JPH09215877A - Bed mat easy to recycle - Google Patents

Abstract

(57) [Abstract] [Problem] It is easy to recycle, has insect repellent properties and flexibility, is hard to settle against compression, is soft, has high moisture permeability and water permeability, and has a comfortable feeling of use. Moreover, it provides a bed mat that is less likely to cause environmental problems. SOLUTION: The bed mat is a fiber mat containing at least insect-proofed polyester fiber A, and most of the constituent fibers of the mat mat are in the thickness direction of the mat mat. The fiber axis direction is arranged substantially parallel to the cross section (bdef), and arranged in a random direction within the cross section (bdef) in the thickness direction of the mat middle material, and the mat middle material is prepared by the method described in the text. Easy to recycle, characterized in that the measured bending amount is 5 to 20 cm, and that the mat intermediate material, the mat cover, and the sewing thread of the mat that compose the bed mat are all composed of fibers made of polyester-based polymer. Bed mat.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention has an effect of being easy to recycle and having the flexibility required for medical bed mats and the like, repelling harmful insects such as mites or suppressing the growth of harmful insects. The present invention relates to a bed mat having the effect that it is durable against dry cleaning and has a comfortable feeling of use with high moisture permeability and water permeability.

[0002]

2. Description of the Related Art In recent years, due to two needs, that is, environmental protection of the earth and efficient use of resources, the problem of treatment and reuse of industrial waste and general household waste has been increasing in importance. In many areas, many people are interested. However, in the field of bed mats, most used bed mats have been incinerated or landfilled so far, and recycling technology is still in the development stage.

Conventionally, the recycling techniques proposed for textile products are roughly classified into the following three types.

[0004] The first is thermal recycling. In this method, products are cut into appropriate forms, burned, and reused as in-house power generation and various types of heat energy. However, this method is not preferable from the viewpoint of resource reuse.

[0005] The second is material recycling. This method differs from the following chemical recycling in that it is pelletized physically and mechanically. When this recycled pellet is reused, it is divided into two cases. One is to develop a product as a new material in consideration of the fact that various materials are mixed, such as flower beds, pots for bonsai, and decorative piles for sidewalks. The other is disclosed in Japanese Unexamined Patent Publication Nos. Hei 5-212935 and Hei 6-123052.
In this case, it is composed of 0% of the same material, collected, pelletized, melted and reused. However, in this method, all the constituent elements are the same, so in 100% nylon of Japanese Patent Laid-Open No. 5-219935, a tuft puncture base cloth, a sealing layer,
It may be uneconomical to change the backing layer from an inexpensive material to an expensive material.

The third is chemical recycling. The chemical recycling that best matches the basic concept of recycling is chemical recycling, which collects products, decomposes them, and returns them to their original raw materials. However, since few fiber products are generally made from a single material and the material composition is diverse, it takes some time to develop an economical depolymerization system. Means for solving this problem, for example, in the case of carpet products, is described in Japanese Patent Application Laid-Open No. 5-117441. As an auxiliary means for improving the efficiency of depolymerization, the carpet is divided into small pieces, and a separator is used to separate the pieces containing nylon 6 which is the pile material and the other pieces, and the small pieces containing nylon 6 are supplied to the depolymerization system. In this way, the raw material ε-caprolactam is recovered. However, even if the fiber product is made into small pieces and separated by a mechanical means such as a difference in specific gravity due to a cyclone, it is difficult to efficiently recycle them.

On the other hand, a resin foam such as polyurethane has generally been mainly used as a matting material for bed mats. However, the resin foam has a problem in terms of environment, such as using CFC gas or its substitute gas during foaming and generating toxic gas during combustion. In addition, it has low breathability and moisture permeability, it easily gets damp, and when it is exposed to a solution such as water or urine, it has low water permeability, so it accumulates on the mat and is difficult to dry,
It could be uncomfortable.

A cushion material (fiber stuffing material) is used as a matting material for solving these problems.
2155, Japanese Patent Publication No. 1-18183, Japanese Patent Publication No. 4-33478, Japanese Patent Application Laid-Open No. 3-140185. These cushion materials use a low-melting point fiber as a heat-adhesive fiber, or use a high-melting point thermoplastic resin as a core part and a low-melting point thermoplastic resin as a sheath part. Although some results have been obtained by using, it is desired to improve further.

[0009]

DISCLOSURE OF THE INVENTION The object of the present invention is that it is easy to recycle, has insect repellency and flexibility, is hard to settle against compression, is soft, has high moisture permeability and water permeability, and is comfortable. It is to provide a bed mat that has a feeling of use and is less likely to cause environmental problems.

[0010]

The bed mat of the present invention has the following constitution in order to solve the above-mentioned problems.

That is, the bed mat is a bed mat in which the mat material of the bed mat contains at least the insect-proofed polyester fiber A, and most of the constituent fibers of the mat material are in the thickness direction of the mat material. Cross section (bde
The fiber axis direction is arranged substantially parallel to f) and arranged in a random direction within the cross section (bdef) in the thickness direction of the mat intermediate material, and the mat intermediate material is measured by the method described in the text. An easily recyclable bed characterized in that the amount of flexure is 5 to 20 cm, and that the mat intermediate material, the mat cover, and the sewing thread of the mat that compose the bed mat are all composed of fibers made of a polyester polymer. It's Matt.

[0012]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, a bed mat of the present invention will be described in detail with reference to the drawings and with reference to embodiments.

The present invention is a bed mat that is easy to recycle. As described above, a general bed mat has a structure in which a resin foam such as polyurethane is used as an inner material of the bed mat, and the core material is wrapped with a cover such as cotton or polyester. Further, as for the cover, a fabric such as cotton or polyester is composed of sewing threads having different chemical compositions, fasteners and quality indicating labels.
Although it is not easy to recycle a bed mat composed of these various materials, the bed mat of the present invention is to obtain a bed mat that is easy to recycle while maintaining the original required quality of the bed mat.

In the bed mat of the present invention, the bed mat is made of a fiber molding, and the cloth and the sewing thread constituting the cover of the bed mat are composed of fibers of polyester polymer to make the bed mat easy to recycle. Is. In addition, it is preferable that the fasteners and accessories such as a quality display label are also made of fibers made of a polyester-based polymer, if necessary.

The bed mat of the present invention can be recycled by any of material recycling, chemical recycling and thermal recycling, but the bed mat intermediate material, the cloth constituting the cover of the bed mat, and the sewing thread are polyester fibers. Therefore, it is easy and preferable that the collected bed mat is cut, opened, melted and pelletized and reused.

FIG. 1 is a perspective view showing an example of a fiber arrangement in a block shape of a fiber molding for a mat intermediate material of a bed mat according to the present invention.

The fiber molded body is a fiber molded body composed of two or more kinds of fibers, contains at least a polyester fiber A which has been subjected to insect repellent treatment, and is usually polyester (R2).
Thermoplastic polymer R1 having a core component of 20 ° C. or more lower than that of insect-proof polyester fiber A, polyester fiber B not subjected to insect-proof treatment, and ordinary polyester (R2)
A composite fiber C having at least the fiber surface side and a polyester fiber A that has been subjected to insect repellent treatment, or is composed of the composite fiber C and the polyester fiber A that has been subjected to insect repellent treatment and a polyester fiber B that has not been repelled. At least a part of the contact points between the composite fibers C and between the composite fibers C and the polyester fibers A and B are adhered and molded, and most of the constituent fibers of the mat intermediate material are in the thickness direction of the mat intermediate material. The fiber axis direction is arranged substantially parallel to the cross section (bdef) so that the cross section (bd
It is arranged in a random direction in ef).

Here, in order to improve the flexibility of the mat middle material, most of the constituent fibers are arranged substantially parallel to the fiber axial direction with respect to the cross section (bdef) in the thickness direction of the fiber molded body as shown in FIG. 1, for example. , And in the cross section of the fiber molded body in the thickness direction (bde
In the case of being used as a cushion body, the fibers arranged in a random direction in (f) will have many fibers arranged substantially parallel to the thickness direction, that is, the direction to be subjected to the compression action. It also has a structure that raises.

Most of the constituent fibers are arranged in the fiber axial direction substantially parallel to the cross section (bdef) in the thickness direction of the fiber molding as shown in FIG. 1, and within the cross section (bdef) in the thickness direction of the fiber molding. ), The main purpose of arranging in a random direction is to change the bed from the sleeping position to the sitting position, such as a medical bed. To prevent the bed mat only from rising from the bed body. For that purpose, the longitudinal direction of the mat mat material for the bed mat (cushion material) is made to coincide with the ab line direction of the fiber molded body, and the fiber axis direction is substantially parallel to the cross section (bdef) in the thickness direction of the mat mat material. Array
In addition, it is important to arrange the fiber axis directions in a random direction in a cross section (bdef) in the thickness direction so that the longitudinal direction of the bed mat can be easily bent. Regarding the degree of flexibility, it is important that the amount of flexure measured by the characteristic evaluation method described later is 5 to 20 cm. If it is less than 5 cm, the flexibility is poor and the mat floats from the bed or wrinkles are formed, which is not preferable. If it exceeds 20 cm, problems such as poor handleability when the mat is moved for washing or the like occur.

Further, most of the constituent fibers are arranged in the fiber axial direction in parallel to the cross section (bdef) in the thickness direction of the fiber molded body, and within the cross section (bde) in the thickness direction of the fiber molded body.
By arranging them in a random direction in f), the fiber has good durability, is highly durable to washing and use, has high moisture permeability and water permeability, and is comfortable to use even though it has good flexibility. A molded body is obtained.

Here, although there are many cross sections in the thickness direction, such as a surface at an angle along line ae in FIG. 1 and a surface at an angle along line ab in FIG. 1, the cross section in the thickness direction in which fibers are arranged substantially in parallel ( bdef) is only the surface of the angle along the line be, and the fibers are arranged substantially parallel to the surface of this angle. Therefore, when the fiber molded body is stretched or distorted, it is comparatively more than the surface of other angles. It is an angled surface that is easy to peel off.

As the bed mat intermediate material structure, the intermediate material having the above-mentioned fiber arrangement is preferable, but in addition, the fibers to be used are mixed and opened, and the card is further mixed and opened to form a web, and the cotton is formed. Bed mat middle material with improved flexibility by forming a laminated web with a machine and then folding the web into a wave shape and fixing it with low melting point fibers in the fibers used so that the wave height of the wave is the thickness of the mat Is obtained.

Insect repellent polyester fiber A, non-insect repellent polyester fiber B and composite fiber C
The ratio of the insect repellent polyester fiber is 40
The total weight of the polyester fiber B, which is not less than 60% by weight and is not treated with insect repellent, is 80% in total weight with the insect repellent polyester fiber A
Those containing less than wt% are preferred. The content of the composite fiber C is 2 in view of shape retention, durability, cushioning property, soft feeling, and insect repellent property of the fiber molded body of the bed matting material.
The content is preferably 0% by weight or more and less than 60% by weight. Particularly, the range of 20 to 50% by weight is preferable.

The composite fiber C is composed of the two components R1 and R2, and as R1, for example, a polyolefin or olefin such as polyethylene, polypropylene, ethylene propylene copolymer, ethylene butene copolymer, ethylene vinyl acetate copolymer and the like. At least one polymer selected from the group consisting of copolymers, polyesters such as polyhexamethylene terephthalate, polyhexamethylene butylene terephthalate and polyhexamethylene terephthalate isophthalate or thermoplastic polymers such as copolymerized polyesters can be mentioned. Although R2 is not particularly limited, for example, terephthalic acid, 2,6-naphthalenedicarboxylic acid or an ester thereof as a main dicarboxylic acid component, and ethylene glycol or tetramethylene glycol as a main glycol component, polyethylene terephthalate, polybutylene terephthalate,
Alternatively, polyester such as polyethylene 2,6-naphthalate may be used.

In selecting R1, the melting point is made lower than the lowest melting point among the fibers A, the other fibers B and R2, and it is preferably 20 ° C. or more from the viewpoint of thermal adhesiveness, and 50 ° C. More preferably, it is lower.

From the viewpoint of the effect of adhesion and prevention of thermal deterioration, the melting point of R1 is preferably in the range of 80 to 170 ° C, more preferably in the range of 100 to 170 ° C.

The weight ratio represented by R1 / R2 in the composite fiber C is 20 in terms of the shape retention and durability of the fiber mat intermediate bed material, the cushioning property, the recovery efficiency in the case of recycling, the cost and the like. It is preferably in the range of / 80 to 60/40.

In addition to the above, the composite fiber C may contain R if necessary.
In addition to pigments such as titanium oxide and carbon black other than 1, R2, antioxidants, anti-coloring agents, light-proofing agents, antistatic agents, etc. may be added. Such a composite fiber C
Can be produced by a conventional composite spinning method.

Next, in order to impart bulkiness and a soft feeling to the fiber molding of the present invention and improve the recovery property against compression,
The composite fiber C preferably has a mechanical crimp or the like. The number of crimps may be appropriately selected depending on the use of the fiber molding, but it is preferable that the number of crimps is at least 3 peaks / 25 mm and the crimping degree is at least 5%.

The composite fiber C constituting the fiber molding has a fineness of 0.5 to 3 from the viewpoints of bulkiness and softness.
Short fibers having 0 denier and a fiber length of 10 to 100 mm are preferably used.

The insect-repellent polyester fiber A used in the fiber molded article of the present invention is preferably one to which a pyrethroid compound is added. As the pyrethroid-based compound, phenothrin (a 2: 8 mixture with 3-phenoxybenzyl ester of d-cis chrysanthemic acid), synthetic pyrethrin, alectrin, furaltrin, barthrin, dimethrin, natural pyrethrin, and the like can be used. Among these pyrethroid compounds, even when subjected to a high temperature treatment of 150 ° C. or more, the volatility is low, and the compatibility with amino silicon described later is good, and the mite repellent effect and the reduction of the mite growth inhibitory effect by washing are reduced. Phenothrin represented by the following chemical formula is preferable from the viewpoints of low safety and excellent safety.

[0032]

Embedded image In the present invention, as a synergist of the pyrethroid compound, generally known piperonyl butoxide,
Piperonyl cyclone, propyl isomer, sulfoxide (octyl sulfoxide of isosafrole),
The combined use of safloxane, tropical, sezoxane, sinepirins and the like is preferable because the mite control effect can be further enhanced.

The amount of the pyrethroid compound attached to the insect-controlling polyester fiber A of the present invention is 0.01% by weight or more and 1.0
% By weight or less is preferred. More preferably 0.02 to 0.
It is 5% by weight.

The aminosilicon used in the present invention has an amino group in the molecule of the silicone polymer, and may have other substituents such as an epoxy group in addition to the amino group.

The amino equivalent of aminosilicon is 4.
It is preferably 5 × 10 ^{2 to} 6.5 × 10 ³ gram equivalent / mol. When the amino equivalent is too small, the compatibility with the pyrethroid compound and the rust preventive agent is good, and the washing durability is good, but the tick repelling effect may be low. This is probably because the pyrethroid-based compound is firmly covered with the silicon polymer. On the other hand, when the amino equivalent is too large, the initial mites repellency effect is excellent, but the repellency performance may decrease due to washing such as dry cleaning.

When a fiber molding is produced using the insect-controlling polyester fiber of the present invention, a blending machine, an opening machine, a carding machine,
A machine such as a molding machine may be rusted, and it is preferable to add a rust preventive agent to the fiber. In the present invention, as the rust preventive agent, an amino compound represented by the above general formula is used. The rust preventives other than the amino compounds having such a structure have a problem that the pyrethroid compound used in the present invention inhibits the mite repellent effect and mite growth inhibitory effect. The following compounds can be used as specific examples of such amino compounds.

[0037]

Embedded image Here, X means an alkali metal such as Na or K.

[0038]

Embedded image Wherein, R ₁ represents an alkyl group of C _{4 ~ 18,} R ₂ is C
_2-4 alkylene groups, X means an alkali metal such as Na or K.

The rust preventive represented by the general formula is
Further, it is preferable to use an alkyl phosphate compound such as octyl phosphate potassium salt in combination with sodium sulfite, because the rust preventive effect of the compound represented by the general formula is further improved.

In the present invention, the weight ratio of aminosilicon to pyrethroid compound is preferably 1: 1 to 1:20. If the weight ratio of aminosilicon to the pyrethroid compound is too small, the mite-proof washing durability may be significantly reduced. On the other hand, if the weight ratio is too high, the insect repellent effect becomes low.
This is presumably because the pyrethroid compound is covered with the aminosilicon film and the pyrethroid compound hardly appears on the surface.

In the present invention, the weight ratio of the rust preventive agent to the pyrethroid compound is preferably 1: 0.5 to 1:10. If the weight ratio of the rust preventive agent to the pyrethroid compound is too small, the rust preventive effect is low. On the other hand, if the weight ratio is too high, the insect repellant effect may be reduced and the washing durability of the insect repellant effect may be reduced. . It is considered that this is because the rust-preventive agent generally has a strong inorganic property, which adversely affects the film forming property of aminosilicon and reduces the affinity with the polyester fiber.

As the method for producing the insect-controlling polyester fiber of the present invention, for example, the above-mentioned pyrethroid compound, aminosilicone and rust preventive agent are emulsified and dispersed with a nonionic surfactant or anionic surfactant or a combination thereof. A water-based emulsion composition prepared by mixing the fibers so that the target amount of fibers is applied to the fibers by spraying, dipping,
After applying by centrifugal dehydration method, if necessary, 80-120 ℃
It can be manufactured by heat-drying at 150 to 200 [deg.] C. after preliminary drying in.

Next, the cross-sectional shape of the insect-repellent polyester fiber A or the polyester fiber B which has not been subjected to insect-proof treatment may be a polygonal shape, an elliptic shape or other irregular cross-section hollow shape, in addition to the round hollow shape.

Further, in order to impart bulkiness and softness to the fiber molded product of the present invention and improve recovery property against compression, the insect-proof polyester fiber A and the polyester fiber B not subjected to the insect-proof treatment have mechanical crimps. Is preferred.
The number of crimps may be appropriately selected depending on the use of the fiber molding, but it is preferable that the number of crimps is at least 3 peaks / 25 mm and the crimping degree is at least 5%. In order to impart more bulkiness, it is preferable that the crimp is a latent crimp developed by asymmetric cooling or the like during spinning.

The insect-repellent polyester fibers A and the polyester fibers B not subjected to the insect-repellent treatment, which form the fiber molded article, have a fineness of 0.5 to 30 denier, from the viewpoint of the morphological fixability of the fiber molded article and imparting a soft feeling. Fiber length is 10 to 10
Short fibers of 0 mm are preferably used.

In addition, insect-proof polyester fibers A and polyester fibers B not subjected to insect-proof treatment may optionally contain pigments such as titanium oxide and carbon black, as well as antioxidants, anti-coloring agents, light-proofing agents and antistatic agents. Of course, it may be added.

Next, an example of a method for producing the fiber molded body which is the mat intermediate material of the bed mat of the present invention will be described. FIG.
FIG. 3 is a vertical cross-sectional view of a mold of an apparatus used in an example of the method for producing a fiber molded body of the present invention.

The fiber A and the composite fiber C or the fiber A and the other fiber B and the composite fiber C are sufficiently mixed and opened by a cotton feeding machine, a cotton mixing machine and a fiber opening machine used in a usual spinning process. , The air-permeable mold having a shape suitable for the purpose is blown and filled together with a gas such as an air flow by a cotton-blowing fan.

For blowing and filling, a mold having a proper breathability is used. For example, JIS L
1079-1966 As measured by a Frazier-type air permeability tester, air permeability is 5 to 200 cc / cm.
A range of ² · sec is preferable.

As such a mold, for example, dies 1 and 2 using a punching metal plate shown in FIG. 2 can be used. The fiber mixture 4 blown from the blowing port 3 into the air-permeable mold is in a state of being randomly arranged in the length, width, and thickness directions.

Next, the filled fiber mixture is compressed by the mold 2 to an appropriate density. Density is 0.025-0.05
It is preferably 5 g / cm ³ . If the density is too low, the fiber molding is too soft and the morphological stability deteriorates,
It may be difficult to cut and mold into the desired shape. Also,
If the density is too high, the soft feeling of the fiber molded product may be deteriorated.

This compression treatment also has the effect of enhancing the desired flexibility by arranging the fiber molding of the present invention in a direction substantially parallel to the cross section (bdef) in the thickness direction of the fiber molding using the fiber axis direction. is there.

The compressed packing is heat treated to give a composite fiber C.
The shapes are fixed by adhering some of the contact points between the fibers C and the fibers A and the other fibers B to each other. The heat treatment temperature may be a temperature at which R1 of the fiber C melts and adheres, and generally 80 to 200 ° C. is preferable.

Further, according to the present invention, at a temperature lower than the melting point of the thermoplastic polymer R1 of the composite fiber C, two directions in two directions perpendicular to the compression direction after the blow filling or one direction in two directions. It is also preferable that the fiber compact of the present invention is obtained by finishing secondary compression treatment once or more in the range of 5 to 80%. The fiber molded product of the present invention has excellent compression elasticity, flexibility, moisture permeability, and water permeability, and therefore, the constituent fibers are formed on the surface in the direction in which it is subjected to a compression action in, for example, the sitting position or the sleeping position of the intended use. Many of the fiber axis directions are arranged in parallel. for that purpose,
The direction in which the secondary compression treatment direction in the production of the fiber molded body is used, for example, the direction in which a compression action is applied in the sitting position or the sleeping position,
In other words, the thickness direction of the application. In this case, the secondary compression treatment has an effect of previously removing unnecessary bonding points melt-bonded at R1 of the fiber A to improve soft feeling and compression recovery when using the fiber molded body.

[0055]

Next, the present invention will be described more specifically with reference to examples. The measuring methods of various characteristics described in the present invention are as follows.

(1) Deflection amount Three rectangular mat middle material test pieces having a width of 10 cm, a thickness of 5 cm and a length of 50 cm were prepared, placed on a horizontal table, and the test piece was slid to extend from the edge of the table. After leaving for 1 minute in a state of 30 cm, the difference in height between the upper surface of the table and the lower surface of the tip of the test piece (deflection amount mm) was read on a scale and expressed as an average value of three times.

(2) Insect repellency (repelling rate of mites) A powder feed <Nippon Clare Co., Ltd. CF-2> during breeding of mites is spread as evenly as possible on a petri dish having a diameter of 200 mm and a height of 30 mm, and 1 g of the fiber is placed thereon. Open the molded body to 8 ×
Spread it into an approximately 8 cm square, and separate 1 g of ordinary polyester cotton, which has not been insect-proofed, into 8 squares as above.
The pieces were spread into approximately 8 cm squares and placed one by one symmetrically. At a height of 1.4 cm at the center of the cotton, a powder feed (15% moisture) containing no mites
g of 2.8 cm in diameter and place at room temperature 25 ± 2.
After placing in an incubator adjusted to a temperature range of 70 to 80% RH for 40 hours, the number of mites that had invaded the feed in the container was counted by a saline floatation method, and the mite repellent rate was calculated by the following equation. Was.

Mite repellency rate (%) = {(A−B) / A} × 100 where A is the number of mite of ordinary polyester cotton, and B is the number of mite of opened cotton of the fiber molded body.

(3) Fineness The fineness was measured according to the method of JIS L1015-7-51A.

(4) Average Fiber Length <Cut Length> The average fiber length was measured according to JIS L 1015A method (staple diagram method). (5) Number of crimps and degree of crimping The number of crimps and the degree of crimping are JIS L1015-7-12-
1 and the method of JIS L1015-7-12-2.

(6) Packing density Test piece (vertical: 20 cm, horizontal: 20 cm, thickness: 20
cm) was allowed to stand in an atmosphere of 20 ° C. × 65% RH for 24 hours, and the weight (w) was measured and determined by the following equation. Density (g / cm ³ ) = w / 8000 [Examples 1 to 3 and Comparative Examples 1 and 2] As the insect-controlling polyester fiber A for the matte material of the bed mat, the melting point is 25.
Unstretched yarn, which was asymmetrically cooled at the exit of the spinneret, was spun from 5 ° C. normal polyethylene terephthalate chips at a spinning temperature of 280 ° C. and a take-up speed of 1350 m / min.

Then, the undrawn yarn is drawn at a drawing bath temperature of 80.degree.
And mechanical crimping was performed with a crimper. Further, phenothrin as a pyrethroid-based compound is emulsified with 9 mol of nonylphenol ethylene oxide, so that the pyrethroid-based compound becomes 0.1% by weight, and the amino equivalent as a binder is 3.5 × 10 ³ gram equivalent / Amino silicone (TK Silicone AS
65, manufactured by Takamatsu Yushi Co., Ltd.) in an amount of 0.5% by weight in terms of solid content.
And ethylenediamine 4 as a rust inhibitor.
A water emulsion composition prepared by adjusting the disodium salt of acetic acid to a solid content of 0.15 wt% was applied by spraying, cut into a cut length of 30 mm, and heat-treated at 175 ° C. to obtain a fineness of 13 denier and wound. Reduced 4.5 peaks / 25 mm,
Insect-repellent polyester fiber A having a circular hollow cross-section structure with a crimping degree of 25.2% and a hollow ratio of 30% was obtained. The fiber A had a phenothrin deposition amount of 0.15% by weight, an aminosilicone deposition amount of 0.5% by weight, and a rust inhibitor deposition amount of 0.15% by weight. This staple is 100% rust-proof, is coated with hydrochloric acid and oil-removed iron wire is wrapped in the cotton 2
Even after leaving for 72 hours in a thermo-hygrostat at 5 ° C. and 75% RH, almost no rust was generated, and the mite repellency was 99.
It was 94.1% after repeating the step of washing with 4% Perkren solution at 40 ° C. for 10 minutes three times.

Separately from this, as the matting medium composite fiber C, R2 is a normal polyethylene terephthalate chip having a melting point of 255 ° C., and R1 is a polyethylene terephthalate system having a melting point of 110 ° C. copolymerized with 40 mol% of isophthalic acid. Using polyester, a spinning temperature of 285 ° C., a take-up speed of 1350 m / min, a weight ratio represented by R1 / R2 of 50/50, R2 was used as a core portion, and R1 was used as a sheath portion of a concentric composite fiber C. The undrawn yarn was spun.

Then, the undrawn yarn is drawn at a drawing bath temperature of 80.degree.
And mechanical crimping was performed with a crimper. In addition, 7
After drying with a heat setter at 0 ° C, apply a finishing oil agent, cut into a cut length of 51 mm, and have a fineness of about 4 denier,
A composite fiber C having a melting point of the surface layer of about 110 ° C. was obtained.

The above fibers A and C were mixed at the mixing ratio shown in Table 1, further mixed and opened with a roller card, and punched on each surface from the blow port of the mold as shown in FIG. A lower mold 3 having an inner surface width x length x depth of 82 x 84 x 100 cm was blown and filled with an air flow. The blown fiber mixture 4 is compressed by the upper die 2 having punched surfaces, and the packing density is 0.04 g / cm ³ and the thickness is 50.
Fixed in cm. The fiber mixture 4 filled in the mold and compressed,
Using the heat setter used for setting the spun yarn, heat setting was performed by steaming at 130 ° C. for 25 minutes to obtain a fiber molded body.
Next, the direction perpendicular to the compression direction of the obtained fiber molded body is defined as the vertical direction (thickness direction), sliced to a thickness of 7 cm, the sliced sheets are laid side by side and bonded to each other, and then cut. Width 82 cm, length 192 cm, thickness 7c
m bed mat middle material.

Further, as shown in Table 1, the bed mat intermediate materials of Examples 1 and 2 and Comparative Example 2 were subjected to 5 times finish compression treatment at room temperature in a thickness direction at a compression rate of 50% using a large hydraulic machine. did.

Further, as a cover (side material) of the bed mat, a double-sided circular knitted fabric using a false twisted yarn of 75 denier polyester is sewn with a polyester spun sewing thread, and a polyester spun bond is used as a label for quality and handling. Used as a bed mat.

When this bed mat was used for one year, the bending amount of the bed mats of Examples 1 to 3 was 5.1 to 2.
At 0 cm, it follows the electric changes of gadgets well, has good flexibility, insect repellency (mite repellent rate), good handleability in washing, etc., and excellent drainability in washing, It had good wettability and water permeability, and had a comfortable feeling of use.

On the other hand, in Comparative Example 1, the bending amount is 4.6.
In cm, the flexibility as a gadget bed was slightly poor, the sitting comfort in sitting position was poor, and the insect repellent property was also poor.

Comparative Example 2 has good flexibility and insect repellency, but has a bending amount of 23.1 cm and is slightly bent, and it is difficult to insert the mat inner material into the cover, and at the same time, the mat is moved by washing or the like. It was inferior in handling when it was made.

The used bed mats of Examples 1 to 3 were collected, defibrated by a fluffing machine, and the spread fibers were melt-pelletized, melt-spun and stretched again, and a polyester of 13 denier and 30 mm was used. I used staples. The obtained staple was a slightly grayish polyester staple, which had a slightly lower strength than the commercially available normal polyester staple, but was sufficiently usable as a cotton wadding.

Table 1 shows the processing methods and properties of the bed mat intermediate materials of Examples 1 to 3 and Comparative Examples 1 and 2.

[Example 4] In Example 1, when the insect repellent polyester fiber A was produced, the staples not subjected to the insect repellent treatment were the polyester fibers B, the insect repellent polyester fiber A was 40% by weight, and the insect repellent not subjected to the insect repellent treatment. A bed mat was used in the same manner as in Example 2 except that 20% by weight of B and 40% by weight of the composite fiber C were mixed and used for 1 year. The bed mat has flexibility, insect repellency, handleability in washing, etc., excellent drainability in washing, moisture permeability,
It had a good water permeability and a comfortable feel.

The bed mat after use in Example 4 was collected, defibrated by a fluffing machine, and the spread fibers were melted and pelletized, and melt-spun and stretched again to obtain a denier of 13
It was a 30 mm polyester staple. The obtained staple was a slightly grayish polyester staple, which had a slightly lower strength than the commercially available normal polyester staple, but was sufficiently usable as a cotton wadding.

Table 1 shows the processing method and properties of the bed matting material of Example 4.

[0076]

[Table 1] The repellency rate is the value for the mat middle material immediately after the bed mat is manufactured. L-0 is the case without dry washing, L-3 is 40 ° C. for 10 minutes, and L-3 is washed with the solvent, and the step of removing the solvent 3 times. This is the value when repeated.

[0077]

INDUSTRIAL APPLICABILITY According to the present invention, an insect repellent effect that can be efficiently recycled, has the flexibility required for medical beds, etc., repels pests such as mites, or suppresses the growth of pests is provided. Moreover, it is possible to obtain a bed mat having the effect that it is durable against dry cleaning, has high moisture permeability and water permeability, has a comfortable feeling of use, and is less likely to cause environmental problems.

[Brief description of drawings]

FIG. 1 is a perspective view showing an example of a block-shaped fiber molded body used in the present invention.

FIG. 2 is a vertical cross-sectional view showing an example of an apparatus for producing a fiber molded body used in the present invention.

[Explanation of symbols]

 1: Lower mold 2: Upper mold 3: Gas blowing port 4: Fiber mixture

Claims (12)

[Claims] 1. A bed mat, wherein the mat intermediate material of the bed mat is a fiber molding containing at least insect-proof polyester fiber A, and most of the constituent fibers of the mat intermediate material are in the thickness direction of the mat intermediate material. The fiber axis direction is arranged substantially parallel to the cross section (bdef) of the mat, and arranged in a random direction within the cross section (bdef) in the thickness direction of the mat middle material, and the mat middle material is the method described in the text. The amount of flexure measured according to 1. is 5 to 20 cm, and the mat intermediate material, the cover of the mat, and the sewing thread of the mat that compose the bed mat are all composed of fibers made of polyester-based polymer. Easy bed mat. 2. The easily recyclable bed mat according to claim 1, wherein the proportion of the polyester fiber A contained in the matting material of the bed mat is 40% by weight or more. 3. The matting material for a bed mat is polyester R2, polyester fiber A and polyester R2.
A fiber molding containing a composite fiber C with a polyester R1 having a melting point lower than any of the above, and between the composite fibers C and between the composite fiber C and the polyester fiber A.
The easily recyclable bed mat according to claim 1 or 2, wherein at least a part of a contact point between and is formed by adhering. 4. The easy recycle according to claim 3, wherein the composite fiber C contained in the matting material of the bed mat is a composite fiber containing polyester R2 as a core component and polyester R1 as a sheath component. Bed mat. 5. The easily recyclable bed mat according to claim 3, wherein the weight ratio represented by R1 / R2 of the composite fiber C is in the range of 20/80 to 60/40. 6. The easy recycling according to any one of claims 3 to 5, wherein the ratio of the composite fiber C contained in the matting material of the bed mat is 20% by weight or more and less than 60% by weight. Bed mat. 7. A fiber molding, wherein the matting material of the bed mat is composed of two or more kinds of fibers, wherein the polyester fiber A is 40% by weight or more, and the polyester fiber A is not insect-proofed. B is the polyester fiber A
7. The bed mat according to any one of claims 1 to 6, which is a fiber molded product containing less than 80% by weight in total. 8. A polyester fiber A which has been subjected to insect repellent treatment,
The bed mat according to any one of claims 1 to 7, which is treated with a pyrethroid compound. 9. A polyester fiber A which has been subjected to insect repellent treatment,
Pyrethroid compound, amino equivalent 4.5 × 10 ² ~
It was treated with a treatment solution containing 6.5 × 10 ³ gram equivalent / mol of aminosilicon and a rust preventive agent, and the weight ratio of the aminosilicon to the pyrethroid compound in the deposit on the fiber surface was 1 : 1 to 1:20, the weight ratio of the rust preventive agent to the pyrethroid compound is 1:
The easily recyclable bed mat according to any one of claims 1 to 8, wherein the amount of the pyrethroid compound attached is 0.5 to 1:10 and 0.01 to 1% by weight. 10. The easily recyclable bed mat according to claim 9, wherein the rust preventive agent is a compound represented by the following general formula (1). Embedded image (Wherein, in the formula, R: an alkyl group of C _{2 to} C ₄ , Y ₁ :
Alkyl C ₈ -C ₁₈ or - (CH ₂₎ n-COO
Group _{(n: 1~3), Y 2} , Y 3, Y 4 :-( CH 2) n
-COO groups _{(n: 1~3), X 1} : No, H, Na or _{K, X 2, 2X 3,} X 4: H, indicating the Na or K) 11. The easily recyclable bed mat according to any one of claims 8 to 10, wherein the pyrethroid compound is phenothrin. 12. The easily recyclable bed mat according to any one of claims 1 to 11, wherein the tick repellent rate defined in the present text is 40% or more.