JPH05176830A - Cushion material and its production - Google Patents

Abstract

PURPOSE:To easily produce an excellent cushion material, by arranging a plurality of packed materials enveloping coil springs with integrated fibers which are combined fibers of heat-melting fibers and non-heat-melting fibers shaped to form a sheet, a cylinder, a bag, etc., and by arranging sheets made of the combined fibers at the upper and lower sides and heating them in a metal molding to make it a unit. CONSTITUTION:A first integrated fibrous material 2 having a sheet shape, a cylinder shape, a bag shape, etc., is formed by a combined fibrous material composed of heat-melting and non heat-melting fibers. A packed material 3 is formed by enveloping coil springs 1 with the first integrated fibrous material 2, a plurality of the packed materials 3 are arranged to form a disposition. Next, a second integrated fibrous material 4 having a sheet form made of the combined fibers likewise as the above is arranged at least at one of the upper and the lower faces of the disposition and contained in a metal mold to heat it and seal the heat-melting fibrous materials. In this way, a cushion material, which is excellent in the appearance, simple in the structure and also has not much lateral swings and creak of springs, can be easily produced.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cushioning material and a method of manufacturing the same, and more specifically, it has a coil spring having independence and a partial hardness can be adjusted by combining the coil springs in a block unit. Further, the present invention relates to a cushioning material having an even hardness, a light weight, and a low noise due to an integral structure of a coil spring and an outer skin, and a method of manufacturing the cushioning material which is more excellent for human health. INDUSTRIAL APPLICABILITY The present invention is used for bed mattresses, chairs, automobile sofas, and other mattresses.

[0002]

2. Description of the Related Art In a conventional mattress, the upper and lower surfaces of a plurality of coil springs arranged in rows and columns are connected by helical lines to form a plurality of spring units. An outer frame line is provided in the peripheral portion of the spring, and the outer frame line and the upper surface of each spring are fixed by a joint member. An elastic body is arranged on the spring unit. In addition, a pocket coil spring unit and the like are known as those using an independent coil spring (actually disclosed in Japanese Utility Model Laid-Open No. 2-1272).
68).

[0003]

However, in the above-mentioned conventional mattress, a step of winding a helical wire is required, and the helical wire may come out by being used. Further, an outer frame line is required, which makes it heavy, and since each joining member is attached individually, the process is complicated. Further, when arranging the coil springs, it is practically difficult to change the diameter or the number of the springs to form a functional structure, and the spring unit and the elastic bodies arranged above and below the spring unit are not integrated. Therefore, there has been a problem that buttoning or the like is required in the subsequent process. Further, even when the above-mentioned known pocket coil spring unit is used, the outer frame line is similarly required to fix and hold the whole, which is heavy and has a problem in appearance, and the like. Further, even if the outer frame line is not required, it is necessary to bond the adjacent pocket coils, which complicates the manufacturing process. Furthermore, there is a problem that lateral shake easily occurs.

The present invention overcomes the above-mentioned drawbacks and has an excellent appearance, a simple structure, less lateral vibration, no squeaking noise of the spring, light weight, and easy partial hardness adjustment. It is an object of the present invention to provide an integrally structured cushioning material which has an independent coil spring and is more excellent for human health, and a manufacturing method thereof.

[0005]

A method for manufacturing a cushioning material according to the first aspect of the present invention is directed to a sheet-like or plate-like or tubular shape composed of a first mixed fiber containing a heat-welding fiber and a non-heat-welding fiber. A coil spring is wrapped around the bag-shaped first fiber assembly to produce a package, and then a plurality of the packages are arranged adjacent to each other to form an array of packages, and then at least the array is formed. A sheet-like or plate-like second fiber aggregate composed of a second mixed fiber containing a heat-welding fiber and a non-heat-welding fiber is arranged on the upper surface and the lower surface, and these are heated and integrally molded. Is characterized by.

The manufacturing method according to the second aspect of the present invention provides a sheet-shaped or plate-shaped, tubular or bag-shaped first fiber aggregate composed of the first mixed fiber containing the heat-welding fiber and the non-heat-welding fiber. Wrap the coil spring to make a package,
After that, a plurality of the packages are arranged adjacent to each other to form an array of the packages, and then a hardness adjusting material having a lattice or a mesh is provided on at least one of the upper surface and the lower surface of the array. Arranging and then arranging, on at least the upper surface and the lower surface of these arrays, a second fibrous assembly consisting of a second mixed fiber comprising heat-weldable fibers and non-heat-weldable fibers and heating them. It is characterized by being integrally molded. In addition, a sheet-shaped or plate-shaped second fiber aggregate composed of a second mixed fiber containing a heat-welding fiber and a non-heat-welding fiber is provided between the array of the packages and the hardness adjusting material. It can also be arranged.

The manufacturing method according to the fourth aspect of the present invention provides a sheet-shaped or plate-shaped, tubular or bag-shaped first fiber aggregate composed of a first mixed fiber containing a heat-welding fiber and a non-heat-welding fiber. Wrap the coil spring to make a package,
Then, a plurality of the packages are arranged adjacent to each other to form an array of the packages, and then (A) heat-welding fibers or heat-welding is provided on at least one of the upper surface and the lower surface of the array. (B) heat-fusible fiber or heat-fusible resin powder mixed with a heat-resistant resin powder is adhered or arranged on the surface,
Alternatively, (C) a sheet-shaped or plate-shaped palm fiber assembly obtained by sewing or adhering a sheet-shaped fiber assembly containing heat-fusible fibers on the surface and arranging them, and then at least the upper surface of these array bodies And a second mixed fiber including a heat-welding fiber and a non-heat-welding fiber on the lower surface.
It is characterized in that the fiber assembly is arranged and these are heated and integrally molded. In addition, as shown in FIG. 6, a sheet-like or plate made of a third mixed fiber composed of a heat-welding fiber and a non-heat-welding fiber between the packing body array and the palm fiber assembly. The third fibrous aggregate 6 having a shape can be arranged. Further, the first, second and third mixed fibers may be blended with antibacterial fibers or super absorbent fibers.
The upper surface and the lower surface of the cushion material are composed of a mixed fiber containing at least one of antibacterial fiber and super absorbent fiber and at least heat-fusible fiber (that is, non-heat-weldable fiber may also be included). It is also possible to dispose an antibacterial fiber assembly or the like.

The cushioning material of the seventeenth aspect of the present invention is composed of a plurality of coil springs arranged at intervals and integrally formed so as to cover the coil springs, and comprises heat-welding fibers and non-heat-welding fibers. And a fiber-welded coating having a joint formed by heat-welding the heat-weldable fiber,
Is integrally provided.

In the cushioning material of the eighteenth aspect of the present invention, a hardness adjusting material having a lattice or a mesh is arranged inside the fiber-welded molded body portion located on at least one of the upper surface and the lower surface of the coil spring. , The hardness adjusting material,
It is characterized in that the coil spring and the fiber welded molding are integrally formed.

The cushion material according to the nineteenth aspect of the present invention comprises: (A) a heat-welding fiber or a heat-welding fiber inside a fiber-welded molded body located on at least one of the upper surface and the lower surface of the coil spring. Blended with resin powder,
A sheet in which (B) heat-fusible fiber or heat-fusible resin powder is adhered or arranged on the surface, or (C) a sheet-like fiber assembly containing the heat-fusible fiber is sewn or bonded to the surface and joined. A palm fiber welded body having a joint formed by heat-welding the heat-weldable fibers in a sheet-shaped or plate-shaped palm fiber aggregate, the palm fiber aggregate, the coil spring, and the fiber-welded molding The body is characterized in that it is constructed in one piece.

In the above invention, the shape and size of the coil spring, the thickness of the wire, the number of uses, the number of turns of one spring, etc. are variously selected according to the purpose and application. The above-mentioned heat-fusible fiber mainly has heat-bonding (welding, fusing) action, and has a low melting point polyester fiber, polyethylene fiber, polypropylene fiber, polyvinyl chloride fiber, nylon fiber and ethylene vinyl acetate copolymer. One kind or two or more kinds of fibers and the like can be used. When these are heated to a high temperature, they disappear to become balls and have a function of bonding fibers. In addition, when only the surface is melted without being heated to a high temperature up to this point, the fiber itself does not disappear. Further, an adhesive core-sheath type comprising a core made of a high melting point polyester fiber and a coating part made of a thermoplastic resin which covers the core and has a melting point lower than the melting point of the high melting point polyester fiber by 30 ° C. or more. It can also be a fiber. In the case of this core-sheath fiber, since it does not disappear by itself, there is little decrease in volume, and because the core fiber is a high melting point polyester, it has excellent thermal properties (heat resistance, etc.) and mechanical properties. The “core” of the core-sheath fiber may be a solid body or a hollow body. In the case of this hollow body, it is more lightweight and more elastic. Also, rubber elastic fibers can be used as the core.

As the non-heat-welding fiber, one having a melting point higher than that of the heat-welding fiber may be used, and a fiber having a high melting point of 150 to 280 ° C. is usually used. As this fiber, polyethylene terephthalate,
Polyester fibers made of polyhexamethylene terephthalate, polytetramethylene terephthalate, etc., other synthetic fibers, natural fibers and the like can be used.

The mixing ratio of the above-mentioned heat-weldable fiber and non-heat-weldable fiber is usually appropriately selected within the range of 10:90 to 80:20 by weight. This makes it possible to obtain a cushion material having desired performance. That is, if the blending ratio of the heat-fusible fiber is increased, a soft material can be obtained throughout the cushion material, while if it is decreased, a soft material can be obtained throughout the cushion material. If the content of the heat-weldable fiber is less than 10%, the heat-bonding between the adhesive fibers is insufficient and the cushioning property tends to be deteriorated. On the other hand, if it exceeds 80%, the bonding point becomes excessive and the produced cushioning material is Because it is too hard. Therefore, it is possible to fill each of the coil springs with the mixed fibers in which the mixing ratio of the heat-welding fibers and the non-heat-welding fibers is changed to change the hardness depending on the site. Also, heat-weldable fiber,
The shape of the non-heat-welding fiber (whether curled or not), thickness, length, etc. can be variously selected according to the purpose and application.

The above heating is for melting or sufficiently softening the fibers so that the adhesive fibers are heat-bonded to each other. As the heating means, hot water, steam, wet heat means such as high-pressure steam, hot air, dry heat means such as heating furnace, far-infrared ray heating, high-frequency heating and the like can be used. It can also be used together. Further, not only the atmosphere but also the above heating air or heating steam may be introduced under vacuum to perform heating.

Further, (A) it is possible to press and arrange a predetermined array in a predetermined mold, particularly a mold (upper mold, lower mold, etc.), and heat the mold. It may have a shallow depth, or (B) it is possible to heat only the upper side or the upper side and the lower side while pressing them with a predetermined plate-like body or a belt, etc.
(C) There is no such thing, and it is also possible to heat the array as it is so as not to separate it. In order to obtain a molded product having a desired shape, it is preferable to heat in a pressed state. Furthermore, the method of arranging each package is not particularly limited, and may be arranged in a matrix, alternately arranged in a dense arrangement, or arranged randomly.
Other arrangement methods may be used.

Furthermore, the above-mentioned mixed fibers can be provided with antibacterial properties by adding antibacterial fibers in addition to the heat fusible fibers and non-heat fusible fibers.
That is, the antibacterial fiber can be blended in at least one place (a desired place where antibacterial action is expected) of the first to third fiber aggregates containing the heat-welding fiber and the non-heat-welding fiber. As the antibacterial fiber, for example, kneading type antibacterial property produced by kneading an inorganic antibacterial agent into a fiber raw material polymer and spinning it can be used. As the inorganic antibacterial agent, one obtained by adding and absorbing a bactericidal metal ion to zeolite, further kneaded with a simple antibacterial inorganic compound, or one adsorbed on the fiber surface is used. Since these materials have heat resistance, they can be safely heated in the subsequent process.

An organic or organic polymer antibacterial material can be used in the same range as long as it can withstand the heating temperature used in the subsequent step. Further, those obtained by encapsulating these antibacterial agents and adhering the capsules to fibers can also be used. In addition to antibacterial properties, it is also effective to impart various performances such as deodorant properties, aromatic properties, and antifungal properties.
Further, the amount of the antibacterial fiber used in these cases is 100 in total of the heat-welding fiber and the non-heat-welding fiber in the mixed fiber.
It is preferable to add 30 to 60 parts by weight with respect to parts by weight. This is because if the amount of use is less than 30 parts by weight, effective antibacterial performance cannot be exhibited, while if the amount of use exceeds 60 parts by weight, the effect is saturated and it becomes uneconomical.

On the other hand, a sheet-shaped antibacterial fiber aggregate composed of mixed fibers containing antibacterial fibers and the like is arranged on at least one of the upper surface and the lower surface of the cushion material, heated, and integrated. It may be a cushion material formed in the above. In this case, the amount of the antibacterial fiber used can be suppressed to be lower than that in the case where the antibacterial fiber is mixed in the whole mixed fiber, and the cost can be reduced.

Further, by blending the above-mentioned mixed fiber with a highly water-absorbent fiber, it is possible to improve the water absorption capacity of the cushioning material, the ammonia adsorption performance, the comfort of use and the like. Here, as the superabsorbent fiber, for example, fibers made of various superabsorbent polymers such as starch-based, cellulose-based, and synthetic polymer-based can be selected and used according to the intended use. The amount of super absorbent fiber used is
It is preferable to add 10 to 20 parts by weight to the total 100 parts by weight of the heat-welding fiber and the non-heat-welding fiber in the mixed fiber. If the amount used is less than 10 parts by weight, the water absorption cannot be remarkably improved. On the other hand, if the amount used exceeds 20 parts by weight, it becomes uneconomical and rather causes a cushioning action (reduction in elastic force). It should be noted that the performance of the cushioning material can be further improved by incorporating both the antibacterial fiber and the super absorbent fiber into the mixed fiber.

[0020]

EXAMPLES The present invention will be specifically described below with reference to examples. Example 1 In this example, as shown in FIGS. 1, 3 and 7, a cushion cushion for a mattress is manufactured.
First, about 25-35 mm (length) x 32-40 mm (width)
The coil spring 1 is packaged using the first fiber assembly 2 having a thickness of 5 to 15 mm (thickness) to produce the package 3. The way of wrapping is not particularly limited, but it is to wrap it around and insert the protruding parts of both ends inside.
This fiber assembly 2 is preferable because it cannot be easily removed. This coil spring has a drum shape (or drum shape),
3 to 5 rolls, diameter of both sides is about 65 mm, diameter of center is about 40
mm, wire thickness about 2 mm, and overall height 140 mm. As the fiber assembly 2, a lightly punched one made of a mixed fiber composed of a heat-welding fiber and a non-heat-welding fiber was used. The first fibrous structure may not be punched, and the degree of punching is not particularly limited.

The heat-weldable fiber has a fineness of 2 to 15
A denier fiber having a fiber length of about 51 mm was used. Polyethylene having a melting point of 110 to 130 ° C. was used as the sheath portion of this fiber, and polyester fiber having a high melting point (about 250 to 280 ° C.) was used as the core portion. The non-heat-weldable fiber has a melting point of about 250 ° C. (13 denier,
A fiber length of 51 mm) was used. The weight ratio (non-heat-welding fiber / heat-welding fiber) is [80/20] to [30/7].
0] was appropriately blended.

This package 3 is arranged in a matrix form [9 rows × 26 pieces (1
Columns)]. Then, a sheet-shaped second fiber assembly (thickness: about 40 to 60 mm) composed of the same mixed fibers is provided on the upper surface, the lower surface and the side periphery of the array of the package 3.
4 and 5 are arranged respectively. These were heated in a mold in a pressed state at 160 to 200 ° C. for about 30 to 60 minutes, and the fusible fibers were welded to each other and integrally molded to manufacture the cushioning material shown in FIG.

The present cushioning material completely covers the coil spring with the fiber-welded aggregate, and they are integrally formed, and since there is no frame line and locking clip, the appearance is good and the weight is reduced. Moreover, the manufacturing thereof is extremely simple, there is no lateral vibration, there is no squeaking noise generated from the coil, and the cushion material having a desired shape corresponding to the cavity shape of the mold can be easily manufactured. Further, since the coil springs are not coupled to each other and are independent, they function as independent springs.

Further, since the fusible fiber used has a high melting point polyester fiber as a core, the fusible fiber does not disappear even after heating and the volume of the molded product shrinks little, so that there is no particular compression step. However, it is possible to manufacture a molded product having a desired shape and to maintain sufficient elasticity. Furthermore, since polyester fibers are used for both the fusible fibers and the non-fusible fibers, they have excellent heat resistance, durability, weather resistance, strength, etc., and therefore can be safely used in automobiles. In addition, as a core material of the heat-weldable fiber, a hollow body made of polyester (fineness of 5 to 10 denier, fiber length of 25 to 60 mm) was used in the same manner, and a slightly high elasticity and similarly high-quality cushion were manufactured. did it.

Example 2 In this example, as shown in FIGS. 4 and 8, the hardness adjusting material 7 is provided on the third fiber assembly 6 arranged on the array of the package 3.
Are arranged in the same manner as in Example 1 to manufacture a cushion material which is an integrally molded product shown in FIG. As shown in FIG. 8, the hardness adjusting material 7 is integrally formed inside the fiber-welded molded body portion 9. As this hardness adjusting material, a mesh is 20 to 40 mm, the width of the constituent line portion is 3 to 5 mm, and the thickness is 2 to 4 mm, which is a resin-made integral lattice-like material (insulator). The material of the hardness adjusting material, the size of the mesh, the line width, etc. can be variously changed and used depending on the purpose and application. This cushion material is used in Example 1
In addition to the above effect, the hardness of the cushion is appropriately adjusted, and it is suitable as a bed cushion. Further, even if such a hardness adjusting material is used, since it has a mesh, it is completely fixed between the welded fibers and is excellent in its integrity.

Example 3 In this example, the palm fiber assembly 8 is used as an intermediate placement material. For example, as shown in FIG. 5, the palm fiber aggregated body 8 is directly arranged on the arrayed body of the packaging bodies 3 to manufacture the cushioning material which is an integrally molded article shown in FIG. 9. Further, as shown in FIG. 6, the third fiber assembly 6 is arranged on the array of the packaging bodies 3, and the palm fiber assembly 8 is arranged thereon to manufacture a cushion material which is an integrally molded product. You can also This palm fiber assembly 8 is shown in FIG.
As shown in FIG. 3, the fiber-welded molded body portion 9 is integrally configured inside.

In this case, the palm fiber assembly may be one that is heat-welded with the heat-welded fibers arranged above and below the fiber to be integrated (bonded). For example, when (A) this palm fiber assembly is manufactured, a predetermined palm fiber and a predetermined amount of heat-welding fiber or heat-welding resin powder are mixed, and (B) conventional palm fiber assembly Those which are heat-welded fibers or heat-weldable resin powder adhered and fixed to both sides of the same with an adhesive, or are sprinkled with the fibers or the like on both sides thereof and filled and arranged between the palm fibers to some extent, further , (C) a sheet-shaped fiber assembly containing the heat-fusible fiber may be sewn or adhered to the surface to be joined. Here, the heat-welding resin powder may be, for example, one made of a material forming the heat-welding fiber, or one in which the fiber (or a mixed fiber containing the same) is lumped. Since the palm fiber aggregate is integrally provided in the product of this example, it provides appropriate hardness and is also excellent in breathability and water absorption.

Example 4 In this example, instead of the mixed fiber composed of the heat-weldable fiber and the non-heat-weldable fiber used in Example 1, a heat-weldable fiber,
A cushioning material for a mattress for a bed was produced in the same manner as in Example 1 except that the mixed fiber containing the non-heat-welding fiber and the antibacterial fiber was used. Here, in this example, a mixed fiber was prepared in which the antibacterial fiber was mixed at a ratio of 50 parts by weight with respect to a total of 100 parts by weight of the heat-welding fiber and the non-heat-welding fiber. The antibacterial fiber used in this example is obtained by kneading an inorganic antibacterial agent into polyester fiber (fineness 2 denier × 51 mm). This cushion material also produces no bad odor and has the same effect as in Example 1. Further, since it also contains 50 parts by weight of antibacterial fiber, it is obvious that it exhibits an antibacterial effect. It can be said to be a sex cushion.

Example 5 In this example, instead of the mixed fiber composed of the heat-weldable fiber and the non-heat-weldable fiber used in Example 1, the heat-weldable fiber, the non-heat-weldable fiber and the super absorbent fiber were used. A mattress cushioning material for a bed was produced in the same manner as in Example 1 except that the heating temperature was 120 to 140 ° C. and the heating time was 30 minutes to 1 hour using the mixed fiber. Here, in this example, the superabsorbent fiber (hydrolysis system of acrylic fiber, 5 denier) was added at a ratio of 10 and 30 parts by weight to a total of 100 parts by weight of the heat-welding fiber and the non-heat-welding fiber. , 51 mm) was used. According to this, it is possible to improve the water absorption capacity of the cushion material, the ammonia adsorption performance, the comfort of use, etc., and it is extremely useful for human health.

The present invention is not limited to the specific examples described above, and various modifications may be made within the scope of the present invention depending on the purpose and application. That is,
The shape and size of the coil spring, the thickness of the wire used, etc.
The size of the coil sung row, the presence / absence of lamination, the kind of mixed fibers, the mixing ratio, and the like can be variously selected depending on the purpose and application. In order to increase the contact surface of each package, a drum-shaped coil spring is preferable, and when a drum-shaped spring is used, it is preferable to package the drum so that there is less constriction in the middle. The first fibrous structure and the second fibrous structure may be of the same kind or of different kinds, and the number of layers of this fibrous structure is not limited to one, and may be many if desired to be thick. The thickness may be increased.

The means for wrapping the coil spring in the fibrous body is not particularly limited. For example, not only in the case of wrapping the coil spring in the above embodiment, but also as shown in FIG. Insert the spring in (3a)
Alternatively, the spring may be inserted into a predetermined cylindrical body, and both ends of the spring may be inserted into the inside.

As the used fibers, used fibers can be used. In this case, the resources can be reused excellently and the cost can be reduced. Further, the second fibrous structure may be provided only on the upper and lower surfaces of the array of packaging bodies, and the side circumference thereof may not be covered. Even when covering the side circumference, it is not necessary to completely cover the side circumference as in the above embodiment. But some of them (for example,
It may be configured to cover the upper side and the lower side).

Further, mixed fibers having different mixing ratios of the heat-welded fibers and the non-heat-welded fibers can be filled by changing the position. For example, the central portion where the person lies down is a hard cushion portion, and the surrounding portion is surrounded. One can also use a slightly soft cushion part. Further, the cushion material is not limited to the bed cushion material, and may be an automobile cushion material as shown in FIG. 10 or the like, and can be freely designed by using a mold according to the target shape. Also in FIG. 10, the a portion can be made hard and the b portion can be made soft. In this case, in the portion a, the mixing ratio (weight ratio) of the weldable fiber and the non-weldable fiber used in the above example should be about 70/30, while in the portion b, about 20/80. You can

Further, both the palm fiber assembly and the hardness adjusting material may be used in combination, or they may be arranged not only on one surface of the array of package but also on both surfaces. Further, it is also possible to alternately laminate these with another fiber assembly. The above invention is used to include such a laminated body. In addition, these hardness adjusting materials or palm fiber aggregates can be arranged in a desired portion to be hardened. Even in this case, these hardness adjusting materials and the like are integrally fixed and held in the molded body.
Further, as shown in FIG. 11, an assembled body in which cushioning materials having different hardnesses are manufactured and arranged according to the purpose, for example, the centrally arranged one (A) is more than the other one (B). It can also be a hardened configuration.

Further, a sheet-shaped or other antibacterial superabsorbent fiber aggregate composed of mixed fibers containing antibacterial fibers and the like is arranged on at least one of the upper surface and the lower surface of the cushion material to form a cushion material. You may add an antibacterial effect. Furthermore, antibacterial action and high water absorption may be added to the cushioning material at the same time, and other performances such as deodorant property, aromatic property and mildewproof property may be selected according to the purpose and application. It is also effective to give it. Furthermore, in the present invention, the first, second, and third mixed fibers include both heat-welded fibers and non-heat-welded fibers, but do not include non-heat-welded fibers and only heat-welded fibers as the main fiber. Can be included. As the heat-welding fiber in this case, a core-sheath type fiber having a hollow core as described above is used. This is because this fiber has sufficient elasticity required for a cushion. As mentioned above,
This fiber may contain the above-mentioned antibacterial fiber and / or superabsorbent fiber.

[0036]

As described above, according to the cushioning material and the manufacturing method thereof of the present invention, the appearance is excellent, the structure is simple,
It is possible to provide an integrally structured cushioning material that has less lateral vibration, eliminates the squeaking noise of the spring, has excellent independent cushioning performance, and facilitates partial adjustment of hardness. Further, in the case of the cushioning material containing the antibacterial fiber, generation of mites, Escherichia coli, etc. can be suppressed, so that it is comfortable and excellent in human health. In the case of super absorbent fiber, it absorbs and removes water discharged by humans and water in the environment.
At the same time, it is comfortable and healthy.

[Brief description of drawings]

FIG. 1 is a perspective view of a package according to a first embodiment.

FIG. 2 is a perspective view of a package using the bag-shaped first fiber assembly.

FIG. 3 is a schematic explanatory diagram illustrating a method for manufacturing a cushion material according to the first embodiment.

FIG. 4 is a schematic explanatory view showing a method for manufacturing a cushioning material in Example 2.

FIG. 5 is a schematic explanatory view showing a method of manufacturing a cushioning material in Example 3.

FIG. 6 is a schematic explanatory view of a method for manufacturing a cushioning material showing another aspect of the third embodiment.

FIG. 7 is a partial explanatory cross-sectional view of the cushion material manufactured in Example 1.

FIG. 8 is a partial explanatory cross-sectional view of a cushion material manufactured in Example 2.

FIG. 9 is a partial explanatory cross-sectional view of a cushion material manufactured in Example 3.

FIG. 10 is a perspective view of a cushion material for an automobile.

FIG. 11 is an overall perspective view of an assembled body in which five cushion materials are combined.

FIG. 12 is a partial explanatory cross-sectional view of a cushioning material having an antibacterial action (high water absorption performance) used in Example 4 (Example 5).

[Explanation of symbols]

 1 Coil Spring 2 First Fiber Aggregate 3 Package 4 Second Fiber Aggregate 5 Second Fiber Aggregate 6 Third Fiber Aggregate 7 Hardness Adjusting Material (Insulator) 8 Palm Fiber Aggregate 9 Fiber Weld Molded Part 10 Antibacterial Layer (water absorption layer)

Claims (28)

[Claims] 1. A coil spring is wrapped by using a sheet-shaped or plate-shaped or tubular or bag-shaped first fiber aggregate composed of a first mixed fiber containing a heat-welding fiber and a non-heat-welding fiber. A packaging body is manufactured, and thereafter, a plurality of the packaging bodies are arranged adjacent to each other to form an array body of the packaging body, and then at least an upper surface and a lower surface of the array body include a heat-welding fiber and a non-heat-welding fiber. A method for manufacturing a cushioning material, comprising arranging a sheet-shaped or plate-shaped second fiber aggregate composed of a second mixed fiber, and heating these to integrally mold them. 2. A coil spring is wrapped by using a sheet-shaped or plate-shaped, tubular-shaped or bag-shaped first fiber aggregate composed of a first mixed fiber containing a heat-welding fiber and a non-heat-welding fiber. A package is produced, and then a plurality of the packages are arranged adjacent to each other to form an array of the packages, and then a lattice or a mesh is formed on at least one of the upper surface and the lower surface of the array. And then a second fibrous aggregate composed of a second mixed fiber containing a heat-welding fiber and a non-heat-welding fiber is placed on at least the upper surface and the lower surface of these arrays. Then, a method for manufacturing a cushioning material, characterized in that these are heated and integrally molded. 3. A sheet-shaped or plate-shaped second fiber composed of a second mixed fiber containing a heat-welding fiber and a non-heat-welding fiber between the array of the packages and the hardness adjusting material. The method for manufacturing a cushioning material according to claim 2, wherein an aggregate is arranged. 4. A coil spring is wrapped by using a sheet-shaped or plate-shaped, tubular-shaped or bag-shaped first fiber aggregate composed of a first mixed fiber containing a heat-welding fiber and a non-heat-welding fiber. A package is manufactured, and then a plurality of the packages are arranged adjacent to each other to form an array of the packages, and then (A) heat is applied on at least one of the upper surface and the lower surface of the array. (B) heat-fusible fiber or heat-fusible resin powder was admixed with or placed on the surface, or (C)
A sheet-shaped or plate-shaped palm fiber assembly is sewn or bonded to the surface of the sheet-shaped fiber assembly including the heat-fusible fiber, and the palm-shaped fiber assembly is arranged, and then, at least the upper surface and the lower surface of these arrays are arranged. A method for manufacturing a cushioning material, comprising arranging a second fibrous aggregate composed of a second mixed fiber containing a heat-welding fiber and a non-heat-welding fiber, and heating these to integrally mold them. .. 5. A sheet-like or plate-like third composed of a third mixed fiber containing a heat-welding fiber and a non-heat-welding fiber between the array of the packages and the palm fiber assembly.
The method for manufacturing a cushioning material according to claim 4, wherein a fiber assembly is arranged. 6. The heat-fusible fiber includes a core made of low melting point polyester fiber, polyethylene fiber, polypropylene fiber, polyvinyl chloride fiber, nylon fiber, ethylene vinyl acetate copolymer fiber, and high melting point type polyester fiber, and the core. Is higher than the melting point of the high melting point polyester fiber
The method for producing a cushioning material according to claim 1, which is one kind or two or more kinds of the adhesive core-sheath type fiber composed of a coating portion made of a thermoplastic resin having a melting point lower than 0 ° C. 7. The heat-fusible fiber comprises a core made of high melting point polyester fiber and a coating part made of a thermoplastic resin which covers the core and has a melting point lower than the melting point of the high melting point polyester fiber by 30 ° C. or more. The method for producing a cushioning material according to claim 1, wherein the constituent core-sheath fibers and the non-heat-welding fibers are high-melting-point polyester fibers. 8. A coil spring is filled with each of the first mixed fibers in which the mixing ratio of the heat-welding fiber and the non-heat-welding fiber is changed, and the hardness is changed depending on the site.
A method for manufacturing the described cushion material. 9. The first fiber assembly is obtained by appropriately entwining and joining the fibers with a needle punch.
The manufacturing method of the cushioning material of Claim 8. 10. At least one of the first, second and third mixed fibers is a heat-weldable fiber and a non-heat-weldable fiber,
The method for producing a cushioning material according to claim 1, further comprising antibacterial fibers. 11. The blending amount of the antibacterial fiber is 100 parts by weight with respect to a total of 100 parts by weight of the heat-welding fiber and the non-heat-welding fiber.
The method for producing a cushion material according to claim 10, wherein the amount is 30 to 60 parts by weight. 12. A sheet-like or plate-like structure comprising a mixed fiber containing at least one of an antibacterial fiber and a superabsorbent fiber and at least a heat-welding fiber on at least one of the upper surface and the lower surface of the cushion material. 2. The antibacterial fiber assembly of claim 1 is arranged, heated and integrally formed.
The manufacturing method of the cushioning material of Claim 9. 13. At least one of the first, second and third mixed fibers is a heat-weldable fiber and a non-heat-weldable fiber,
The method for manufacturing a cushioning material according to claim 1, further comprising a highly absorbent fiber. 14. The production of a cushioning material according to claim 13, wherein the blending amount of the super absorbent fiber is 10 to 20 parts by weight based on 100 parts by weight of the total amount of the heat-welding fiber and the non-heat-welding fiber. Method. 15. At least one of the first, second and third mixed fibers is a heat-weldable fiber and a non-heat-weldable fiber,
The method for producing a cushioning material according to claim 1, further comprising an antibacterial fiber and a super absorbent fiber. 16. The amount of the antibacterial fiber blended is 100 parts by weight based on 100 parts by weight of the total amount of the heat-welding fiber and the non-heat-welding fiber.
The cushion according to claim 15, which is 30 to 60 parts by weight, and the compounding amount of the superabsorbent fiber is 10 to 20 parts by weight based on 100 parts by weight of the total amount of the heat-welding fiber and the non-heat-welding fiber. Method of manufacturing wood. 17. A plurality of coil springs arranged at intervals, integrally constituted so as to cover the coil springs, and composed of heat-welding fibers and non-heat-welding fibers, and the heat-welding fibers. And a fiber-welded type covering body having a joint formed by heat-welding. 18. The cushioning material according to claim 17, wherein a hardness adjusting material having a lattice or a mesh is provided inside the fiber-welded molded body portion located on at least one of the upper surface and the lower surface of the coil spring. The cushioning material according to claim 17, wherein the cushioning material, the hardness adjusting material, the coil spring, and the fiber-welded molded body are integrally formed. 19. The cushion material according to claim 17, wherein (A) the heat-welding fiber or the heat-welding fiber is provided inside the fiber-welded molded body portion located on at least one of the upper surface and the lower surface of the coil spring. Or (B) heat-fusible fiber or heat-fusible resin powder admixed with or placed on the surface, or (C) a sheet-like fiber assembly containing the heat-fusible fiber is sewn on the surface, or A sheet-shaped or plate-shaped palm fiber aggregate having a joint portion formed by heat-welding the heat-weldable fibers in the sheet-shaped or plate-shaped palm fiber aggregate is arranged, and the palm fiber aggregate is The cushion material according to claim 17, wherein the coil spring and the fiber-welded molded body are integrally configured. 20. The heat-fusible fiber includes a core made of low melting point polyester fiber, polyethylene fiber, polypropylene fiber, polyvinyl chloride fiber, nylon fiber, ethylene vinyl acetate copolymer fiber, and high melting point type polyester fiber, and the core. From the melting point of the high melting point polyester fiber
One or two of the adhesive core-sheath type fibers and the like, which are composed of a covering portion made of a thermoplastic resin having a low melting point of 0 ° C. or more
20. The cushioning material according to claim 17, which is more than one kind. 21. The heat-fusible fiber comprises a core made of a high melting point polyester fiber and a coating part made of a thermoplastic resin which covers the core and has a melting point lower than the melting point of the high melting point polyester fiber by 30 ° C. or more. 20. The cushioning material according to claim 17, wherein the cushioning material is an adhesive core-sheath type fiber, and the non-heat-welding fiber is a high melting point type polyester fiber. 22. The cushioning material according to claim 17, wherein an antibacterial fiber is further mixed with the mixed fiber containing the heat-welding fiber and the non-heat-welding fiber. 23. The amount of the antibacterial fiber blended is 100 parts by weight based on a total of 100 parts by weight of the heat-welding fiber and the non-heat-welding fiber.
The cushion material according to claim 22, which is 30 to 60 parts by weight. 24. At least one of the upper surface and the lower surface of the cushion material includes at least one of an antibacterial fiber and a superabsorbent fiber, and at least a heat-welding fiber, and is integrally configured on the surface. The cushioning material according to claim 17, wherein an antibacterial layer is formed. 25. The cushioning material according to claim 17, wherein a super absorbent fiber is further mixed with the mixed fiber containing the heat-welding fiber and the non-heat-welding fiber. 26. The cushioning material according to claim 25, wherein the blending amount of the super absorbent fiber is 10 to 20 parts by weight based on 100 parts by weight of the total amount of the heat-welding fiber and the non-heat-welding fiber. 27. The cushioning material according to claim 17, wherein the heat-welding fiber and the non-heat-welding fiber are further mixed with antibacterial fiber and super absorbent fiber. 28. The content of the antibacterial fiber is 100 parts by weight with respect to a total of 100 parts by weight of the heat-welding fiber and the non-heat-welding fiber.
The cushion according to claim 27, which is 30 to 60 parts by weight, and the compounding amount of the superabsorbent fiber is 10 to 20 parts by weight based on 100 parts by weight of the total amount of the heat-welding fiber and the non-heat-welding fiber. Material.