JPH08336920A - Mat and manufacture thereof - Google Patents

Abstract

PURPOSE: To provide a mat optimum for a bed, a futon or mattress, a square floor cushion or a furniture for a general home, a hospital or a hotel having hard steaming, excellent heat insulation, form retentivity, excellent feeling in bed, durability and molding bendability and capable of being cleaned and always holding clean. CONSTITUTION: The mat is provided by forming a three-dimensional stereoscopic structure in which a continuous strand having a size of 5mm or less and made of thermoplastic elastic resin is wound to be brought into contact with each other while forming a loop so that most of the contact parts are fusion bonded is formed and at least one side of a cushioning layer of a net-like material substantially flattened at both surfaces and having an apparent density of 0.005 to 0.10g/cm<3> , a thickness of 5mm or more is covered with a side cloth obtained by sandwiching it between two knitted woven fabrics of wadding layers having matrix of mainly natural fiber and apparent density of 0.1g/cm<3> or less and sewed by quilting, and a method for manufacturing the same is provided.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION The present invention is suitable for general household use, which is difficult to get stuffy, has excellent heat retention and body shape retention, is comfortable to sleep, has excellent durability and bendability, can be washed, and can always maintain cleanliness. The present invention relates to a bed mat most suitable for beds for hospitals and hotels, a mat also suitable for cushioning materials such as bedding, cushions and furniture, and a manufacturing method thereof.

[0002]

2. Description of the Related Art At present, bed mats for beds use a hard steel wire spring or a foamed material such as styrofoam for a cushion layer, and a wadding layer laminated with resin cotton or hard cotton with adhered urethane foam or inelastic crimped fiber. Integrated,
Also, a cushion body made of only a foamed material such as urethane having the same composition or a resin cotton or a hard cotton to which an inelastic crimped fiber is adhered is used.

However, the one using a hard steel wire spring for the cushion layer is remarkably excellent in supportability, but is inferior in bending property, and the hard steel wire spring is separated and treated at the time of disposal. Complexity is a big problem. The cushion layer or wadding layer or the one using foam-crosslinking type urethane for the cushion body has very good durability as a cushion body, but it has poor moisture permeability and heat storage property, so it easily gets damp and slightly bendable. In addition, since it is not thermoplastic and it is difficult to recycle it and it is incinerated, the incinerator is greatly damaged and the cost of removing toxic gas is high. For this reason, landfilling has become more frequent, but it is difficult to stabilize the ground, and there is a problem that landfilling sites are limited and costs increase. Further, although it has excellent processability, it also has a problem of pollution of chemicals used during manufacturing. In addition, recently, bed mats need to be washed due to the problem that hospital beds become hot beds such as MRSA, but urethane, which has poor water permeability, cannot be washed, which has become a social problem.

A resin cotton, in which a cushion layer or a wadding layer or a cushion body is formed by adhering polyester fibers with an adhesive,
For example, as an adhesive using a rubber system, Japanese Patent Laid-Open No. 60-
11352, JP-A-61-141388,
There is JP-A-61-141391. In addition, as one using a crosslinkable urethane, Japanese Patent Laid-Open No. 61-137732
There is a bulletin, etc. Those using these as a cushion layer or a wadding layer can improve breathability and reduce stuffiness, but are inferior in durability and bendability, and are not thermoplastic or single composition and therefore cannot be recycled. There are also problems such as complexity of processability and pollution of chemicals used during manufacturing. Also, although it can be washed, it has a problem of poor drainage.

Polyester hard cotton for the cushion layer or the wadding layer or the cushion body, for example, JP-A-58-311.
50, JP-A-2-154050, JP-A-3
However, since an amorphous polymer in which the adhesive component of the heat-adhesive fiber used is brittle is used (for example, JP-A-58-136828 and JP-A-3-24).
(Patent No. 9213, etc.) There is a problem that durability is inferior such that the bonded portion is brittle and the bonded portion is easily broken during use, and the form and elasticity are lowered. Furthermore, it is inferior in bendability. Also, although it can be washed, it has a problem of poor drainage. As a method for improving durability, a method of entanglement treatment has been proposed in Japanese Patent Laid-Open No. 4-245965 and the like, but brittleness of an adhesive portion is not solved and elasticity is largely reduced, and there is a problem that bending property is poor. . In addition, there is complexity during processing. Further, there is a problem that the bonded portion is hard to be deformed and soft cushioning is hard to be imparted. Therefore, a heat-bonded fiber using a polyester elastomer which is soft and recovers even if it is deformed to some extent and uses an inelastic polyester as a core component is disclosed in JP-A-4-240219, and a cushion using the fiber is disclosed. The body is WO-91 / 19032, JP-A-5-155651, JP-A-5-163.
No. 654, etc. The adhesive component used in this fiber structure contains 30 to 50% by weight of polyalkylene glycol as the soft segment of polyester elastomer, and 50 to 80 mol% of terephthalic acid as the acid component of the hard segment. However, similar to the fiber described in JP-B-60-1404 as another acid component composition, isophthalic acid is added to increase the amorphous property, and the melting point becomes 180 ° C. or lower, resulting in low melt viscosity and thermal bonding. The amoebar-shaped adhesive part is formed by improving the part formation, but it is easy to plastically deform, and because the core component is an inelastic polyester, the plastic deformation becomes remarkable especially under heating, and the heat resistance and compression resistance are high. There is a problem that it deteriorates, and it is inferior in bendability and can be washed, but it has a problem that drainability is poor. As a method of further improving the durability, a structure comprising only a polyester polyester elastomer containing isophthalic acid as a sheath component and a heat-bonding conjugate fiber using an inelastic polyester as a core component is disclosed in JP-A-5-163654. Although proposed, the plastic deformation under heating becomes remarkable due to the above-mentioned reason, the heat resistance and compression resistance are lowered, and there is a problem in using it for the cushion body.
Further, Japanese Patent Laid-Open No. 63-158094 proposes a method in which a silicone oil is added to a hard cotton base material to lower the coefficient of friction of fibers to improve durability and improve the texture.
However, there is a problem with the adhesiveness of the heat-adhesive fiber and the durability is poor, so it is not preferable for use in a cushion body. On the other hand, as a method of improving the bendability, a method of forming a folding structure is disclosed in JP-A-55-36373 and JP-A-2-142513.
As disclosed in Japanese Patent Laid-Open No. 5-3894 and Japanese Patent Laid-Open No. 5-3894, the bending property is improved, but the durability and the problem at the time of washing are not improved, and there are many problems when used as a cushion body. is there. In addition, a cavity is formed in the bent portion to improve the bendability, for example, Japanese Patent Laid-Open No. 5-28.
Although there is a publication such as Japanese Patent No. 5031, the problem of foam such as urethane or the problem of hard cotton cannot be solved at all.

A thermoplastic olefin network used for civil engineering work is disclosed in JP-A-47-44839. As a cushion body using them, Shokai 58
No. 93270 discloses a laminated structure of a hard structure and a soft structure. No. 58-95760 discloses a structure having an air conditioning unit inside a net having a hard structure.
Although Japanese Patent Laid-Open No. 05714 describes that a net-like body that is assumed to have a hard structure is used, no consideration is given to heat resistance and durability, comfortableness to sleep, handleability such as weight reduction and washability.
Japanese Unexamined Patent Publication (Kokai) No. 58-109670 proposes a mesh body having irregularities on one side, but unlike a cushion made of thin fibers, the surface is uneven and the touch is bad, and heat resistance durability, sleeping comfort and weight reduction are achieved. No consideration was given to handling such as washing and washing. Japanese Unexamined Patent Publication No. 6-327723 discloses a reticulated body having a hole portion into which a cleaning pipe, a ventilation pipe, etc. can be mounted. However, since the material is olefin, the heat resistance and durability are remarkably inferior, and the weight reduction and the washability are achieved. It is not possible to use it as a wadding layer or cushioning material because it is not considered in handling. In addition, Japanese Patent Publication No. 3-1766
Japanese Patent Laid-Open No. 6-61 also discloses a method in which ejection filaments having different fineness are fused to each other to form a mole, but a net-like structure which is not suitable as a cushion material. Japanese Examined Patent Publication No. 3-55583 describes a method of thinning only a very surface with a thinning device such as a rotating body before cooling. With this method, the surface cannot be flattened and a thick thin linear layer cannot be formed. Therefore, it does not provide a comfortable cushioning material. Japanese Unexamined Patent Publication No. 1-207462 discloses a vinyl chloride floor mat, but it is not preferable as a cushioning material because it has poor compression recovery at room temperature and remarkably poor heat resistance. Note that no consideration is given to the bed mat in the above structure.

Japanese Unexamined Patent Publication (Kokai) No. 6-269345 discloses a pad for a futon in which a cotton material is sandwiched between sheets and quilted, which covers a bedding member such as a non-woven fabric having a far infrared radiation function. There is a problem that attention is not paid to improvement of sleeping comfort such as a holding function and a stuffiness preventing function, heat resistance and durability, washability such as draining property and drying property, and bending property. Actual Kaihei 6
Japanese Patent No. 48453 discloses a comforter wrapped in a quilted stuffed cotton-filled wrapping cloth made of hard cotton with folds. As a mattress, it has good foldability and heat retention, but it is inferior in breathability, tends to get stuffy, has insufficient body retention, and does not take into consideration washability such as heat resistance and durability, draining and drying. .

[0008]

To solve the above problems,
It is hard to get stuffy, has good heat retention, shape retention, etc., has good heat resistance and durability, and is easy to use.
It is an object of the present invention to provide an optimal mat for a bed, a mattress, a seat cushion, a furniture cushion that can be recycled if separated, and a manufacturing method thereof.

[0009]

[Means for Solving the Problems] Means for solving the above problems, that is, the present invention is a mat in which a cushion layer is wrapped with a side material made of knitted fabric, and the structure of the side material on at least one side of the cushion layer is The wading layer is sandwiched between two knitted fabric sheets and quilted and sewn. The cushion layer is made of thermoplastic elastic resin and has a linear diameter of 5 mm or less. A loop is formed, and most of the contact portions of each loop are fused and formed of a three-dimensional three-dimensional structure network,
The three-dimensional three-dimensional structure network is substantially flattened on both upper and lower surfaces and has an apparent density of 0.005 to 0.10 g.
/ Cm ³ , thickness is 5 mm or more, and the wadding layer has an apparent density of 0.1 g with natural fiber as the main matrix.
/ Cm ³ or less of a web, and the thermoplastic elastic resin forming the cushion layer has a recovery rate after room temperature elongation of 300% (room temperature elongation recovery rate) of 20%. As described above, the mat has a recovery rate (70 ° C. elongation recovery rate) of 30% or more after holding 10% elongation at 70 ° C. for 24 hours, and the wire diameter of the reticulate body constituting the cushion layer is 0.01 mm or more. , Apparent density is 0.01g / cm ³
To 0.08 g / cm ³ and a thickness of 10 mm or more, and the wire diameter of the net-like body constituting the cushion layer is 0.1.
A mat having an apparent density of 0.02 g / cm ³ to 0.06 g / cm ³ and a thickness of 20 mm to 500 mm, and the component made of thermoplastic elastic resin is measured by a differential scanning calorimeter. Is a mat using a reticulated body having an endothermic peak at a temperature above room temperature and below the melting point in the melting curve
A mat in which the cross-sectional shape of the filaments of the reticulate body forming the cushion layer is a hollow cross section and / or an irregular cross section, and the thermoplastic elastic resin forming the cushion body is polyester, and both sides of the wadding layer are knitted. Covered with fabric,
The sewn side fabric is a mat having an air permeability of 20 cc / cm ² seconds or more, the natural fiber is a silk mat, the natural fiber is a wool mat, and the natural fiber is a hemp mat. , A thermoplastic elastic resin is discharged downward from the nozzle at a melting temperature 20 to 80 ° C. higher than its melting point from a multi-row nozzle having a plurality of orifices to form a continuous linear loop in a molten state, After the loops of No. 3 were brought into contact with each other and fused to form a three-dimensional structure, they were sandwiched by a take-up device and cooled in a cooling tank, and then obtained
A method for producing a mat, characterized in that the upper and lower surfaces of the three-dimensional structure or one side of a web mainly composed of natural fibers are covered with a knitted fabric and covered with a quilting sewn side cloth. , A mat production method in which a pseudo crystallization treatment by annealing is performed at a temperature of at least 10 ° C. or lower than the melting point of a thermoplastic elastic resin forming a reticulated body in any step leading to commercialization.

The thermoplastic elastic resin in the present invention means, as the soft segment, an ether type glycol, a polyester type glycol, a polycarbonate type glycol or a long chain hydrocarbon having a molecular weight of 300 to 5,000. Polyester elastomer obtained by block-copolymerizing an olefinic compound having a carboxylic acid or a hydroxyl group at the terminal, a polyamide elastomer, a polyurethane elastomer,
Examples include polyolefin elastomers. By using a thermoplastic elastic resin, it becomes possible to regenerate by remelting, and thus recycling becomes easy. For example, as the polyester elastomer, a polyester ether block copolymer having a thermoplastic polyester as a hard segment and a polyalkylenediol as a soft segment, or a polyester ester having an aliphatic polyester as a soft segment A block copolymer can be illustrated. More specific examples of the polyester ether block copolymer include aromatic 8 dicarboxylic acids such as terephthalic acid, isophthalic acid, naphthalene 2.6 dicarboxylic acid, naphthalene 2.7 dicarboxylic acid and diphenyl 4.4 'dicarboxylic acid. At least 1 of an alicyclic dicarboxylic acid such as 1,4-cyclohexanedicarboxylic acid, an aliphatic dicarboxylic acid such as succinic acid, adipic acid, and sebacic acid dimer acid, or a dicarboxylic acid selected from these ester-forming derivatives Seeds and aliphatic diols such as 1.4 butanediol, ethylene glycol, trimethylene glycol, tetremethylene glycol, pentamethylene glycol and hexamethylene glycol, 1.1 cyclohexane Alicyclic diols such as dimethanol and 1,4-cyclohexane dimethanol, or these Of at least one diole component selected from the ester-forming derivatives thereof and polyethylene glycol having an average molecular weight of about 300 to 5,000.
It is a ternary block copolymer composed of at least one of polyalkylenediol such as glycol, polypropylene glycol, polytetramethylene glycol, glycol made of ethylene oxide-propylene oxide copolymer and the like. . The polyester ester block copolymer is a ternary block copolymer composed of at least one of the above dicarboxylic acids, diol, and polyester diol such as polylactone having an average molecular weight of about 300 to 5,000. . Thermal adhesion, hydrolysis resistance, stretchability,
Considering heat resistance and the like, terephthalic acid as dicarboxylic acid, or naphthalene 2.6 dicarboxylic acid, 1.4 butanediol as diole component, and polytetramethylene glycol as polyalkylenediol. The terpolymer block copolymer or the terpolymer block copolymer of polylactone as the polyester diol is particularly preferable. In a special case, it is possible to use the one in which a polysiloxane-based soft segment is introduced. In addition, the above elastomer is blended with a non-elastomer component,
Those obtained by copolymerization and those obtained by softening the polyolefin component are also included in the thermoplastic elastic resin of the present invention. As a polyamide elastomer, the hard segment is nylon 6, nylon 66, nylon 610,
Polyethylene glycol, polypropylene glycol, polytetramethylene glycol, ethylene oxide having an average molecular weight of about 300 to 5000 is used as the soft segment in the skeleton of nylon 612, nylon 11, nylon 12, etc. and their copolymerized nylon. -A block copolymer composed of at least one kind of polyalkylenediol such as glycol composed of a propylene oxide copolymer may be used alone or in combination of two or more kinds. Furthermore, blends of non-elastomer components and copolymers thereof can be used in the present invention. Examples of the polyurethane elastomer include (A) a polyester and / or a polyester having a hydroxyl group at the terminal and having a number average molecular weight of 1,000 to 6000 in the presence or absence of a usual solvent (dimethylformamide, dimethylacetamide, etc.). ) A typical example is a polyurethane elastomer obtained by reacting a polyisocyanate containing an organic diisocyanate as a main component with a prepolymer having isocyanate groups at both ends and (C) extending the chain with a polyamine containing a diamine as a main component. Can be illustrated as (A) Polyester, Polyester
The tellers have an average molecular weight of about 1000 to 6000,
Preferably from 1300 to 5000 polybutylene adipates
Copolyester, polyethylene glycol, polypropylene glycol, polytetramethylene glycol
Polyalkylenediol such as glycol and ethylene oxide-propylene oxide copolymer glycol is preferable, and as the polyisocyanate of (B), a conventionally known polyisocyanate can be used. An isocyanate mainly composed of 4'diisocyanate may be used, and if necessary, a trace amount of conventionally known triisocyanate may be added and used. As the polyamine (C), known diamines such as ethylenediamine and 1.2-propylenediamine are mainly used, and if necessary, trace amounts of triamine and tetraamine may be used in combination. These polyurethane elastomers may be used alone or in combination of two or more. The melting point of the thermoplastic elastic resin of the present invention is preferably 140 ° C. or higher at which heat resistance and durability can be maintained,
It is more preferable to use a material having a temperature of 160 ° C. or higher because the heat resistance and durability are improved. In addition, since the reticulate body constituting the bed mat of the present invention contains a phosphorus compound for imparting flame retardancy as a preferred embodiment, the thermal stability is slightly inferior to that not containing a flame retardant. It is particularly preferable to add an antioxidant or the like to improve heat resistance and durability. The antioxidant is preferably a hindered phenol-based antioxidant and a hindered amine-based antioxidant, and a nitrogen-free hindered phenol-based antioxidant is 1% to 5%. It is particularly preferable to suppress the thermal decomposition by adding it, because the generation of toxic gas with a small lethal amount at the time of combustion can be suppressed. The elongation recovery measured by the method described later of the thermoplastic elastic resin forming the cushion layer, which is a mat that can have both favorable durability and cushioning property, which is the object of the present invention, is the recovery rate after 300% elongation at room temperature. (Room temperature elongation recovery rate) is 20% or more, and the recovery rate after holding 10% elongation at 70 ° C. for 24 hours (70 ° C. elongation recovery rate) is 30% or more, more preferably room temperature elongation recovery rate. 30% or more,
The 70 ° C extension recovery rate is 40% or more, and most preferably, the room temperature extension recovery rate is 40% or more, and the 70 ° C extension recovery rate is 50% or more. The soft segment content of the thermoplastic elastic resin constituting the component imparting such elongation recovery is preferably 15% by weight or more, more preferably 30% by weight or more, and 80% by weight from the viewpoint of heat and fatigue resistance. The following is preferable, and 70% by weight or less is more preferable. That is, the soft segment content of the component having the function of absorbing vibrations and stress of the elastic network of the present invention is preferably 15% by weight or more and 80% by weight or less, more preferably 30% by weight or more and 70% by weight or less. .

Since it is necessary to impart flame retardancy as a preferred embodiment of the mat of the present invention, the phosphorus content (Bppm) in the thermoplastic elastic resin is the soft segment content (A% by weight).
On the other hand, it is preferable to satisfy the relationship of 60A + 200 ≦ B ≦ 100,000. If not satisfied, flame retardancy may be inferior. If it exceeds 100,000 ppm, the plastic deformation due to the plasticizing effect becomes large and the heat resistance of the thermoplastic elastic resin becomes poor, which is not preferable. A preferable phosphorus content (Bppm) is 30A + with respect to the soft segment content (A weight%).
1800 ≦ B ≦ 100,000, and more preferable phosphorus content (Bppm) is 16A + 2600 ≦ B ≦ 50000 with respect to the soft segment content (A weight%). For flame retardancy, there is a method to add a high level of flame retardancy by adding a large amount of halides and inorganic substances, but when burning, a large amount of toxic halogen gas with a small lethal amount is generated, and there is a problem of poisoning during fire. Therefore, in the incineration, the damage of the incinerator becomes large, so that in the present invention, the preferable halide content is 10% by weight or less, the more preferable halide content is 5% by weight or less, and the most preferable halide content is It does not. Examples of the phosphorus-based flame retardant of the present invention include:
In the case of a polyester-based thermoplastic elastic resin, as a flame retardant in the hard segment portion at the time of resin polymerization, for example, as described in JP-A-51-82392, 10 [2.3]
・ Di (2-hydroxyethoxy) -carbonylpropyl] 9,10 ・ dihydro ・ 9 ・ oxa ・ 10 phosphaphenalene ・ 10 Polyester obtained by copolymerizing a carboxylic acid such as oxylo as a part of the acid component of the hard segment A flame-retardant property is imparted by adding a phosphorus-based compound such as tris (2.4-di-t-butylphenyl) fusphite to the thermoplastic elastic resin in a later step or a method of forming the thermoplastic elastic resin. be able to. Other flame retardants capable of imparting flame retardancy include various phosphoric acid esters, phosphorous acid esters, phosphonic acid esters (the above phosphoric acid esters containing a halogen element as necessary), or polymers derived from these phosphorus compounds. It can be illustrated. In the present invention, various modifiers, additives, colorants and the like can be added to the thermoplastic elastic resin as needed. Phosphorus is added to the flame-retardant adhesive component of the cushion layer netting or wadding layer constituting the bed mat of the present invention in order to provide flame retardancy. The reason is, as described above, from the viewpoint of safety. The goal is to minimize the use of toxic gases, such as cyanogen gas and halogen gas, which are produced in the event of fire and have a low lethal dose. Therefore, the toxicity index of the combustion gas of the reticulate body constituting the mats of the present invention is preferably 6 or less, more preferably 5.5 or less. The combustion gas toxicity index of the wadding layer is preferably 12 or less, more preferably 10 or less, and most preferably 7 or less. Cellulose is most preferable as a natural fiber that can reduce the toxicity index, and when using protein fiber silk, wool, feathers, etc., a polyester fiber with a low toxicity index is used for the heat-bonding fiber or the fiber mixed in the matrix. It is desirable to make the fiber mixing ratio as high as possible. Further, it is preferable to use a material having a high polyester fiber mixing ratio also for the side surface. It is preferable that the thermoplastic elastic resins forming the mesh body of the cushion layer are of the same type. For example, when the polyester-based thermoplastic elastic resin is used, the cushion layer can be recycled and recycled without separately separating it.

The component comprising the thermoplastic elastic resin constituting the mat of the present invention preferably has an endothermic peak below the melting point in the melting curve measured by a differential scanning calorimeter. Those having an endothermic peak below the melting point have significantly improved heat resistance and sag resistance than those having no endothermic peak. For example, as a preferable polyester-based thermoplastic resin of the present invention, terephthalic acid or naphthalene 2.6 dicarboxylic acid having rigidity in the acid component of the hard segment is used.
The content of 0 mol% or more, more preferably the content of terephthalic acid or naphthalene 2.6 dicarboxylic acid is 95 mol% or more, and particularly preferably 100 mol% to the required degree of polymerization after transesterification of the glycol component. Polymerize, then
As the polyalkylene diol, 15 polytetramethylene glycol having an average molecular weight of 500 or more and 5000 or less, particularly preferably 1000 or more and 3000 or less is preferably used.
% To 70% by weight, more preferably 30% by weight
When the amount of copolymerization is 60% by weight or more, the crystallinity of the hard segment is improved if the content of terephthalic acid or naphthalene 2.6 dicarboxylic acid having rigidity in the acid component of the hard segment is large. Although it is less likely to undergo plastic deformation and the heat resistance and sag resistance are improved, the heat resistance and sag resistance is further improved by performing an annealing treatment at a temperature lower than the melting point by at least 10 ° C. or more after melt heat bonding. If annealing is performed after applying compressive strain, heat resistance and sag resistance are further improved. The reticulated body treated in this way has a melting curve measured by a differential scanning calorimeter, and more clearly shows an endothermic peak at a temperature of room temperature or higher and melting point or lower. If annealing is not performed, no endothermic peak appears in the melting curve above room temperature and below the melting point. By analogy with this, it is considered that the annealing causes rearrangement of the hard segments and formation of pseudo-crystallization-like cross-linking points to improve the heat resistance and sag resistance. (This treatment is defined as pseudo crystallization treatment.) This pseudo crystallization treatment effect is also effective for polyamide elastic resin and polyurethane elastic resin.

The natural fibers in the present invention include cotton, hemp, palm shell fibers, cellulosic fibers such as jute, wool, silk,
It refers to naturally occurring organic fibers such as protein fibers such as feathers. In the present invention, the term "matrix composed mainly of natural fibers" means a system in which at least 50% by weight or more of the matrix fibers are composed of natural fibers. In the present invention, the mixing ratio of the natural fiber in the matrix fiber is 50% or more, preferably 6 in order to sufficiently exhibit the hygroscopicity and water absorption of the natural fiber.
It is 5% or more, and more preferably 100%. Then
In the present invention, in consideration of enabling washing, it is necessary to increase the drying rate by mixing synthetic fibers having a low equilibrium moisture content to increase the drying rate in consideration of the drainage property after washing and the drying rate. The mixing ratio of the low synthetic fibers is preferably at least 15% by weight or more, more preferably 30% by weight or more.
It is less than 0% by weight. On the other hand, there is toxicity of combustion gas in safety at the time of fire, and in order to reduce toxicity of combustion gas, cellulosic fiber is preferable, and when protein fiber is used, as described above, synthesis with low toxicity index is performed. It is desirable to mix the resin fibers to reduce the toxicity index. In the present invention,
The toxicity index of the wadding layer is at least 15 or less, preferably 10 or less, more preferably 7 or less. Since the protein fiber also has flame retardancy, the present invention
At least 50% or more of the natural fiber is contained in the wadding layer. In a preferred embodiment of the present invention, it is desirable to use natural fibers to which a desired function is added by various treatments such as flame retardation treatment and shrinkage reduction treatment, as desired.

The synthetic resin in the present invention means a thermoplastic resin. Thermoplastic resins include polyester, polyamide,
Examples include polyolefins. In the present invention, it is preferable to use one having a glass transition temperature of 40 ° C. or higher. For example, for polyester, polyethylene terephthalate (PET), polyethylene naphthalate
(PEN), polycyclohexylene dimethylene terephthalate (PCHDT), polycyclohexylene dimethylene naphthalate (PCHDN), polybutylene terephthalate (PBT), polybutylene naphthalate (PB)
N), polyarylate, etc., and copolyesters thereof can be exemplified. For polyamide, polycaprolactam (NY6), polyhexamethylene adipamide (NY)
66), polyhexamethylene sebacamide (NY6-1)
0) etc. can be illustrated. Examples of the polyolefin include polypropylene (PP) and polybutene-1 (PB-1). As the thermoplastic resin used in the present invention, when polyester is used for the cushion layer and the side material, polyester such as PET, PEN, PBN, or PCHDT that can be recycled if separated when discarded and has good heat resistance is used. Particularly preferred. Furthermore, PET, PEN, PB
A flame-retardant polyester (hereinafter abbreviated as flame-retardant polyester) obtained by polycondensation with N, PCHDT or the like to copolymerize a phosphorus-containing ester-forming compound or containing a phosphorus-containing flame retardant is preferable. -82392, JP-A-55-7888, JP-B-55-41610 and the like are exemplified. Although vinyl chloride has self-extinguishing properties, it produces a large amount of toxic gas when burned, and its heat resistance and durability are poor, so it is not preferable to use it in the present invention.

The basic cushion layer of the mats of the present invention is
A continuous filament made of a thermoplastic elastic resin having a fiber diameter of 5 mm or less is bent and brought into contact with each other to form a three-dimensional solid structure in which most of the contact portions are fused and integrated, and both sides are substantially Due to the flattened reticulated body, even if externally applied deformation through the wadding layer, especially when a large deformation stress is locally applied, the flattened reticulated body surface receives the deformation stress Since the deformation stress is dispersed and the filaments made of thermoplastic elastic resin form a three-dimensional structure and are fused and integrated, the entire structure is deformed and the deformation stress is absorbed by energy conversion. Since it receives the deformation stress with a low repulsive force due to rubber elasticity,
It exhibits a preferable body shape holding function capable of preventing extreme local depression and supporting the body shape with a soft gripping force on the human body. The betting mat is also required to have a vibration absorbing function. The cushion layer made of the mesh body of the present invention absorbs and attenuates most of the vibration applied from the outside by the vibration absorbing function of the thermoplastic elastic resin at the time of bed-in or turning over,
A preferable vibration absorbing function is also developed. When the deformation stress is released, the rubber elasticity of the thermoplastic elastic resin has a function of easily recovering the original shape, and therefore the sag resistance is also good. Furthermore,
The porosity is high, and the ventilation hole diameter is extremely large, so the ventilation resistance is low and the ventilation is extremely good. When the deformation stress changes due to rolling over, etc., the linear line having the rubber elasticity of the thermoplastic elastic resin is a three-dimensional structure. Since the structure is fused and integrated, the entire structure is compressed and recovered by deformation, and the air containing steam and heat accumulated in the cushion layer that has permeated through the wadding layer is discharged during compression and fresh during recovery. The mats have a pump function of exchanging with the outside air, so that heat and steam can be easily transferred between the wadding layer and the cushion layer, and the mats can provide comfortable sleeping that is hard to stuff. From this purpose,
The wire diameter of the thermoplastic elastic resin having good vibration absorption and elastic recovery forming the mesh body of the present invention is 5 mm or less. 5 mm when the apparent density is 0.2 g / cm ² or less
If it exceeds, the number of constituents decreases, a density unevenness is generated, and a structure having poor durability is partially formed, and fatigue due to stress concentration increases and durability deteriorates, which is not preferable. If the wire diameter of the filament made of the thermoplastic elastic resin of the present invention is too small, the anti-compression property becomes too low and the stress absorbability due to deformation decreases, so it is 0.01 mm or more. It is 3 mm or less so as not to impair compactness. More preferably, it is 0.05 mm or more and 2 mm or less. The average diameter of the continuous loop random loops forming the reticulate body of the present invention is preferably 50 mm or less, and particularly preferably 2 to 25 mm in order to achieve the object. When the apparent density of the reticulate body of the present invention is 0.005 g / cm ³ , the repulsive force is lost, the deforming stress absorbing ability and the vibration absorbing ability are insufficient, and the cushioning function may not be easily expressed. If it is cm ³ or more, the repulsive force may be too high and the sitting comfort may be poor, but in the present invention, it is 0.10 g / cm ³ or less for the purpose of reducing the weight and improving the handleability. It is preferably 0.01 g / cm ³ or more and 0.08 g / cm ³ or less, more preferably 0.02 g / cm ³ or more 0.0, in which the function as a cushion body is easily expressed by utilizing the vibration absorbing ability and the deformation stress absorbing function.
It is 6 g / cm ³ or less. As a preferred embodiment, a method in which the reticulate body in the present invention has a different fineness laminated structure in which linear shapes having different wire diameters are combined with an apparent density to have an optimum configuration can be selected. The thickness of the mesh body of the present invention is required to be 5 mm or more. If the thickness is less than 5 mm, the stress absorbing function and the stress dispersing function are deteriorated, which is not preferable. A preferable thickness is 10 mm or more, more preferably 20 mm or more, as a surface function for dispersing force and a function of absorbing vibration and deformation stress.
It is less than 00 mm. If the thickness of a single plate is 500 mm or more, the bendability described below deteriorates. Therefore, when a thicker cushion layer is desired, a cushion layer having a thin thickness of 500 mm or less, preferably 200 mm or less is not bonded as desired. By stacking with, it is possible to prevent the bending property from being impaired. In the case of stacking so as to have a thickness of 500 mm or less, the interface may be joined, and even if it is not joined, since the surface is flat, the transmission of stress is transmitted by the surface, so there is no problem in deformability. If the surface of the mesh is not substantially flattened, the local external force transmitted from the wadding layer through the knitted fabric cannot receive the deformation stress on the surface, and the lines and bonding points on the surface. Since the function to disperse the deformation stress is selectively transmitted up to the part, stress concentration may occur, and fatigue due to stress concentration may occur against such external force, resulting in sag resistance. It may decrease. When the filaments are made of thermoplastic elastic resin, the entire structure is deformed in the three-dimensional structure portion, so stress concentration is relieved, but the body shape retention function is also deteriorated as the fatigue is advanced. In the case of non-elastic resin, stress concentrates on the bonding point as it is, causing structural destruction and cannot be recovered. Furthermore, if the surface is not substantially flattened and has irregularities, it gives a feeling of foreign matter to the back, buttocks, etc. when the person sleeps, which is unfavorable because it makes the sleeping comfort worse. When the linear shape is not continuous, the adhesive point of the filament becomes a stress transmitting point, so that remarkable stress concentration occurs at the adhesive point and structural destruction occurs, resulting in poor heat resistance and durability, which is not preferable. There is a problem that the compression resistance is inferior even at the stage where the structure is not destroyed, and the body shape retention property is inferior.If the density is increased to solve this problem, the porosity decreases, the air permeability decreases and the comfort decreases, and the weight also decreases. It becomes heavy and the handling is extremely poor. If they are not fused, the shape cannot be maintained and the structure does not deform integrally, resulting in a fatigue phenomenon due to stress concentration and poor durability, and at the same time deforming the shape and making it impossible to maintain the body shape, which is not preferable. . The more preferable degree of fusion bonding of the cushion layer of the present invention is a state in which most of the portions in contact with the filaments are fused, and most preferably all the contact portions are fused. In a net-like body composed of known filaments made only of non-elastic resin, when it receives a large deformation stress that cannot be absorbed by the surface layer, it does not have rubber elasticity and it does not easily deform and shows a large repulsive force. No
Since it has a strong repulsive force, it gives an unpleasant body-supporting feeling and exhibits an unfavorable body-shape holding function. Further, due to the compressive deformation, plastic deformation occurs and the recovery is lost, and the durability is poor. Further, since it has almost no pump function by compression recovery, the function of reducing stuffiness is inferior. The cross-linkable polyurethane has excellent vibration absorption function and sag resistance because it is an elastic resin, but it has a structure that facilitates stress transmission, so it can easily follow local deformation to prevent extreme local subsidence. Occurs, and the function of maintaining body shape is poor.
Further, the foamed polyurethane is a cushioning layer which becomes a mat which is apt to be stuffy and does not provide comfortable sleeping because the air permeability is extremely poor. The mat of the present invention moves sweat and moisture from the skin surface through the wadding layer as quickly as possible, does not give a stuffy feeling, and retains the body shape with proper heat retention and a favorable fit, and permanently provides a comfortable sleep. Therefore, a wadding layer made of a web having a natural fiber as a main matrix and an apparent density of 0.1 g / cm ³ or less was wrapped on the front surface side and / or the back surface side with a knitted woven fabric and quilted and sewn. It's Matt. By covering both sides of the wading layer made of a web with a knitted fabric and wrapping the cushion layer with the quilted side, the cushion layer can be individually taken out and washed at the time of washing. Also, if desired, cushion layers having different characteristics (for example, replacement for summer and winter, replacement for slightly harder and slightly softer, etc.) are replaced to facilitate personal preference. On the contrary, the wadding layer described below can be changed to satisfy the taste, or both of them can be changed. Since the wadding layer uses natural fibers as a matrix, the excellent hygroscopicity and water absorption of the natural fibers allow the sweat and water vapor, whose temperature has risen to the body temperature on the skin surface, to move from the skin surface to the wading layer through the lateral surface. Then, the cushion layer has a pump function to replace with fresh air, so the heat and moisture transferred to the wadding layer are released to the outside through the cushion layer. It also reduces the stuffy feeling as the temperature decreases. Thus, when the natural fiber absorbs water or absorbs heat, heat is generated, heat transfer is reduced, and excessive cooling can be prevented.
Further, since natural fiber maintains a constant vapor pressure once it absorbs or absorbs water, the moving speeds of heat and moisture are suppressed, and an appropriate vapor pressure can be maintained on the skin surface to maintain the heat retaining effect. The water vapor pressure difference between the wadding layer and the cushion layer becomes remarkable, and the moisture absorbed or absorbed by the natural fibers is efficiently discharged to the cushion layer, so that the water vapor pressure of the wadding layer can be prevented from becoming extremely high. If the apparent density exceeds 0.1 g / cm ³ , the wadding layer has poor air permeability and the movement of water is extremely reduced. Therefore, the apparent density from the movement of water is preferably 0.06 g / cm ³ or less, It is preferably 0.04 g / cm ³ or less. Thus, the synergistic effect of the wadding layer and the cushion layer makes it possible to develop a mat function that is resistant to stuffiness and has excellent heat retention. As another function of the wadding layer, since a structure in which natural fibers are joined and integrated with the side ground by quilting is formed, there is a large degree of freedom with respect to the deformation stress of the fiber, and when the local deformation stress is applied, the fiber When the movement occurs, the entire structure is deformed and the stress transmitted to the side ground is absorbed by the cushion layer made of thermoplastic elastic resin by the energy conversion, and the deformation stress is low due to the rubber elasticity. As a result, the local high compressive stress points that come into contact with the human body are less likely to be formed due to the synergistic effect of supporting the human body with a soft gripping force against the human body, and a wadding function that is less likely to cause congestion can be expressed. This function sends fresh air to the surface of the skin through the lateral side, and as a further synergistic effect, effectively works to prevent floor rubs. In order to impart such a particularly remarkable effect, the air permeability of the air exhausted from the surface of the wadding layer covered on both sides with the knitted fabric to the side surface of the cushion layer is set to 1
It is desirable that the structure be 0 cc / cm ² seconds or more. The air permeability of the knitted fabric covering the wadding layer of the present invention is not particularly limited, but in order to impart the floor rubbing prevention effect, the air permeability of the knitted fabric separating the wadding layer and the cushion layer,
It is preferably 30 cc / cm ² seconds or more. The air permeability of the knitted fabric on the surface side is preferably 30 cc / cm ² seconds or more. In the side material that constitutes the mat of the present invention, the side surface of the mat is constituted only by the knitted fabric, and by improving the air permeability between the cushion layer and the outside air, the pump function of the cushion layer can be more effectively utilized. preferable. If the apparent density of the web constituting the wadding layer of the present invention is too high, the congestion-preventing function is reduced due to an increase in the high-compression-stress supporting area, the air permeability is poor, and the stuffiness-preventing effect is also reduced, so that the apparent density is 0.
1 g / cm ³ or less is required. When the apparent density is too low, the anti-compression property is deteriorated and the function of the wadding layer is deteriorated. Therefore, the preferable apparent density is 0.01 g / cm ³ or more and 0.0 or more.
6 g / cm ³ or less, more preferably an apparent density of 0.03
g / cm ³ or more 0.05 g / cm ³ or less. If the thickness of the wadding layer is less than 2 mm, the function of the wading layer will deteriorate. When the thickness is 30 mm or more, the useful function described above, which has a synergistic effect with the cushion layer, and a proper sinking and a soft gripping force for supporting the body are reduced. The preferred thickness is 3 mm or more and 15 mm or less, more preferably 5 mm or more 1.
It is 0 mm or less. The natural fiber in the matrix fiber used for the wadding layer of the bed of the present invention is as described above.
In addition to the drying property at the time of washing, flame retardancy and combustion gas toxicity, it is possible to change the type and mixing ratio according to the user's preference for heat retention and stuffiness. For example, when a person who is relatively chilly desires warm eyes, the mixing ratio of protein fibers such as wool and cotton (silk) in the matrix fibers is preferably 60% or more, more preferably 80% or more and 100%. When a soft touch and good heat retention are desired, it is preferable that the mixing ratio of cotton (silk) and feathers in the matrix fiber is 70% or more.
0% or more and 100% is more preferable. On the other hand, when a slightly cooler sleeping comfort is desired, it is preferable to increase the mixing ratio of cellulosic fibers such as hemp and cotton in the matrix fiber, and particularly the amount of dust is small, and the mixing ratio of hemp having a large fiber diameter is 80%. It is more preferable to set it as above. Depending on the taste, the desired different wadding layers may be laminated on both sides of the cushion layer to use them differently in summer and winter. Further, other materials may be laminated on the cushion layer and / or the wadding layer as long as the basic function of the present invention is not lost. Further, the fiber mixed with the natural fiber in the matrix fiber is not particularly limited as long as the fiber can be mixed with the natural fiber. The fiber mixed with the natural fiber in the matrix fiber is a fiber containing, for example, an anti-mite agent, an antibacterial agent, a deodorant, a flame retardant, an aromatic agent, etc., in order to add a property that the natural fiber of the wadding layer does not have. To improve the function, improve the water-drying and drying properties by utilizing the properties such as water repellency and hydrophobicity, and mix fine fibers and thick fibers to identify the defects and features of natural fibers. It is desirable to mix fibers capable of imparting a function such as doubling. The fineness of the fiber is selected as desired, but the fineness that can be used in ordinary card opening is from 0.5 denier to 1
It is 00 denier. In special cases, fineness up to 500 denier can be selected. The material is selected as necessary, but usually polyester fiber may be used. The mat of the present invention has good washability. That is, compared with a cushion layer made of ordinary fibers having a fiber diameter of 0.001 mm or less, the wire diameter of the cushion layer constituting most of the cushion body of the present invention is 0.01 mm or more, and the web of the wadding layer is made of fibers. However, since the average number of constituents in the entire cushion body is small, the surface area of the filaments is extremely small and the moisture adhering to the surface of the filaments can be reduced, resulting in excellent drainage. Since it has good draining property, the drying time can be shortened. In addition, since the web constituting the wadding layer of the present invention is quilted, even if the side cloth is washed, the felt is less likely to be formed due to the unevenness or entanglement of the web. The fineness of the quilting is not particularly limited, but the pitch is preferably 3 cm or more and 15 cm or less, and more preferably 5 cm or more and 10 cm or less. Therefore, the mat of the present invention can be washed frequently and, as a result, a clean mat can always be used. The mat of the present invention can be washed by washing with a circle, but since the draining property after washing is slightly inferior to the wadding layer, drying takes a long time when washed with a circle. It is preferable to adopt a washing method capable of increasing the drainage property and the drying speed by making the thickness thin. As a preferred embodiment of the present invention, it is preferable that the cushion layer has an opening / closing port that can be closed at the side so that the cushion layer can be easily taken out and inserted. Further, since the mat of the present invention uses the thermoplastic elastic resin for the cushion layer, the mat has elasticity, so that the bending is improved. Further, in the present invention, since the cushion layer and the wadding layer made of a web having a high degree of freedom of deformation are separated and quilted, the bendability is further improved. That is, when the wadding layer is joined to the cushion layer surface, it has the function of enhancing the surface rigidity, preventing the bending property from being deteriorated as compared with the one not joined, and at the same time providing the function of the quilting part serving as a bending point to improve the bending property. doing. This function can be used for a bed for care or the like that requires the user to raise the head or upper body. When used as a thin mattress, it can be folded and stored. If the cushion layer is made of non-elastic resin, it is difficult to bend. If the material made of a hard material is bent forcibly, the bent part may be destroyed, and if the material made of a soft material is plastically deformed, the cushion is dented near the bent part, and if repeatedly bent, it breaks due to bending fatigue. Since the cushioning layer of the present invention made of a thermoplastic elastic resin and the web are quilted, the laminated structure of the wadding layer has a high degree of freedom with respect to deformation, so that it can be folded and is resistant to plastic deformation even when repeatedly folded The excellent property is a point that is greatly different from the present invention and the hard cotton. In order to improve the foldability of hard cotton, a fold structure has been proposed, but unlike the cushion layer of the present invention, a non-elastic resin is used for the cushion layer, so that the durability is poor. Commercial beds may be sterilized as needed. For sterilization, ethylene oxide gas below 100 ° C or steam at 130 ° C is generally used. In the preferred embodiment of the mat of the present invention, for example, the natural fiber of the wadding layer is subjected to low shrinkage-shape retention treatment or descaling treatment, it is not deformed by sterilization in less than 15 minutes without applying compressive stress. It is possible to sterilize the
The use of a ruthenium-based material is different from the present invention in that it has poor heat resistance and plastically deforms due to heating during sterilization, resulting in bulk reduction. By performing the above-mentioned pseudo-crystallization treatment at any stage from the reticulated body forming step to a commercialized product, the components composed of the thermoplastic elastic resin in the reticulated body are measured at room temperature on a melting curve measured by a differential scanning calorimeter. It is more preferable to have an endothermic peak at a temperature equal to or lower than the melting point, because the stretchability and heat resistance of the thermoplastic elastic resin are remarkably improved, and the heat resistance durability of the product is remarkably improved.

The cross-sectional shape of the filaments of the net-like body constituting the cushion layer of the present invention is not particularly limited, but a hollow section or a modified cross section can impart preferable anti-compression property (repulsive force) and touch. It is particularly preferable because it is possible. The compression resistance can be adjusted by adjusting the fiber diameter and the modulus of the material used to make the wire diameter thinner, and for soft materials, the hollowness and irregularity can be increased to adjust the gradient of the initial compression stress, and the wire diameter can be made slightly thicker. Or, if the material has a slightly high modulus, the hollowness and the degree of irregularity are lowered to give the good anti-compression property with good sleeping comfort. As another effect of the hollow cross section and irregular cross section, by increasing the hollow ratio and the degree of irregularity, it is possible to reduce the weight even if the same anti-compression property is given, and in the case of replacing the mat for the bed, the duvet, the cushion, etc. Improves the handleability when raising and lowering. As another preferable method for imparting preferable anti-compression property (repulsive force) and touch, there is a method of forming the filament of the reticulated body of the present invention into a composite structure. Examples of the composite structure include a score core structure, a side-by-side structure, and a combination structure thereof. However, in particular, 50% or more of the linear surface is made of a soft thermoplastic elastic resin in order to obtain a three-dimensional structure in which vibration and deformation stress that cannot be energy-converted even if the cushion layer is largely deformed can be energy-converted and recovered. And a side-by-side structure and a combination thereof. In the sheath core structure, the sheath component is a thermoplastic elastic resin with a large content of soft segments that can easily convert energy into vibration and deformation stress, and the core component is a thermoplastic elastic resin with a small content of soft segments that exhibits anti-compression properties. It is made of resin and can give a comfortable touch to contact parts such as the back and buttocks due to an appropriate degree of depression. With the side-by-side structure, the melt viscosity of a thermoplastic elastic resin with a high soft segment content that facilitates energy conversion of vibration and deformation stress is lower than the melt viscosity of a thermoplastic elastic resin with a low soft segment content that exhibits anti-compression properties. A structure in which the proportion of thermoplastic elastic resin occupying a linear surface and having a large amount of soft segment is increased (metaphorically, a structure in which a thermoplastic elastic resin is arranged in an eccentric sheath-core structure) ), The proportion of the thermoplastic elastic resin occupying the linear surface and having a large soft segment content is 80%.
The above-mentioned ones are particularly preferable, and most preferable is a sheath core in which the proportion of the thermoplastic elastic resin having a large soft segment content occupying the linear surface is 100%. When the proportion of the thermoplastic elastic resin with a large soft segment content that occupies the linear surface is large, the flowability when melting and fusing is high, so there is the effect of strengthening the adhesion, and the structure deforms as a unit. In this case, the fatigue resistance against stress concentration at the bonding points is improved, and the heat resistance and durability are further improved. The mats of the present invention have a cushioning layer on one side of which is provided with a wadding layer quilted with a web mainly composed of natural fibers, and on the other side, hard cotton, synthetic fiber web, non-woven fabric, knitted fabric, and fabrics. It is also possible to wrap the cushion layer with the side ground integrated by quilting. The mat of the present invention is particularly useful for commercial seats such as ships' seats, vehicles, ships, hospitals, and hospital beds, futons, cushions, furniture mats, etc., but also seats for vehicles, chairs for furniture, It is also useful as a cushion for office chairs.

Next, the manufacturing method of the present invention will be described. A three-dimensional structure in which a thermoplastic elastic resin is discharged downward from the nozzle at a melting temperature of 20 ° C. to 80 ° C. higher than its melting point from a multi-row nozzle having a plurality of orifices, and is brought into contact with each other in a molten state to be fused. While forming a sheet, it is sandwiched by a take-up device and cooled in a cooling tank, then both sides or one side of a web with a matrix of natural fibers is covered with a knitted fabric, and a side ground wrapped with a side ground sewn by quilting is covered. This is a method for producing a mat, and a method for producing a mat in which a pseudo crystallization treatment by annealing is performed at a temperature of at least 10 ° C. or lower than a melting point of a thermoplastic elastic resin forming a reticulate body in an arbitrary step leading to commercialization. The reticulate body is obtained by melting a thermoplastic elastic resin by using a general melt extruder, supplying the multi-row nozzle having a plurality of orifices, and discharging the resin downward from the orifices. The melting temperature at this time is 20 ° C. to 80 ° C. from the melting point of the thermoplastic elastic resin.
℃ higher temperature. 80 ° C from the melting point of the thermoplastic elastic resin
If the melting temperature is higher than this, thermal decomposition will be remarkable and the rubber elasticity of the thermoplastic elastic resin will be deteriorated, which is not preferable. On the other hand, unless the temperature is higher than the melting point of the thermoplastic elastic resin by 10 ° C. or more, melt fracture occurs and normal filament formation cannot be performed. Further, when the filament is formed by looping after discharge and is brought into contact and fused. The temperature may be lowered and the filaments may not be fused to each other, resulting in a network having insufficient adhesion, which is not preferable. The preferred melting temperature is 20 ° C to 60 ° C above the melting point
Higher temperatures, more preferably 25 ° C to 40 ° C above the melting point. The shape of the orifice is not particularly limited, but may be a hollow cross section (for example, a triangular hollow, a round hollow, a shape with a projection, etc.) and / or an irregular cross section (for example, a triangular, Y-shaped, star-shaped cross-section secondary mode). In addition to the above effects, it is difficult for the three-dimensional structure formed by the discharge filaments in the molten state to relax the flow, and on the contrary, the flow time at the contact point is maintained for a long time to strengthen the adhesion point. It is particularly preferable because it can be When heating for adhesion as described in Japanese Patent Application Laid-Open No. 1-2075, the three-dimensional structure is easily relaxed, a planar structure is formed, and a three-dimensional three-dimensional structure becomes difficult, which is not preferable. As an effect of improving the properties of the reticulate body, the apparent bulk can be increased, the weight can be reduced, the anti-compression property can be improved, and the elasticity can be improved, which is difficult to obtain. The hollow section has a hollow ratio of 8
If it exceeds 0%, the cross section tends to be crushed, so that it is preferably 10% or more and 70% or less, more preferably 20% or more and 60% or less so that the effect of weight reduction can be exhibited. The pitch between the holes of the orifice needs to be a pitch with which the loop formed by the line can sufficiently contact. The pitch between holes is shortened for a dense structure, and the pitch between holes is lengthened for a coarse structure. The pitch between the holes of the present invention is preferably 3 mm to 20 mm, more preferably 5 mm to 10 mm. In the present invention, different densities and different fineness can be obtained as desired. The different density layer can be formed by a configuration in which the pitch between rows or the pitch between holes is also changed, or a method in which the pitch between both rows and holes is also changed. Also, if the pressure loss difference at the time of discharge is given by changing the cross-sectional area of the orifice, the principle that the discharged amount of molten thermoplastic elastic resin extruded from the same nozzle at a constant pressure becomes smaller for the orifice with larger pressure loss, is used. It is possible to manufacture a reticulated structure composed of filaments of different fineness by using a nozzle having at least a plurality of rows having different cross-sectional areas of orifices in a section in the longitudinal direction. Then, discharge downward from the nozzle,
While forming a loop, they are brought into contact with each other in a molten state and fused to form a three-dimensional structure, and are sandwiched by a take-up net, and the winding winding filaments in the molten state on the surface of the mesh body are bent by 45 ° or more. After deforming to flatten the surface and at the same time form a structure by adhering the contact points with the discharge line that is not bent, a cooling medium (usually using room temperature water can increase the cooling rate, It is preferable because it is cheap in terms of cost), and is rapidly cooled to obtain the three-dimensional three-dimensional net-structured net-like body of the present invention. The distance between the nozzle surface and the take-off point is preferably at least 40 cm or less to prevent the discharge filament from being cooled and the contact portion not being fused. If the discharge amount of the discharge line is 5g / hole or more, 10cm-40
cm is preferable, and 5 cm to 20 cm is preferable when the discharge amount of the discharge filament is less than 5 g / hole. The thickness of the net-like body is determined by the opening width (interval between the take-up nets) of the take-up net sandwiching both surfaces of the three-dimensional structure in the molten state. In the present invention, the opening width of the take-up net is set to 5 mm or more for the above reason. Next, it is drained and dried, but if a surfactant or the like is added to the cooling medium, draining and drying may be difficult, or the thermoplastic elastic resin may swell, which is not preferable. still,
The distance between the nozzle surface and the take-up conveyor installed on the cooling medium for solidifying the resin, the melt viscosity of the resin (the melt viscosity at the time of forming the reticulate body is preferably 500 poises to 10000 poises, and when it exceeds 20000 poise, It is not preferable because the forming speed becomes slower and it becomes difficult to form a dense network structure.), And the desired loop diameter and wire diameter can be determined by the hole diameter of the orifice and the discharge amount. A pair of take-up conveyors with adjustable intervals installed on the cooling medium sandwich and hold the molten discharge filaments to fuse the parts that are in contact with each other and continuously draw in the cooling medium to solidify them. By adjusting the distance between the conveyors when forming the body, the thickness can be adjusted while the fused net-like body is in a molten state, and a desired thickness can be obtained. If the conveyor speed is too high, the formation of contact points may be insufficient, or the contact point may be cooled until the fusion point is sufficiently formed, resulting in insufficient fusion of the contact portion. Further, if the speed is too slow, the melt will stay too much and the density will increase, so it is necessary to set the conveyor speed suitable for the desired apparent density. Next, in the present invention, the reticulated body is once cooled and then continuously or discontinuously pseudo-crystallized to be cut into a predetermined size, or after being cut, pseudo-crystallized. On the other hand, matrix fibers (synthetic fibers) made of synthetic resin other than natural fibers mixed in the matrix of the wadding layer may be staples obtained by a known method, but it is preferable to use a thermoplastic inelastic resin in an asymmetric cooling method or a composite method. It is preferred that the latent crimping ability is imparted by the spinning method, and the three-dimensional crimps are developed by the heat treatment after stretching to be cut, or the three-dimensional crimps are developed by the heat treatment after cutting. Since synthetic fibers are also required to have sag resistance and heat resistance, those having an initial tensile resistance of at least 35 g / denier and an initial tensile resistance at 70 ° C. of at least 10 g / denier are preferred. preferable. The crimp degree of the three-dimensional crimp is 1 due to its bulkiness and anti-compression property.
5% or more, and the number of crimps is preferably 10 to 25 crimps / inch.
The synthetic fiber thus obtained is mixed with the natural fiber, which is the main matrix of the wadding layer, in a desired blending amount and opened. The mixing ratio of natural fiber and synthetic fiber is 100 / 0-50
/ 50 weight ratio, pre-opening mixing with an opener, etc., followed by opening with a card etc. to form an opening web having a three-dimensional structure, and an apparent density of 0.1 g / cm ³ or less. , Preferably with an apparent density of 0.01 g / cm ³ to 0.06 g / cm
^The wadding layer is obtained by stacking the wading layers so that the number of layers becomes ^3, and cutting into a predetermined size. Then, both sides of the wadding layer are covered with a knitted fabric to be quilted, and the cushion layer to be inserted is inserted on both sides or one side of the cushion layer.
It is sewn on the side fabric of a predetermined size with an opening / closing port for taking out. Since the side surface of the mat of the present invention is configured such that only the knitted fabric is installed on the side surface of the mat, if the air permeability of the side surface is increased, the pump function of the cushion layer for replacing fresh outside air can be further improved. preferable. Then, a cushion layer is inserted into the side ground to obtain the mat of the present invention. The crystallization treatment in the present invention is carried out at a temperature of at least 10 ° C. from at least the melting point (Tm) of the thermoplastic elastic resin in any step leading to commercialization.
It is lower than the above, and the α dispersion rising temperature of Tan δ (Tαc
r) Perform above. By this treatment, the heat-resistant sag resistance is remarkably improved as compared with the one having no endothermic peak (having no endothermic peak) having an endothermic peak below the melting point. The preferred pseudo-crystallization treatment temperature of the present invention is (Tαcr + 10 ° C.)
To (Tm-20 ° C). If it is pseudo-crystallized by simple heat treatment, heat resistance and sag resistance are improved. In addition,
It is more preferable to give compressive deformation of 10% or more and anneal so that the heat and sag resistance can be remarkably improved.
Further, when the reticulated body is once cooled and then subjected to a drying step,
By setting the drying temperature to the annealing temperature, the pseudo crystallization process can be performed at the same time. Also, a pseudo crystallization treatment can be separately performed in the process of commercialization.

In the mat of the present invention, in addition to a bed, a mattress, a cushion, a furniture mat, etc., only the cushion body or the cushion layer can be used by utilizing its function.
For example, it can be used for vehicle seats, boat seats, chairs, furniture, etc. simply by molding it into a shape suitable for the purpose of use by using a molding die or the like to the extent that the three-dimensional structure is not impaired, and covering the side ground. Of course, it is also possible to use it in combination with another material that should meet the required performance in relation to the application, for example, a different mesh body, a hard cotton cushion material composed of a short fiber aggregate, a non-woven fabric, or the like. In addition, other than the resin manufacturing process, the molded product is processed from the manufacturing process to the extent that performance is not deteriorated, and at any stage of commercialization, it becomes flame retardant, insecticidal, antibacterial, heat resistant, water / oil repellent, colored, aromatic, etc. It is possible to perform the processing such as the addition of chemicals to add the function.

[0019]

EXAMPLES The present invention will be described in detail below with reference to examples.

The evaluations in the examples were carried out by the following methods. 1. Melting point (Tm) and endothermic peak below melting point The endothermic peak (melting peak) is measured from the endothermic curve measured using a Shimadzu TA50, DSC50 type differential thermal analyzer at a heating rate of 20 ° C / min. -H) The temperature was determined. 2. Tαcr polymer is heated to a melting point of + 10 ° C to a thickness of about 300 μm.
Film was prepared and measured using a Vibron DDVII type manufactured by Orientec Co., Ltd. at a rate of 110 Hz and a heating rate of 1 ° C./min. Tan δ (the ratio of the imaginary elastic modulus M ″ to the real part M ′ of the elastic modulus M ″ / The rising temperature of α dispersion corresponding to the transition temperature from the rubber elastic region to the melting region of M ′). 3. Room temperature elongation recovery rate Polymer is heated to melting point + 10 ° C and thickness is about 300μm.
Of the film, using Tensilon UTM4 type manufactured by Orientec Co., Ltd., the strain was returned to 0% after stretching 300% at a stretching speed of 100%, and was allowed to stand for 2 minutes and then stretched to break again. Elongation rate at which stress develops is 300
The value obtained by dividing the elongation rate subtracted from% by 300% is shown in%. (N = 3) 4. 70 ° C. elongation recovery rate Polymer is heated to a melting point + 10 ° C. to have a thickness of about 300 μm.
24 film was prepared by using Tensilon UTM4 type manufactured by Orientec Co., Ltd. and applying a 10% elongation strain at a elongation rate of 100% in a heating oven in an atmosphere of 70 ° C.
After holding for a period of time, the strain is returned to 0%, and after being left for 5 minutes and then stretched to break again, the value obtained by subtracting the stretch rate at which stress develops again at 10% from the stretch rate at 10% is divided by 10%. Shown in%. (N = 3) 5. Apparent Density The sample is cut into a size of 15 cm × 15 cm, the heights at four locations are measured, the volume is calculated, and the weight of the sample is divided by the volume. (Average value of n = 4) 6. Fiber diameter of filaments Each filament portion is cut out from 10 locations, embedded with acrylic resin, the cross section is cut out to make a section, and a cross-section photograph is obtained. The value obtained by obtaining the wire diameter from the enlarged cross-sectional photograph and enlarging it with the magnifying power (n = 10 average value) 7. Fusing By hand, check the fibers that are adhered to each other to see if the sample is fused or not. It is judged whether or not something that cannot be removed is fused by pulling. 8. Heat resistance and durability (residual strain at 70 ° C) Cut the sample into a size of 15 cm x 15 cm, compress it by 50%, leave it in dry heat at 70 ° C for 22 hours, cool it to remove the compression strain, and leave it for one day after leaving it. The ratio of the difference in thickness before treatment to the thickness before treatment is shown in% (n = 3 average value) 9. Cyclic compression strain The sample was cut into a size of 15 cm x 15 cm, and the lateral side, wadding layer, and cushion were cut. In order to prevent the layers from slipping and coming off, the four corners of the interface were joined with sewing thread, and compression recovery was performed at a cycle of 1 Hz to a thickness of 50% in a room at 25 ° C and 65% RH with a Servo pulsar manufactured by Shimadzu Corporation. The ratio of the difference between the thickness after standing for 1 day and the thickness before the treatment and the thickness before the treatment of the sample after repeating 20,000 times is shown in%. (Average value of n = 3) 10. Air permeability The diameter of the side material covered with knitted fabric on both sides of the wadding layer is 10
It is punched out into a cylindrical shape of cm and put in a metal tube with an inner diameter of 10 cm at a height corresponding to the thickness of the side that can be sealed in a state of 5% compression, and the top and bottom are sealed with a packing of 5% compression thickness. A sample was created to prevent side leakage, and an air flow rate measurement device manufactured by Techno World Co., Ltd. (Cosmo instrument design product),
The air permeability (cc / cm ² sec) measured using the high pressure type is shown as the air permeability. 11. Bendability Extrude the created mat from the horizontal surface with one end suppressed, 4
The length until contacting the sloped surface cut out at 5 ° is shown by the following criteria. Less than 100 cm: ◎, less than 130 cm: ○, 15
Less than 0 cm: △, 150 cm or more: × 12. Drainability After measuring the weight of the prepared mat, immerse it in a water tank after 10 minutes, remove it as much as possible, and drain at 30 ° C RH 65%
After standing for 24 hours in a room with the atmosphere described above, the weight was measured after standing for 24 hours, and the amount of residual water was determined and evaluated according to the following criteria.
Residual water content is 5% or less: ◎, Residual water content is 7% or less: ◯, Residual water content is 10% or less: △, Residual water content is 10% or more: × 13. Comfortable sleep Set the created mat on the bed frame, 28 ° C
The following evaluation was performed with the paneller laid down in a RH 75% room. (N = 5) Sheets were laid on the bed mats, 1.8 / kg down / feather: 90/10 mixed feathers were put in the comforter, and pillows used at home were used. (1) Feeling uncomfortable: The degree of "feeling uncomfortable on the back" when sleeping was qualitatively and qualitatively evaluated. No feeling; ◎, almost no feeling; ○, slightly felt; △, felt; × (2) Depression: The degree of body retention when sleeping was sensitized qualitatively. Very comfortable with moderate subduction;
◎, slightly depressed or slightly large, comfortable; ○, slightly depressed or large, slightly lacking in comfort; △, too deep or not submerging and does not feel comfortable; × (3) Feeling of stuffiness: A qualitative qualitative evaluation was performed on the stuffiness felt on the buttocks, the back, and the like in contact with the bed mat after sleeping for 2 hours. Almost no feeling: ◎, slightly stuffy; ○, slightly stuffy; △, remarkably stuffy; × (4) Pressure of body pressure: how much you can endure without moving after sleeping: 30 minutes or less; ×, 1 hour or less; △, 2 hours or less; ○, 2 hours or more; ◎ (5) Comprehensive evaluation: 4 points out of ◎ from (1) to (5)
3 points, △ is 2 points, × is 1 point and does not include Δ with 12 points or more; very good (⊚), that with 12 points or more; Good (○), 10 points or more is x It was evaluated as those which did not contain; those which were somewhat bad (Δ) and those which contained x; bad (x).

Example 1 As a polyester elastomer, dimethyl terephthalate (DMT) or dimethyl naphthalate (DM) was used.
N) and 1.4 butanediol (1.4 BD) were charged with a small amount of a catalyst, and after transesterification by a conventional method, polytetramethylene glycol (PTMG) was added and polycondensation was performed while heating and depressurizing. -The heat obtained by forming a terester block copolymer elastomer, then adding and mixing 1% of an antioxidant and 10% of a flame retardant (phosphorus content: 5000 to 10000 ppm), pelletizing, and vacuum drying at 50 ° C for 48 hours. Table 1 shows the formulation of the plastic elastic resin raw material.

[0022]

[Table 1]

On the effective surface of the nozzle having a width of 120 cm and a length of 10 cm, the pitch of the holes in the width direction is 5 mm, and the pitch of the holes in the length direction is 10 mm.
The zigzag array of orifices has an outer diameter of 2 mm and an inner diameter of 1.
The obtained thermoplastic elastic resin raw material is melted in a separate extruder into a nozzle having a hollow-forming cross section of a triple bridge of 6 mm, and A-1 is used as a sheath component and A-2 is used as a core component. Dispensing just before the orifice, the discharge rate per single hole is 2.0 g / min (A-1: 1 g /
Min., A-2: 1 g / min), the cooling water is placed 12 cm below the nozzle surface, and a pair of take-up conveyors are placed parallel to each other with an endless net made of stainless steel having a width of 140 cm at intervals of 10 cm. The melted discharge line is bent to form a loop and the contact portions are fused together to form a three-dimensional network structure. While sandwiching both sides with a take-up conveyor, it is drawn into cooling water at 25 ° C. at a speed of 1 m / min to solidify and flatten both sides, then taken off, drained, and continuously 120 ° C.
After passing through a setter in which heated air is circulated for 15 minutes to cool and then cutting to a predetermined size, the reticulated body has a triangular cross-sectional hollow cross-section with a cis core structure and a hollow ratio of 40. %, The filament having an endothermic peep at 126 ° C. in addition to the melting point of 1.2 mm is almost joined by fusion bonding at the contact points of the formed loops, and both sides are substantially flattened. Average apparent density 0.046 g / cm ² , thickness 9.
5 cm, cyclic compression strain 2.8%, heat resistance durability 11.2%
Met. Separately, synthetic fibers are distributed in a conventional manner with PET having an intrinsic viscosity of 0.63 and 0.56 at a weight ratio of 50/50 and 3.0 g / minute per single hole (1 g / minute: 1 g / minute).
As a composite spinning at a spinning speed of 265 ° C. at a spinning speed of 1300 m / min, and then drawn in two steps at 70 ° C. and 180 ° C. to obtain a drawn yarn, which is cut into 64 mm and free-heat treated at 170 ° C. Crimping is developed and the hollow section has a hollow ratio of 32%
A synthetic fiber having a sheath-core structure with a fineness of 6 denier, an initial tensile resistance of 38 g / denier, a crimp degree of 20%, and a crimp number of 18 crimps / inch was obtained. Then, as the matrix fiber, the epi layer on the surface of the cuticle layer was removed, and the flame-retarded merino wool and the synthetic fiber were mixed in a weight ratio of 85/15, and
A web obtained by pre-opening with a planer and opening with a card was laminated so that the apparent density was 0.05 g / cm ^2, and cut into a predetermined size to obtain a wadding layer. Air permeability of 30 cm / c made of Toyobo's Heim polyester fiber
It is covered with a broad square of m ² seconds and quilted in a rhombic lattice at intervals of 10 cm, wadding layers are installed on the front and back of the cushion layer, and there is no wadding layer on the side surface, and there is an opening and closing opening that allows the cushion layer to be inserted and removed. The cushion layer was inserted into the side ground sewn on to obtain a bed mat of the present invention. Table 2 shows the evaluation results of the obtained mat for betting. As is clear from Table 2, this bet mat is excellent in heat resistance, durability, bendability, drainability, and has good breathability on the side fabric and good sleeping comfort. The mat for this bed showed flame retardancy, and the toxicity index of combustion gas was 6.0. From this, it can be seen that the mat for betting is highly safe in case of fire.

[0024]

[Table 2]

Example 2 A nozzle having a width of 120 cm and a length of 5 cm and having a staggered arrangement with a hole-to-hole pitch of 5 mm in the width direction and a hole-to-hole pitch of 10 mm in the length direction on a nozzle effective surface is a nozzle having an outer diameter of 1 mm and a round cross section. The obtained thermoplastic elastic resin raw material A-5 was melted by an extruder, and the discharge amount per single hole was 2.0 g at a melting temperature of 245 ° C.
Discharge at the bottom of the nozzle at a rate of 1 / min, place cooling water 15 cm below the nozzle surface, and put a pair of take-up conveyors on the water surface in parallel with the stainless endless net with a width of 140 cm at intervals of 4.5 cm. The melted discharge line is bent to form a loop and the contact portions are fused to form a three-dimensional network structure, and both sides of the melted network are drawn. While sandwiching it with a conveyor, it is drawn into cooling water at 25 ° C at a speed of 1 m / min to be solidified and flattened on both sides, then taken off, drained, and then in a setter in which heated air at 120 ° C is continuously circulated for 15 minutes. The reticulate body obtained by passing and cooling and then cutting it into a predetermined size has a round cross-section, and a linear line having an endothermic peak at 126 ° C is formed in addition to the melting point of the wire diameter of 0.9 mm. -The contact points of the Surface is substantially flattened, the apparent density of the average 0.048 g / cm ^2, thickness 4.5 cm,
The cyclic compression strain was 7.5%, and the heat resistance durability was 18.4%. Then, the laminated cotton formalin-processed with spread cotton and the synthetic fiber used in Example 1 were mixed in a weight ratio of 85/15, pre-opened with an opener, and then opened with a card. apparent density obtained web is laminated so that the 0.05 g / cm ^2, covered with a permeability of 30 cc / cm ² sec br composed of polyester fibers manufactured by Toyobo Heim and quilt rhombic lattice 8cm interval In the present invention, the wadding layer is provided on the front and back surfaces of the cushion layer, the side surface is free of the wadding layer, and the cushion layer is inserted into the side material sewn into a structure having an opening / closing opening through which the cushion layer can be inserted and removed. To obtain a betting mat. Table 2 shows the evaluation results of the obtained mat for betting. As is clear from Table 2, the bed mat is excellent in heat resistance, durability, bendability, and drainability, and has good breathability on the side fabric and good sleeping comfort. The matte had a combustion gas toxicity index of 5.0. From this, it can be seen that the mat has good safety in case of fire.

Example 3 A staggered array of orifices having an outer diameter of 2 mm and an inner diameter of 1.6 mm was formed on a nozzle effective surface having a width of 120 cm and a length of 5 cm with a hole-to-hole pitch of 5 mm in the width direction and a hole-to-hole pitch of 10 mm in the length direction. The obtained thermoplastic elastic resin A-3 was melted in an extruder with a nozzle having a triple bridge hollow forming cross section, and the melting temperature was 2
3. Discharge at a discharge rate of 2.0 g / min per single hole at 35 ° C. below the nozzle, arrange cooling water 12 cm below the nozzle surface, and make stainless endless nets 140 cm wide in parallel.
A pair of take-up conveyors are arranged at intervals of 5 cm so as to partially protrude above the surface of the water, and the discharge line in the molten state is bent to form loops to fuse the contact portions to form a three-dimensional net structure. Was formed, and was drawn into cooling water at 25 ° C. at a rate of 1 m / min for solidification, then taken off, drained, and passed through a setter in which heated air at 120 ° C. was continuously circulated for 15 minutes to cool, The net-like body obtained by cutting into a predetermined size and having both sides substantially flat is a hollow rice ball-shaped cross section, and a wire having an endothermic peak at 126 ° C in addition to a melting point of 1.2 mm. The contact points of the loops formed by the stripes are almost joined by fusion bonding, and the average apparent density is 0.048 g /
cm ² , thickness 4.5 cm, cyclic compression strain 5.8%, heat resistance durability 10.8%. Then, a cotton cut into a cut length of 65 mm and the synthetic fiber obtained in Example 1 were mixed in a weight ratio of 70/30, and a web as a wadding layer obtained in the same manner as in Example 1 was mixed with Toyobo Heim's polyester fiber. Example 2 with a broad air permeability of 30 cc / cm ² seconds
Quilt in the same manner as above, and the wadding layer is installed on the front and back of the cushion layer, the side surface has no wadding layer, and the cushion layer is sewn on the side with the opening and closing opening that allows the cushion layer to be inserted and removed. The evaluation results of the mat for betting of the present invention obtained by inserting are shown in Table 2. As is clear from Table 2, the bed mat is excellent in heat resistance, durability, bendability, and drainability, and has good breathability on the side fabric and good sleeping comfort. The bed gas mat had a combustion gas toxicity index of 5.6. From this, it is understood that the mat for betting has good safety in case of fire.

Example 4 As a polyurethane elastomer, 4,4'-diphenylmethane diisocyanate (MDI), PTMG and 1.4BD as a chain extender were added and polymerized, and then 2% of an antioxidant was added and mixed. Table 3 shows the formulation of the polyether urethane polymer after kneading, pelletizing and vacuum drying.

[0028]

[Table 3]

The thermoplastic elastic resin thus obtained (seed component:
B-1 and core component: B-2) except that the melting temperature was 220 ° C., and the cross-sectional shape of the cis-core structure of the filaments of the reticulate body obtained in the same manner as in Example 1 was a hollow in the shape of a triangular rice ball. In addition to the melting point with a rate of 40% and a wire diameter of 1.1 mm, the filaments that have an endothermic peak at 126 ° C are joined by fusion bonding at the contact points of the loops formed, and both sides are substantially flattened. The average apparent density is 0.047 g / cm ² , and the thickness is 9.
5 cm, cyclic compression strain 3.6%, heat resistance durability 7.5%. Next, Table 2 shows the evaluation results of the betting mat of the present invention obtained by inserting the cushion layer into the side material used in Example 2. As is clear from Table 2, this bet mat is excellent in heat resistance, durability, bendability and drainability, and has good breathability on the side fabric and good sleeping comfort.

Comparative Example 1 A reticulate body obtained in the same manner as in Example 2 except that only the polypropylene (PP) single component having a melt index of 12 had a melting temperature of 250 ° C. has a solid round cross section and a wire diameter of 1 .8m
The filaments having no endothermic peak other than the melting points of m and m are joined by fusion bonding at the contact points of the formed loops, the both surfaces are substantially flattened, and the average apparent density is 0.
047 g / cm ² , thickness 4.5 cm, repeated compressive strain 30.
It was 2% and the heat resistance durability was 49.5%. Then, the scoured Indian cotton and the synthetic fiber used in Example 1 were mixed with 70/30.
The web obtained by mixing in a weight ratio, pre-opening with an opener and then opening with a card has an apparent density of 0.05 g / cm.
^A web with a wadding layer laminated to be ² has a breathability of TOYOBO HEIM polyester fiber 3
It is covered with 0cc / cm ² seconds broad and is quilted into a 12cm rhombus lattice. Wadding layers are installed on the front and back of the cushion layer. There is no wading layer on the side surface and there is an opening / closing opening for inserting and removing the cushion layer. Table 2 shows the evaluation results of the mat for betting of the present invention obtained by inserting the cushion layer into the side ground sewn into the structure. As is clear from Table 2, since it is a reticulated body made of non-elastic olefin, it is excellent in drainability, but has good heat resistance, durability, bendability, and breathability of the side material, but it is inferior in sleeping comfort other than stuffiness. It is a bed mat that also fails flame retardancy and has problems during a fire.

COMPARATIVE EXAMPLE 2 A nozzle having a width of 120 cm and a length of 10 cm and a staggered arrangement with a hole-to-hole pitch of 5 mm in the width direction and a hole-to-hole pitch of 10 mm in the length direction on an effective surface of the nozzle has an outer diameter of 1 mm and a round cross section. ,
The obtained thermoplastic elastic resin raw material A-5 was melted with an extruder, and the melting amount was 235 ° C., and the discharge amount per single hole was 3.0 g.
/ Min, and the cooling water is placed under the nozzle surface 5 cm, and a pair of take-up conveyors are partially projected on the water surface in parallel with the stainless endless net of width 140 cm at intervals of 9.5 cm. The melted discharge line is bent to form a loop and the contact portions are fused to form a three-dimensional network structure, and both sides of the melted network are drawn. While being sandwiched by a conveyor, it is drawn into cooling water at 25 ° C. at a speed of 1 m / min to be solidified and flattened on both sides, then taken out, drained, and cut into a predetermined size. In the cross section, the filaments having no endothermic peak other than the melting point of 5.9 mm in diameter are formed by joining most of the contact points of the loops formed by fusion bonding and substantially flattening both sides. Average apparent density is 0.074g / cm
² , the thickness was 9.5 cm, the cyclic compression strain was 18.3%, and the heat resistance was 28.4%. Next, Table 2 shows the evaluation results of the mat for betting obtained by inserting the cushion layer into the side material used in Comparative Example 1. As is clear from Table 2, the mat for betting is excellent in drainage and less dampness, but inferior in sleep comfort other than heat resistance, durability, bendability and dampness. The combustion gas toxicity index of this bed mat was 5.1.

Comparative Example 3 A reticulate body obtained in the same manner as in Comparative Example 2 except that a take-up conveyor net was placed 30 cm below the nozzle surface at a melting temperature of 245 ° C. and the take-up speed was 0.3 m / min. Is a round cross-section with a wire diameter of 1.9 mm, which has no endothermic peak other than the melting point, and the contact points of the loops formed are almost joined by fusion, and both sides are substantially Is flattened,
Average apparent density is 0.24 g / cm ² , thickness is 9.5 cm,
The cyclic compression strain was 19.8% and the heat resistance durability was 29.4%. Next, Table 2 shows the evaluation results of the betting mats obtained in the same manner as in Comparative Example 2. As is clear from Table 2, although excellent in drainage and less dampness, heat resistance, durability,
It is a mat for betting that is inferior in sleeping comfort other than bendability and dampness. The bed gas mat had a combustion gas toxicity index of 5.1.

COMPARATIVE EXAMPLE 4 The discharge amount per single hole was 0.3 g / min, a take-up conveyor net was placed 5 cm below the nozzle surface, and the take-up speed was 1.9.
The reticulate body obtained by the same method as in Comparative Example 3 except that m / min was a cross section having a round cross section, and a line having no endothermic peak other than the melting point of 0.4 mm was formed. Almost all contact points of the loops are joined by fusion bonding, both sides are substantially flattened, and the average apparent density is 0.004 g / cm ² ,
The thickness was 9.5 cm, the cyclic compression strain was 13.6%, and the heat resistance durability was 22.4%. Next, Table 2 shows the evaluation results of the betting mats obtained in the same manner as in Comparative Example 2. As is clear from Table 2, it has excellent breathability, bendability, and drainability,
It is a bed mat that has poor heat resistance, durability, and sleeping comfort.

Comparative Example 5 At a melting temperature of 230 ° C., the discharge amount per single hole was 1.5 g /
Minutes, a take-up conveyor net was placed 60 cm below the nozzle surface, and the take-up speed was set to 1 m / min. The filament has no endothermic peak other than the melting point of 1.9 mm, but the filament does not form a loop and almost no contact point is formed.
No reticulate was formed. Forcing this wire into a web with an apparent density of 0.05 g / cm ² and a thickness of 9.5 cm,
Next, Table 2 shows the evaluation results of the betting mats obtained in the same manner as in Comparative Example 2. As is clear from Table 2, when the contact points are not joined, the bed mat is inferior in sleeping comfort.
Since this bed mat has poor sleeping comfort, no other evaluation was made.

Comparative Example 6 At a melting temperature of 245 ° C., the discharge amount per single hole was 1.5 g /
In the same manner as in Comparative Example 2, except that a take-up conveyor net was placed 20 cm below the nozzle surface and the surface of one side of the conveyor net had irregularities of 5 mm, and the take-up speed was 1 m / min. The obtained reticulate body has a round cross section,
Wires having no endothermic peak other than the melting point of the wire diameter of 0.9 mm, the contact points of the loops to be formed are almost joined by fusion, and one side is substantially flattened. The other surface has irregularities, the average apparent density is 0.035 g / cm
² , thickness of the thickest place 9.5cm, repeated compressive strain 1
The heat resistance and durability were 9.5% and 29.2%, respectively. Next, Table 2 shows the evaluation results of the betting mats obtained in the same manner as in Comparative Example 2. As is clear from Table 2, it is excellent in terms of bendability, drainability, stuffiness, and pressure but it is slightly inferior in heat resistance and durability. It's Matt. The combustion gas toxicity index of this bed mat was 5.1.

Comparative Example 7 A nozzle having a width of 120 cm and a length of 1 cm and a staggered arrangement with a hole-to-hole pitch of 5 mm in the width direction and a hole-to-hole pitch of 5 mm in the length direction on a nozzle effective surface was used. Used,
The discharge rate per single hole is 0.3 g / min, a take-up conveyor net is placed 5 cm below the nozzle surface, and a pair of take-up conveyors are placed at 0.4 cm intervals so that they partially come out on the water surface. The reticulate body obtained in the same manner as in Comparative Example 3 except that the speed was 1.0 m / min had a round cross section and a wire diameter of 0.
The filaments having no endothermic peak other than the melting point of 4 mm are formed by almost fusion-bonding the contact points of the formed loops, substantially flattening both surfaces, and an average apparent density of 0.
064 g / cm ² , thickness 0.4 cm, cyclic compressive strain 18.
It was 6% and the heat resistance durability was 29.8%. Next, Table 2 shows the evaluation results of the betting mats obtained in the same manner as in Comparative Example 2. As is clear from Table 2, the bed mat is excellent in bendability and drainability, but inferior in heat resistance and durability, and the cushion layer is too thin, resulting in remarkably inferior sleeping comfort.

Comparative Example 8 The characteristics of the reticulate body obtained in the same manner as in Example 2 except that the pseudo crystallization treatment was not carried out were that the cross-sectional shape was a round cross section and the wire diameter was 0.9 mm.
In addition to the melting point of, the filaments that have no endothermic peak at 126 ° C
Almost all the contact points of the loops to be formed are joined by fusion bonding and both sides are substantially flattened, the average apparent density is 0.048 g / cm ² , the thickness is 4.5 cm, and the cyclic compression strain is 16.5. %, And the heat resistance durability was 26.4%. Separately, 70% of scoured Indian cotton and the synthetic fiber used in Example 1 were used.
A web obtained by mixing 30 weight ratios, pre-opening with an opener and then opening with a card has an apparent density of 0.15 g.
Table 2 shows the evaluation results of the mat for betting obtained by inserting the cushion layer into the side material obtained in the same manner as in Comparative Example 1 except that the mats were laminated so as to have a thickness of / cm ² . As is clear from Table 2, since the density of the wadding layer was too high, the breathability and bendability of the side fabric was poor, and the mat for a bed was inferior in sleeping comfort.

Comparative Example 9 70% of the scoured Indian cotton and the synthetic fiber used in Example 1 were used.
/ 30 weight ratio, pre-opened with an opener and then opened with a card to obtain a web having an apparent density of 0.05.
A web layer laminated to g / cm ² was covered with a broad air permeability of 30 cc / cm ² seconds made of TOYOBO HEIM polyester fiber, and a wadding layer was placed on the front and back of the cushion layer without quilting. Evaluation results of a mat for betting obtained by inserting the cushion layer obtained in Comparative Example 8 into a side material sewn into a structure having an opening / closing opening through which the side surface does not have a wadding layer and the cushion layer can be inserted and removed. Table 2
Shown in As is clear from Table 2, it was a mat for betting which had good bending properties and comfortable to sleep, but was poor in heat resistance and durability, and had a problem that the wadding layer after washing became felt because it was not quilted.

Comparative Example 10 Comparative Example 2 was repeated except that a commercially available polyester hard cotton having an apparent density of 0.05 g / cm ³ was sliced into a thickness of 5 mm and cut into a predetermined size to form a wadding layer. Table 2 shows the evaluation results of the betting mat obtained by inserting the net-like body obtained in Comparative Example 8 into the obtained side fabric. As is clear from Table 2, the mat for bed is slightly comfortable to sleep but inferior in heat resistance, durability, bendability and drainability.

Comparative Example 11 Commercially available polyester hard cotton having an apparent density of 0.05 g / cm ³ was sliced to a thickness of 5 mm and cut into a predetermined size.
A commercially available rubber adhesive was applied to both surfaces of the two reticulate bodies used in Comparative Example 8 to bond hard cotton to the reticulate body, and a side cloth made of polyester fiber sewn to a predetermined size was applied. Table 2 shows the evaluation results of the mat for betting obtained by inserting.
As is clear from Table 2, the mat for bed is slightly comfortable to sleep but inferior in heat resistance, durability, bendability and drainability.

Comparative Example 12 A bed obtained by inserting a commercially available polyester hard cotton having a thickness of 10 cm and an apparent density of 0.05 g / cm ³ into a cushion material and inserting it into a side cloth made of polyester fiber sewn to a predetermined size. Table 2 shows the evaluation results of the mat. As is clear from Table 2, the mat for betting is a bed mat which is slightly comfortable but has little sinking and is inferior in heat resistance, durability, bendability and drainability.

Comparative Example 13 A mat for betting obtained by using a commercially available foamed polyurethane having a thickness of 10 cm and an apparent density of 0.05 g / cm ³ as a cushioning material and inserting the padding into the side fabric using the wadding layer used in Comparative Example 2. The evaluation results of are shown in Table 2. As is clear from Table 2,
A bed mat that has excellent heat resistance and durability, but has good bendability, drainability, and breathability on the side, but is inferior in sleeping comfort.

Example 5 The mattress obtained by inserting the reticulate body obtained in Example 2 into a lateral fabric obtained in the same manner as in Example 1 except that the thickness was changed shows heat resistance, durability, and It was a mattress with excellent foldability, drainability, and sleeping comfort.

Example 6 A dentition was obtained by inserting the reticulate body obtained in Example 2 into the lateral ground obtained in the same manner as in Example 1 except that the thickness was changed. According to the evaluation results of the obtained zakka, the zakka was excellent in heat resistance, durability, drainability and sitting comfort.

[0045]

EFFECTS OF THE INVENTION A wadding layer made of a web that takes advantage of the characteristics of natural fibers is fixed by quilting and sewn to a side fabric, and a filament made of a thermoplastic elastic resin having good elongation recovery is fused and integrated to form a surface. A mat with a cushion layer made of a flattened mesh and a manufacturing method, so that it does not get stuffy easily and has good sleeping comfort. The most suitable mat for household use, hospital and hotel beds, mattresses, cushions, and furniture that can be washed to remove miscellaneous bacteria such as MRSA and a manufacturing method can be provided. .

Claims (13)

[Claims] 1. A mat in which a cushion layer is wrapped with a side fabric made of a knitted fabric, and the structure of the side fabric on at least one side of the cushion layer is quilted and sewn with a wadding layer sandwiched between two knitted fabric sheets. The cushion layer has a structure in which a continuous line made of a thermoplastic elastic resin and having a diameter of 5 mm or less is bent to form a random loop, and most of the contact portions of each loop are fused. The three-dimensional three-dimensional network has a substantially flat upper and lower surfaces, and has an apparent density of 0.005 to 0.10 g / cm ³ ,
A mat having a thickness of 5 mm or more and a wadding layer comprising a web having a natural fiber as a main matrix and an apparent density of 0.1 g / cm ³ or less. 2. The thermoplastic elastic resin constituting the cushion layer has a recovery rate after room temperature elongation of 300% (room temperature elongation recovery rate) of 20% or more and after holding 10% elongation at 70 ° C. for 24 hours. The mat according to claim 1, which has a recovery rate (70 ° C extension recovery rate) of 30% or more. 3. The net-like body constituting the cushion layer has a wire diameter of 0.01 mm or more, an apparent density of 0.01 g / cm ³ to 0.08 g / cm ³ , and a thickness of 10 mm or more. mat. 4. The wire diameter of the net-like body constituting the cushion layer is 0.1 mm or more and 2 mm or less, and the apparent density is 0.02 g / cm.
The mat according to claim 1, which has a thickness of ³ to 0.06 g / cm ³ and a thickness of 20 mm or more and 500 mm or less. 5. A reticulated body having an endothermic peak at a temperature above room temperature and below the melting point in a melting curve of a component comprising a thermoplastic elastic resin measured by a differential scanning calorimeter in the cushion layer. mat. 6. The cross-sectional shape of the filaments of the net-like body that constitutes the cushion layer is a hollow cross section or an irregular cross section.
The listed mat. 7. The mat according to claim 1, wherein the thermoplastic elastic resin forming the cushion body is polyester. 8. A woven fabric on both sides of the wadding layer,
The mat according to claim 1, wherein the sewn side fabric has an air permeability of 20 cc / cm ² seconds or more. 9. The mat according to claim 1, wherein the natural fiber is silk. 10. The mat according to claim 1, wherein the natural fiber is wool. 11. The mat according to claim 1, wherein the natural fiber comprises hemp. 12. A thermoplastic elastic resin is discharged downward from the nozzle at a melting temperature 20 to 80 ° C. higher than the melting point of the multi-row nozzle having a plurality of orifices, and a continuous linear loop is formed in a molten state. After being formed, the respective loops were brought into contact with each other and fused to form a three-dimensional structure, which was sandwiched by a take-up device and cooled in a cooling tank.
A method for producing a mat, characterized in that the upper and lower surfaces of a three-dimensional structure, or both sides of one side of a web mainly composed of natural fibers are covered with a knitted fabric and covered with a quilted side. 13. The method for producing a mat according to claim 12, wherein pseudo-crystallization treatment by annealing is performed at a temperature of at least 10 ° C. or lower than the melting point of the thermoplastic elastic resin forming the reticulated body in any step leading to commercialization. ..