JPH07197366A - Thermally adhesive netty structure and its production - Google Patents

Abstract

PURPOSE:To provide a thermally adhesive netty structure suitable for cushion materials excellent in heat resistance, durability and cushioning properties and not becoming stuffy, and capable of being thermally bonded and formed. CONSTITUTION:The characteristic of a thermally adhesive netty structure comprises that threads composing the surface part or both the surface parts of a netty structure product are made up from a low melting point elastomer having a melting point lower by at least >=10 deg.C than the melting point of high melting point elastomer threads contacting with the surface part or both the surface parts, the netty structure product being formed by curving and bringing the threads comprising the thermoplastic elastomers into contact with each other and melt-bonding most of the contacted parts to form a three-dimensional structure. The characteristics of a method for producing the thermally adhesive netty structure comprise extruding the low melting point thermoplastic elastomer and the high melting point thermoplastic elastomer from nozzles at melting temperatures higher by 10-120 deg.C than the melting points of the resins, respectively, melt-bonding the extruded threads to each other in the melt state to form a three-dimensional structure, simultaneously nipping the three-dimensional structure with a take-off device, and subsequently cooling the flattened structure to form the netty structure. The nozzles are distributed so that the layer or layers of the low melting point thermoplastic elastomer and the layer of the high melting point elastomer are formed at the surface part or both the surface parts of the net-like structure and at the other parts, respectively.

Description

Detailed Description of the Invention

[0001]

The present invention relates to a futon, furniture, bed,
The present invention relates to a heat-bonding net-like structure having excellent cushioning properties and heat resistance durability suitable for a vehicle cushioning material, a heat insulating material and the like, and a heat-bonding process, and a manufacturing method thereof.

[0002]

2. Description of the Related Art Currently, as cushion materials for futons, furniture, beds, trains, automobiles, etc., urethane foam, non-elastic crimp fiber stuffed cotton, and resin cotton or hard cotton to which non-elastic crimp fiber is adhered are used. Has been done.

However, although the foamed-crosslinked urethane has good durability as a cushioning material, it is apt to be stuffy due to its poor moisture permeability and heat storage and has a heat storage property, and it is difficult to recycle because it is not thermoplastic, and is burned. The damage to the incinerator is large and the cost for 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, since the fibers are not fixed in the thermoplastic polyester fiber wadding, the form may collapse during use, the fibers may move, and the crimp may cause a decrease in bulkiness and elasticity. become.

As a resin cotton in which polyester fibers are adhered with an adhesive, for example, a rubber-based adhesive is used, Japanese Patent Application Laid-Open No.
0-11352, JP-A 61-141388, JP-A 61-141391 and the like. Further, as a method using a cross-linkable urethane, JP-A-61-1377
No. 32 publication and the like. These cushion materials have inferior durability, and also have problems such as not being recyclable because they are neither thermoplastic nor single composition, and there are problems such as complexity of processability and pollution of chemicals used during manufacturing. .

Polyester hard cotton, for example, JP-A-58-3
1150, JP-A-2-154050, JP-A-3-220354, etc., but since an amorphous polymer having a brittle adhesive component of the heat-bonding fiber used is used (for example, JP-A-58). -136828, Japanese Patent Application Laid-Open No. 3-
However, there is a problem in that durability is poor such that the bonded portion is brittle and the bonded portion is easily broken during use and the form and elasticity are reduced. As an improved method, a method of entanglement treatment has been proposed in Japanese Patent Laid-Open No. 4-245965, but there is a problem that the brittleness of the bonded portion is not solved and the elasticity is largely reduced. 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. For this reason, the polyester elastomer that is soft even at the bonded portion and recovers even if it is deformed to some extent
A heat-bonding fiber using a non-elastic polyester as a core component is disclosed in JP-A-4-240219, and a cushion material using the fiber is disclosed in WO-91 / 19032, JP-A-5-155651. It is proposed in Japanese Patent Laid-Open No. 5-163654. The adhesive component used in this fiber structure has a polyalkylene glycol content of 30 to 50 as a soft segment of polyester elastomer.
Wt%, 5% terephthalic acid as the acid component of the hard segment
It contains 0 to 80 mol% and contains isophthalic acid as another acid component composition to increase the amorphousness, and the melting point is 180
The temperature is below ℃, and the heat-bonded part is well formed with a low melt viscosity to form an ameber-shaped bonded part, but it is easy to plastically deform, and because the core component is an inelastic polyester, plastic deformation especially under heating Becomes remarkable, and there is a problem that the heat resistance and compression resistance are lowered. In addition, this fiber is
Since it is recognized to be the same as the fiber described in Japanese Patent No. 404, it cannot be said that the fiber is an improved version of the prior art.

A thermoplastic olefin network used for civil engineering work is disclosed in JP-A-47-44839. However, unlike a cushion made of fine fibers, the surface is uneven and the touch is poor, and since the material is olefin, the heat resistance durability is extremely poor and it cannot be used as a cushion material. In Japanese Patent Publication No. 3-17666, there is a method in which ejection filaments having different fineness are fused to each other to form a mold, 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. JP-A-1-207
Japanese Patent Laid-Open No. 462 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. There is no one that has a self-heat-adhesive property with non-woven fabrics and side fabrics, and there is a problem that the processing cost becomes high because an adhesive is used for higher-order processing or a foam is impregnated. .

[0007]

To solve the above problems,
To provide a heat-bonding reticulate structure and a manufacturing method which are suitable for a cushioning material having excellent heat resistance and cushioning properties, and which are resistant to stuffiness, and which are made of a thermoplastic elastic resin having a self-heat-bonding property with good high-order processability. With the goal.

[0008]

[Means for Solving the Problems] Means for solving the above-mentioned problems, that is, the present invention comprises a thermoplastic elastic resin having a high melting point and a low melting point, and is 10 ° C. higher than the melting point of the high melting thermoplastic elastic resin.
A network structure made of a low-melting point thermoplastic elastic resin having a low melting point forms a heat-bonding layer, and a network structure made of a high-melting point thermoplastic elastic resin forms a basic layer. Adhesive reticulated structure, the reticulated structure forms a large number of loops by twisting continuous filaments, and each loop is brought into contact with each other, and most of the contact portions are fused and have a constant width. And a thickness of the three-dimensional random loop structure, wherein one side or both sides of the heat-bonding network structure is formed by a substantially flat heat-bonding layer, and the thickness of the heat-bonding layer is 1 mm or more and 10 mm. A heat-adhesive network structure characterized by being the following and a heat-bonding layer made of a low melting point thermoplastic elastic resin is formed on one side or both sides of the network structure, and the thermoplastic elastic layer is formed in a portion other than the heat-bonding layer. At least 10 ° C above the melting point of the resin The molten resin is discharged downward from the nozzles distributed so that a basic layer made of a thermoplastic elastic resin having a high melting point is formed at a temperature 10 to 120 ° C. higher than the melting point of each resin to melt the resin. Form a number of loops in the state, contact each loop, and fuse to form a three-dimensional random loop structure with a constant width and thickness, sandwiched by the take-up device, substantially the surface This is a method for producing a heat-bondable reticulated structure, which comprises flattening and cooling in a cooling tank to integrally form a reticulated structure.

The thermoplastic elastic resin in the present invention is block-copolymerized with a soft segment, such as polyether glycol, polyester glycol, or polycarbonate glycol having a molecular weight of 300 to 5000. Polyester elastomer, polyamide elastomer,
Examples include polyurethane 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 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 alicyclic dicarboxylic acids such as 1.4 cyclohexanedicarboxylic acid, aliphatic dicarboxylic acids such as succinic acid, adipic acid, sebacic acid dimer acid, and dicarboxylic acids selected from ester-forming derivatives thereof Seeds and 1.4 butanediol, ethylene glycol
, Trimethylene glycol, tetremethylene glycol
Aliphatic diols such as phenol, pentamethylene glycol and hexamethylene glycol, alicyclic diols such as 1.1 cyclohexane dimethanol and 1.4 cyclohexane dimethanol, or these At least one diole component selected from ester-forming derivatives 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 polyalkylene glycols such as polypropylene, polypropylene glycol, polytetramethylene glycol, and ethylene oxide-propylene oxide copolymer. 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. .
Considering heat adhesion, hydrolysis resistance, stretchability, heat resistance, etc., terephthalic acid as dicarboxylic acid, or naphthalene 2.6 dicarboxylic acid, 1.4 butanediol as diole component, and poly The alkylene diol is particularly preferably a terpolymer block copolymer of polytetramethylene glycol or the terpolymer block copolymer of polylactone as the polyester diol. In a special case,
The thing which introduce | transduced the polysiloxane type soft segment can also be used. Also, the thermoplastic elastomer resin of the present invention includes those obtained by blending the above elastomer with a non-elastomer component and those obtained by copolymerization. Further, if necessary, an antioxidant, a light-proofing agent or the like may be added to improve durability. The melting point of the thermoplastic high-melting point elastic resin (abbreviated as high-melting point elastic resin) of the present invention is preferably 140 ° C. or higher at which heat resistance durability can be maintained, and when 160 ° C. or higher is used, heat resistance durability is improved. preferable. If the melting point of the thermoplastic low melting point elastic resin (abbreviated as low melting point elastic resin), which is the heat-bonding component, is not lower than at least 10 ° C., the network structure made of the high-melting point elastic resin is softened and deformed during heat bonding, If there is no difference, it is not preferable because the structure melts and the network structure disappears. If the melting point difference with the high-melting point elastic resin is significantly lower than 100 ° C., when the reticulate body is manufactured at the same melting temperature, the long melting time causes the thermal decomposition of the low-melting point elastic resin to be remarkable and the molecular weight necessary for the adhesive function to be increased. The retention time at high temperature must be significantly shortened because it cannot be retained. The melting point difference of the low melting point elastic resin for holding the network structure composed of the high melting point elastic resin needs to be 10 ° C. or higher, preferably 15 ° C. or higher and 80 ° C. or lower, and more preferably 20 ° C. or higher and 50 ° C. or lower. . Further, a lower temperature at the time of heat bonding is preferable from the viewpoint of productivity, but a higher temperature is preferable to maintain heat resistance. Since the cushioning material for automobiles, which is required to have heat resistance, has a heat resistance of 70 ° C. or higher, the melting point of the low melting point elastic resin is preferably 80 ° C. or higher and 220 ° C. or lower, more preferably 120 ° C. or higher and 200 ° C.
It is the following.

The filaments constituting the network structure of the present invention preferably have 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 remarkably good elongation recovery at room temperature and high temperature, and therefore the heat-resistant sag resistance of the network structure is significantly improved as compared with those having no endothermic peak. For example,
As a preferred polyester elastomer of the present invention,
Those containing 90 mol% or more of terephthalic acid or naphthalene 2.6 dicarboxylic acid as an acid component, more preferably terephthalic acid or naphthalene 2.6 dicarboxylic acid content of 95 mol% or more, particularly preferably 100 mol% After transesterification of the glycol component, polymerization is carried out to a required degree of polymerization, and then, as the polyalkylene diol, preferably 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 15 wt% or more and 70 wt% or less, more preferably 30 wt% or more and 60 wt% or less,
When the content of terephthalic acid or naphthalene 2.6 dicarboxylic acid is high, the crystallinity of the hard segment is improved, the plastic deformation is less likely to occur, and the heat resistance and fatigue resistance are improved. When the annealing treatment is performed at a temperature lower than at least 10 ° C., the heat resistance and sag resistance is further improved.
If annealing is performed after applying compressive strain, heat resistance and sag resistance are further improved. When the melting curve of the linear structure of the network structure thus treated is measured by a differential scanning calorimeter (DSC), an endothermic peak is more clearly expressed at a temperature of the glass transition temperature of the hard segment or higher and the melting point or lower. . If not annealed, the endothermic peak will be below the melting point.
Does not manifest. By analogy with this, it is conceivable 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 process is defined as a pseudo crystallization process.)

The net-like structure of the present invention allows the filaments made of a thermoplastic elastic resin to meander and contact each other,
The contact portions are fused to form a three-dimensional network structure. As a result, even if a large amount of deformation is applied with a very large stress, the entire fused and integrated three-dimensional network structure deforms and absorbs the stress, and when the stress is released, the rubber elasticity of the elastic resin develops. The structure can then be restored to its original form. In a net-like structural body composed of known filaments made of non-elastic resin, plastic deformation occurs, and such recovery does not occur, so that heat resistance and durability are deteriorated. If they are not fused, the shape cannot be maintained,
Since the structure is not integrally deformed, a fatigue phenomenon due to stress concentration occurs and durability is deteriorated, and at the same time, the shape is deformed, which is not preferable. The more preferable degree of fusion in the present invention is that most of the portions where the filaments are in contact are fused, and most preferably all the contact portions are in fusion.

The reticulated structure comprising the thermoplastic elastic resin of the present invention has a melting point of the filaments constituting one or both sides of the reticulated structure which is at least 10 ° C. higher than the melting point of the filament of the high melting point elastic resin in contact with the surface. By forming a layer having a thickness of 1 mm or more and 10 mm or less and made of a low low melting point elastic resin, the low melting point elastic resin becomes a thermal bonding component and enables thermal bonding processing.
If you want to bond a mesh, non-woven fabric, knitted fabric, hard cotton, film, foam, metal, powder, fibrous material etc. on one side, form a layer of thermal adhesive component on one side, both sides if you want to adhere to both sides With the structure in which the heat-adhesive component is formed, it is possible to obtain a new molded product by heat-adhesion without applying an adhesive or adding an adhesive layer. If the thickness is less than 1 mm, the adhesion will be insufficient, and if it exceeds 10 mm, the thickness will be significantly reduced during heat bonding, which is not preferable. The preferred thickness of the present invention is 2 mm to 8 mm, more preferably 2.5 mm to 7.5 mm. As described above, the melting point difference between the low melting point elastic resin and the high melting point elastic resin is 10 ° C.
As described above, the temperature is preferably 15 ° C or higher and 80 ° C or lower, and more preferably 20 ° C or higher and 50 ° C or lower. In this range, the thermal adhesive network structure of the present invention, which is not subjected to pseudo-crystallization treatment, is heat-bonded by heating the entire system in addition to holding the network structure made of a high melting point elastic resin. When molding a new structure, if the heat-bonding temperature is higher than the melting point of the low-melting point elastic resin and is 10 ° C. or more lower than the melting point of the high-melting point elastic resin, a reticulated structure consisting of the high-melting point elastic resin is obtained at the same time. The effect of pseudo crystallization can also be obtained. By performing the heat-bonding treatment under such conditions, a new structure is formed by heat-bonding with a higher degree of heat resistance and durability than the high melting point elastic resin in the original heat-bonding reticulated structure. It has a feature that can be given when doing. After thermal bonding, by further annealing the new structure at a temperature lower than the melting point of the low melting point elastic resin by 10 ° C. or more, the elongation recovery of the adhesive layer is significantly improved. Since the adhesive layer and the net-like structure are made of elastic resin even if the structure in Figure 3 is largely deformed by external force, the entire structure can easily follow the deformation and absorb the deformation strain, and if the external force is released, the elastic resin Since the rubber elastic property is exhibited and the structure can be restored to the original form, a new molded product obtained by using the thermoadhesive network structure of the present invention has a high degree of fatigue resistance at room temperature and high temperature. It can impart sex. On the other hand, only the adhesive surface, for example, far infrared rays or heating roller-
In the case of heating by using such as the above and thermally adhering, it is preferable to use a quasi-crystallized one for the network structure made of the high melting point elastic resin. Also in this case, it is preferable to further anneal the new structure at a temperature lower than the melting point of the low melting point elastic resin by 10 ° C. or more after the heat bonding for the above reason. Cushioning material if the thickness of the heat-adhesive component layer is a little thicker than 10 mm or less only when the heat-adhesion component layer is heated by a method capable of maintaining the network structure of the adhesive component layer only when the heat-adhesive component surface is heated. As a slightly soft layer, it can also have the function of a layer (surface layer) that gives a comfortable touch to the buttocks by a proper depression and evenly distributes the pressure distribution in the buttocks. In the present invention, it is also possible to provide a thermal adhesive layer on the surface layer. When used as a cushion material, the cushion layer functions as a layer (basic layer) responsible for absorbing vibration and maintaining body shape,
By integrating the surface layers, it is necessary to integrally deform and absorb stress and vibration to improve the sitting comfort. Further, since the surface layer and the base layer are fused and integrated, the external force can be deformed and absorbed by the entire structure, so that the sag resistance and the heat resistance durability can be prevented from lowering. If the surface layer and the base layer are not melt-bonded to each other, the surface layer is likely to be selectively depressed, which is not preferable. The present invention can provide a network structure in which the basic layer and the surface layer are formed of filaments made of thermoplastic elastic resin, each layer being arbitrarily different depending on the required functions, and fused and integrated. The preferred structure that exhibits the above-mentioned functions is that the surface layer or the layer that also serves as a heat-bonding layer with a thickness of 10 mm or less has good softness (modulus is slightly low) and recoverability, for example, 50% to 70% of softness. From a thermoplastic elastic resin containing a segment (in the present invention, the layer also serving as a thermal adhesive layer is a low melting point elastic resin, and when the surface layer has a thermal adhesive layer, the surface layer is a high melting point elastic resin) It is possible to exemplify that it is formed with a linear strip. The base layer contains a hard segment (having a slightly high modulus) and good recoverability, for example, a soft segment of 20% to 50%, and the hard segment contains a thermoplastic naphthalate resin (in the present invention, a rigid naphthalate). Since it is made of filaments made of high melting point elastic resin and the surface layer and the basic layer are not a single layer but a multilayer, it is possible to easily control the cushioning property and evenly disperse the compressive stress. To form a surface layer or a basic layer in which a linear layer composed of two or more, more preferably three or more kinds of a thermoplastic elastic resin of a soft component and a thermoplastic resin of a hard component is integrated in multiple layers. Is a more preferred example of the present invention. In a net-like structure composed of a single component that also serves as a heat-adhesive component, if the surface layer function is given, it becomes too soft and loses the function of the base layer, and if the function of the base layer is given, it becomes hard and the surface layer function is lost. Since it is lost, the functions of the surface layer and the base layer cannot be satisfied at the same time. On the other hand, the surface opposite to the surface layer can also have a thermal adhesive layer in the present invention. For this reason, a reinforcing material having a high modulus and good shape retention is heat-bonded to the surface of the cushioning material that is in contact with the frame to uniformly transmit the vibration and repulsive stress received from the frame surface to the cushioning layer. It is possible to deform the whole body that is integrated and convert it into energy, which makes it possible to improve the sitting comfort and improve the durability of the cushion. It is preferable to heat-bond a reinforcing material having a vibration absorbing layer because the riding comfort is further improved. In order to impart a function, an optimal combination with the fineness and density of each layer can be arbitrarily selected in consideration of the filament component.

The thickness and cross-sectional shape of the filaments constituting the reticulated structure of the present invention are not particularly limited, but if it is too thin, it becomes too soft and the body shape retention and appropriate anti-compression resilience are reduced, so that the high The thickness of the filaments forming the network structure made of the melting point elastic resin is preferably 0.001 to 10 mm, more preferably 0.01 to 5 mm. If the low melting point elastic resin that forms the adhesive layer is too thick, it is difficult to heat and melt it, and the number of adhesive points on the adhesive surface decreases, so it is preferable to set it to 5 mm or less.
More preferably, it is 0.001 mm to 2 mm. The cross-sectional shape of the filaments constituting the network structure made of the high melting point elastic resin of the present invention is preferably a hollow cross section or a modified cross section because it can impart anti-compression property and bulkiness. The anti-compressibility can be adjusted by the modulus of the thermoplastic elastic resin used, and the soft thermoplastic elastic resin can be adjusted to increase the hollow ratio and the degree of irregularity to adjust the gradient of the initial compressive stress. By lowering the ratio and the degree of irregularity, or by reducing the secondary cross-section moment as a round cross-section, it is possible to impart anti-compression property with good sitting comfort. As another effect of the hollow cross section and the irregular cross section, if the hollowness and the irregularity are increased to give the same anti-compression property, the apparent density can be reduced and the weight can be further reduced. If you use it, you can save energy, and in the case of a futon,
Improves handling when lifting and lowering. The cross-sectional shape of the low melting point elastic resin forming the adhesive layer is also preferably a modified cross-section, because the adhesive area can be increased and the adhesive strength can be improved.

The apparent density of the reticulated structure of the present invention is not particularly limited, but the reticulated structure composed of the high melting point elastic resin easily exhibits the function as a cushion body.
005g / cm ³ or more 0.20 g / cm ³ or less,
More preferably 0.01 g / cm ³ or more and 0.10 g / cm ³
It is the following. The apparent density of the adhesive layer made of a low melting point elastic resin is one side or both sides of a mesh body, non-woven fabric, knitted fabric,
Obtaining a new molded article with strong thermal bonding by causing some migration at the interface between the layer to be thermally bonded and the adhesive layer of hard cotton, film, foam, metal, powder, fibrous material, etc. It is preferably 0.01 g / cm ³ or more and 0.20 g / cm ³ or less. When the network structure made of the high melting point elastic resin is integrated with two or more types of layers, the apparent density of each layer can be changed to impart preferable characteristics.
For example, the apparent density of the surface layer is slightly increased to 0.04 to 0.06 g / cm ³ by using a thermoplastic elastic resin having a slightly low modulus and good recoverability for the surface layer and increasing the number of filaments. The stress received by one of the filaments is reduced to improve the dispersion of stress, and the cushion layer is a filament of thermoplastic elastic resin having a slightly high modulus of 0.04 to 0.06 g / cm ³
With a medium density, the cushioning property to support the buttocks is improved, and the vibration and repulsive stress received from the frame surface are evenly transmitted to the cushion layer, and the entire cushion layer and surface layer are deformed and the engi -It can be converted to make it more comfortable to sit in and improve the durability of the cushion. Further, in order to add thickness and tension to the side of the seat, the fineness can be made slightly thin to increase the density. As described above, each layer composed of filaments having different finenesses can be arbitrarily selected for its preferable density and fineness including the combination with the characteristics of the thermoplastic elastic resin according to its purpose. The thickness of each layer of the network structure is not particularly limited,
The net-like structure made of a high melting point elastic resin preferably has a thickness of 3 mm or more so that the function as a cushion body is easily exhibited. The thickness of the adhesive layer composed of the low melting point elastic resin is preferably 2 mm or more and 10 mm or less in order to have an adhesive function and reduce the thickness change during molding. The size of the random loop can be arbitrarily selected according to the intended use, but a diameter of 1 to 5 mm, particularly 2 to 15 mm is preferable.

When a line made of a thermoplastic elastic resin having a meandering shape on the surface of the net-like structure is a horizontal line in the thickness direction, the angle from the line is bent by 45 ° or more to substantially flatten the surface. Thus, it is a preferred embodiment of the present invention that most of the contact portion is fused. In the present invention, one or both surfaces of the reticulated structure surface is formed by a heat-bonding layer made of a low melting point elastic resin, and the heat-bonding surface is substantially flattened so that the reticulate body, the non-woven fabric, the knitted fabric, the hard Since the contact area with the surface of the heat-bonded material such as cotton, film, foam, metal, etc. can be widened, the heat-bonded area can be widened, and a new molded article with strong heat bonding can be obtained. This means that the contact points of the filaments of the network structure layer made of a high melting point elastic resin and the thermal bonding layer are also significantly increased to form the bonding points, and therefore local external force is also received by the structural surface. Is deformed as a whole and the entire internal structure is also deformed to absorb the stress, and when the stress is released, the rubber elasticity of the elastic resin is developed and the structure can be restored to the original form. It is possible to obtain a molded product having good sitting comfort and excellent cushion durability. Similar effects are exhibited when one surface is made of a high melting point elastic resin. When not substantially flattened, the contact surface between the heat-bonded surface and the network structure layer made of a high melting point elastic resin is small on the uneven bonding surface, so the area of the heat bonding point is also small and the external force It is not preferable because the transmission concentrates on the heat-bonding points and fatigue occurs due to stress concentration and the sag resistance decreases. Further, since the adhesion is insufficient, problems such as peeling may occur.
In the non-elastic resin, even if the surface is substantially flattened, stress concentrates at the bonding point as it is, causing structural destruction and making recovery difficult.

Next, the manufacturing method of the present invention will be described. The reticulated structure of the present invention has a low melting point thermoplastic elastic resin layer formed on one or both sides of the reticulated structure, and a high melting point thermoplastic elastic resin layer formed on the other part. From the distributed nozzles, each resin should be 10 ℃ or more above the melting point, 12
It is discharged downward from the nozzle at a melting temperature of 0 ° C or less, and the melted discharge filaments are bent and brought into contact with each other to fuse most contact parts and form a three-dimensional structure It is a method for producing a heat-bonding reticulated structure, which is characterized in that it is sandwiched by a device and then cooled in a cooling tank to form a reticulated body in one step. In order to obtain the network structure of the present invention, at least a two-component extruder, preferably a three-component extruder, is used to prepare a low-melting point thermoplastic elastic resin as a heat-adhesive component and a high-melting point thermoplastic elastic resin as a cushion body. Melt each individual component and distribute the low melting point elastic resin on the back side of the nozzle so as to form one side or both sides of the network structure, and distribute the high melting point thermoplastic elastic resin to the other part from the nozzle orifice. Discharge. In a preferred embodiment of the present invention, for example, in the case of an orifice shape having a circular cross section with an effective width in the longitudinal direction of 50 mm, a pitch between holes in a row in the width direction of the nozzle is fixed at 10 mm, and a pitch between rows is fixed at 5 mm, a thermal bonding layer is provided. If the low melting point elastic resin that forms the
The thickness of the heat-adhesive component layer in the first to second columns, or in the case of arranging on both sides, the first and eleventh columns or the first to second and eleventh columns or the tenth to eleventh columns. Of the high-melting point elastic resin is distributed to other rows so that the thickness of the high-melting point elastic resin is 1 mm or more and 10 mm or less, and the layers of the respective components are preferably at the same melting temperature of 10 ° C. or higher and 120 ° C. or lower than the melting points of the respective components. Is a desired apparent density, for example, the single-hole discharge amount is 2.5 g / min for the thermal adhesive layer portion and 2 g / min for the cushion body portion. A gear pump sends the molten elastic resin to the nozzle and discharges it downward from each orifice. According to a more preferred embodiment of the present invention, when the number of constituents is increased by the heat-bonding layer, for example, the pitch between holes in the first to second rows is 5 mm, and the pitch between holes in the tenth and eleventh rows is 6. If the total discharge amount of each component is the same and the discharge amount is changed to 67 mm, the apparent density of the thermal bonding layer will be 0.06.
08 g / cm ³ , the layer forming the cushion body 0.0404
Double the number of components without changing g / cm ³ and about 1.5
It is possible to make a dense thermal adhesive layer that is doubled. Of course, the cushion characteristics can be optimized by changing the pore density of a specific portion of the layer of the high melting point elastic resin which becomes the cushion body. Moreover, if the cross-sectional area of the orifice is changed to give a pressure loss difference at the time of discharge, the principle of reducing the discharge amount of the melted thermoplastic elastic resin extruded from the same nozzle at a constant pressure for an orifice having a large pressure loss is used. It is also possible to manufacture a net-like structure composed of filaments of different fineness within and between rows. The orifice shape of the nozzle used in the present invention may have a round cross section. However, in the present invention, the three-dimensional structure formed by the discharge filament in a molten state is difficult to relax due to the hollow or irregular cross section of the filament. In particular, the flow time at the contact point can be maintained for a long time to strengthen the adhesion point, which is particularly preferable. 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. Next, both sides of the three-dimensional structure in a molten state are sandwiched by a take-up net, and the winding ejection lines in the molten state on both sides are bent by 45 ° or more to deform and flatten the surface, and at the same time, the ejection lines that are not bent. After forming the structure by adhering the contact points with, a rapid cooling with a cooling medium (usually, it is preferable to use water at room temperature is preferable because the cooling rate can be increased and the cost can be reduced). Obtain a three-dimensional three-dimensional network structure. 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. As a preferred method of the present invention, pseudo-crystallization treatment is performed after cooling once. The pseudo-crystallization treatment temperature is at least 10 ° C. lower than the melting point (Tm), and is higher than the α dispersion rising temperature (Tαcr) of Tan δ. This treatment has an endothermic peak below the melting point and does not have pseudo-crystallization treatment (no endothermic peak)
The heat resistance and sag resistance are remarkably improved. The preferred pseudo-crystallization treatment temperature of the present invention is (Tαcr +
10 ° C.) to low melting point elastic resin (Tm−20 ° C.). If it is pseudo-crystallized by simple heat treatment, heat resistance and sag resistance are improved. However, it is more preferable that the material is cooled once and then subjected to compressive deformation of 10% or more and annealed to significantly improve the heat resistance and sag resistance. When the drying step is performed after cooling once, the pseudo crystallization treatment can be performed at the same time by setting the drying temperature to the annealing temperature.
In addition, a pseudo crystallization treatment can be separately performed during or after the heat-bonding molding. Then, it is cut into a desired length or shape and used as a cushion material. The desired loop diameter and wire diameter can be determined by 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 orifice hole diameter and the discharge amount, and the like. A pair of take-up conveyors with adjustable spacing installed on the cooling medium sandwiches and holds the melted discharge filaments to fuse the parts that are in contact with each other and continuously draw in the cooling medium to solidify it. 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. The distance between the take-up conveyor and the nozzle surface is preferably within 30 cm, and if it is too long, the molten filaments are cooled and the contact portion is not fused, which is not preferable. 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.

When the reticulated structure of the present invention is used as a cushioning material, a resin used depending on the purpose and site of use,
It is necessary to select the fineness, the loop diameter, and the bulk density. For example, the wadding portion of the surface layer preferably has a low density, a fine fineness, and a fine loop diameter in order to impart a soft touch, an appropriate subsidence, and a bulge with tension. In order to lower the resonance frequency, change the appropriate hardness and the hysteresis at the time of compression linearly to improve body retention, and maintain durability, medium density, thick fineness, and slightly large loop diameter Is preferred. In addition, it is preferable to select a heat-adhesive component having good compatibility in order to obtain the adhesive strength between the cushion layer and the heat-bonded material.
It can be molded into a shape suitable for the intended purpose by using a molding die or the like to the extent that the three-dimensional structure is not damaged. In addition, in addition to the resin manufacturing process, it is necessary to add functions such as flame retardancy, insect repellent antibacterial, heat resistance, water and oil repellency, coloring, and aroma at any stage of processing into a molded product from the manufacturing process to the extent that performance is not degraded. It can be processed by adding chemicals.

[0018]

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. Endothermic peak (melting peak) from melting point (Tm) and endothermic peak below melting point TA50, DSC50 type differential thermal analyzer manufactured by Shimadzu ) The temperature was determined. Tαcr polymer is heated to the melting point + 10 ° C and the thickness is 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 temperature rising rate of 1 ° C./min. Tan δ (ratio M ″ / imaginary elastic modulus M ″ to real part M ′ of elastic modulus) The rising temperature of α dispersion corresponding to the transition temperature from the rubber elastic region to the melting region of M ′). Apparent Density The sample is cut into a size of 15 cm × 15 cm, the heights at four positions are measured, the volume is determined, and the weight of the sample is shown as a value divided by the volume. (Average value of n = 4) Fusing Whether or not the sample is fused by visual judgment is that the fibers that are adhered are pulled by hand and cannot be detached depending on whether they are fused. to decide. Heat resistance and durability (residual strain at 70 ° C) Cut a 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 1 day before treatment. The thickness ratio of is shown in% (n =
Average value of 3) Cyclic compression strain A sample was cut into a size of 15 cm x 15 cm, and a Shimadzu servo pulsar 50% was used at 25 ° C and 65% RH room.
The compression recovery was repeated at a cycle of 1 Hz to the thickness of 20,000 times, and the ratio of the thickness of the sample after standing 20,000 times to the thickness before treatment was%.
Indicate. (Average value of n = 3) Thermal adhesive strength A sample was cut into a size of 15 cm × 15 cm, and a polyester woven fabric was folded back with a release sheet sandwiched between the thermal bonded faces, so that the folded side would come to the center of the sample. The heat-bonded molded article obtained by arranging two sheets on a sheet and sandwiching them with a heat press to preheat the woven fabric and the heat-bonded surface at a temperature 10 ° C. higher than the melting point of the low melting point elastic resin, and then compressing and heat-bonding them. Using the release sheet, folded back, sandwiching the part of the woven fabric on the side that is not heat-bonded to the chuck, pulling the woven fabric from both sides to measure the peeling force between the woven fabric and the heat-bonded reticulated structure, The peel strength per 1 cm width was converted to obtain the thermal adhesive strength, and the average value of n = 5 was 1 kg.
</ Cm; x, 1 kg / cm or more and less than 3 kg / cm; △, 3 kg /
cm or more and less than 5 kg / cm; ◯, 5 kg / cm or more; Comfortable to sit 30 ° C RH75% Bucket seat for seat frame in room
A paneler sits on a seat formed by hanging a polyester moquette side cloth on a cushion shaped like a tongue (n = 5) (1) Feeling with the floor: "Dosun" when sitting and the degree of touching the floor Was evaluated qualitatively. Not felt; ◎, hardly felt; ○, slightly felt; △, felt; × (2) Feeling of stuffiness: Feeling stuffy when sitting for 2 hours and the buttocks and the part of the crotch that contacts the seat inside the crotch Qualitatively evaluated. Almost no feeling: ◎, slightly stuffy; ○, slightly stuffy; △, significantly stuffy; × (3) How long you can sit in the seat within 8 hours: within 1 hour; × within 2 hours; △ within 4 hours;
○ 4 hours or more; ◎ (4) A qualitative qualitative evaluation was performed on the degree of waist fatigue when the user sat in the seat for 4 hours. None; ◎, hardly tired; ○, slightly tired; △, very tired; × (5) Overall evaluation: 4 out of ◎ in the evaluation from (1) to (4), ○
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).

Examples 1 and 2 As the polyester type 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. Table 1 shows the formulation of the thermoplastic elastic resin raw material obtained by producing a terester block copolymer elastomer, then adding and mixing 1% of an antioxidant, kneading, pelletizing and drying at 50 ° C. for 48 hours.

[0021]

[Table 1]

The two polyester-based thermoplastic elastic resins thus obtained were melted by two extruders, and a nozzle having a width of 50 cm and a length of 5 cm was provided with an inter-row pitch of 5 mm and an orifice diameter on the effective surface of the nozzle. Is 0.7 mm, and the pitch between the holes in the 1st, 2nd and 11th rows is 5mm, and the pitch between the holes in the 3rd to 10th rows is 10mm. And A-2 are distributed to the second and eleventh rows, A-2 is distributed to the third to tenth rows, and the single hole discharge amount is A- at a melting temperature of 240 ° C.
No. 1 was discharged at 1.26 g / min and A-2 was discharged at 2.00 g / min, cooling water was placed 12 cm below the nozzle surface, and width was 60 cm.
The stainless steel endless nets are arranged in parallel at 5 cm intervals so that a pair of take-up conveyors are arranged so as to partially come out on the surface of the water, and are picked up, while fusing the contact parts while sandwiching both sides at a speed of 1 m / min Table 3 shows the properties of the reticulated structure obtained by pulling it into cooling water at 25 ° C to solidify it, then performing pseudo-crystallization treatment in a hot air dryer at 100 ° C for 20 minutes, and then cutting it into a predetermined size. Average apparent density is 0.047
5g / cm ³ , the apparent density and thickness of each layer is 1 of A-1 layer
The layer (front) of the second and second rows is 0.0675 g / cm ³ and is about 8 m
m, the 11th row layer (back) is 0.102 g / cm ³ and is about 3 m
m, A-2 layer is about 41 mm at 0.0404 g / cm ³ , and the A-1 layer made of a low melting point elastic resin which is a heat-bonding layer is a dense layer having a substantially flat surface and a large number of components. there were.

Example 2 As a polyester elastomer, 80 mol% of dimethyl terephthalate (DMT), 20 mol% of dimethyl isophthalate (DMI), and 1.4 butanediol (1
・ 4BD) was charged with a small amount of catalyst, and after transesterification by a conventional method, polytetramethylene glycol (PTMG) was added and polycondensation was performed while heating and decompressing to produce a polyester ester block copolymer elastomer. Then, add 1% of antioxidant, mix and knead into pellets,
Thermoplastic elastic resin raw material (A-
The formulation of 3) is shown in Table 1. Next, Table 3 shows the characteristics of the network structure obtained in the same manner as in Example 1 except that A-3 was used as the low-melting point elastic resin to be the heat-bonding layer. The apparent density and the thickness were almost the same as those in Example 1, and the A-3 layer was also a densified layer with a large number of constituents whose surfaces were substantially flattened.

Example 3 As a polyurethane elastomer, 4,4'-diphenylmethane diisocyanate (MDI), PTMG and 1.4BD as a chain extender were added and polymerized, and then 1% of an antioxidant was added. After mixing and kneading, the mixture was pelletized and dried to use polyether urethane as a thermoplastic elastic resin raw material. The prescription is shown in Table 2.

[0025]

[Table 2]

The two polyurethane-based thermoplastic elastic resins thus obtained were divided into B-1 in the first, second and eleventh rows, and B-2 in the third to tenth rows. Then, at the melting temperature of 215 ° C., the single hole discharge amount was 1.26 g / B-1.
Table 3 shows the characteristics of the reticulated structure obtained in the same manner as in Example 1 except that the holes B-2 were discharged at 2.00 g / hole and the pseudo-crystallization treatment was not performed. The obtained net-like structural body was made of a low melting point elastic resin B, which serves as a heat-bonding layer, as in Example 1.
The -1 layer was a densified layer having a large number of constituents whose surface was substantially flattened. The apparent density and thickness were almost the same as in Example 1.

Comparative Examples 1 and 2 Polyester (PEIT) having a melting point of 115 ° C. obtained by copolymerizing 45 mol% of isophthalic acid having an intrinsic viscosity of 0.61 with 55 mol% of terephthalic acid and ethylene glycol was used in the first and second columns. The polyethylene terephthalate (PET) having an intrinsic viscosity of 0.63 was distributed to the 3rd to 10th rows and the single hole discharge amount in each row at a melting temperature of 280 ° C. The network structure obtained in the same manner as in Example 1 and polyethylene (PE) having a melt index of 10 were distributed in the first row, the second row and the 11th row, and polypropylene (PP) having a melt index of 35 was distributed in the third row. To the 10th row,
Table 3 shows the characteristics of the net-like structure obtained in the same manner as in Example 1 at the melting temperature of 220 ° C. and the single hole discharge amount in each row.

[0028]

[Table 3]

COMPARATIVE EXAMPLE 3 The nozzle hole arrangement was such that the row pitch was 5 mm and the hole pitch was 10 mm.
And a nozzle with an orifice diameter of φ0.7 mm
Table 3 shows the characteristics of the reticulated structure obtained under the same conditions as in Example 2 except that only the thermoplastic elastic resin of No. -3 was discharged at 235 ° C. at a single hole discharge rate of 2.0 g / min. Show. The average apparent density was 0.048 g / cm ³ and the thickness was about 50 mm. When the adhesive treatment was performed to measure the thermal adhesive strength, the thickness decreased to about 32 mm and the recovery was not achieved.

COMPARATIVE EXAMPLE 4 Example 1 was repeated except that a take-up conveyor net was placed 60 cm below the nozzle surface and no pseudo-crystallization treatment was performed after the take-up conveyor net was taken out.
Table 3 shows some of the properties of the network structure obtained by the same method as described above. The apparent density, residual strain at 70 ° C., repeated compressive strain, and thermal adhesive strength were not evaluated because the adhered state was poor and the shape retention was poor.

Example 1 is a preferable net-like structure using a polyester polymer, which is soft and has an appropriate degree of subsidence and is suitable for a cushioning material having good heat resistance and durability, and also has good thermal adhesive strength. Example 2 is an example in which the temperature of the thermal adhesive component was lowered, and the thermal adhesive strength was improved. Example 3 is an example in which a pseudo crystallization treatment using a polyurethane polymer was not performed, and the sitting comfort exhibited very good cushioning properties and the adhesive strength was also good. Comparative Examples 1 and 2 are examples using a thermoplastic non-elastic resin, which does not have an endothermic peak below the melting point even when subjected to pseudo-crystallization treatment, has a significantly poor heat resistance durability, and is hard and comfortable to sit on. This is an extremely bad example which is not suitable for a cushion material. However, the adhesive strength was good. Comparative Example 3 is an example of a single-component elastic resin layer that is outside the scope of the present invention. Durability and sitting comfort are inferior to those in Example 1, and the thickness of the cushion layer decreases due to partial melting during bonding. The problem at the time of molding also becomes great. Comparative Example 4 is an example in which the fibers are not fused to each other, and the shape retention is extremely poor and is not suitable for a cushion material.

[0032]

EFFECT OF THE INVENTION Since the network structure of the present invention has a heat-adhesive layer made of a thermoplastic low melting point elastic resin in which filaments made of a thermoplastic elastic resin are fused and integrated with each other, A new molded body can be easily formed by gluing, and the heat-bonding layer and the cushioning function layer made of a high melting point elastic resin are integrally deformed by the external deformation of the glued layer to be stressed. When the external force is removed, it can recover to its original shape by the rubber elasticity peculiar to the elastic resin, so that it has improved seating comfort, heat resistance durability, bulkiness, and moderate compression repulsion force. A heat-bonding net-like structure suitable for a cushioning material that is resistant to stuffiness and easily recyclable, which is useful for vehicle seats, boat seats, furniture cushions, and bedding products. It can be used alone or in combination with other materials. Further, it is a heat-adhesive reticulated structure which is also useful for heat insulating materials, interior materials, heat insulating materials, stretchable nonwoven fabrics, and the like.

Continuation of the front page (51) Int.Cl. ⁶ Identification code Office reference number FI Technical display area D04H 3/00 E

Claims (4)

[Claims] 1. A net-like structure comprising a thermoplastic resin having a high melting point and a thermoplastic resin having a low melting point, and a thermoplastic resin having a low melting point having a melting point of 10 ° C. or more lower than the melting point of the thermoplastic resin having a high melting point forms a thermal adhesive layer. However, a network structure made of a high-melting point thermoplastic elastic resin forms a basic layer, and is a heat-bonding network structure in which both layers are integrated, and the network structure is formed by winding continuous filaments. A large number of loops are formed, each loop is brought into contact with each other, most of the contact portions are fused, and a three-dimensional random loop structure having a constant width and thickness is maintained. One or both sides are formed with a substantially flat thermal adhesive layer, and the thermal adhesive layer has a thickness of 1
A thermoadhesive network structure having a thickness of at least 10 mm. 2. A loop forming a reticulated structure is pressed and bent by 45 ° or more from the baseline with the thickness direction of the reticulated structure as a base line in the middle of the loop, and most of the contact portions are fused. The thermoadhesive network structure according to claim 1, wherein the structure is substantially flattened. 3. A thermoadhesive layer made of a thermoplastic resin having a low melting point is formed on one or both surfaces of the network structure, and a melting point higher than the melting point of the thermoplastic elastic resin by at least 10 ° C. is formed in a portion other than the thermoadhesive layer. The molten resin is discharged downward at a temperature 10 to 120 ° C. higher than the melting point of each resin from nozzles distributed so that a basic layer made of a thermoplastic elastic resin having Loops are formed, and the loops are brought into contact with each other and fused to form a three-dimensional random loop structure that maintains a constant width and thickness, and is sandwiched by a take-up device to substantially flatten the surface. A method for producing a heat-bondable reticulated structure, which comprises integrally forming a reticulated structure by cooling in a cooling tank. 4. Once cooled, at least 10 ° C. above the melting point
The method for producing a thermoadhesive network structure according to claim 3, wherein annealing is performed at the above low temperature.