a method for manufacturing the same.

In order to achieve the above object, the present invention is characterized in that the content of the hollow polyester fibers having a hollow ratio of 10 to 40% is defined as A, the content of the elastic composite fiber composed of the polyester elastomer or the polyurethane- C: 10 to 70:20 to 80: 5 to 20 (weight) of a low-melting-point elastic composite fiber composed of a low-melting polyester elastomer and a polyester- A: B: C = 25 to 50%, wherein the uppermost layer comprises a nonwoven fabric consisting of a nonwoven fabric consisting of A: B: C = 20 to 80:10 to 70: 5 to 20% Wherein the nonwoven fabric comprises an innermost layer comprising a nonwoven fabric consisting of 55:25 to 55:10 to 40% by weight and a nonwoven fabric consisting of A: B: C = 10 to 70:20 to 80: 5 to 20 (% Wherein the cushioning material is laminated on the outermost layer.

Also, the elastic composite fiber and the low melting point elastic composite fiber are fibers selected from the group consisting of a side-by-side type, a sheath-core type, and an eccentric sheath-core type.

Further, the high-elasticity cushioning material satisfies all of the following expressions.

1) Each layer of the uppermost outermost layer and the bottom outermost layer is B> A> C

2) The upper middle layer is A> B> C

3) C of each layer of the uppermost outermost layer and the lowermost outermost layer C

4) C in the upper middle layer C

The high elastic cushioning material may further comprise a lower intermediate layer between the innermost layer and the lowermost outermost layer and including a nonwoven fabric of A: B: C = 20 to 80:10 to 70: 5 to 20 (wt%) Thereby providing a highly elastic cushioning material.

Further, the elastic cushioning material satisfies all of the following expressions.

1) Each layer of the uppermost outermost layer and the bottom outermost layer is B> A> C

2) The upper middle layer is A> B> C

3) C of each layer of the uppermost outermost layer and the lowermost outermost layer C

4) C in the upper middle layer C

5) The lower middle layer is A> B> C

6) C in the lower middle layer C

Further, the hollow polyester fiber has a strength of 2 to 5 g / d, an elongation of 30 to 60%, a compressibility of 10 to 50%, and a compression recovery rate of 80 to 100%.

The low melting point polyester elastomer is formed of an acid component and a diol component, wherein the acid component is a mixture of 70 to 90 mol% of terephthalic acid or dimethyl terephthalate and 10 to 30 mol% of isophthalic acid or dimethyl isophthalate, Wherein the diol component is a mixture of 80 to 95 mol% of 1,4-butanediol and 5 to 20 mol% of poly (tetramethylene ether) glycol.

The nonwoven fabric layers included in the layers of the uppermost outermost layer, the uppermost intermediate layer, the innermost layer, the lower intermediate layer, or the lowermost outermost layer have a thickness of 5 to 50 mm, and each layer has a multi- The cushioning material has a thickness of 100 to 200 mm.

Further, the present invention is characterized in that the content of the hollow polyester fibers having a hollow ratio of 10 to 40% is defined as A, the content of the elastic composite fiber composed of a polyester-based elastomer or a polyurethane-based elastomer and a polyester- C: 10 to 70:20 to 80: 5 to 20 (weight of the uppermost outermost layer) of the low melting point elastic composite fiber composed of the low melting point polyester elastomer and the low melting point elastic composite fiber composed of the polyester- B: C = 20 to 80:10 to 70: 5 to 20 (weight%) and the innermost layer as A: B: C = 25 to 55:25 to 55:10 to 40 A fiber mixing step of forming a fiber mixture by mixing the fibers constituting each layer with a lower outermost layer of A: B: C = 10 to 70: 20 to 80: 5 to 20 (% by weight); A non-woven fabric manufacturing step of producing a respective non-woven fabric by subjecting the fiber mixture contained in each layer to carding and heat treatment; A step of laminating each of the nonwoven fabrics in the order of an uppermost outermost layer, an uppermost intermediate layer, an innermost layer, and a lowermost outermost layer, The present invention also provides a method of manufacturing a high-elastic cushioning material.

The present invention also provides a method of manufacturing a highly elastic cushioning material, wherein the elastic composite fiber and the low melting point elastic composite fiber are fibers selected from the group consisting of a side-by-side type, a sheath-core type, and an eccentric sheath-core type .

Further, in the fiber mixing step, the lower intermediate layer may be further comprised between the innermost layer and the lowermost outermost layer in a ratio of A: B: C = 20 to 80: 10 to 70: 5 to 20 (wt%

Further, the present invention provides a method of manufacturing a high-elasticity cushioning material, wherein the intermediate layer is further laminated between the innermost layer and the bottom outermost layer in the lamination molding step.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. First, it should be noted that, in the drawings, the same components or parts have the same reference numerals as much as possible. In the following description of the present invention, a detailed description of known functions and configurations incorporated herein will be omitted so as to avoid obscuring the subject matter of the present invention.

The terms "about "," substantially ", etc. used to the extent that they are used herein are intended to be taken to mean an approximation of, or approximation to, the numerical values of manufacturing and material tolerances inherent in the meanings mentioned, Accurate or absolute numbers are used to help prevent unauthorized exploitation by unauthorized intruders of the referenced disclosure.

FIG. 1 is a cross-sectional view of a high-elasticity cushioning material according to a preferred embodiment of the present invention, and FIG. 2 is a view illustrating a manufacturing process of a high-elasticity cushioning material according to an exemplary embodiment of the present invention.

1 is a sectional view of a highly elastic cushioning material according to a preferred embodiment of the present invention. 1, the high-elasticity cushioning material of the present invention is composed of hollow polyester fibers, polyester-based elastomers or elastic composite fibers composed of a polyurethane-based elastomer and a polyester-based polymer, a low-melting-point polyester-based elastomer and a polyester- (A) the high-elasticity cushioning material 110 is laminated on the uppermost outermost layer 11, the upper intermediate layer 31, the innermost layer 50 and the lowermost outermost layer 13, or (b) the high-elasticity cushioning material 130 is laminated on the innermost layer 50 (The uppermost outermost layer 11, the upper intermediate layer 31, the innermost layer 50, the lower intermediate layer 33, and the lower outermost layer 13) so that the lower intermediate layer 33 is further included between the uppermost outermost layer and the lower outermost layer 13, And elasticity, the upper middle layer or the lower middle layer provides cushioning and light weight, and the innermost layer provides shape stability.

The high-elasticity cushioning material of the present invention comprises 5 to 80% by weight of a hollow polyester fiber having a hollow ratio of 20 to 60%, 5 to 80% by weight of a polyester-based elastomer or an elastomeric composite fiber composed of a polyurethane- A nonwoven fabric comprising 5 to 80% by weight of a low melting point elastic composite fiber composed of a low melting point polyester elastomer and a polyester polymer at 180 DEG C is laminated on the uppermost outermost layer 11, the upper intermediate layer 31, the innermost layer 50, The nonwoven fabric of each layer may be configured differently depending on the mixing ratio or the content of the hollow polyester fiber, the elastic conjugate fiber and the low-melting elastic composite fiber so that the characteristic of each fiber is highlighted.

In addition, the high-elasticity cushioning material of the present invention further includes a lower intermediate layer 33 between the innermost layer 50 and the lowermost outermost layer 13, so that the rebound resilience of the cushioning material can be further enhanced.

In the present invention, since the low melting point elastic composite fiber contained in the nonwoven fabric is used to adhere the fibers and the nonwoven fabric to each other without using an adhesive containing an organic solvent or the like, they are thermally adhered to each other so that the environmentally friendly high elasticity Cushioning material is provided.

First, a hollow polyester fiber having a hollow ratio of 10 to 40% can produce a product that is lighter than a product that does not include a hollow fiber due to hollow fiber, and exhibits high elasticity. It is manufactured by spinning using two to six leaf hollow nests and mainly using three leaf hollow nests. The hollow ratio can be calculated according to the following equation.

Hollowness (%) = cross-sectional area of the hollow section / shear area of the fiber (including cross-sectional area of the hollow section) X 100

The hollow polyester fiber of the present invention has a hollow ratio of 10 to 40%, preferably 30 to 40%. If the hollow ratio is less than 10%, the cross-sectional size of the fiber becomes large, and the elasticity is low, so that the buffering property may not be exhibited. If it is more than 40%, the properties such as strength and elongation of the fiber are lowered, There is a problem to lose. The hollow polyester fiber of the present invention is suitable for exhibiting elasticity while maintaining the strength required to have a strength of 2 to 5 g / d, an elongation of 30 to 60%, a compression rate of 10 to 50%, and a compression recovery rate of 80 to 100%.

The elastic composite fiber is a fiber composed of a polyester-based elastomer or a polyurethane-based elastomer and a polyester-based polymer.

The polyester-based elastomer is preferably a polyester-based elastomer having an intrinsic viscosity of 1.0 to 1.7 (dl / g), and the polyester-based polymer is a polyester-based polymer having an intrinsic viscosity of 0.5 to 1.0 (dl / g) It would be preferable to use it.

The polyurethane-based elastomer may be any of polyurethane-based elastomers prepared from fibers, which is a polymer compound bonded with an urethane bond formed by bonding an alcohol group and an isocyanate group.

The polyester-based elastomer may be an elastomer such as a polyester elastomer or a polyetherester elastomer whose elasticity is enhanced through copolymerization. Examples of the polyester-based elastomer include polytrimethylene terephthalate and polybutylene terephthalate whose intrinsic viscosity of the polyester resin is adjusted to 1.0 to 1.7 Terephthalate, and polyethylene terephthalate may be selectively used. The polyester-based polymer having an intrinsic viscosity of 0.5 to 1.0 may be polyethylene terephthalate which is generally manufactured and sold.

The low-melting-point elastic composite fiber is a fiber composed of a low-melting-point polyester-based elastomer and a polyester-based polymer having a melting point of 120 to 180 ° C. Even if the heat treatment is performed at a lower temperature than that of a general polyester having a degree of similarity, it has similar physical properties and can be subjected to a low temperature heat treatment, thereby reducing the heat treatment cost for subsequent fusion. If the melting point is lower than 120 ° C, there is a fear that the heat resistance of the product is lowered. When the melting point exceeds 180 ° C, the heat treatment cost is not reduced.

The low melting point polyester-based elastomer having a melting point of 120 to 180 DEG C is obtained by reacting terephthalic acid (TPA), isophthalic acid (TPA) having a -COOH or -COOR (R is an alkyl group or an arylalkyl group of C1 to C10) Poly (tetramethylene ether) glycol (PTMG), 1,4-butanediol, 1,4-butanediol, 1,4-butanediol, 1,4-butanediol, 1,4-cyclohexanedimethanol, -Butanediol (1,4-BD), and ethylene glycol (EG), and has a heat-sealable property by heating and pressing, and at the same time has high elasticity And has a recovery rate.

The acid component constituting the low melting point polyester elastomer is a mixture of 70 to 80 mol% of terephthalic acid or dimethyl terephthalate and 20 to 30 mol% of isophthalic acid or dimethyl isophthalate, and the diol component is 80 to 95 mol% 1,4-butanediol, 5-20 mole% poly (tetramethylene ether) glycol and ethylene glycol (EG).

When the content of isophthalic acid or dimethylisophthalate in the acid component constituting the low melting point polyester elastomer is less than 20 mol%, the melting point of the elastomer rises and the heat treatment temperature of the nonwoven fabric generally ranges from 180 to 190 DEG C, Min, the adhesion between the fibers may not be sufficiently achieved, and the morphological stability of the nonwoven fabric may be deteriorated. On the other hand, if it exceeds 30 mol%, the melting point of the elastomer becomes too low and the possibility of occurrence of deterioration during high- The specific gravity of the amorphous region in the elastomer is high, and there is a possibility that the possibility of deformation at room temperature and the storage property are lowered due to low Tg. When the content of poly (tetramethylene ether) glycol in the diol component is less than 5 mol%, the specific gravity of the hard segment in the elastomer may be high and the elasticity of the composite fiber may be deteriorated. On the other hand, , The strength of the composite fibers may be lowered, resulting in poor processability and shape stability after the nonwoven fabric.

As described above, the elastic conjugate fiber and the low-melting-point elastic conjugated fiber used in the present invention are composed of two components, and the difference in intrinsic viscosity of the fiber and the polymer or the subsequent heat treatment process conditions, And the structural elasticity in the staple fiber state is manifested by the expression, and the chemical structural elasticity and the elastic recovery rate are manifested by the structure of the hard segment and the soft segment of the thermoplastic polyester elastomer.

The elastic conjugate fiber and the low melting point elastic conjugated fiber may be of the side-by-side type, the sheath-core type, and the eccentric sheath-core type.

Preferably, the elastic composite fiber is formed as a side-by-side type, and the low-melting-point elastic composite fiber is formed as an eccentric sheath-core type.

The elastic composite fiber preferably exhibits excellent elasticity with a strength of 2 to 7 g / d, an elongation of 30 to 80%, a crimp number of 10 to 15, a crimp degree of 10 to 20, a shrinkage rate of 2 to 15% and a fiber length of 10 to 150 mm .

Wherein the low melting point elastic composite fiber has a melting point of 120 to 180 ° C, an intensity of 2 to 6 g / d, an elongation of 20 to 80%, a crimp number of 5 to 15, a crimp degree of 10 to 20, and a shrinkage ratio of 2 to 10% It is good for maintaining shape stability, light weight, soft touch.

Further, the present invention is characterized in that the hollow polyester fiber has a thickness of 4 to 15 And the low-melting-point elastic conjugate fiber has a denier of 2 to 15 deniers, and the low-melting-point elastic conjugate fiber has a denier of 2 to 15 denier. The elasticity and strength of the final product are good and the soft touch is exhibited. When the thickness is less than the above range, the strength and elongation of the fiber are lowered. If the thickness is more than the above range, the weight of the final product is too large and the surface touch may become rough.

The present invention is characterized in that the content of the hollow polyester fibers having a hollow ratio of 10 to 40% is defined as A, the content of the elastic composite fiber composed of a polyester-based elastomer or a polyurethane-based elastomer and a polyester-based polymer is defined as B, When the content of the low melting point elastic composite fiber composed of the melting polyester series elastomer and the polyester series polymer is C,

An upper outermost layer 11 composed of A: B: C = 10 to 70: 20 to 80: 5 to 20 (wt%);

An upper intermediate layer 31 composed of A: B: C = 20 to 80: 10 to 70: 5 to 20 (wt%);

An innermost layer 50 composed of A: B: C = 25 to 55: 25 to 55: 10 to 40 (wt%);

A lower outermost layer 13 composed of A: B: C = 10 to 70: 20 to 80: 5 to 20 (% by weight);

Strength, and durability of the high-elasticity cushioning material 100 laminated with the elastic material. If the thickness is out of the above range, the elasticity of each layer does not coincide and only the characteristic of any one of the fibers may be highlighted, so that the elasticity can not be applied to the cushioning material because the elasticity and strength are not supported.

The present invention further includes a lower intermediate layer 33 made of A: B: C = 20 to 80: 10 to 70: 5 to 20 (weight%) between the innermost layer 50 and the lowermost outermost layer 13, .

In the present invention, the hollow polyester fibers and the elastic composite fibers have higher contents than the low-melting-point elastic conjugated fibers serving as heat-sealable binders in the respective layers of the uppermost outermost layer, the lowermost outermost layer and the uppermost intermediate layer or the lower intermediate layer And exhibits an effect of increasing the elasticity, and the content of the low melting point elastic conjugated fiber in the innermost layer is high, thereby stably adhering to the applied substrate, thereby improving the shape stability.

More preferably, the high-elasticity cushioning material of the present invention is characterized by satisfying all the following expressions.

1) The upper outermost layer 11 or the lower outermost layer 13 has B> A> C

2) The upper middle layer 31 is A> B> C

3) C of the uppermost outermost layer 11 or the lowermost outermost layer 13 C of the innermost layer 50

4) C of the upper intermediate layer 31 C

In addition, when the high-elasticity cushioning material of the present invention further includes a lower intermediate layer, it is characterized by satisfying all of the following expressions.

1) Each layer of the uppermost outermost layer or the bottom outermost layer is B> A> C

2) The upper middle layer is A> B> C

3) C of each layer of the uppermost outermost layer or lower outermost layer C

4) C in the upper middle layer C

5) The lower middle layer is A> B> C

6) C in the lower middle layer C

Therefore, when the cushioning material is applied as a cushioning material to the uppermost outermost layer or the lowermost outermost layer by increasing the content of the elastic composite fibers, the surface of the uppermost outermost layer or the lowermost outermost layer is softened, The weight of the entire cushioning material is reduced by increasing the content of the polyester fiber, and the cushion feeling is enhanced. In addition, since the low-melting-point elastic composite fiber serving as a thermally fusible binder is contained in each layer of the uppermost outermost layer, the lowermost outermost layer, the upper intermediate layer, or the lower intermediate layer in a higher content than the innermost layer, As a high-elastic cushioning material.

In addition, for the required physical properties, it is preferable to adjust the ratio of each fiber within the above-mentioned range in accordance with the application.

The hollow polyester fiber, the elastic conjugate fiber and the low-melting-point elastic conjugate fiber of the present invention can be easily produced by a conventional nonwoven fabric manufacturing facility, To be applied to various applications. The thickness of each nonwoven fabric of each layer of the uppermost outermost layer, the uppermost intermediate layer, the innermost layer, the lower intermediate layer, and the lowermost outermost layer of the present invention is preferably in the range of 5 to 50 mm for exhibiting elasticity and buffering properties. There is a possibility that the elasticity effect is weakened when pressed by a hand, and when it is more than 50 mm, the heat stability of the nonwoven fabric is difficult due to the heat transfer to the inside. In particular, each layer may be composed of one layer of nonwoven fabric constituting each layer, but may be composed of various layers. Each of the upper intermediate layer or the lower intermediate layer is composed of more layers than the respective layers of the uppermost outermost layer or the lower outermost layer and is composed of more layers than the innermost layer, The cushioning material which is thicker than the thickness of the outermost layer of each of the lower outermost layers and thicker than the thickness of the innermost layer increases the content of the hollow fibers so that the weight of the cushioning material becomes lighter and the rebound resilience also excellently exerts.

In addition, the high-elasticity cushioning material of the present invention is characterized in that the non-woven fabric having a thickness of 5 to 50 mm in each layer is composed of a plurality of layers having a total thickness of 100 to 200 mm, And is particularly preferable when it is applied to an automotive seat, but the application is not limited thereto.

2 is a view illustrating a manufacturing process of a highly elastic cushioning material according to a preferred embodiment of the present invention. Referring to FIG. 2, the high-elastic cushioning material of the present invention can be manufactured including a fiber mixing step S100, a nonwoven fabric manufacturing step S200, and a lamination forming step S300. The high-elasticity cushioning material of the present invention can be manufactured easily by controlling the fiber mixing ratio and the heat treatment temperature without using a new apparatus and manufacturing the nonwoven fabric by using a conventional apparatus for producing a nonwoven fabric, So that the cushioning material of the present invention can be used in various applications.

More specifically, in the fiber mixing step S100, the content of the hollow polyester fibers having a hollow ratio of 10 to 40% is defined as A, the content of the elastic composite fiber composed of the polyester-based elastomer or polyurethane-based elastomer and the polyester- , And a low-melting-point elastic composite fiber composed of a low-melting-point polyester-based elastomer and a polyester-based polymer having a melting point of 120 to 180 ° C,

And the uppermost outermost layer is A: B: C = 10 to 70: 20 to 80: 5 to 20 (% by weight)

The upper intermediate layer was formed by mixing A: B: C = 20 to 80:10 to 70: 5 to 20 (% by weight)

And the innermost layer was A: B: C = 25 to 55:25 to 55:10 to 40 (wt%),

And the lower outermost layer is composed of A: B: C = 10 to 70:20 to 80: 5 to 20 (% by weight), and the fibers constituting each layer are mixed to form a fiber mixture to adjust the mixing ratio to meet the required physical properties Followed by mixing to produce a short fiber mixture. Further, in the fiber mixing step, a lower intermediate layer is further included between the innermost layer and the lower outermost layer in a ratio of A: B: C = 20 to 80: 10 to 70: 5 to 20 (weight% .

Next, in the nonwoven fabric manufacturing step S200, the fiber mixture contained in each of the layers is subjected to heat treatment at 80 to 200 DEG C after carding, and the nonwoven fabric manufacturing step of each layer is progressed. The heat treatment is performed at the above temperature by a conveyor belt method It is preferable that the nonwoven fabric manufacturing step is carried out by heat treatment and the heat treatment is performed again on the final roller. It is preferable that the temperature is maintained so as not to lower the physical properties of each fiber and maintain the tactile sensation, It is good to make one drying.

Then, in the lamination molding step S300, the respective nonwoven fabrics are laminated in the order of the uppermost outermost layer, the upper intermediate layer, the innermost layer and the lower outermost layer, and in the fiber mixing step, the lower intermediate layer is defined as A: B The uppermost layer, the uppermost intermediate layer, the innermost layer, the lower intermediate layer, and the lowermost outermost layer in the order of C = 20 to 80: 10 to 70: 5 to 20 (weight% The cushioning material of the present invention can be manufactured in various forms by using a molding frame that is in conformity with the required shape.

As described above, the high-elasticity cushioning material of the present invention is an elastic cushioning material comprising a hollow polyester fiber, a polyester-based elastomer or an elastomeric composite fiber composed of a polyurethane-based elastomer and a polyester-based polymer, and a low- The nonwoven fabric of which the content of the melting point elastic composite fiber is adjusted to the characteristics of each fiber is manufactured for the outermost layer, the intermediate layer and the innermost layer, and the nonwoven fabric of each layer is laminated, Shape stability and durability are excellent.

Further, the high-elasticity cushioning material of the present invention has various mixing ratios of the fibers constituting the outermost layer, the intermediate layer and the innermost layer in various layers, so that the properties of the respective fibers are easily controlled so that they can be variously applied There is an effect that can be done.

The high-elasticity cushioning material of the present invention has an effect of being applied to a cushioning material such as a cover sheet of a car seat, an inner skin material of a vehicle interior material, a mattress of a bedding material, a pad for a cushion, a braid wick, a ski suit or a padding material of a winter coat.

1 is a sectional view of a highly elastic cushioning material according to a preferred embodiment of the present invention;
2 is a view showing a process for manufacturing a high-elastic cushioning material according to a preferred embodiment of the present invention.

Hereinafter, embodiments of the high-elasticity cushioning material according to the present invention will be described, but the present invention is not limited to these embodiments.

Manufacturing example  One

45% by weight of hollow polyethylene terephthalate (PET) fiber (fiber A) having a fiber density of 8.0 denier, a strength of 3.3 g / d, an elongation of 51%, a compression ratio of 46%, a compression recovery rate of 91% (PET) having an intrinsic viscosity of 0.65 and a polyester elastomer (Elastomer) having an intrinsic viscosity of 1.5 and a denier of 3.5 g / d, an elongation of 70%, a shrinkage of 5%, a fiber length of 64 mm, and an eccentric side- Melting elastic hybrid fibers having a fiber length of 45 mm and a density of 5.5 denier, a strength of 3.5 g / d, an elongation of 75%, a number of crimp of 12.6, a crimp of 17.5, a shrinkage of 6.4% 10% by weight of the fibers C) were mixed and subjected to a carding process to produce a laminated web. The web was subjected to a needle punching process, followed by heat treatment in a conveyer belt method using hot air at 170 ° C. After passing through a final roller at 150 ° C, Cooled to a thickness of 15 mm and a weight of 330 g / Four were prepared.

Manufacturing example  2

A nonwoven fabric having a thickness of 15 mm and a weight of 290 g / m 2 was prepared in the same manner as in Production Example 1 by mixing 70 wt% of fibers A, 20 wt% of fibers B, and 10 wt% of fibers C.

Production Example 3

20% by weight of fibers A, 70% by weight of fibers B and 10% by weight of fibers C were mixed to prepare a nonwoven fabric having a thickness of 15 mm and a weight of 350 g / m 2.

Manufacturing example  4

35% by weight of fibers A, 35% by weight of fibers B and 30% by weight of fibers C were mixed to prepare a nonwoven fabric having a thickness of 15 mm and a weight of 410 g / m 2.

compare Manufacturing example  One

45% by weight hollow fiber polyethylene terephthalate (PET) fiber (fiber A) having a fiber size of 8.0 denier, a strength of 3.3 g / d, an elongation of 51%, a compression rate of 46%, a compression recovery rate of 91%, a hollow fiber ratio of 30% (PTT) having an intrinsic viscosity of 0.95 with a fiber length of 64 mm and a polyethylene terephthalate (PET) with an intrinsic viscosity of 0.52. A thermally fusible binder polyethylene terephthalate fiber having a fiber length of 45% by weight, a fineness of 4.5 denier, a strength of 3.6 g / d, an elongation of 40%, a crimp number of 9.4, a crimp ratio of 16.5, a shrinkage ratio of 6.4% C) were mixed and carded to produce a laminated web, which was subjected to a needle punching process, followed by heat treatment in a conveyor belt method at 170 ° C with hot air, passing through a final roller at 150 ° C, To a thickness of 15 mm and a weight of 330 g / m2 To prepare a non-woven fabric.

compare Manufacturing example  2

A nonwoven fabric having a thickness of 15 mm and a weight of 290 g / m 2 was prepared in the same manner as in Production Example 1 by mixing 70 wt% of fibers A, 20 wt% of fibers B, and 10 wt% of fibers C.

compare Manufacturing example  3

20% by weight of fibers A, 70% by weight of fibers B and 10% by weight of fibers C were mixed to prepare a nonwoven fabric having a thickness of 15 mm and a weight of 350 g / m 2.

compare Manufacturing example  4

35% by weight of fibers A, 35% by weight of fibers B and 30% by weight of fibers C were mixed to prepare a nonwoven fabric having a thickness of 15 mm and a weight of 410 g / m 2.

Example  One

The uppermost outermost layer in Production Example 1, the uppermost outermost layer in Production Example 3, the uppermost intermediate layer in Production Example 3, the innermost layer in Production Example 4 in three layers, and the single outermost layer in Production Example 2, The innermost layer and the bottom outermost layer were laminated in this order and placed in a mold for a car seat, followed by molding heat treatment at 200 ° C for 20 minutes to produce a high elasticity cushioning agent having a total thickness of 150 mm and a weight of 3.5 kg / m 2.

Example 2

Production Example 1 was divided into two layers, that is, the uppermost outermost layer, Production Example 3 had the upper half layer, Production Example 4 had the innermost layer, and Example 3 had the lower half layer. The uppermost layer, the upper middle layer, the innermost layer, the lower middle layer, and the lowermost layer were laminated in the order of the uppermost layer, the uppermost layer, the lowermostmost layer, and the molding layer for automobile sheet at 200 ° C for 20 minutes to have a total thickness of 150 mm and a weight of 3.8 kg / To prepare an elastic cushioning agent.

Comparative Example 1

Comparative Production Example 1 was divided into an uppermost outermost layer as the uppermost outermost layer, Comparative Production Example 3 as the upper intermediate layer, Comparative Production Example 4 as the innermost layer, Comparative Production Example 2 as one layer, , The upper middle layer, the innermost layer, and the lowermost outermost layer in this order, put in a mold for a car seat, and subjected to molding heat treatment at 200 ° C for 20 minutes to prepare an elastic cushioning agent having a total thickness of 150 mm and a weight of 3.5 kg / m 2.

compare Example  2

Comparative Preparation Example 1 was used as the uppermost outermost layer, Comparative Preparation Example 3 was used as the upper intermediate layer, Comparative Preparation Example 4 was used as the innermost layer, Comparative Preparation Example 3 was used as the lower intermediate layer, The uppermost layer, the upper middle layer, the innermost layer, the lower middle layer, and the lowermost outer layer were laminated in the order of the uppermost layer, the lowermost layer, and the uppermost layer. The laminate was then subjected to molding heat treatment at 200 ° C for 20 minutes, Thereby producing an elastic cushioning agent having a density of 3.8 kg / m 2.

* Test Methods

1) Rebound elastic modulus

: Measures the height of springs that rebound by dropping iron beads on a nonwoven sample at a constant height (ASTM D 3574).

2) Permanent compression strain

: A nonwoven fabric sample is compressed at a constant rate and stored at a constant temperature and humidity for a certain period of time, and then the deformed height is measured (ASTM D 3574).

3) Repeated compressive strain

: Repeatedly compressing a sample of nonwoven fabric of a certain size to measure the deformed hardness and thickness (KS K 6672).

division unit Example 1 Example 2 Comparative Example 1 Comparative Example 2 Rebound modulus % 60.2 62.7 50.0 54.5 Permanent compressive strain % 35.5 34.6 40.9 42.7 Repeated compressive strain % 6 5 11 11

As shown in Table 1, it can be seen that Examples 1 and 2 which are high-elastic cushioning materials according to the present invention have better rebound resilience than Comparative Examples 1 and 2, and Examples 1 and 2 have permanent compression strain and repeated compression It is understood that the deformation rate is smaller than that of Comparative Examples 1 and 2.

In addition, it can be seen that Example 2 is superior to Example 1 in the evaluation of the test, and the high-elastic cushioning material in which one layer is further added is superior.

110,130: High elasticity cushion 11: Upper outermost layer
31: upper intermediate layer 50: innermost layer
33: lower intermediate layer 13: lower outermost layer

Claims (11)

When the content of the hollow polyester fibers having a hollow ratio of 10 to 40% is defined as A, the content of the elastomeric composite fiber composed of the polyester elastomer or polyurethane elastomer and the polyester polymer is defined as B, a low melting point polyester having a melting point of 120 to 180 캜 When the content of the low-melting-point elastic composite fiber composed of the elastomer and the polyester-based polymer is C,
An upper outermost layer comprising a nonwoven fabric made of A: B: C = 10 to 70: 20 to 80: 5 to 20 (% by weight)
An upper intermediate layer comprising a nonwoven fabric consisting of A: B: C = 20 to 80: 10 to 70: 5 to 20 (% by weight)
A: B: C = 10 to 70: 20 to 80: 5 to 20 (% by weight), which comprises a nonwoven fabric comprising a nonwoven fabric consisting of A: B: C = 25 to 55:25 to 55:10 to 40 And a lower outermost layer including a nonwoven fabric made of a nonwoven fabric. The method according to claim 1,
Wherein the elastic composite fiber and the low melting point elastic composite fiber are fibers selected from the group consisting of a side-by-side type, a sheath-core type, and an eccentric sheath-core type. The method according to claim 1,
Wherein the high-elasticity cushioning material satisfies all of the following expressions.
1) Each layer of the uppermost outermost layer and the bottom outermost layer is B>A> C
2) The upper middle layer is A>B> C
3) C of each layer of the uppermost outermost layer and the lowermost outermost layer C
4) C in the upper middle layer C The method according to claim 1,
The high-elasticity cushioning material is provided between the innermost layer and the lowermost outermost layer
And a lower intermediate layer comprising a nonwoven fabric consisting of A: B: C = 20 to 80: 10 to 70: 5 to 20 (% by weight). 5. The method of claim 4,
Wherein the elastic cushioning material satisfies all of the following expressions.
1) Each layer of the uppermost outermost layer and the bottom outermost layer is B>A> C
2) The upper middle layer is A>B> C
3) C of each layer of the uppermost outermost layer and the lowermost outermost layer C
4) C in the upper middle layer C
5) The lower middle layer is A>B> C
6) C in the lower middle layer C The method according to claim 1,
Wherein the hollow polyester fiber has a strength of 2 to 5 g / d, an elongation of 30 to 60%, a compression rate of 10 to 50%, and a compression recovery rate of 80 to 100%. The method according to claim 1,
The low-melting-point polyester-based elastomer is formed of an acid component and a diol component,
Wherein the acid component is a mixture of 70 to 90 mol% of terephthalic acid or dimethyl terephthalate and 10 to 30 mol% of isophthalic acid or dimethyl isophthalate, the diol component is a mixture of 80 to 95 mol% 1,4-butanediol, 5 to 20 mol% Mol% of a poly (tetramethylene ether) glycol. The method according to claim 1 or 4,
The nonwoven fabric layers included in the layers of the uppermost outermost layer, the uppermost intermediate layer, the innermost layer, the lower intermediate layer, and the lowermost outermost layer are 5 to 50 mm in thickness, and each layer has a multi- 100 to 200 mm. When the content of the hollow polyester fibers having a hollow ratio of 10 to 40% is defined as A, the content of the elastomeric composite fiber composed of the polyester elastomer or polyurethane elastomer and the polyester polymer is defined as B, a low melting point polyester having a melting point of 120 to 180 캜 When the content of the low-melting-point elastic composite fiber composed of the elastomer and the polyester-based polymer is C,
And the uppermost outermost layer was A: B: C = 10 to 70:20 to 80: 5 to 20 (% by weight)
The upper intermediate layer was formed by mixing A: B: C = 20 to 80:10 to 70: 5 to 20 (% by weight)
And the innermost layer was A: B: C = 25 to 55:25 to 55:10 to 40 (wt%),
A fiber mixing step in which the lower outermost layer is composed of A: B: C = 10 to 70:20 to 80: 5 to 20 (weight%), and fibers constituting each layer are mixed to form a fiber mixture;
A non-woven fabric manufacturing step of producing a respective non-woven fabric by subjecting the fiber mixture contained in each layer to carding and heat treatment;
A step of laminating each of the nonwoven fabrics in the order of an uppermost outermost layer, an uppermost intermediate layer, an innermost layer, and a lowermost outermost layer,
Wherein the high elasticity cushioning material has a high elasticity. 10. The method of claim 9,
Wherein the elastic composite fiber and the low melting point elastic composite fiber are fibers selected from the group consisting of a side-by-side type, a sheath-core type, and an eccentric sheath-core type. 10. The method of claim 9,
Wherein the lower intermediate layer is further comprised of A: B: C = 20 to 80: 10 to 70: 5 to 20 (% by weight) between the innermost layer and the lowermost outermost layer in the fiber mixing step,
Further comprising a lower intermediate layer between the innermost layer and the lowermost outermost layer in the lamination molding step.

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