JPH01164312A - Cushion material - Google Patents

Abstract

PURPOSE: To obtain a cushion material with excellent resilience, touch feeling, durability of compression restoring, and permeability, by forming deep random crimping unevenness on the cushion material surface. CONSTITUTION: On one face of a mesh structure consisting of polyolefin, a staple fiber layer, which mainly consists of thermoplastic synthetic fiber with a contraction rate lower than that of the polyolefin mesh structure and having hardness not higher than 30 degree and thickness of 3-100mm, is laminated by partially fusing. A crimping unevenness pattern is formed on the staple fiber layer surface. The laminated body is partially fixed at arbitrary intervals by quilting or welder processing. Then the laminated body is heat-processed by passing through a dry heating setter, etc., to express contraction of the net mesh fabric with honeycomb structure consisting of polyolefin. The contraction is adjusted as desired by changing heating temperature and heating time. Thus, a cushion material with a crimp unevenness pattern on the stable fiber layer surface can be obtained.

Description

Detailed Description of the Invention (Field of Industrial Application) The present invention is used as a cushion material for mats, cushions, futons, pillows, etc.
Suitable for all cushioning materials that require breathability.

(Prior art) As a method for forming an uneven pattern on a fiber sheet such as a nonwoven fabric made of a laminate of synthetic fibers, a sheet of hard cotton, or a knitted fabric made of synthetic fiber yarn, there is a method of forming an uneven pattern on a fiber sheet such as a nonwoven fabric made of a laminate of synthetic fibers, a sheet of hard cotton, or a knitted fabric made of synthetic fiber yarn. A concavo-convex forming method in which the fibers are compressed and formed by shifting the fibers at the nip between a roller and an ultrasonic oscillation horn, or a method in which quilt-like seams are provided to the fiber sheet described above are known. On the other hand, recently, hard molded products have been known in which the difference in the unevenness of the uneven pattern is increased in order to provide a more comfortable sleeping, sitting, or usable feeling.

However, these sheet-like products with uneven patterns or hard cotton molded products with large differences in unevenness have the disadvantage that sufficient elasticity cannot be obtained if the unevenness is not deeply formed. Ta.

In addition, when the difference in unevenness is increased, while the comfort of sleeping and sitting can be improved to a certain extent, sufficient elasticity and compression durability are lacking, and sufficient breathability is obtained. There was a drawback that there was no

(Problems to be Solved by the Invention) The present invention solves the above-mentioned drawbacks of conventional molded products made of a laminate of staple fiber layers and having an uneven pattern formed on the surface. Even if the difference in unevenness is increased or decreased, sufficient elasticity cannot be obtained, and the durability of compression recovery is poor.
Furthermore, we aim to eliminate the disadvantages of the material's poor breathability, and provide a new cushioning material that has unprecedented elasticity and tactile sensation, as well as excellent compression recovery durability and breathability. .

(Means for Solving the Problems) That is, the present invention provides at least one side of a network structure made of polyolefin with a hardness of 30% consisting mainly of thermoplastic synthetic fibers having a smaller shrinkage rate than that of the polyolefin network structure.
A cushion material characterized in that staple fiber layers having a thickness of 3 to 100 aos are partially fused and laminated, and a grain-like uneven pattern is formed on the surface of the staple fiber layer. be.

The network structure made of polyolefin in the present invention may be any sheet-like structure as long as it undergoes shrinkage stress greater than the change in the staple fiber layer when heated; Even if it is an array type non-woven product, it is also read.

As the material for the network structure, polyolefins such as polyethylene and polypropylene are preferred, and woven fabrics using threads made of these materials, particularly monofilaments of 50 to 2000 d, are preferred. As for the structure of the woven fabric, for example, the implant density is 10 to 50 pieces/inch vertically and 10 to 50 pieces/inch horizontally.
The fibers are most preferably honeycomb or plain weave.

Thermoplastic synthetic fibers in the present invention include polyester,
Examples include fibers such as nylon and acrylic, and although not particularly limited, polyester is particularly preferred since the fibers have excellent crimp characteristics, bulk, and layer characteristics.

The single yarn denier of the thermoplastic synthetic fiber used in the present invention is 0.
It is preferable to set the denier to 5 to 50 denier. If the single yarn denier is less than 0.5 denier, the carding property becomes poor and the desired staple fiber layer will not be formed, so it is not preferable.

On the other hand, if it exceeds 50 denier, the resulting staple fiber
This is not preferable because the texture of the fibrous layer deteriorates and it becomes hard.

The staple fiber WiN in the present invention can be produced by passing thermoplastic synthetic fiber short fibers through a card, laminating the obtained web and then needle punching, or by mixing binder fibers into the short fibers in advance and passing the card through the card. It can be obtained by laminating the web and heating it to melt the binder fibers while compressing it to a predetermined thickness to maintain the shape of the web.

The fiber length of the short fibers constituting the staple layer is as follows:
Although not particularly limited, a staple length of 28 to 120 tm is preferable, and a staple length of less than 28 seconds is not preferable because carding properties deteriorate.

On the other hand, if the staple length exceeds 100 m, carding becomes difficult as described above, which is not preferable.

The fibers constituting the staple layer of the present invention are mainly composed of the above-mentioned thermoplastic synthetic fibers, but other natural TM fibers may be used as long as they do not impair the required performance of the intended cushioning material.
There is no problem even if fibers, etc. are mixed in.

When the hardness of the staple fiber layer of the present invention exceeds 30 degrees of rubber hardness, it is not preferable because it is too hard and does not shrink, has no elasticity or cushioning properties, and is poor in comfort and breathability.

More preferably, the rubber hardness is 1 degree to 30 degrees.

In the present invention, rubber hardness is measured using an F-type rubber hardness meter manufactured by Kobunshi Keiki Co., Ltd.

If the apparent thickness of the staple fiber layer of the present invention is less than 3 m, it will not exhibit elasticity as a cushion material, which is undesirable. On the other hand, if it exceeds 100 mm, the elasticity due to the shrinkage effect of graining will not be exhibited. undesirable,
A more preferable thickness is 5 to 50++a.

The most distinctive feature of the present invention is that a grain-like uneven pattern is formed on the surface of the staple fiber layer constituting the cushion material.

This grain-like unevenness is not seen at all in conventionally known uneven pattern molded products, and is formed by the special manufacturing method described below.

The grain-like uneven pattern referred to in the present invention means that the apparent surface area forming a single convex portion of the grain pattern is 0.1 cd to 100 e.
d, and its size is formed relatively randomly.

If the surface area forming a single convex portion of the grain is less than 0.1 m, it is undesirable because the unique elasticity and tactile sensation provided by the present invention cannot be obtained, and if it exceeds 100 m,
Since sufficient shrinkage has occurred in the staple fiber layer,
This is not preferable because durability of compression recovery and sufficient air permeability cannot be obtained.

Hereinafter, the method for manufacturing the cushion material of the present invention will be explained.

The cushion material of the present invention can be obtained, for example, as follows.

Polyester staple cotton is placed on both the upper and lower surfaces through a net-like fabric with a honeycomb structure made of polyolefin.
Either as it is or on the outside of this polyester staple cotton, a side fabric is placed and laminated.

This laminate is partially fixed at arbitrary intervals by quilting or welding.

Next, this material is heat-treated through a dry heat setter or the like to cause the honeycomb-structured net-like fabric made of the polyolefin used above to shrink.

The shrinkage at this time can be adjusted as desired by changing the heating temperature and heating time.

By doing so, a cushion material having a grain-like uneven pattern on the surface of the staple fiber layer intended in the present invention can be obtained.

(Examples) The present invention will be explained below with reference to Examples, but the present invention is not limited to these Examples.

A net-like fabric with a honeycomb structure woven with 300 denier polypropylene yarn at a density of 39 threads/inch in the vertical direction and 32 threads/inch in the horizontal direction, with the net-like fabric sandwiched between the top and bottom,
Laminated sheet-like hard cotton made of polyester drawn cut cotton with a thickness of 30cm and a basis weight of 300g/nf, and then sandwiching the laminate above and below with polyester with a basis weight of 120cm.
g/rrr tricot fabric is placed as the side fabric, total 5
A stack of layers was formed.

This laminate was fixed by ultrasonic welding in parallel at a pitch of 10c+s in the middle direction, and this partially fixed laminate was heated to It was fed at a feed speed of 6 m/min (overfeed method) under the conditions of 140° C. and a conveyor set speed of 3 m/min, and passed through a 2 m setter.

The obtained cushion material has a hardness of 20 degrees and an apparent total thickness of the staple fiber layer of 80 am (40 m on one side x 2).
The staple layer was partially fused, and the surface of the staple layer was formed with deep, bulging, grain-like unevenness integrally with the side fabric. FIG. 1 shows an outline of the cushion material obtained in this example.

(Effects of the Invention) The cushion material of the present invention has deep unevenness in a random grain pattern formed on the surface of the cushion material in the birch seen in the example obtained above. Since it is formed by a method unique to the present invention, it is possible to provide a new cushioning material that has excellent elasticity and feel, as well as excellent compression recovery durability and air permeability.

[Brief explanation of the drawing]

FIG. 1 is a perspective view showing one embodiment of the present invention. Patent applicant: Toyobo Co., Ltd.

Claims (1)

[Claims] (1) On at least one side of the polyolefin network structure, a staple fiber layer with a hardness of 30 degrees or less and an apparent thickness of 3 to 100 mm, mainly made of thermoplastic synthetic fibers with a smaller shrinkage rate than the polyolefin network structure. What is claimed is: 1. A cushioning material characterized in that the staple fiber layers are partially fused and laminated, and a grain-like uneven pattern is formed on the surface of the staple fiber layer.