JPH0723834A - Laminate - Google Patents

Abstract

PURPOSE:To provide the laminate for a seat which is light in weight, is inexpensive and has an excellent cushining property by laminating a foam and/or non- woven fabric to at least one surface of a flat plate body of a net structure which is formed by partially fusing continuous wire-shaped fibers consisting of a thermoplastic resin and has a specific apparent density and providing the laminate formed in such a manner with the specific apparent density. CONSTITUTION:The foam 2 and/or the non-woven fabric 3 is laminated and integrated to at least one surface of the flat plate body of the net structure which is formed by partially fusing the continuous wire-shaped fibers consisting of the thermoplastic resin of >=100 denier, has <=0.010g/cm<2> apparent density and is flat in both surfaces. The apparent density of this non-woven fabric 3 is confined to <=0.04g/cm<2>. The thermosetting resin is preferably a polyester and the fineness thereof is preferably set at 500 to 1000 denier. The net structural body is usually laminated with the fibers consisting of the thermoplastic resin by drawing loops. The fibers are fused to each other in the contact parts to form the three-dimensional net structure which is substantially flat in both surfaces.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a lightweight and cushioned laminated structure suitable for furniture, beds, cushioning materials for vehicles and the like.

[0002]

2. Description of the Related Art Currently, it is used as a cushion material for furniture, beds, trains, automobiles, etc., using urethane foam, non-elastic crimped fiber wadding,
In addition, resin cotton or hard cotton to which non-elastic crimped fibers are adhered is used.

However, the high-density foamed / crosslinked urethane has good durability as a cushioning material and is inexpensive, but it has poor air permeability and heat storage property, and therefore tends to be stuffy. On the other hand, if the density is lowered, there is a problem that durability is lowered.

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 are inferior in durability, have a high bulk density, are complicated to manufacture, and have a significantly high processing cost.

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 the brittleness of the bonded portion is not solved and there is a problem that the processing cost is high. Therefore, WO-91 / 19032 proposes a hard cotton non-woven fabric using a polyester elastomer which is soft at the bonded portion and recovers even if it is deformed. The adhesive component used in this fiber structure contains isophthalic acid, etc. in the acid component of the hard segment of polyester elastomer, and since it has a low melting point, it also increases amorphousness, resulting in a low melt viscosity and Although the formation is improved to form the amoebar-shaped adhesive portion, there is a problem that the heat resistance and compression resistance are deteriorated because it is easily plastically deformed. Further, there is a problem that the raw material cost and the processing cost of the heat-bonded fiber become very high.

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. Therefore, as an improved method, actual Kaihei 1-1684
A method of forming a laminate with a non-woven fabric or a woven fabric is proposed in Japanese Patent No. 8 or the like. This proposal is unsuitable as a cushioning material for a seat because it is laminated on a net-like body having a large number of peaks and troughs, and when the user sits down, he / she feels a foreign substance and is uncomfortable to sit on.

[0007]

SUMMARY OF THE INVENTION It is an object of the present invention to solve the above conventional problems and to provide a lightweight and inexpensive laminate suitable for seats having excellent cushioning properties.

[0008]

[Means for Solving the Problems] To solve the above problems
Of the present invention, that is, the present invention, the thermoplastic of 100 denier or more
Filaments made of flexible resin should not be partially fused.
The apparent density is 0.010 g / cm³Practically both below
At least one surface of the flat net-like structure has a foamed material.
And / or non-woven fabric are laminated and integrated, and apparent density
Is 0.04 g / cm ³Laminated body characterized in that
Is.

Examples of the thermoplastic resin constituting the network structure in the present invention include polyester, nylon, polyolefin, polyurethane and the like, but polyester having a relatively high glass transition temperature is preferable. Examples of fibers made of polyester include polyethylene terephthalate (PET) and polyethylene naphthalate (PE
N), polycyclohexylene dimethylene terephthalate (PCHDT), polybutylene terephthalate (PB)
T), polyarylate, and the like, and a fiber made of a polymer selected from those copolymerized polyesters, block copolymerized polyetheresters, polyesteresters, and the like. PEN, PCHDT, etc. are preferable because they have a high glass transition temperature and are unlikely to undergo plastic deformation.
Fibers made of an elastic resin such as a terester or a polyester ester are particularly preferable because they have good recoverability. The fineness, fiber cross-sectional shape, mechanical properties, etc. of these polyester fibers are determined depending on the desired application, but the fineness is 100 to 10
It is 0000 denier, preferably 500 to 10,000 denier. The cross-sectional shape is not particularly limited, but a hollow cross-section or a modified cross-section such as a polygonal shape or a multi-lobed shape in which the bending rigidity is improved by increasing the secondary moment of the cross section is preferable.

In the reticulated structure constituting the laminated structure of the present invention, fibers made of a thermoplastic resin are usually laminated in a loop, and the fibers are fused at the contacting portions to form substantially both surfaces. It forms a flat three-dimensional network structure. As a result, even if a large stress is applied, the stress can be gripped on the entire surface, so it is difficult to deform, and thermoplastic resin with a high glass transition temperature is hard to plastically deform and exhibits the function of a cushion base layer excellent in shape retention. Therefore, it is preferable. In addition, since both sides are substantially flattened, even if the foam or the nonwoven fabric laminated on the surface is soft, the buttocks do not feel a sense of foreign matter. If the fibers are not fused at the contact portion, they are easily deformed and buckled when a slightly large stress is applied, which is not preferable because the shape retention is poor. Further, since the surface is not substantially flat, even if a foam or a non-woven fabric is laminated on the surface, the fibers move when the user sits down, and a foreign body feels. The more preferable degree of fusion of the present invention is that most of the portions in contact with the fibers are fused, and most preferably all the contacted portions are fused.

The apparent density of the network structure formed by partially fusion-bonding the continuous linear fibers made of the thermoplastic resin of the present invention is 0.10 g / cm ³ or less. Apparent density is 0.10
If it exceeds g / cm ³ , not only the elasticity becomes strong and the sitting comfort becomes poor, but also it becomes difficult to reduce the weight of the seat, which is not preferable. The apparent density is preferably 0.01 g / cm ³ or more and 0.08 g / cm ³ or less, more preferably 0.01 to 0.
It is 05 g / cm ³ . The thickness of the net-like structure is not particularly limited, but it is preferably 3 mm or more so that the function as a cushion body is easily exhibited.

In the laminate of the present invention, at least one surface of the reticulated structure is laminated and integrated with the foam and / or the non-woven fabric so that the buttocks do not come into direct contact with the reticulated structure having a slightly hard texture when sitting. A soft touch foam and / or a non-woven fabric can provide cushioning properties due to an appropriate depression to reduce the feeling of flooring. In the laminated body of the present invention, the back surface in contact with the spring is laminated with a reinforcing non-woven fabric, the surface is a soft cotton non-woven fabric with a touch, the side material is laminated on top of it, and the foam etc. It is preferable because it is not alleviated, and the cushioning property due to an appropriate depression is given to suppress the feeling of flooring. The surface is made by laminating and heat-bonding a hard cotton nonwoven fabric containing soft elastic fibers and a mesh made of elastic fibers, and between the hard cotton nonwoven fabric and the side ground above with a nonwoven fabric containing elastic polyester thermal bonding fibers. It is more preferable that the non-woven fabric containing the elastic polyester thermal bonding fiber is laminated and bonded between the soft net-like structures composed of the slightly hard net-like structures and the elastic fibers, and between the soft net-like structures and the side fabrics. It is a particularly preferred embodiment because the hard cotton non-woven fabric to be laminated also contains the elastic polyester-based thermo-adhesive fiber because the heat resistance durability and the cushioning property are further improved. When a generally known non-elastic thermoplastic resin-based heat-bonding fiber is used, it is preferable to use a heat-bonding component which is as amorphous as possible. Incidentally, the nonwoven fabric referred to in the present invention, spunbond obtained by a known method, entanglement treatment obtained by melt blow, or a long fiber nonwoven fabric adhered without entanglement, and after opening short fibers,
It includes a heat-bonded non-woven fabric obtained by entanglement treatment such as a spun lace or a needle punch, a resin bond, a heat-bonded fiber, or a non-woven fabric obtained by a papermaking method. The heat-bonded non-woven fabric includes a thick hard cotton non-woven fabric, a heat-bonded fiber made of only heat-bonded fiber, and the like. Further, the foam includes a closed-cell or open-cell foam such as polyurethane. The apparent density of these non-woven fabrics and foams is 0.01 to 0.04 g.
Using / cm ³ is preferable because the apparent density of the integrated laminate can be lowered. The apparent density of the integrated laminate of the present invention is 0.04 g / cm ³ or less. Apparent density is 0.0
In 4g / cm ³ or more, can not be lighter than the apparent density 0.05 g / cm ³ of the seat of the polyurethane is not preferred. The preferred apparent density of the present invention is 0.035 g / cm ³
Below, it is 0.01 g / cm ³ or more.

The reticulated structure can be manufactured directly and is inexpensive, and the cost of the foam having open cells is relatively low. By combining these with a slightly expensive non-woven fabric, it is possible to provide an integrated laminate suitable for a cushioning material at a relatively low cost as compared with a costly hard cotton non-woven fabric.

A method for producing a reticulated structure made of a thermoplastic resin is a method in which a plurality of thermoplastic elastic resins obtained by a known method such as JP-A-55-120626 are melted using a general melt extruder. When ejected downward from a nozzle with an orifice and let it fall naturally, the ejection line swirls and
Form a loop. At this time, the loop diameter and the wire diameter are determined by the distance between the nozzle surface and the take-up conveyor installed on the cooling medium that solidifies the resin, the melt viscosity of the resin, the hole diameter of the orifice and the discharge amount, and the like. Then, the melted discharge filaments are sandwiched and retained by a pair of take-up conveyors with adjustable intervals installed on the cooling medium to fuse the portions in contact with each other and continuously draw in the cooling medium to solidify. Form a network structure. By adjusting the distance between the conveyors, the thickness can be adjusted while the fused net-like body is in a molten state, and a desired thickness can be obtained. If the conveyor speed is too fast, it will be cooled before fusion and the contact part will not be fused. Also, if the speed is too slow, the melt will stay too much,
Since the density is high, it is necessary to set the conveyor speed suitable for the desired apparent density. The cushion material can be manufactured at low cost by directly forming the thermoplastic resin into a net structure. When a net-like structure made of an elastic resin is used as the most preferred embodiment of the present invention, a pseudo crystallization process is then performed. In this process, the pseudo crystallization process can be performed simultaneously with cooling by setting the temperature of the cooling medium to the annealing temperature. 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 process can be performed separately. Then, it is cut into a desired length and used as a cushion material. 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. With this treatment, the heat resistance and sag resistance are remarkably improved as compared with those having a heat absorption peak below the melting point and having no pseudo-crystallization treatment (those having no heat absorption peak). The preferred pseudo-crystallization treatment temperature of the present invention is (Tαcr + 10 ° C) to (Tm-20 ° C). When the net-like structure is used for the cushion layer, its intended purpose,
It is necessary to select the resin to be used, the fineness, the loop diameter, and the bulk density depending on the part to be used. For example, when used as a surface wadding layer, it is preferable to have a low density, a fine fineness, and a fine loop diameter in order to give a soft touch, an appropriate subsidence, and a bulge with tension. For the layer, the resonance frequency is lowered, the hardness and the hysteresis at the time of compression are changed linearly to improve the body retention, and in order to maintain the durability, medium density, thick fineness and slightly large -Preferable diameter. Further, it can be molded into a shape suitable for the purpose of use by using a molding die or the like to the extent that the three-dimensional structure is not damaged. In addition, at any stage from the manufacturing process to processing into a molded body, it is possible to perform processing such as addition of chemicals to impart functions such as flame retardancy, insect repellent antibacterial, heat resistance, water / oil repellency, coloring, and aroma.

The monolithic laminate of the present invention is obtained by laminating and integrating the reticulated structure obtained by the above-mentioned method with a foam and / or a nonwoven fabric. The nonwoven fabric can be obtained by a known method. Also, regarding the non-woven fabric made of thermoplastic elastomer,
For example, a spunbonded non-woven fabric can be obtained by the production method according to JP-A-63-12746, and a melt-blown nonwoven fabric can be obtained by the production method according to JP-A-3-119164. Moreover, as a short-fiber nonwoven fabric, Japanese Patent Application No. 4-340
It is possible to obtain a hard cotton non-woven fabric having good heat resistance and durability using an elastomer-based heat-bonding fiber by the method described in Japanese Patent Application No. 483, Japanese Patent Application No. 4-342577, or the like. As a preferred embodiment of the present invention, from the surface, a non-woven fabric-elastomer-heat resistant and durable hard cotton non-woven fabric using thermo-bonding fibers-a meltblown non-woven fabric-a foam having communication holes-from an elastomer- Melt blown non-woven fabric-Network structure-Elastomer melt blown non-woven fabric-Reinforcing polyethylene terephthalate (PET) spunbonded non-woven fabric is laminated and compressed to a required thickness, 10 ℃ to 25 ℃ from melting point
It can be thermoformed at a high temperature to be integrated, or the side can be removed and integrated, and then the side can be attached to form a seat. In this way, by thermal bonding and integration with an elastomer, the structure is recovered even if it is deformed, and the shape retention is remarkably improved. Then, it may be laminated without being heat-bonded, and the laminated structure may be covered with the side material to be integrated. Further, it can be molded into a shape suitable for the intended purpose by using a molding die or the like. In addition, at any stage from the manufacturing process to processing into a molded body, it is possible to perform processing such as addition of chemicals to impart functions such as flame retardancy, insect repellent antibacterial, heat resistance, water / oil repellency, coloring, and aroma.

[0016]

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. Apparent Bulk Density A flat plate 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 divided by the volume. (Average value of n = 4) The sample molded on the seat is obtained by molding the molded body to obtain the volume, and the weight of the molded seat is divided by the volume. Ride comfort The seat part made into an integral laminated body was set on the seat frame of an automobile, and five panelists were made to drive each of them for 4 hours, and the following points were sensory-evaluated and evaluated by the average value of five people. (1) Feeling of floor: None (good), a little (small), a little (medium), remarkable (large) (2) Tumbling: None, a little (small), a little (medium), remarkable ( Large) (3) Cushioning property: good (◎), no pain for about 2 hours (○), vibration can be felt for 1 hour (△), direct vibration can not be held for 30 minutes (×)

Example Dimethyl terephthalate (DMT) 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) having a molecular weight of 2000 was prepared. ) Is added and polycondensation is performed while heating and decompressing to generate a polyester ester block copolymer elastomer having a melting point of 179 ° C. and Tαcr58 ° C., and then 1% of an antioxidant is added and mixed and kneaded into pellets. The thermoplastic elastic resin raw material obtained by liquefying and vacuum drying at 50 ° C. for 48 hours has a width of 50 cm and a length of 5 cm, and orifices with a hole diameter of 0.5 mm are arranged at a pitch of 5 mm on the effective surface of the nozzle. Discharge at a rate of 2 g / min, place cooling water 50 cm below the nozzle surface, and pair stainless steel endless nets with a width of 60 cm in parallel at 5 cm intervals. (A) Place it on the surface of the water so that it partially comes out, pull it out, fuse the contact parts, and while sandwiching both sides, draw it into cooling water heated to 70 ° C at a speed of 1 m / min to solidify, After the chemical treatment, it is cut into a predetermined size and the net-like structure having an apparent density of 0.04 g / cm ³ (the net-like structure No.
A-1) was obtained.

PET having an intrinsic viscosity of 0.63 was set at 285 ° C. with a single hole discharge rate of 2.5 g / min, cooling water was placed 50 cm below the nozzle surface, and stainless endless nets with a width of 60 cm were arranged in parallel at intervals of 5 cm. Then, a pair of take-up conveyors were arranged so as to partially come out on the water surface, and then picked up, and while the contact portions were fused, both sides were sandwiched and drawn into cooling water at 20 ° C. at a speed of 1 m / min to be solidified. After that, it is cut into a predetermined size to form a net-like structure having an apparent density of 0.05 g / cm ³ (net-like structure No.
A-2) was obtained.

A single hole discharge rate of 10 g / min is obtained from a nozzle in which polypropylene (PP) of melt index 50 is 50 cm in width and 5 cm in length, and orifices having a hole diameter of 0.5 mm are arranged at an interval of 5 mm between holes on an effective surface of the nozzle. The cooling water is placed 50 cm below the nozzle surface, and stainless steel endless nets with a width of 60 cm are placed in parallel at intervals of 5 cm so that a pair of take-up conveyors are partially exposed above the water surface and then taken into contact. While fusion-bonding the parts, sandwiching both sides, and drawing in into cooling water at 20 ° C. at a speed of 1 m / min to solidify, cut into a predetermined size and a net-like structure having an apparent density of 0.22 g / cm ³ ( A reticulated structure No. A-3) was obtained.

A single hole discharge rate of 2 g / min is obtained from a nozzle in which polypropylene (PP) of melt index 50 is 50 cm in width and 5 cm in length, and orifices having a hole diameter of 0.5 mm are arranged at an interval of 5 mm between holes on an effective surface of the nozzle. The cooling water is placed 50 cm below the nozzle surface, and stainless steel endless nets with a width of 60 cm are placed in parallel at 5 cm intervals so that a pair of take-up conveyors are placed below the surface of the water, and the contact portion is drawn. Without fusion, both sides are sandwiched and drawn into cooling water at 20 ° C. at a speed of 1 m / min to solidify the fibers and not to be fused. A net-like structure with an apparent density of 0.04 g / cm ³ (net-like structure No. .A-4) was obtained.

4 Denier obtained by a conventional method using the polyether ester block copolymer elastomer used in A-1 as a sheath component and polyethylene terephthalate (PET) as a core component (50/50 weight ratio). -Using a heat-bonded fiber and a PET having an intrinsic viscosity of 0.63, a fineness of 6 denier having a three-dimensional crimp obtained by a conventional method, an initial tensile resistance of 40 g / denier, and a short fiber having a hollow cross section are used. 30/70 weight ratio mixed fiber,
After opening and stacking with a card, compress and press with hot air at 205 ° C for 5
After bonding for a minute, cool once, then compress by 50%,
Hard cotton nonwoven fabric with good heat resistance and durability (nonwoven fabric No. B-) using elastomer-based heat-bonding fiber with apparent density of 0.02 g / cm ³ obtained by pseudo-crystallization treatment with hot air at 100 ° C. for 15 minutes.
1) was obtained.

DMT and hexanediol (HD) and 1
・ 4BD was charged with a small amount of catalyst, and after transesterification by a conventional method, 78% by weight of PTMG having a molecular weight of 3000 was added to cause polycondensation while heating and decompressing, and a melting point of 142 ° C.
To generate a terester block copolymer elastomer,
Then add 1% of antioxidant and knead into pellets,
The thermoplastic elastic resin raw material obtained by vacuum drying at 40 ° C. for 48 hours was used to obtain a melt blown nonwoven fabric (nonwoven fabric No. C-1) having a basis weight of 10 g / m ² by a conventional method.

A non-woven fabric C-1 / with a metal fitting for fixing the lateral ground on the mesh structure in a female mold for a seat having a large number of holes
A commercially available foamed polyurethane / nonwoven fabric C-1 / nonwoven fabric B having communication holes having an apparent density of 0.02 was laminated so as to be laminated, and compressed by a seat male die having many holes, It was treated with hot air having a temperature higher than the melting point by 10 ° C. for 5 minutes to obtain a laminated body in the form of a seat. Then the seat frame
A laminated body with a side cover was attached to the frame, and sitting comfort and durability were evaluated. For comparison, a mesh structure having only a seat form was prepared and similarly mounted on the seat and evaluated. Table 1 shows the structure of the laminate and the evaluation results.

[0025]

[Table 1]

The laminates of Examples 1 and 2 satisfying the requirements of the present invention were suitable for seats with no floor feeling, less stuffiness, and good cushioning properties. Comparative Example 1 is an example using a high-density mesh structure, and because it uses a foam, it has a good feeling of flooring, stuffiness, and cushioning properties, but the seat density is high, which is not preferable as a seat. is there. Comparative example 2
Since the net-like structure is not fused, the cushioning property is inferior due to the feeling of foreign matter in the buttocks. This seat also becomes inferior in shape retention and durability.

[0027]

EFFECTS OF THE INVENTION Since the laminate of the present invention is suitable for a cushioning material which does not have a feeling of flooring and is stuffy and comfortable to sit on, it is comfortable to drive for a long time even when used for a vehicle seat. Since it is possible and inexpensive, it has versatility and is useful not only for vehicle seats but also for boat seats, furniture cushions, cots for bedding products, and the like.

[Brief description of drawings]

FIG. 1 is a view showing a cross section of a laminate of the present invention.

[Explanation of symbols]

Reference numeral 1 is a reticulated structure, 2 is a foam, 3 is a nonwoven fabric, and 4 is an adhesive nonwoven fabric.

Claims (1)

[Claims] 1. A net-like structure flat plate having an apparent density of 0.010 g / cm ³ or less and substantially flat on both sides, which is formed by partially fusing continuous filament fibers made of a thermoplastic resin having a denier of 100 denier or more. Foam and / or non-woven fabric is laminated and integrated on at least one side of the body, and the apparent density is 0.04 g.
/ Cm ³ or less, a laminate.