JPH0741105B2 - Hard cotton molding - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a padded material such as a futon, a pillow, a chair mat, and a cushion, and a hard cotton molded product suitable for a shoe insole, slippers, and the like.

(Prior Art) Nonwoven fabric made of a laminated body of synthetic fibers, sheet-shaped hard cotton,
Alternatively, as a method for forming a concavo-convex pattern on a fiber sheet such as a knitted or woven fabric made of synthetic fiber yarn, the concavo-convex molding in which the fiber sheet is passed through the nip portion between the metal saucer having the concavo-convex pattern and the ultrasonic oscillation horn and compression molding Although a method or a method of imparting a quilt-like seam to the above-mentioned fiber sheet is known, none of them produces an uneven pattern having a large difference in unevenness. However, in recent years, in order to obtain a more comfortable sleeping comfort, sitting comfort, or a comfortable feeling of use, a hard-cured molded product having a large difference in the unevenness of the uneven pattern has been required, and the applicant has satisfied this requirement. Previously, there was proposed a hard cotton molded product in which a concave pattern portion, which is harder than the hard cotton and melt-cured, is exposed on at least one surface of the sheet-shaped hard cotton. However, even if a pattern with large irregularities is obtained on the surface of the hard cotton molded product, the compression elastic recovery is small, and if the compression elastic recovery is to be increased, the basis weight of the sheet-shaped hard cotton must be increased. However, it has the drawback of being expensive and heavy.

(Problems to be Solved by the Invention) The present invention provides a bedclothes, such as a bedding, a pillow, etc., which clearly forms an uneven pattern having a large unevenness difference on a hard-wafer molded product and has a large compression elastic recovery rate and has a comfortable sleeping comfort. The object of the present invention is to obtain a hard mat molding suitable for padding such as chair mats and cushions having a comfortable sitting comfort, cushions, etc., or insoles and slippers having a comfortable feeling of use.

(Means for Solving Problems) The present invention provides a laminated sheet, which is composed mainly of a thermoplastic synthetic fiber, and a porous sheet, which is harder than the sheet and melts at least on one side. It is a hard-cotton molding showing a cured concave pattern portion.

Here, the sheet-like material is hard cotton, needle punched sheet, resin cotton, card web, etc., and in any case, it is necessary that the thermoplastic synthetic fiber is the main component, and the mixing ratio is 30% or more. Preferably.
When using a stiff cotton, the stiff cotton can be needle-punched after laminating a card web obtained from thermoplastic synthetic fiber short fibers through a card, or by pre-blending a binder fiber into a short fiber and laminating a card web obtained through a card. Then, the binder fiber is melted while being compressed to a predetermined thickness to melt the binder fiber, and the web is shaped.
The hardness of the sheet-shaped hard cotton is preferably 5 to 90 degrees in terms of rubber hardness. If the rubber hardness is less than 5 degrees, it is too soft and the shape retention is not sufficient, and the handling and functionality are poor, and if the rubber hardness exceeds 90 degrees, it is too hard and there is no elasticity and cushioning, and comfort is improved. It is not preferable because it becomes scarce. More preferably, the rubber hardness is 20 to 60 degrees. In the present invention, the rubber hardness is measured by an F-type rubber hardness meter manufactured by Kobunshi Keiki Co., Ltd. Flame retardancy may be imparted to the sheet material, if necessary. The thickness of the sheet material is preferably 3 to 100 mm, more preferably 5 to 50 mm. 3mm thick
If it is less than 100 mm, it is too thin to form a mat, and if it exceeds 100 mm, it is too thick and it is difficult to form a molded product, which is not preferable. The porous sheet laminated with the above sheet-like material is preferably polyurethane foam, polyethylene foam, polystyrene foam or the like, and has an apparent specific gravity of 0.016 g / cm ³
Any one may be used as long as it is about 1.0 g / cm ³ . The apparent thickness may be in the range of 5 to 100 mm. The above-mentioned sheet-like material and porous sheet are laminated in one or more layers. The arrangement of the laminated layers and the number of laminated layers may be either. For example, place sheet-like objects on both outer surfaces,
A porous sheet may be arranged in the middle, or a sheet-like material and a porous sheet may be arranged one by one.

A concave pattern portion is formed on at least one surface of the above-mentioned laminated sheet. The pattern means a striped pattern, a lattice pattern, a dot pattern or the like. The pattern portion is harder than the sheet-like material and needs to be melt-cured. The interval between the concave pattern portions is determined by the intended final product, but in the case of a striped pattern portion, it is preferable that the pattern portions are formed at intervals of 5 to 200 mm and a width of 1 to 25 mm. In the case of a lattice pattern, it is preferable that the width is 1 to 25 mm at intervals of 5 to 200 mm in both the vertical direction and the horizontal direction. Further, the uneven pattern portion may be formed on one surface of the sheet-like material, or may be formed on both front and back surfaces of the sheet-like material as shown in the sectional view of FIG. The pattern portion is formed as follows. (Second described as one embodiment
In FIG. 1, 11 is a sheet-like material and 12 is a porous sheet. Laminated sheet 1 fixed on the surface of metal flat plate 5
When the tool horn 2 is pressed against the upper surface of the tool by a press machine 9 and ultrasonic vibration is applied to the tool horn 2, the synthetic fibers constituting the stiff pad generate heat due to internal friction associated with the ultrasonic vibration. By fusing for a very short time of 2 seconds and applying compression, the apparent volume is reduced and the hardness is increased, and the portion 3 where the tool horn 2 is not pressed is maintained in the original state. Therefore, the portion 4 where the tool horn is in pressure contact is a concave portion, and the portion 3 where the tool horn is not in pressure contact is a convex portion,
When the tool horn is pressed continuously in the vertical or horizontal direction of the sheet material, a concave stripe pattern is formed.When the tool horn is continuously pressed in both the vertical direction and the horizontal direction, the concave grid is formed. A pattern is formed. The preferable frequency of ultrasonic vibration is 10 to 50 KHz, and the preferable amplitude is 18 μ or more. If the frequency and the amplitude deviate from the above ranges, it may take a long time to generate heat or no heat may be generated. Also,
When the tool horn 2 is pressed into contact with the tool horn 2, the thickness of the concave pattern portion to be hardened can be easily controlled by limiting the entry thereof by the stopper 8. Also, depending on the vibration frequency of the ultrasonic vibration, the amplitude, and the distance of the stopper,
The uneven pattern is formed on one side or both sides of the sheet-like material.

(Example) Example High-melting-point cut cotton (melting point 263 ° C, thickness 10 denier, fiber length 64 mm) 70% made of polyester stretched fiber and low-melting binder fiber cut cotton (melting point made of polyester stretched fiber) 130 ℃, thickness 4 denier, fiber length 51mm) 30%
Laminated mixed webs made by blending and with Drymax 160
Heat treated at ℃, rubber hardness 30 degrees, thickness 20mm, basis weight 1000g / m ²
To obtain a sheet-shaped hard cotton. Apparent thickness of the sheet-like hard cotton and polyurethane foam having an apparent specific gravity of 0.022 g / cm ^3.
20 mm and hard cotton were laminated in order of polyurethane foam and hard cotton to obtain a laminated sheet. The laminated sheet 1 is the second
As shown in the figure, it is fixed on the metal flat plate 5 and the width is 2 cm and the length is 45 c.
The tool horn 2 of m is lowered, and the electric signal generated by the ultrasonic oscillator 6 is mechanically vibrated by the vibrator 7 (Seidensha ultrasonic oscillator SONOPET 2100B-73A: frequency 15 KHz, amplitude
25 μ) and transmitted to the tool horn 2, and the press machine 9 melts for 2 seconds, cools for 2 seconds, press pressure 4 kg / cm ³
And then ultrasonically processed. The ultrasonic processing was performed in parallel in both vertical and horizontal directions at intervals of 10 cm, and the fibers of the heating portion were fused and solidified to form a concave shape, forming a concave grid pattern portion, and the non-pressure contact portion was convex. A hard cotton was obtained in which swelling and distinct irregularities were formed. The compression elastic recovery rate of the laminated sheet was 92%.

Comparative Example 70% high-melting cut cotton made of stretched polyester fiber (melting point 263 ° C, thickness 10 denier, fiber length 64 mm) and low-melting binder fiber cut cotton made of stretched polyester fiber (melting point 130 ° C, thick 4 denier, fiber length 51mm) 30%
Laminated mixed webs made by mixing and
Heat treated at 0 ℃, rubber hardness 30 degrees, thickness 20mm, basis weight 1500g / m
² sheets of hard cotton were obtained. Ultrasonic processing was performed on the sheet-shaped hard cotton in the same manner as in the example except that the fusing time was 3 seconds and the pressing pressure was 6 kg / cm ² . The compression elastic recovery rate of the sheet-shaped hard cotton was 80%. The compression elastic recovery rate was calculated by the following equation.

However, t ₀ and t ₁ were measured as follows. The initial thickness of the test piece was measured with a 1/20 mm precision dial gauge. (T ₀ m
m) After that, sandwich the test piece between the parallel flat plates of JIS K6401 cyclic compression tester, and compress the test piece at a speed of 70 times per minute up to 50% of the initial thickness repeatedly for 80000 times, Take out, leave it for 30 minutes, and measure the thickness of the test piece again. (T ₁ mm) As is apparent from the examples and comparative examples, the weight per unit area of the laminated sheet of the example is 1000 g / m ² and that of the comparative example is 1500 g / m ^2.
Although the compression elastic recovery rate is 92% even though it is m ² , that of the comparative example is 80%, and the laminated sheet of the example has a large compression elastic recovery rate despite having a small basis weight. Was economical.

(Effects of the Invention) The hard cotton molded product of the present invention has a large compression elastic recovery rate even though the uneven portion having a large unevenness difference is clearly formed on one surface or both surfaces and the weight of the sheet material is small. Therefore, it provides comfortable sleeping and sitting comfort, and the hardened molded product of the present invention alone or a composite with another material is used as a pad, a pillow, a chair mat, a cushioning padding, an insole, a slipper, etc. In this case, since the portion that comes into contact with the body is not ultrasonically processed, the hardness of the sheet-like material appropriately stimulates the body, and the breathability is improved, so that the sleeping comfort and the sitting comfort are improved. Further, the compression elastic recovery rate is large, but the cost is low and it is economical.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of an embodiment of the present invention, and FIG. 2 is an explanatory view of an example of an apparatus for producing a hardened molded product. 1: Laminated sheet 2: Tool horn 3: Part where tool horn does not press 4: Part where tool horn does press 5: Metal flat plate 6: Ultrasonic oscillator of ultrasonic welder 7: Transducer 8: Stopper 9: Press machine 11 : Sheet material 12: Porous sheet

Claims (1)

[Claims] 1. A concave pattern portion, which is harder than the sheet material and is melt-cured, is formed on at least one surface of a laminated sheet composed of a sheet material mainly composed of thermoplastic synthetic fibers and a porous sheet. A hard-cotton molded product characterized by being exposed.