JP2002030556A - Fiber-molded wadding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a fiber-molded wadding to which protuberances have been imparted and which can give good touch and good durability. SOLUTION: This fiber-molded, sheet-like wadding comprising a fiber sheet layer in which many fibers constituting the wadding are arranged in a direction approximately vertical to the direction of the flat side of the sheet and are partially adhered to each other, characterized in that at least one side of the fiber sheet layer has discontinuously existing protuberances and base portions on the surface of the sheet, wherein the protuberances of the sheet layer are continued to the base portions, have smaller areas in the tip portions of the protuberances than the areas of the base portions of the protuberances and have a compression stress of >=0.3 Newton/cm2.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fiber-filling material excellent in cushioning property, sleeping comfort, sitting comfort and the like.
More specifically, mattresses used in hospitals and homes,
The present invention relates to a bedding such as a bedding, a pillow, a chair such as furniture, a seat of a vehicle, a ship, and the like, and a fiber molding insert used for a pad used in combination therewith.

[0002]

2. Description of the Related Art Conventionally, as a filling material which has been proposed or used, those using urethane foam, natural fibers or synthetic fibers are mainly used. In addition, a product having a surface that has been subjected to unevenness in order to further improve the usability has been popularly marketed. However, although a product composed of fibers having excellent breathability and practical feeling has been proposed, the convex portion is deformed or dropped off at the time of practical use.

[0003]

DISCLOSURE OF THE INVENTION The present invention solves these problems of the prior art and provides an inner material made of fiber,
It is an object of the present invention to provide a fiber molding filling material which is provided with a convex portion so that a good feeling of use and durability can be provided.

[0004]

The present invention employs the following means in order to solve the above-mentioned problems.

That is, a sheet-like insert made of fiber
And many of the constituent fibers are in the sheet plane direction.
The fibers are almost vertically aligned and the fibers partially adhere to each other
Fiber sheet layer, wherein the fiber sheet layer is at least
One surface is discontinuous on the sheet
The sheet layer has a convex portion and a base portion.
The part and the base part are continuous structures, and the convex part is the convex part top part.
The area of the bottom of the projection is larger than the area of
The compressive stress of the projection is 0.3 Newton / cm^Two Is over
It is a fiber molding insert.

[0006]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The insert of the present invention is composed of fibers, and many of the composed fibers are arranged substantially perpendicular to the sheet plane, while the fibers are partially bonded to each other. It is necessary.

The fibers used may be synthetic or natural fibers or a mixture of both. As such synthetic fibers, any of polyester, polyamide, acrylic, polypropylene, polyethylene and the like can be used, and as natural fibers, wool,
Cotton and hemp can be used. Among these fibers, polyester fibers are preferably used in terms of elasticity and sag.

[0008] When a product is required to absorb moisture, it is advisable to use a mixture of natural fibers having excellent moisture absorption properties and synthetic fibers having excellent elasticity and sag.

The fineness of the above-mentioned fiber is preferably 1 to
1000 dtex, more preferably 3 to 200 dte
The fiber x is preferably used from the viewpoints of hand, washability, elasticity and sag resistance. Such fibers may be either short fibers or long fibers, but when short fibers are used, preferably 10 mm or more, more preferably 30 to
Those having a fiber length of 100 mm are preferred.

The cross section of such a fiber is solid, hollow, T-shaped,
Various forms, such as flat, can be used. In the case of a fiber having crimps, the form can be any of a corrugated and spiral type, and can be used in any form such as an eclectic type of both. Fibers having a spiral crimp are preferably used from the viewpoint of sag resistance. In addition, the number of such crimps is insufficient in elasticity and hardness when the number is small, and causes trouble in processing when the number is too large.
200 peaks / 25 mm, more preferably 10 to 50 peaks /
25 mm is used.

It is necessary that the fibers constituting the fiber molded sheet are partially adhered to each other, and the kind of the adhesive used may be any of synthetic resin, rubber and the like.
The shape of the adhesive used may be any of a film, a particle, a liquid, and a fiber. Among these, synthetic resin,
And, a fibrous material is preferably used for processing or practical use, but a more preferable shape is polyester, and a composite fibrous material composed of a high melting polymer and a low melting polymer is used. Is preferred. As the composite form, a so-called core-sheath type, bimetal type, orange cross-sectional type, or the like can be used.

The mixing ratio of the fiber and the adhesive is preferably in the range of fiber: adhesive = 30: 70% by weight to 95: 5% by weight, more preferably 40: 60% by weight to 90: 10% by weight. Good. The mixing ratio of the adhesive is 5% by weight.
If it is less than 70%, adhesion may be insufficient, and the formability and form stability as a fiber molded sheet material tend to be inferior. If it exceeds 70% by weight, excessive adhesion may occur, resulting in a hard plate. It is not preferable because cushioning property (elasticity) tends to be inferior.

[0013] As the means for such adhesion, there are methods such as drying, pressure, heat and the like, and any method may be used. However, from the viewpoint of simplicity of processing, a melting method using heat is preferably used. 20 to 15 from the melting temperature of the fiber
It is preferred to use a 0 ° C. lower temperature adhesive.

Many of the fibers are arranged so that the fiber axis is substantially perpendicular to the plane direction of the inner material sheet layer.
Means for arranging in this manner include, for example, mixing the main constituent fibers and the adhesive fibers with a cotton blender, further blending and opening with a carding machine, and then reducing the fibers by a pin cylinder that rotates at a high speed. The obtained fiber mass can be obtained by a method in which the obtained fiber mass is packed in a container with high-pressure air, and the adhesive fiber is melted and solidified by heat.

It is necessary that the sheet layer constituting the insert material of the present invention has at least one surface having an independently present convex portion which is not continuous in all plane directions. As a result, the human body is supported by the convex portions, so that the human body has good air permeability, and does not get tired even after long use.

A method of obtaining such a convex portion is as follows. A fiber sheet having a flat thickness is passed through a pair of compression rollers having irregularities, and a central portion of the sheet in the thickness direction of the sheet is compressed by a band knife while the sheet is compressed. Can be obtained by so-called profile processing, which is obtained by cutting.

It is necessary that the convex portion has a larger base area than a vertex area. For example, it has a shape like an inverted mortar. As a result, the compression area gradually increases from the time the vertex is compressed,
The stress naturally rises, and it is possible to obtain the performance that the waist gradually comes out softly little by little.

The conventionally-produced foamed resin and fiber laminate product having an uneven surface is deformed immediately in a low load region when the convex portion is softened and compressed, and becomes the same height as the base portion. The present invention, by arranging the fibers in the compression direction, can utilize the countersinking torsional stress of the single fiber, support the human body without deforming to a high load area,
The ventilation and comfortable practical feeling can be obtained.

[0019] For this purpose, according to the findings of the present inventors, the compressive stress of the projections is required to be 0.3 Newtons / cm ² or more, the actual use is less than 0.3 Newtons / cm ² I can't feel the protrusions. On the other hand, 50
You may undesirably may feel the pain for too stiff if Newton / cm ² or more, more preferably from 0.5 to 10 Newtons / cm ^2.

The compression stress is measured according to JIS K64
According to a method according to 01 5.4 “Hardness test”, the thickness of the sample is measured at a base of 5 mm in addition to the height of the projection, the diameter of the pressure plate is 100 mm, and the compression speed of the pressure plate is 200 mm / min. The compression distance is expressed by the stress at this time when the sample is compressed to 5 mm leaving the base of the sample. When the thickness of the main part is less than 5 mm, the compression distance is measured by compressing while leaving the thickness of the base part corresponding to the thickness.

The height of the projection is preferably from 5 mm to 50 mm, and if it is less than 5 mm, the height of the projection is too low, so that the practical feeling and air permeability as described above cannot be obtained in practical use. When the thickness exceeds 50 mm, performance can be obtained, but it is not possible to use because the set of the convex portion becomes large and collapse occurs.

The height of the projections to the apex should be determined by the required thickness of various end products, and is not limited, but the thickness of the base layer that receives the projections is at least 5 mm.
mm is preferable, and as described above, the minimum height of the projection is 5 mm, and the minimum height up to the top of the projection including the base is preferably 10 mm. If it is less than 10 mm, structural destruction tends to occur, which is not preferable. The maximum height has a smaller technical constraint like the minimum height, and may be determined mainly based on the requirements of the product. However, it is realistic that the maximum height is about 200 mm from the viewpoint of cushioning property and economy.

The base and the projection are preferably continuous. Continuous means that the same material and the same structure are formed with continuity, and by doing so, even if used for a long time, only the convex portion or only the base portion will not be deformed, Processing is simple and cost reduction can be realized.

However, if the whole or a part of the convex portion of the sheet layer and the base portion are formed of different materials or structures, the performance can be exhibited depending on the purpose. For example, when a higher degree of softness and elasticity is desired to be imparted to the convex portion, it is also preferable to laminate the urethane foam and form only the convex portion or a part of the convex portion with the urethane foam. When this is compressed, the urethane foam in the convex portion reacts in the low load area, and the fiber layer reacts additionally at the high load, so that a product with more softness and hardness can be obtained. is there.

As the different material, for example, various materials having elasticity and thickness such as foamed resin, natural rubber or synthetic rubber can be used, and are not particularly limited. In addition, as a different structure, in addition to the above-described materials, a fiber structure in which constituent fibers are arranged in a plane or a fiber having a different fiber density can be used in an appropriate combination. For example, it is also preferable to combine with a sheet made of cellulose for products requiring water absorption and hygroscopicity.

The specific gravity of the sheet layer is preferably from 0.015 g / cc to 0.07 g / cc, and is preferably 0.015 g / cc.
If it is less than cc, it may be inferior to applications requiring durability and it is difficult to use. Also,
If it exceeds 0.07 g / cc, the weight becomes too large at the same time as being too hard, which is not preferable because it also has an adverse effect on cost. Particularly preferred specific gravity is 0.02 g / c.
It is 0.04 g / cc from c.

The number of protrusions may be 30 to 1000 / m ² , preferably 100 to 800 / m ² .

The sheet layer according to the present invention preferably has flexibility. For example, in a bed mat application used for nursing care, since the bed body generally has a function of improving careability by bending, it is required to favorably follow the bending of the bed body. You.

From such a point, it is preferable that the fiber filling material according to the present invention has a flexibility of 5 cm or more.
If the bendability is less than 5 cm, the bed cannot be bent as it is. In addition, bendability is also required for applications such as bedding, pats, and a chair having a reclining function. The larger the flexibility, the better, but if it is too large, it is difficult to handle, so it is preferably up to 25 cm.

As means for obtaining such flexibility, the fibers constituting the sheet layer are three-dimensionally arranged such that the fiber axes are arranged in a direction substantially perpendicular to the plane direction of the sheet as in the present invention. Thereby, it is possible to obtain good flexibility as if it were an accordion. For example, when the fibers are arranged in parallel with the sheet plane direction, the flexibility is poor.

The measurement of the flexibility is expressed by the distance at which the tip of a sample of 10 cm in width and 50 cm in length having an arbitrary thickness required as a product is protruded by 30 cm from the desk and the tip is hung down.

In practical use, a sheet layer having a convex portion made of fiber may be peeled off due to the bonding force between fibers and the arrangement direction of short fibers. Conventionally proposed ones have a strong tendency, and cannot be used for a long time. According to the findings of the present inventors, the tensile strength of the convex portion is at least 0.
5 Newton / cm ² is preferably located, 0.5 if less than Newton / cm ² is sometimes problems in terms of strength, more preferably 1 Newton / cm
² or more. The higher one is not critical, but generally about 10 Newton / cm ² is sufficient.

The tensile strength was measured according to JIS K
According to the method A of 5.2 of 6767 “Tensile strength and elongation”, the sample was sliced from the convex portion to a thickness of 10 mm, a width of 10 mm, and a length of 10 m or more, and the sample was pulled in the length direction at a grip interval of 10 mm. Find strength. When the width is less than 10 mm, the width is measured as 5 mm and the conversion is corrected. When the height is less than 10 mm, a sample including a base portion is used.

As a means for obtaining such strength, the fibers can be obtained by bonding the constituent fibers to each other and orienting the fiber axis in the direction from the bottom to the apex of the projection. Conventionally proposed products in which the fiber axis is oriented in a plane cannot be used because of their low tensile strength. The strength can be further improved by using a large amount of an adhesive in order to firmly bond the fibers to each other.

In the use according to the present invention, it is often desired to have an effect of preventing the occurrence of mites. In particular,
It is also hygienic to prevent the house dust mite, Dermatophagoides farinae. Therefore, it is preferable to configure the fiber filling material to have an antibacterial property in whole or in part. Specifically, it is effective in mitigating mites, and it is preferable to use a safe drug or the like to impart an anti-mite effect, and such a drug is not particularly limited. An organic compound such as an ammonium salt-based compound or a pyrethroid-based compound may be fixed to the surface of a fiber together with an adhesive, so as to have an effect of repelling mites. As a repellent effect, a remarkable effect is obtained if it is 30% or more, preferably 50%.
% Or more.

The repellency of the mites was measured by the “glass tube method” specified by the Mite Prevention Products Association, specifically, a mite culture medium and a test cotton were placed in a glass tube having a diameter of 20 mm and a length of 100 mm. The number of surviving mites that passed through the test cotton was read. On the other hand, a blank cotton having no anti-mite properties was tested in the same manner, and the test was repeated five times to calculate the repellent rate.

It is also preferable that the antibacterial property is effective. It is preferable to add an organic or inorganic antibacterial agent in order to prevent the propagation of Staphylococcus aureus that occurs in sweat or the like. Any substance having antibacterial properties can be used, but in organic substances, quaternary ammonium salt compounds, chlorhexidine, etc., in inorganic substances, silver zeolite,
Copper sulfide or the like can be used. Also, imparting antibacterial property is preferable because it can prevent the odor generated by bacteria.

As a means for applying the antibacterial agent, a method can be proposed in which the material is mixed with synthetic fibers or synthetic resin and then attached to the surface together with an adhesive during post-processing, but any method may be used. The antibacterial property is measured by the unified test method specified by the Textile Product New Function Evaluation Council, and it is sufficient if the bacteriostatic activity value is 2 or more.

An embodiment of the fiber molding insert according to the present invention will be described in more detail with reference to the drawings.

FIG. 1 and FIG. 2 are cross-sectional views showing one example of the shape of the fiber insert during fiber molding of the present invention. FIG. 1 is a cross-sectional view. The fiber filling material of the present invention comprises a convex portion 1 and a base portion 2. FIG. 2 is a conceptual view showing the state of the single fibers constituting the fiber molding insert according to the present invention. The single fibers 3 are partially adhered to each other as if their intersections 4 were welded by an adhesive.

[0041]

The present invention will be described in more detail with reference to the following examples. Example 1 Raw polyester staple cotton 14.4 dtex, length 6
A 4 mm, hollow cross section, 12 shrinkage / 25 mm shrinkage degree, 20% shrinkage degree, 20% shrinkage, three-dimensional shrinkage product having a surface coated with a quaternary ammonium salt compound in a weight ratio of 1% together with a binder was used. Polyester staple composite fiber (sheath melting temperature: 110 ° C., 4.4 dtex, length: 51 mm) is laminated as an adhesive in a sandwich structure in a ratio of creased fiber: adhesive fiber = 60: 40% by weight and opened. After mixing with a machine, the cotton was opened and put on a card machine to form a web.

Further, after the web was set on a fiber opening machine, the web was compressed with high-pressure air to a thickness of 50 cm and a length of 100 c.
7.65 kg was packed in a mold having a width of 90 cm and a width of 90 cm.
This form is compressed by 50 cm from the length direction, and the thickness is reduced to 50 c.
m, width 90 cm, length 50 cm. The fiber block form is then placed in a high pressure steam setter and
After heat treatment at 30 ° C. for 30 minutes, it is cooled to a density of
A 4 g / cc fiber block was obtained. The fiber blocks were combined with each other by pressing the compressed surfaces together with a rubber-based solvent type adhesive to form a large block.

The large block was sliced with a cutter having a thickness of 12 cm from the same direction as that in which the mold was compressed and a belt-shaped blade was rotated to form a sheet layer having a size of 50 cm × 200 cm and a thickness of 13 cm. This sheet layer was subjected to a profile processing machine used for urethane to obtain a fiber sheet layer 1 of the present invention having a height of the convex portion of 30 mm and a thickness up to the peak of the convex portion of 80 mm.

Example 2 Similarly, using the large block of Example 1, the thickness was 4 cm,
Two sheets were prepared so as to have a length of 200 cm and a width of 50 cm. On the other hand, a 90 cm wide, 200 cm long, 4 cm thick sheet of cellulose foam made from pulp is bonded with a rubber-based solvent adhesive so that both sides are sandwiched with the previously made fiber sheet, and three layers are bonded. Created a sheet.

This sheet was processed by a profile processing machine in the same manner as in Example 1 to have a projection of 30 mm and a height up to the top of 80 m.
m of fiber sheets 2 according to the present invention were obtained. Such a sheet consists of a cellulosic foam up to 2 cm below the apex of the protrusion. Cellulose foam has a water absorption of 24% and a moisture absorption of 25
It is 11.5% under the environment of 80 ° C. and 80% RH.

Example 3 Raw polyester staple cotton 5.5 dtex, length 64
mm, a number of shrinkage of 12 peaks / 25 mm, a degree of shrinkage of 20%, and a three-dimensional shrinkage product obtained by adding a pyrethroid-based compound as a tick-proofing agent to the surface at a weight ratio of 0.4% together with a binder, The manufacturing method was the same as in the example, and 6.75 kg was packed in a mold. Density was 0.03 g / cc. Similarly, thickness 5cm, width 90cm, length 200c
m, and a fiber sheet was prepared. As in the first embodiment, the height of the convex portion is 25 mm, and the total height up to the top is 3
The fiber sheet 3 according to the present invention was obtained by being profiled to have a thickness of 5 mm.

Example 4 Raw polyester staple cotton 14.4 dtex, length 6
4 mm, hollow cross section, number of shrinkage 12 peaks / 25 mm, degree of shrinkage 20%, shrinkage of three-dimensional shrinkage 20% by weight, wool about 6 dte
x, length of about 60 mm 40 wt%, and polyester staple conjugate fiber (sheath melting temperature 110 ° C.,
4.4 dtex (51 mm), and processed in the same manner as in Example 3 to obtain a fiber sheet 4 according to the present invention containing wool.

Comparative Example 1 Raw polyester staple cotton 14.4 dtex, length 6
Polyester staple composite fiber (sheath dissolution temperature 110 ° C, 4.4d)
tex, length 51 mm) in a sandwich structure at a ratio of 60: 40% by weight, mixed with a cotton opener, opened, put on a card machine to form a web, and polymerized and laminated with a cross wrapper. 175 ° C with air-through heat treatment machine
For 30 seconds to produce a fiber sheet having a thickness of 13 cm. The specific gravity was 0.035 g / cc.

A fiber sheet layer of Comparative Example 1 having a profile of 30 mm in height and a thickness of 80 mm up to the peak of the projection was obtained in the same manner as in Example 1.

Comparative Example 2 Raw polyester staple cotton 5.5 dtex, length 64
mm, the number of sagging 12/25 mm, the degree of sagging 20%, the adhesive fiber and the manufacturing method are the same as in Comparative Example 1, and the height of the convex part having a specific gravity of 0.033 g / cc is 1
A fiber sheet layer of Comparative Example 2 having a thickness of 5 mm and a thickness up to the peak of the convex portion of 25 mm was obtained.

The results of measuring the characteristics of Examples 1, 2, 3, 4 and Comparative Examples 1 and 2 are shown in Table 1.

[0052]

[Table 1]

Examples 1 and 2 in which the application is a bed mat
When a side lining was made of a polyester flat knitted fabric on the prototype of Comparative Example 1 and put to practical use, Examples 1 and 2 according to the present invention did not suffer from falling-off deformation of the convex portion, and took advantage of the shape of the convex portion. Since it can be used, it has good ventilation and can be used comfortably.

In Comparative Example 1, which has been conventionally proposed, the convex portion is deformed and falls off as the convex portion is rubbed, and the concave portion of the convex portion is large, so that the user does not feel the convex portion.

Moreover, in use for a care bed,
Embodiments 1 and 2 are excellent in following the bending of the mat due to the rising of the back of the bed, and can be used without any problem.

Further, in Examples 3 and 4 and Comparative Example 2 of the present invention in which pad products were formed on the same side cloth, the same results were obtained under the same wearing conditions.

[0057]

According to the present invention, the convex portion has a high deformation stress in practical use and can be used with the convex portion left, so that it is comfortable and at the same time, the convex portion does not fall off even in long-term practical use and is stable. Available in condition.

[Brief description of the drawings]

FIG. 1 is a cross-sectional model diagram illustrating an example structure of a fiber molding insert according to the present invention.

FIG. 2 is a schematic model diagram illustrating an example of a state of a fiber constituting a filling material during fiber molding according to the present invention.

[Explanation of Signs] 1: convex part 2: base part 3: fiber 4: fiber bonding intersection

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Tokuji Nakagami 1-1-1, Oe, Otsu City, Shiga Prefecture Inside the Seta Plant of Toray Industries, Inc. (72) Inventor Tomonori Shintaku 1-1-1, Oe, Otsu City, Shiga Prefecture No. 1 F-term in the Toray Industries Seta Plant (reference) 3B096 AB01 BA02 4C058 AA03 BB07 JJ04 4L047 AA21 AB02 BA09 BB06 BB09 CA02 CB10 CC07

Claims (13)

[Claims] 1. A sheet-like insert made of fibers,
Many of the constituent fibers are arranged substantially perpendicularly to the sheet plane direction, and the fiber sheet layer is a fiber sheet layer in which the fibers are partially adhered to each other. At least one surface of the fiber sheet layer is discontinuous on the sheet. The sheet layer has a convex portion and a base portion, and the convex portion and the base portion of the sheet layer have a continuous structure. Characterized by having a large area, and having a compression stress of 0.3 Newton / cm ² or more. 2. The fiber molding insert according to claim 1, wherein the fiber molding insert is formed by laminating a plurality of sheet layers of the same type or different types. 3. The fiber molding insert according to claim 1, wherein the whole or a part of the convex portion of the sheet layer and the base portion are made of different materials or structures. 4. The fiber molding insert according to claim 1, wherein the height of the projection is 5 mm or more and 50 mm or less. 5. The specific gravity is not less than 0.015 g / cc and 0.07 g.
/ Cc or less, the fiber molding insert according to any one of claims 1 to 4. 6. The fiber molding insert according to claim 1, which has a flexibility of 5 cm or more. 7. The thickness up to the peak of the projection is 20 mm or more and 200 mm or more.
The fiber filling material according to any one of claims 1 to 6, which is not more than mm. 8. The fiber filling material is formed by mixing a synthetic fiber and a natural fiber.
The fiber filling material according to any one of the above. 9. The tensile strength of the projection is 0.5 Newton / cm.
9. The fiber molding insert according to any one of claims 1 to 8, wherein the number is ² or more. 10. The fiber-filling material according to claim 1, wherein the fiber-filling material has an anti-mite property in whole or in part.
9. The fiber molding insert according to any one of 9 above. 11. The fiber-filling material according to claim 1, wherein the fiber-filling material has an antibacterial property in whole or in part.
0. The fiber-filling insert according to any one of items 0. 12. A fiber molding insert, wherein the fiber molding insert according to any one of claims 1 to 11 is composed in combination with another insert. 13. The fiber molding insert according to any one of claims 1 to 12, wherein the fiber molding insert is for a product of a mattress, a bedding, a chair and a seat material, and a pad.