JPH10276866A - Bed mat material - Google Patents

Abstract

(57) [Summary] [Problem] To provide a recyclable bed mat material having excellent flame retardancy and flexibility. The fiber material includes a fiber A containing a thermoplastic polymer R1 having a melting point lower than that of another fiber, and a flame-retardant fiber B. A and the fibers A substantially adhere to each other and at some of the contact points between the fibers A and other fibers, and most of the constituent fibers of the mat material are in one cross-sectional direction (b
Def), wherein the fiber axis direction is arranged substantially in parallel, and is arranged in a ladam direction in the cross section.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a recyclable bed mat material having excellent flame retardancy and flexibility.

[0002]

2. Description of the Related Art Heretofore, resin foams such as polyurethane have been mainly used as bed mat materials. However, the resin foam has an environmental problem such as the use of chlorofluorocarbon or its substitute gas at the time of foaming, and the generation of a gas which may have an adverse effect on the environment at the time of combustion. In addition, it has low air permeability and low moisture permeability, easily stuffy, and has low water permeability when exposed to water or urine, so it accumulates on the mat,
It is difficult to dry and may give the user discomfort.

[0003] Further, as a material for a bed mat, for example, Japanese Patent Publication No. Sho 62-2155 and Japanese Patent Publication No. 1-1818
No. 3, JP-B-4-33478, JP-A-3-1
A fiber molded body proposed in, for example, Japanese Patent No. 40185 can be used, but further improvement in flame retardancy and flexibility is desired.

[0004] On the other hand, due to the two needs of 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, and many fields have been increasing. , Many people are interested. However, most of the used middle bed mat materials have been incinerated or landfilled, and recycling technology is still in the development stage.

Heretofore, recycling technologies for textile products can be roughly classified into the following three types.

[0006] The first is thermal recycling. In this method, the product is cut into an appropriate form, 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.

[0007] The second is material recycling. This method is different from the following chemical recycling in that it is physically and mechanically pelletized. When this recycled pellet is reused, it is divided into two cases. One is to develop products as a new material in consideration of the mixture of various types of materials, which are reused in flower beds, bonsai pots, sidewalk decorative piles, and the like. The other is composed of 100% the same material as described in JP-A-5-219935 and JP-A-6-123052, and collected, pelletized,
This is the case of melting and reusing.

[0008] 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, fiber products are generally rarely produced as a single material, and the composition of the material is diverse. Therefore, an economical depolymerization system has not yet been successfully developed. Means for solving this problem is described in Japanese Patent Application Laid-Open No. 5-117441, for example, in the case of carpet products. As an auxiliary means for improving the efficiency of depolymerization, the carpet is fragmented, separated into small pieces containing nylon 6 which is a pile material and other small pieces by a separator, and the small pieces containing nylon 6 are supplied to a depolymerization system. This is a method of recovering ε-caprolactam as a raw material. However, even if the fiber product is divided into small pieces and separated by mechanical means such as a specific gravity difference due to a cyclone, it has been difficult to efficiently recycle the fiber product.

[0009]

SUMMARY OF THE INVENTION It is an object of the present invention to provide a recyclable bed material having excellent flame retardancy and flexibility.

[0010]

Means for Solving the Problems A medium for a bed mat according to the present invention has the following constitution in order to solve the above-mentioned problems.

[0011] That is, a fiber mat containing a thermoplastic polymer R1 having at least a melting point lower than the melting points of the other fibers and a flame-retardant fiber B, which are medium materials of a bed mat composed of two or more kinds of fibers, The fibers A substantially adhere to each other between the fibers A and at some of the contact points between the fibers A and other fibers, and most of the constituent fibers of the mat material are in one cross-sectional direction (bdef) of the mat material. The middle material of the bed mat, wherein the fiber axis directions are arranged substantially in parallel only with respect to each other, and the fibers are arranged in a random direction in the cross section.

[0012]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a bed mat according to the present invention;

FIG. 1 is a schematic perspective view schematically showing an example of a fiber arrangement of a middle material of a bed mat according to the present invention.

The middle material of the bed mat is a fiber aggregate composed of at least two kinds of fibers, and one kind of the constituent fibers contains a thermoplastic polymer R1 having a melting point lower than that of the other fibers. It contains fibers A and is substantially adhered and fixed between the fibers A and at a part of contact points between the fibers A and other fibers.

It is preferable that the content of the fiber A is 10% by weight or more from the viewpoints of the shape retention and durability of the bed mat material. In particular, the range of 15 to 60% by weight is preferable.
Fiber A comprises thermoplastic polymer R1 and thermoplastic polymer R
2 is preferred, and thermoplastic polymer R
A core-sheath type composite fiber having two components as a core and a thermoplastic polymer R1 component as a sheath is particularly preferable.

As the thermoplastic polymer R1, for example, in the case of polyester, polyethylene, polypropylene,
Polyolefin or olefin copolymer such as ethylene propylene copolymer, ethylene butene copolymer, ethylene vinyl acetate copolymer, polyester or copolymer such as polyhexamethylene terephthalate, polyhexamethylene butylene terephthalate, polyhexamethylene terephthalate isophthalate At least one kind of polymer selected from thermoplastic polymers such as polyester can be used. The thermoplastic polymer R2 is not particularly limited. For example, polyethylene terephthalate, poly (ethylene terephthalate) having 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 is used. Butylene terephthalate,
Alternatively, a polyester such as polyethylene 2,6-naphthalate can be used.

In the case where the fiber A is of a nylon type, for example, the thermoplastic polymer R2 component may be nylon 6 and the thermoplastic polymer R1 component may be a copolymer of nylon 6 and nylon 66 to lower the melting point. Can be used.

In the selection of the thermoplastic polymer R1, those having a lower melting point than those having the lowest melting point among the fibers other than the fiber A and the thermoplastic polymer R2 are preferable, and are 20 ° C. or higher from the viewpoint of thermal adhesion. Preferably 50 ° C
The lower one is more preferable.

Further, 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., and more preferably in the range of 100 to 170 ° C.

The weight ratio represented by R1 / R2 in the fiber A is preferably in the range of 20/80 to 60/40 from the viewpoint of the shape retention of the bed mat, durability and cost. If necessary, other than pigments such as titanium oxide and carbon black other than R1 and R2, various antioxidants, coloring inhibitors, light stabilizers, antistatic materials, etc. may be added to the fiber A. Of course it is good. Such a fiber A can be produced by an ordinary composite spinning method.

Next, the fiber A preferably has mechanical crimping or the like in order to improve the repulsive force and the resilience to the compression of the middle material of the bed mat of the present invention. The number of crimps is preferably in the range of 3 to 10 peaks / 25 mm, and the degree of crimp is preferably in the range of 5 to 30%. Further, from the viewpoint of improving the repulsive force and the resilience to the compression of the middle material of the bed mat and the processing stability in the manufacturing process, the fineness is 1 to 30 denier and the fiber length is 1
Short fibers of 0 to 100 mm are preferably used.

The medium material of the bed mat of the present invention needs to contain the flame-retardant fiber B as a constituent fiber.

The method of imparting flame retardancy to the fiber may be a method of kneading a flame retardant component into a polymer or a method of imparting the flame retardant component by post-processing. In terms of flame retardancy, a compound containing an element such as phosphorus, halogen, or antimony in the fiber can be preferably used. Among them, phosphorus-based compounds that do not generate harmful gases such as halogen gas during combustion are preferable.

When the flame-retardant fiber B is a polyester fiber and imparts flame retardancy by post-processing, a phosphazene compound having a high phosphorus content is preferred. Further, the phosphazene compound is more effective because it contains nitrogen having a flame retardant assisting action. As the phosphazene compound, a compound containing a linear or cyclic phosphazene compound represented by the following formula or the following formula is more preferable.

[0025]

Embedded image (X1 to X3 in the formula represent an amino group or a phenoxy group, and Y1 to Y3 represent an amino group or a phenoxy group.)

Embedded image (X1 to X4 in the formula represent an amino group or a phenoxy group, and Y1 to Y4 represent an amino group or a phenoxy group.) From the viewpoint of the efficiency of applying the phosphazene compound to the fiber, the total number of phenoxy groups in the phosphazene compound is 2
Preferably, the number is at least. In particular, in the formula, the total number of phenoxy groups is preferably 2 or more and 6 or less. In the formula, the total number of phenoxy groups is preferably 2 or more and 8 or less.

When the flame-retardant fiber of the present invention is polyester,
Controlling the solubility of phosphazene compounds in water, which has been used as a water-soluble compound, in water with a substituent, increases the affinity for polyester, and at room temperature, modifies the compound into a solid that can be exhausted. It is preferable to use those that have been used.

The method of applying a phosphazene compound to a polyester fiber to obtain a flame-retardant fiber may be a method of applying a padding or a spray method and performing dry curing, or a method of treating in a bath similar to dyeing. . Since the phosphazene compound is exhausted by the polyester fiber, the polyester flame-retardant fiber obtained by such a method exhibits high durability even by a treatment such as washing.

The amount of the phosphazene compound to obtain flame retardancy depends on the content of the phosphorus element in the compound. For example, the phosphazene compound is provided so that the polyester fiber contains 0.2% or more of the phosphorus element. Is preferred.

In actual use of the phosphazene compound, it is preferable to use it by dispersing it in water. The method of dispersing in water is not particularly limited, but from the viewpoint of dispersion efficiency, a phosphazene compound, a dispersant and water are mixed,
Stir and disperse. This dispersion is generally crushed and dispersed by a glass bead crusher. As another method for finely dispersing in water, a phosphazene compound may be dissolved in a solvent capable of dissolving it, then stirred and mixed with water to form an emulsion.

When the phosphazene compound is applied to the polyester by treatment in a bath, the treatment temperature is preferably 100 ° C. or higher. From the viewpoint of the exhaustion efficiency, at a temperature of 120 to 135 ° C., 3
It is preferable to carry out the treatment for 0 to 60 minutes, and then perform the usual washing and drying.

Further, it is also preferable to carry out a reduction cleaning after the treatment in the bath or a heat treatment after the drying.

On the other hand, it is applied by padding or spraying,
In the case of dry curing, after drying, a method of exhaustion treatment in an atmosphere of 150 ° C. or more is used. From the viewpoint of providing uniform exhaustion, after drying at 100 to 120 ° C, 170 to 200
It is preferable to perform the exhaust treatment at a temperature of at least ° C. The exhaust heat treatment time is preferably from 10 to 180 seconds or more.

The particle size of the phosphazene compound is preferably 10 μm or less, more preferably 5 μm or less, and even more preferably 1 μm or less, from the viewpoint of uniform exhaustion and stability of the dispersion.

The flame-retardant fiber B constituting the middle material of the bed mat of the present invention is not particularly limited as long as the fiber has a melting point higher than that of the thermoplastic polymer R1 of the fiber A.

Next, the flame-retardant fiber B preferably has a mechanical crimp or the like in order to improve the repulsive force and recovery property of the middle material of the bed mat of the present invention against compression. The number of crimps is 3-1
The range of 0 peaks / 25 mm is preferable, and the degree of crimp is 5 to 30%.
Is preferable. It is more preferable to have a side-by-side composite of a polymer having a viscosity difference when spinning the flame-retardant fiber B, a side-by-side composite of a polymer difference, or a three-dimensional structural difference crimp obtained by asymmetric cooling immediately below a die. Furthermore, the fineness is 1 to 30 denier and the fiber length is 10 to 100 m from the viewpoint of improving the repulsive force and the resilience to the compression of the middle material of the bed mat and the processing stability in the manufacturing process.
m short fibers are preferably used.

The flame-retardant fibers B may contain various pigments such as titanium oxide and carbon black, as required, as well as various antioxidants, anti-coloring agents, light-proofing agents, and antistatic materials. Good. Further, the cross-sectional shape of the fiber may be a round cross-section, an irregular cross-section such as a polygon, a multi-leaf, or an ellipse, or a hollow cross-section thereof.

The fibers constituting the middle material of the bed mat of the present invention may contain other fibers in addition to the fibers A and the flame-retardant fibers B. The other fibers preferably have a mechanical crimp or the like in order to improve the repulsive force and the resilience to the compression of the middle material of the bed mat of the present invention. The number of crimps is preferably in the range of 3 to 10 peaks / 25 mm, and the degree of crimp is preferably in the range of 5 to 30%. It is further preferable to have a crimp by a side-by-side composite of a polymer having a viscosity difference when spinning other fibers, a side-by-side composite of a different polymer, or a three-dimensional structural differential crimp obtained by asymmetric cooling directly below a die. Furthermore, short fibers having a fineness of 1 to 30 denier and a fiber length of 10 to 100 mm are preferably used from the viewpoint of improving the repulsive force and the resilience to the compression of the middle material of the bed mat and the processing stability in the manufacturing process.

Other fibers may optionally contain various antioxidants, anti-coloring agents, light-proofing agents, antistatic materials, etc. in addition to various pigments such as titanium oxide and carbon black. . Further, the cross-sectional shape of the fiber may be a round cross-section, an irregular cross-section such as a polygon, a multi-leaf, or an ellipse, or a hollow cross-section thereof.

The fiber arrangement of the fiber A, the flame-retardant fiber B and other fibers in the bed mat material is, for example, as follows:
As shown in FIG. 1, it is important to arrange the fiber axis direction substantially parallel only to one direction cross section (bdef) of the material in the bed mat, and to arrange them in random directions within the cross section (bdef). is there. By this fiber arrangement, FIG.
Assuming that the b-line is the long direction of the middle material of the bed mat, for example, the fibers arranged in a direction substantially parallel to the thickness direction when used as the middle material of the bed mat, that is, the direction subjected to the compression action, increase from the sleeping position. When the bed is changed to the sitting position, the middle material of the bed mat also undergoes the same deformation, that is, the middle material of the bed mat having good flexibility can be obtained.

Furthermore, most of the constituent fibers are arranged so that the fiber axis direction is substantially parallel to the cross section (bdef) in the thickness direction of the middle material of the bed mat, and within the cross section (bdef) in the thickness direction of the middle material of the bed mat. By arranging in a random direction, despite the good flexibility, the durability of washing and use is high, the moisture permeability and water permeability are high, the comfort of use is high for bed mats Is obtained, and the number of fibers arranged in parallel to the direction subjected to the compressing action increases, so that the structure has improved compression recovery and resilience.

Here, a cross section in the thickness direction, for example, a in FIG.
Although there are many planes with an angle along the e-line, etc., the cross section in the thickness direction (bdef) in which the fibers are arranged substantially in parallel is only the plane at an angle along the be-line, and the fibers are substantially parallel to the plane at this angle. Because of the arrangement, the surface of the bed mat has an angle that is relatively easy to be peeled off when the middle material of the bed mat is pulled or bent as compared with the other angles.

Regarding the degree of flexibility, it is preferable that the material has a flexibility of 5 to 20 cm in bending amount according to a characteristic evaluation method described later.
If the bed mat is less than 5 cm, it will be difficult to follow the deformation of the bed due to poor flexibility, and the appearance and function of the mat such as floating or wrinkling may be impaired. If it exceeds 20 cm, handling when moving the bed mat by washing etc. May deteriorate.

The material in a general fiber bed mat is composed of various structure forming materials and adhesives. It is not easy to recycle bed mat materials made of these various materials. In the bed mat middle material of the present invention, in order to obtain an easily recyclable bed mat middle material while maintaining the required quality of the bed mat middle material, all the fibers constituting the bed mat middle material are made of the same polymer. It is preferred to be composed of fibers. In the present invention, when the fiber made of the same polymer of the bed mat material is a polyester fiber,
It is preferable because it has excellent heat bonding and fixing properties, has low toxicity of combustion gas, and enables material recycling in which the material in the collected bed mat is cut, opened, melted and pelletized and reused. Further, when the fiber made of the same polymer is nylon 6 fiber, the material in the collected bed mat is cut and opened, and for example, Japanese Patent Publication No. 42-18476, Japanese Patent Application No.
Depolymerization by the method disclosed in US Pat.
Purification, recovery as ε-caprolactam, and 6-caprolactam again
It can be reused as a raw material for nylon.

Next, a method for producing a bed mat material of the present invention will be described. FIG. 2 is a schematic vertical sectional view schematically showing an example of a mold of an apparatus used in the method for manufacturing a middle bed mat material of the present invention.

The fiber containing at least the fiber A and the flame-retardant fiber B is blended and spread to a desired blending ratio by a cotton feeder, a blender and a spreader using a usual spinning process. The air-permeable mold is filled with a gas such as an air flow by a cotton fan.

For filling by blowing, it is preferable that the mold has appropriate air permeability. For example, JIS L
1079-1966 when measured with a Frazier-type air permeability tester, the air permeability is 5 to 200 cc / cm ^2.
It is preferably within the range of sec.

As such a mold, for example, an upper mold 2 and a lower mold 1 using a punched metal plate shown in FIG.
Can be used.

In the method of blowing into the air-permeable lower mold 1, first, fibers containing at least the fiber A and the flame-retardant fiber B are mixed, opened, and blown from the blow opening 3. Next, the filling fiber is compressed with the air permeable upper mold 2, and the air permeable upper mold 2 is compressed and fixed at a target density. Further, the compression-fixed fibers are heat-treated together with the air-permeable mold to substantially adhere some of the contact points between the fibers A and between the fibers A and other fibers to fix the form. The temperature of the heat treatment may be a temperature at which the thermoplastic polymer R1 of the fiber A is melted and bonded. In general, the temperature is preferably equal to or higher than the melting point of the thermoplastic polymer R1, and is preferably 200 ° C or lower. The packing density may be appropriately selected depending on the properties of the fibers used for the bed mat material and the required properties of the bed mat material, but generally the packing density is set at 0.1.
The range is preferably from 0.1 to 0.1 g / cm ³ . Density is 0.
If it is less than 01 g / cm ³ , the sound-absorbing material tends to be too soft, resulting in poor form stability, and if it exceeds 0.1 g / cm ³ , it may be disadvantageous in terms of cost.

[0049]

Next, the present invention will be described in more detail with reference to Examples and Comparative Examples. The measuring methods of various characteristics described in the present invention are as follows.

(1) Deflection amount Three rectangular test pieces of 5 cm in thickness, 10 cm in width, and 50 cm in length (length direction of the middle of the bed mat) are prepared, placed on a horizontal table, and placed in the length direction of the test pieces. And left for 30 minutes with the length 30 cm from the edge of the table, read the difference in height (bending amount mm) between the upper surface of the table and the lower surface of the tip of the test piece on a scale, and averaged three times. Expressed as a value.

(2) Fineness The fineness was measured according to the method of JIS L 1015-7-51A.

(3) Average fiber length (cut length) Measured according to JIS L 1015A method (staple diagram method). (4) Number of crimps and degree of crimp The number of crimps and degree of crimp are JIS L 1015-7-12.
-1 and JIS L1015-7-12-2.

(5) Density The material in the bed mat is cut into a length of 20 cm, a width of 20 cm, and a thickness of 1 cm, and is cut in an atmosphere of 20 ° C. × 65% RH.
The weight (w) after being left for a time was measured and determined by the following equation.

Density (g / cm ³ ) = w / 400 (6) Flame retardancy A part of the material in the bed mat is taken out, spread into cotton with a hand spreader, and measured according to the method of JISL 1091D. did.

Example 1 A polyethylene terephthalate-based polyester having a melting point of 110 ° C. copolymerized with 40 mol% of isophthalic acid as the thermoplastic polymer R1 and a normal polyethylene terephthalate having a melting point of 255 ° C. as the thermoplastic polymer R2 were used. The spinning temperature is 285 ° C., the take-off speed is 1350 m / min, and the weight ratio represented by R1 / R2 is 50 /
50 thermoplastic polymer R2 as a core portion, thermoplastic polymer R1
Spinning undrawn yarn of concentric conjugate fiber with the sheath as
This undrawn yarn was drawn at a draw ratio of 3 times at a drawing bath temperature of 80 ° C., and mechanically crimped with a crimper. Furthermore, after drying with a heat setter at 70 ° C., a finishing oil is applied, cut into a cut length of 30 mm, the fineness is about 1.5 denier, the number of crimps is 4.7 / 25 mm, and the degree of crimp is 16. %, A fiber A having a surface layer having a melting point of about 110 ° C.

First, 20 parts by weight of a dispersant composed of a condensation product of naphthalenesulfonic acid and formaldehyde and 60 parts by weight of water were mixed with 100 parts by weight of tetraphenoxydiaminocyclotriphosphazene as a flame retardant, and stirred. After preparing the dispersion, the dispersion was pulverized with a glass bead pulverizer for 18 hours. 10% after grinding
Carboxymethylcellulose solution (etherification degree 0.8
5%) 20 parts by weight are added to the dispersion and mixed thoroughly.
A dispersion of 0% by weight of tetraphenoxydiaminocyclotriphosphazene was obtained.

Separately from this, an undrawn yarn is spun from ordinary polyethylene terephthalate having a melting point of 255 ° C. under a spinning temperature of 280 ° C., a take-up speed of 1350 m / min, and an asymmetric cooling treatment immediately below the spinneret. Stretch magnification 3 times,
Stretching at a stretching bath temperature of 80 ° C, giving mechanical crimp with a crimper,
After cutting to a cut length of 64 mm, the above-mentioned dispersion liquid of tetraphenoxydiaminocyclotriphosphazene was applied by a spraying device, and preliminarily dried at 120 ° C. × 3 minutes, and 165 ° C.
× 2 min, dry heat exhaustion treatment, 7.2% ow exhaustion amount of tetraphenoxydiaminocyclotriphosphazene
f, a phosphorus element exhaustion amount of 1.22% owf, a fineness of about 18 denier, a number of crimps of 4.5 ridges / 25 mm, and a flame-retardant polyester fiber B having a degree of crimp of 15.1%.

The fiber A is mixed with 40% by weight and the flame-retardant polyester fiber B is mixed with 60% by weight, further mixed and opened with a card, and punched on each side through a mold inlet 3 as shown in FIG. The inner surface with vertical is 1000 mm, horizontal 10
It was blown into a lower mold 1 having a thickness of 2000 mm and a height of 2000 mm together with an air flow, compressed by an upper mold 2 having a punched surface, and fixed at a packing density of 0.04 g / cm ³ and a thickness of 500 mm. Using a heat setter used for setting a spun yarn together with the mold filled and compressed with the fiber, steaming 130 ° C
After heat setting for × 20 minutes, the resultant was cooled to produce a fiber block for middle material of a bed mat.

The fiber block has a stable form, and the be (length) of FIG. 1 is 989 mm, the bd (width) is 990 mm, the ab (height) is 500 mm, and the arrangement of the constituent fibers is parallel to the bdef plane. And were arranged in a random direction within the bdef plane, substantially parallel to the plane.

The four fiber blocks are adhered to each other on a surface parallel to the surface bdef using a commercially available adhesive.
m, width of about 990mm, height of about 4000mm and then 80mm, width of 83mm, height of 192m
m, and the height direction was set to the length direction of the bed mat middle material to produce a bed mat middle material. Further, a double-sided circular knitted fabric using polyester rasped knitted fabric on the outer side and a double-sided circular knitted fabric using polyester temporary twisted yarn is used on the outer side to form a bed mat.
The bed mat was manufactured by performing compression finishing once under the condition of 0% compression.

When the flame retardancy (the number of times of flame contact) of the material in the mat of the obtained bed mat was evaluated at three places,
It exhibited excellent flame retardancy and showed a good flexibility with a flexure of 15.8 cm.

After using the bed mat for about one year,
It was cut and opened with an anti-hair machine. The spread fiber is melt-pelletized, melt-spun and drawn again to obtain 6 denier,
It was a polyester staple of 51 mm. The obtained staples were slightly lower in strength than commercially available polyester staples, but were sufficiently usable as wadding.

Comparative Example 1 40% by weight of the fiber A obtained in Example 1 and 60% by weight of the other fiber C obtained in the production of the flame-retardant fiber B in Example 1 without applying a flame retardant with a spraying device A fiber mat was produced in the same manner as in Example 1 except that cotton was mixed, and a bed mat was produced. The mat material of the obtained bed mat shows good flexibility as in Example 1, but when the flame retardancy (the number of times of flame contact) was evaluated at three places, it was 1, 1, 1 and the flame retardancy was low. Met.

Example 2 Example 1 was repeated except that 30% by weight of the fiber A obtained in Example 1 above, 60% by weight of the flame-retardant polyester fiber B, and 10% by weight of the other fiber C obtained in Comparative Example 2 were mixed. A bed mat was manufactured in the same manner as described above.

When the flame resistance (the number of times of flame contact) of the mat material of the obtained bed mat was evaluated at three places,
It exhibited excellent flame retardancy, and showed a good flexibility with a deflection of 17.3 cm.

After using the bed mat for about one year,
It was cut and opened with an anti-hair machine. The spread fiber is melt-pelletized, melt-spun and drawn again to obtain 6 denier,
It was a polyester staple of 51 mm. The obtained staples were slightly lower in strength than commercially available polyester staples, but were sufficiently usable as wadding.

[0067]

According to the present invention, it is possible to provide a middle material for a bed mat which is excellent in flame retardancy and flexibility and can be recycled.

[Brief description of the drawings]

FIG. 1 is a schematic perspective view schematically showing an example of a fiber mat for a middle material of a bed mat according to the present invention.

FIG. 2 is a schematic vertical sectional view schematically showing an example of an apparatus used for manufacturing a fiber block for a middle material of a bed mat according to the present invention.

[Explanation of symbols]

 1: Lower mold 2: Upper mold 3: Gas inlet 4: Fiber

Claims (10)

[Claims] Claims: 1. A bed mat material composed of two or more fibers, comprising a fiber A containing a thermoplastic polymer R1 having at least a melting point lower than the melting points of other fibers, and a flame-retardant fiber B, The fibers A substantially adhere to each other between the fibers A and at some of the contact points between the fibers A and other fibers, and most of the constituent fibers of the mat material are in one cross-sectional direction (b
Def), wherein the fiber axis direction is arranged substantially in parallel, and is arranged in a ladam direction in the cross section. 2. The bed mat material according to claim 1, wherein the amount of deflection described in the text is 5 to 20 cm. 3. The fiber A is a core-sheath type composite fiber, wherein the thermoplastic polymer R1 has a sheath portion, and the thermoplastic polymer R2 having a melting point higher than the melting point of the thermoplastic polymer R1 has a core portion. The middle material of a bed mat according to claim 1 or 2, wherein 4. The medium for a bed mat according to claim 3, wherein the weight ratio of the fibers A represented by R1 / R2 is in the range of 20/80 to 60/40. 5. The bed mat material according to claim 3, wherein the melting point of the thermoplastic polymer R1 is lower than the melting points of the other fibers and is in the range of 80 to 170 ° C. 6. The bed mat material according to claim 1, wherein the flame-retardant fiber B contains a linear or cyclic phosphazene compound represented by the following formula or the following formula. Embedded image (Wherein X1 to X3 represent an amino group or a phenoxy group, and Y1 to Y3 represent an amino group or a phenoxy group). (X1 to X4 in the formula represent an amino group or a phenoxy group, and Y1 to Y4 represent an amino group or a phenoxy group.) 7. The bed mat material according to claim 6, wherein the total number of phenoxy groups in the phosphazene compound is 2 or more. 8. The bed mat according to claim 1, wherein the fineness of the constituent fibers is in the range of 1 to 30 denier. 9. The method according to claim 1, wherein the constituent fibers are all formed from a polyester polymer.
8. The middle material for a bed mat according to any one of 8 above. 10. A fiber according to claim 1, wherein all of the constituent fibers are formed from a nylon 6-based polymer.
8. The middle material for a bed mat according to any one of 8 above.