JP3627230B2 - Cushion material and manufacturing method thereof - Google Patents

Description

【００３８】
【化２】

【００３９】
【表１】

【００４０】
上述の構成とすることで、反発力が高く、熱時のへたりの小さいクッション材を得ることができるが、さらに望ましくは、繊維ＡがＰＥＮホモポリマーを主体としたものであり、繊維ＢがＰＥＮ／ＰＥＴ共重合体よりなるものである。繊維ＡをＰＥＮにするのは、上述の耐熱性、高弾性率である理由から望ましく、繊維Ｂと繊維Ａとの接着性、軟化点の操作が共重合比率によって調整できるため望ましい。繊維Ｂの軟化点は共重合比率によって変化するが、ＰＥＮの融点が２７０℃であることから、使用する場所での雰囲気温度を考慮すると、１８０℃低い軟化点が下限になる。従って、上述の繊維Ｂが選択的に軟化し、良好なる接着性を持つこと、および加熱時に繊維Ａの分子量低下および変質、さらに、装置への付着および加熱の容易さから得られる３０℃以上繊維Ａの軟化点より低くする必要があることと併せて、繊維Ｂの軟化点は帰納的に３０〜１８０℃の範囲内で繊維Ａより低くする必要がある。
【００４１】
さらに、繊維Ｂの含有量は、繊維Ａ、繊維Ｂの合計量に対して５〜１００重量％である。この繊維Ｂは繊維集合体内におけるバインダ機能を担っているため、繊維Ａの含有量が９５重量％以上となると、繊維集合体内の結合点が減少し、繊維集合体としてのまとまりがなくなり、飛散する繊維の量が著しく増加するためである。
【００４２】
繊維Ｂの断面形状は、表面のみを接着させることが望ましいため、反発力の高いＰＥＮを芯部に持つ芯鞘型複合繊維が特に望ましく、さらに、溶融紡糸の口金入手の簡便さからＰＥＮとのサイドバイサイド型複合繊維が望ましい。また、さらに安価な方法として、単成分紡糸用の口金を用いることができる単成分による全融型の繊維での作製も可能である。
【００４３】
また、繊維ＡをＰＥＴにすることで、反発力は小さいが安価な方法として、繊維ＡをＰＥＴにし、繊維ＢをＰＥＮ／ＰＥＴ共重合体にすることもできる。この場合、ＰＥＴの融点が２５０℃であるため、繊維Ｂの表層の軟化点は３０〜１６０℃低い温度にする必要がある。また、繊維Ｂの占める割合は、上述の理由から５〜１００重量％にする必要がある。この場合の繊維Ｂの断面形状についても、表面のみを接着させることが望ましいため、ＰＥＴを芯部に持つ芯鞘型複合繊維が特に望ましく、さらに、溶融紡糸の口金入手の簡便さからＰＥＴとのサイドバイサイド型複合繊維が望ましい。また、さらに安価な方法として、単成分紡糸用の口金を用いることができる単成分による全融型の繊維での作製も可能である。
【００４４】
さらに望ましくは、ＰＥＮ／ＰＥＴ共重合体の共重合比率は、構成するモノマーのモル分率が２０／８０〜８０／２０の範囲であることである。このＰＥＮ／ＰＥＴ共重合体は、ガラス転移点がモル分率に応じてホモＰＥＴの６５℃からホモＰＥＮの１１３℃まで変化するが、モル分率が２０／８０〜８０／２０の範囲では、非晶性を示す。そして、この非晶性の材料は、成型時の加熱温度に対して粘度が線形に変化して密度むらが生じにくい。このため、製造を容易にするモノマーのモル分率が２０／８０〜８０／２０の範囲が望ましい。
【００４５】
同様の理由から、繊維ＡをＰＥＮにし、繊維ＢをＰＥＮを含まないポリエステル系共重合体としたときでも、充分な性能が得られる繊維集合体とすることができることを確かめた。この場合、繊維ＢはＰＥＮとの接着性を良くするため、ポリエステル系であることが必要である。この点から、市場では良く流通し、入手が容易な、ＰＥＴ／ポリエチレンイソフタレート（ＰＥＩ）共重合体、または、ポリブチレンテレフタレート（ＰＢＴ）／ポリεカプロラクトン（ＰＣＬ）共重合体が望ましいが、軟化点、繊維Ａとの接着性が損なわれない範囲内であれば、他の繊維化可能なポリエステル系共重合体であっても良い。
【００４６】
例えば、ＰＥＴのエチレングリコール成分を他の異なるグリコール成分で置換したもの（例えば、ポリヘキサメチレンテレフタレート（ＰＨＴ））、および／またはテレフタル酸成分を他の異なる２塩基酸成分で置換したもの（例えば、ポリブチレンイソフタレート（ＰＢＩ））で置換したものとＰＥＴとの共重合体や置換したもの同士の共重合体であっても良く、また、前記置換体の他にポリδバレロラクトン（ＰＢＬ）等の炭素数４ないし１１の脂肪族ラクトンによる重合体、あるいは、ポリジオールと前記置換体もしくはＰＥＴとの共重合体であっても良い。
【００４７】
すなわち、このような共重合体は、ＰＥＴ、ＰＢＴ、ＰＨＴ、ＰＥＩ、ＰＢＩ、ＰＨＩ（ポリヘキサメチレンイソフタレート）、ＰＥＮ（ポリエチレンナフタレート）、ＰＢＮ（ポリブチレンナフタレート）、ＰＨＮ（ポリヘキサメチレンナフタレート）、ＰＣＬ、ＰＢＬ、ＰＥＧ（ポリエチレングリコール）、ＰＴＭＧ（ポリテトラメチレングリコール）等を構成ユニットとしているものである。
【００４８】
ただし、繊維Ｂの表層がどのポリエステル系共重合体であっても、繊維ＡがＰＥＮであるため、ＰＥＮより３０〜１８０℃低い軟化点であることが必要である。
【００４９】
また、共重合比率は非晶性に近い領域が望ましいため、ＰＥＴ／ＰＥＩもしくはＰＢＴ／ＰＣＬ共重合体ではモノマーのモル分率が２０／８０〜８０／２０の範囲であることが必要である。
【００５０】
このように本発明によって、反発力が高く、熱時のへたりの小さいクッション材を提供することができる。そして、とくに、雰囲気温度が高くなる用途である自動車用シートへの適用が有効である。とりわけ、最もへたり易い座面、背当て面に適用すると、反発力が高く、熱時のへたりの小さい繊維集合体を使用しているため、通気性の良い快適なシートを提供することが可能になる。
【００５１】
本発明によるクッション材の製造に際しては、構成する繊維のうち、繊維Ｂの軟化点を繊維Ａの軟化点よりも低くしているため、カードレイヤ方式やエアレイヤ方式によって、例えば、図１（Ａ）に示すような繊維集合体の積層体１１を作製した後、繊維Ｂの軟化点より１０℃以上高く、且つ、繊維Ａの軟化点以下の温度で加熱した後、例えば、図１（Ａ），（Ｂ）に示すような成形用上型１２と成形用下型１３との間でプレスし、あるいは、加熱しながらプレスしたあと、冷却することによって、例えば、図１（Ｃ）に示すような所望の形状の繊維集合体の成形体１４に腑型することができる。そして、構成繊維間の結合を高めるため、温度は繊維Ｂの軟化点より１０℃以上にすることによって、簡便にクッション材を製造することが可能である。
【００５２】
そして、このようにして得たクッション材は、例えば、図２（Ａ），（Ｂ）に示す自動車用シート２１のごとく、座面の一部を上下部分にわたって構成する座面用クッション材２２や背面の一部を前後部分にわたって構成する背当て面用クッション材２３として使用することができ、また、図３（Ａ），（Ｂ）に示す自動車用シート３１のごとく、座面の一部を上面側部分においてのみ構成する座面用クッション材３２や背面の一部を前面側部分においてのみ構成する背当て面用クッション材３３として使用することができ、あるいはまた、図４（Ａ），（Ｂ）に示す自動車用シート４１のごとく、座面の全部を構成する座面用クッション材４２や背面の全部を構成する背当て面用クッション材４３として使用することができる。
【００５３】
通常の場合、繊維集合体に凝集性と形態安定性を付与する手段としては、熱融着性樹脂粉末を付与する方法、あるいは、溶液型樹脂を付与したり含浸させたりする方法等が一般的に用いられる。しかしながら、樹脂粉末または溶液型樹脂を使用した場合には樹脂粉末が局所的に凝集しやすく、製品による性能バラツキの恐れがある。
【００５４】
これに対し、主体繊維にバインダ繊維を混入した繊維集合体ではバインダ繊維を繊維集合体中に均一に混合することが容易となり、主体繊維とバインダ繊維のそれぞれの軟化点の間の温度で加熱処理することにより、耐熱へたり性を考慮しなければ、バインダの融着による構成繊維相互の形態安定性は得られた。
【００５５】
しかしながら、主体繊維とバインダ繊維を異なる化学組成のもので構成すれば、リサイクルを困難にし、主体繊維にＰＥＴ、バインダ繊維にＰＥＴ系共重合体を用いたものでは、ＰＥＴの耐熱性の低さから、熱時のへたり性を大きくしていた。
【００５６】
ところが、繊維Ａおよび／または繊維ＢにＰＥＮを用いた場合、著しく耐熱性は向上し、高い耐へたり性能を発現する。また、ＰＥＮはＰＥＴに比べて弾性率の高い材料でもあり、従来反発力不足を解消するために用いてきた密度の増加やバインダ繊維の増量などを伴わなくとも、高い反発力を得ることができる。
【００５７】
また、繊維Ａを収縮率の異なるポリマーによって作製されたサイドバイサイド型倦縮繊維を用いることでも反発力を高めることができる。この場合、両者の接着性や入手の簡便さから、ＰＥＴ同士、ＰＥＮ同士あるいはＰＥＴとＰＥＮの組合わせが望ましい。
【００５８】
反発力の向上は、繊維Ａの断面形状を中空率５％以上の中空断面形状にすることでも得ることができる。但し、この場合、中空率が５％未満では中空断面の効果が発現しないので、少なくとも５％以上の中空率が必要である。そして、中空断面形状とすることによって、繊維Ａの曲げ剛性が高まり、同一繊度の繊維集合体よりも高い反発弾性を得ることができ、重量、材料コストの面から有利なクッション材が作製できる。
【００５９】
さらに望ましくは、収縮率の異なるポリマーによって作製されたサイドバイサイド型倦縮繊維を中空断面で作製して使用することである。この時、反発力は飛躍的に上昇し、非常に効果的である。
【００６０】
このようなクッション材の製造に際して、さらに具体的には、所定カット長、所定繊度の繊維Ａ、繊維Ｂのステープル綿、フリース、ラップ等を開繊し、適宜の混合比率で調合した後、カードレイヤー方式やエアレイヤー方式によりコンベア上に噴送し、必要に応じて吸引してコンベア上にウエブを形成し、さらにこのウエブを所定の見かけ密度に圧縮し、所定温度の熱風もしくは加熱蒸気により成形固化する。あるいはまた、コンベア上のウエブをニードルパンチングにより規定の厚みおよび規定の見かけ密度に仕上げ、同様に熱処理を行う。
【００６１】
本発明によるクッション材は、上記繊維集合体の少なくとも片面に、例えば、トリコット、不織布、織布等の表皮を積層することができる。この場合、表皮の材料は特に限定されない。また、上記カードレイヤー方式やエアレイヤー方式は、ウエブの形成に際して用いるものであって、その後の後処理工程に関しては特に限定されない。
【００６２】
【発明の効果】
本発明によるクッション材では、請求項１に記載しているように、繊維集合体を一部または全部に含むクッション材において、繊維集合体を構成する繊維が、繊度１．５〜１００００デニールの高軟化点合成繊維ステープル（繊維Ａ）と、繊度１．５〜１００００デニールで且つ少なくとも繊維表面において繊維Ａよりも少なくとも３０℃低い軟化点を有する低軟化点合成繊維ステープル（繊維Ｂ）とを主たる構成繊維として含んでなる繊維集合体であって、繊維集合体の平均見かけ密度が０．０１〜０．２ｇ／ｃｍ^３であると共に構成繊維の平均カット長が２０〜１００ｍｍであり、繊維Ａもしくは繊維Ｂあるいは繊維Ａおよび繊維Ｂの両方にポリエチレン２，６−ナフタレート（ＰＥＮ）が含まれているものとし、且つ、繊維ＡがＰＥＮを主体として構成され、繊維ＢがＰＥＮを芯成分に持ち且つ繊維Ａおよび繊維Ｂの芯成分の軟化点より３０〜１８０℃低い軟化点を有するＰＥＮ／ポリエチレンテレフタレート（ＰＥＴ）共重合体よりなる芯鞘型複合繊維であり、繊維Ｂが繊維Ａおよび繊維Ｂの合計量に対して５〜１００重量％含有するものとしたから、軽量にして、高い耐へたり性、高い反発力を有する優れた特性のクッション材を提供することが可能であり、自動車シート用クッション材、寝具用マット材、座布団等の用途に適したオールポリエステル製のクッション材を提供することが可能であり、特にＰＥＮの良好なる耐熱性、高弾性率を活用することができ、表面のみでの接着に好ましいと共に高い反発力をもつＰＥＮを芯部に持つ芯鞘型複合繊維とすることによって、反発力が高く熱時のへたりの小さいクッション材を提供することが可能であるという著しく優れた効果がもたらされる。
【００６４】
本発明によるクッション材では、請求項２に記載しているように、繊維集合体を一部または全部に含むクッション材において、繊維集合体を構成する繊維が、繊度１．５〜１００００デニールの高軟化点合成繊維ステープル（繊維Ａ）と、繊度１．５〜１００００デニールで且つ少なくとも繊維表面において繊維Ａよりも少なくとも３０℃低い軟化点を有する低軟化点合成繊維ステープル（繊維Ｂ）とを主たる構成繊維として含んでなる繊維集合体であって、繊維集合体の平均見かけ密度が０．０１〜０．２ｇ／ｃｍ^３であると共に構成繊維の平均カット長が２０〜１００ｍｍであり、繊維Ａもしくは繊維Ｂあるいは繊維Ａおよび繊維Ｂの両方にポリエチレン２，６−ナフタレート（ＰＥＮ）が含まれているものとし、且つ、繊維ＡがＰＥＮを主体として構成され、繊維ＢがＰＥＮを芯成分に持ち且つ繊維Ａおよび繊維Ｂの芯成分の軟化点より３０〜１８０℃低い軟化点を有するＰＥＮ／ＰＥＴ共重合体よりなるサイドバイサイド型複合繊維であり、繊維Ｂが繊維Ａおよび繊維Ｂの合計量に対して５〜１００重量％含有するものとしたから、軽量にして、高い耐へたり性、高い反発力を有する優れた特性のクッション材を提供することが可能であり、自動車シート用クッション材、寝具用マット材、座布団等の用途に適したオールポリエステル製のクッション材を提供することが可能であり、特にＰＥＮの良好なる耐熱性、高弾性率を活用することができ、ＰＥＮとのサイドバイサイド型複合繊維とすることによって、溶融紡糸の口金入手の簡便性を活かすことが可能であるという著しく優れた効果がもたらされる。
【００６５】
本発明によるクッション材では、請求項３に記載しているように、繊維集合体を一部または全部に含むクッション材において、繊維集合体を構成する繊維が、繊度１．５〜１００００デニールの高軟化点合成繊維ステープル（繊維Ａ）と、繊度１．５〜１００００デニールで且つ少なくとも繊維表面において繊維Ａよりも少なくとも３０℃低い軟化点を有する低軟化点合成繊維ステープル（繊維Ｂ）とを主たる構成繊維として含んでなる繊維集合体であって、繊維集合体の平均見かけ密度が０．０１〜０．２ｇ／ｃｍ^３であると共に構成繊維の平均カット長が２０〜１００ｍｍであり、繊維Ａもしくは繊維Ｂあるいは繊維Ａおよび繊維Ｂの両方にポリエチレン２，６−ナフタレート（ＰＥＮ）が含まれているものとし、且つ、繊維ＡがＰＥＮを主体として構成され、繊維Ｂが繊維Ａより３０〜１８０℃低い軟化点を有するＰＥＮ／ＰＥＴ共重合体から構成された単一成分繊維であり、繊維Ｂが繊維Ａおよび繊維Ｂの合計量に対して５〜１００重量％含有するものとしたから、軽量にして、高い耐へたり性、高い反発力を有する優れた特性のクッション材を提供することが可能であり、自動車シート用クッション材、寝具用マット材、座布団等の用途に適したオールポリエステル製のクッション材を提供することが可能であり、特にＰＥＮの良好なる耐熱性、高弾性率を活用することができ、単一成分繊維であるものとすることによって、単成分紡糸用の口金を用いることによるコスト低減をはかることが可能であるいう著しく優れた効果がもたらされる。
【００６６】
そして、請求項４に記載しているように、繊維Ａが、ＰＥＮと、これと収縮率の異なるＰＥＮもしくはＰＥＴとのサイドバイサイド型倦縮繊維で構成されているものとすることによって、高い耐熱へたり性と高い反発力を有する軽量なオールポリエステル製のクッション材を提供することが可能であるという著しく優れた効果がもたらされる。
【００６７】
本発明によるクッション材では、請求項５に記載しているように、繊維集合体を一部または全部に含むクッション材において、繊維集合体を構成する繊維が、繊度１．５〜１００００デニールの高軟化点合成繊維ステープル（繊維Ａ）と、繊度１．５〜１００００デニールで且つ少なくとも繊維表面において繊維Ａよりも少なくとも３０℃低い軟化点を有する低軟化点合成繊維ステープル（繊維Ｂ）とを主たる構成繊維として含んでなる繊維集合体であって、繊維集合体の平均見かけ密度が０．０１〜０．２ｇ／ｃｍ^３であると共に構成繊維の平均カット長が２０〜１００ｍｍであり、繊維Ａもしくは繊維Ｂあるいは繊維Ａおよび繊維Ｂの両方にポリエチレン２，６−ナフタレート（ＰＥＮ）が含まれているものとし、且つ、繊維ＡがＰＥＴを主体として構成され、繊維ＢがＰＥＴを芯成分に持ち且つ繊維Ａおよび繊維Ｂの芯成分の軟化点より３０〜１６０℃低い軟化点を有するＰＥＮ／ＰＥＴ共重合体よりなる芯鞘型複合繊維であり、繊維Ｂが繊維Ａおよび繊維Ｂの合計量に対して５〜１００重量％含有するものとしたから、軽量にして、高い耐へたり性、高い反発力を有する優れた特性のクッション材を提供することが可能であり、自動車シート用クッション材、寝具用マット材、座布団等の用途に適したオールポリエステル製のクッション材を提供することが可能であり、特に反発力はＰＥＮに比べて若干小さいものの安価である利点を活用することができ、表面のみでの接着に好ましいＰＥＴを芯部に持つ芯鞘型複合繊維とすることによって、より安価でかつ熱時のへたりが少なく反発力の良好なクッション材を提供することが可能であるという著しく優れた効果がもたらされる。
【００６８】
本発明によるクッション材では、請求項６に記載しているように、繊維集合体を一部または全部に含むクッション材において、繊維集合体を構成する繊維が、繊度１．５〜１００００デニールの高軟化点合成繊維ステープル（繊維Ａ）と、繊度１．５〜１００００デニールで且つ少なくとも繊維表面において繊維Ａよりも少なくとも３０℃低い軟化点を有する低軟化点合成繊維ステープル（繊維Ｂ）とを主たる構成繊維として含んでなる繊維集合体であって、繊維集合体の平均見かけ密度が０．０１〜０．２ｇ／ｃｍ^３であると共に構成繊維の平均カット長が２０〜１００ｍｍであり、繊維Ａもしくは繊維Ｂあるいは繊維Ａおよび繊維Ｂの両方にポリエチレン２，６−ナフタレート（ＰＥＮ）が含まれているものとし、且つ、繊維ＡがＰＥＴを主体として構成され、繊維ＢがＰＥＴを芯成分に持ち且つ繊維Ａおよび繊維Ｂの芯成分の軟化点より３０〜１６０℃低い軟化点を有するＰＥＮ／ＰＥＴ共重合体よりなるサイドバイサイド型複合繊維であり、繊維Ｂが繊維Ａおよび繊維Ｂの合計量に対して５〜１００重量％含有するものとしたから、軽量にして、高い耐へたり性、高い反発力を有する優れた特性のクッション材を提供することが可能であり、自動車シート用クッション材、寝具用マット材、座布団等の用途に適したオールポリエステル製のクッション材を提供することが可能であり、特に反発力はＰＥＮに比べて若干小さいものの安価である利点を活用することができ、サイドバイサイド型複合繊維とすることによって、溶融紡糸の口金入手の簡便性を活かすことが可能であるという著しく優れた効果がもたらされる。
【００６９】
本発明によるクッション材では、請求項７に記載しているように、繊維集合体を一部または全部に含むクッション材において、繊維集合体を構成する繊維が、繊度１．５〜１００００デニールの高軟化点合成繊維ステープル（繊維Ａ）と、繊度１．５〜１００００デニールで且つ少なくとも繊維表面において繊維Ａよりも少なくとも３０℃低い軟化点を有する低軟化点合成繊維ステープル（繊維Ｂ）とを主たる構成繊維として含んでなる繊維集合体であって、繊維集合体の平均見かけ密度が０．０１〜０．２ｇ／ｃｍ^３であると共に構成繊維の平均カット長が２０〜１００ｍｍであり、繊維Ａもしくは繊維Ｂあるいは繊維Ａおよび繊維Ｂの両方にポリエチレン２，６−ナフタレート（ＰＥＮ）が含まれているものとし、且つ、繊維ＡがＰＥＴを主体として構成され、繊維Ｂが繊維Ａより３０〜１６０℃低い軟化点を有するＰＥＮ／ＰＥＴ共重合体から構成された単一成分繊維であり、繊維Ｂが繊維Ａおよび繊維Ｂの合計量に対して５〜１００重量％含有するものとしたから、軽量にして、高い耐へたり性、高い反発力を有する優れた特性のクッション材を提供することが可能であり、自動車シート用クッション材、寝具用マット材、座布団等の用途に適したオールポリエステル製のクッション材を提供することが可能であり、特に反発力はＰＥＮに比べて若干小さいものの安価である利点を活用することができ、単一成分繊維であるものとすることによって、単成分紡糸用の口金を用いることによるコスト低減をはかることが可能であるいう著しく優れた効果がもたらされる。
【００７０】
そして、請求項８に記載しているように、繊維Ａが、ＰＥＴと、これと異なる収縮率を有するＰＥＴとのサイドバイサイド型倦縮繊維で構成されているものとすることによって、優れた耐熱へたり性と良好なる反発力を有する軽量で安価なオールポリエステル製のクッション材を提供することが可能であるという著しく優れた効果がもたらされる。
【００７１】
そしてまた、請求項９に記載しているように、ＰＥＮ／ＰＥＴ共重合体を構成するモノマーのモル分率が２０／８０〜８０／２０であるものとすることによって、成型時の加熱温度に対して粘度が線形に変化するものとすることができ、密度むらを生じにくいものとすることが可能であって製造性を向上させることが可能であるという著しく優れた効果がもたらされる。
【００７２】
本発明によるクッション材では、請求項１０に記載しているように、繊維集合体を一部または全部に含むクッション材において、繊維集合体を構成する繊維が、繊度１．５〜１００００デニールの高軟化点合成繊維ステープル（繊維Ａ）と、繊度１．５〜１００００デニールで且つ少なくとも繊維表面において繊維Ａよりも少なくとも３０℃低い軟化点を有する低軟化点合成繊維ステープル（繊維Ｂ）とを主たる構成繊維として含んでなる繊維集合体であって、繊維集合体の平均見かけ密度が０．０１〜０．２ｇ／ｃｍ^３であると共に構成繊維の平均カット長が２０〜１００ｍｍであり、繊維Ａもしくは繊維Ｂあるいは繊維Ａおよび繊維Ｂの両方にポリエチレン２，６−ナフタレート（ＰＥＮ）が含まれているものとし、且つ、繊維ＡがＰＥＮを主体として構成され、繊維ＢがＰＥＮを芯成分に持ち且つ繊維Ａおよび繊維Ｂの芯成分の軟化点より３０〜１８０℃低い軟化点を有するＰＥＴ／ポリエチレンイソフタレート（ＰＥＩ）共重合体、または、ポリブチレンテレフタレート（ＰＢＴ）／ポリεカプロラクトン（ＰＣＬ）共重合体よりなる芯鞘型複合繊維であり、繊維Ｂが繊維Ａおよび繊維Ｂの合計量に対して５〜１００重量％含有するものとしたから、軽量にして、高い耐へたり性、高い反発力を有する優れた特性のクッション材を提供することが可能であり、自動車シート用クッション材、寝具用マット材、座布団等の用途に適したオールポリエステル製のクッション材を提供することが可能であり、特にＰＥＮのもつ良好なる耐熱性、高弾性率を活用することができ、表面のみでの接着に好ましいと共に高い反発力をもつＰＥＮを芯部に持つ芯鞘型複合繊維とすることによって、反発力が高く熱時のへたりの小さいクッション材を提供することが可能であるという著しく優れた効果がもたらされる。
【００７３】
本発明によるクッション材では、請求項１１に記載しているように、繊維集合体を一部または全部に含むクッション材において、繊維集合体を構成する繊維が、繊度１．５〜１００００デニールの高軟化点合成繊維ステープル（繊維Ａ）と、繊度１．５〜１００００デニールで且つ少なくとも繊維表面において繊維Ａよりも少なくとも３０℃低い軟化点を有する低軟化点合成繊維ステープル（繊維Ｂ）とを主たる構成繊維として含んでなる繊維集合体であって、繊維集合体の平均見かけ密度が０．０１〜０．２ｇ／ｃｍ^３であると共に構成繊維の平均カット長が２０〜１００ｍｍであり、繊維Ａもしくは繊維Ｂあるいは繊維Ａおよび繊維Ｂの両方にポリエチレン２，６−ナフタレート（ＰＥＮ）が含まれているものとし、且つ、繊維ＡがＰＥＮを主体として構成され、繊維ＢがＰＥＮを芯成分に持ち且つ繊維Ａおよび繊維Ｂの芯成分の軟化点より３０〜１８０℃低い軟化点を有するＰＥＴ／ＰＥＩ共重合体、または、ＰＢＴ／ＰＣＬ共重合体よりなるサイドバイサイド型複合繊維であり、繊維Ｂが繊維Ａおよび繊維Ｂの合計量に対して５〜１００重量％含有するものとしたから、軽量にして、高い耐へたり性、高い反発力を有する優れた特性のクッション材を提供することが可能であり、自動車シート用クッション材、寝具用マット材、座布団等の用途に適したオールポリエステル製のクッション材を提供することが可能であり、特にＰＥＮのもつ良好なる耐熱性、高弾性率を活用することができ、ＰＥＮとのサイドバイサイド型複合繊維とすることによって、溶融紡糸の口金入手の簡便性を活かすことが可能であるという著しく優れた効果がもたらされる。
【００７４】
本発明によるクッション材では、請求項１２に記載しているように、繊維集合体を一部または全部に含むクッション材において、繊維集合体を構成する繊維が、繊度１．５〜１００００デニールの高軟化点合成繊維ステープル（繊維Ａ）と、繊度１．５〜１００００デニールで且つ少なくとも繊維表面において繊維Ａよりも少なくとも３０℃低い軟化点を有する低軟化点合成繊維ステープル（繊維Ｂ）とを主たる構成繊維として含んでなる繊維集合体であって、繊維集合体の平均見かけ密度が０．０１〜０．２ｇ／ｃｍ^３であると共に構成繊維の平均カット長が２０〜１００ｍｍであり、繊維Ａもしくは繊維Ｂあるいは繊維Ａおよび繊維Ｂの両方にポリエチレン２，６−ナフタレート（ＰＥＮ）が含まれているものとし、且つ、繊維ＡがＰＥＮを主体として構成され、繊維Ｂが繊維Ａより３０〜１８０℃低い軟化点を有するＰＥＴ／ＰＥＩ共重合体、または、ＰＢＴ／ＰＣＬ共重合体から構成された単一成分繊維であり、繊維Ｂが繊維Ａおよび繊維Ｂの合計量に対して５〜１００重量％含有するものとしたから、軽量にして、高い耐へたり性、高い反発力を有する優れた特性のクッション材を提供することが可能であり、自動車シート用クッション材、寝具用マット材、座布団等の用途に適したオールポリエステル製のクッション材を提供することが可能であり、特にＰＥＮのもつ良好なる耐熱性、高弾性率を活用することができ、単一成分繊維であるものとすることによって、単成分紡糸用の口金を用いることによるコスト低減をはかることが可能であるいう著しく優れた効果がもたらされる。
【００７５】
そして、請求項１３に記載しているように、繊維Ａが、ＰＥＮと、これと異なる収縮率を有するＰＥＮとのサイドバイサイド型倦縮繊維で構成されているものとすることによって、高い耐熱へたり性と高い反発力を有する軽量なオールポリエステル製のクッション材を提供することが可能であるという著しく優れた効果がもたらされる。
【００７６】
そしてまた、請求項１４に記載しているように、ＰＥＴ／ＰＥＩ共重合体またはＰＢＴ／ＰＣＬ共重合体を構成するモノマーのモル分率が２０／８０〜８０／２０であるものとすることによって、成型時の加熱温度に対して粘度が線形に変化するものとすることができ、密度むらを生じにくいものとすることが可能であって製造性を向上させることが可能であるという著しく優れた効果がもたらされる。
【００７７】
さらにまた、請求項１５に記載しているように、繊維Ａの断面形状が５％以上の中空率を有する中空断面形状繊維であるものとすることによって、繊維Ａの曲げ剛性を高めることができ、反発力のより一層の向上をはかることが可能であるという著しく優れた効果がもたらされる。
【００７８】
本発明による自動車用シート部品は、請求項１６に記載しているように、請求項１ないし１５のいずれかに記載のクッション材を少なくとも座面または背当て面に使用しているものであるから、最もへたりを生じやすい座面，背当て面で、反発力が高く、熱時のへたりが小さく、長期にわたって良好なるクッション性を発揮することができ、繊維集合体を使用しているために通気性も良好である自動車用シート部品を提供することが可能であるという著しく優れた効果がもたらされる。
【００７９】
本発明によるクッション材の製造方法では、請求項１７に記載しているように、請求項１ないし１６のいずれかに記載のクッション材を製造する際、カードレイヤ方式およびエアレイヤ方式の少なくともいずれかによって積層した後、繊維Ｂの軟化点より１０℃以上高く、且つ、繊維Ａの軟化点以下の温度で加熱した後プレスし、あるいは、加熱しながらプレスしたあと、冷却することにより所望の形状に腑型するようにしたから、熱時の耐へたり性に優れ、高い反発力を長期にわたって維持することができるクッション材を生産性良く製造することが可能であるという著しく優れた効果がもたらされる。
【００８０】
ことを特徴としている。
【００８１】
【実施例】
以下に、本発明の実施例について参考例および比較例と共にさらに詳細に示すが、本発明はこのような実施例のみに限定されないものであります。
【００８２】
（実施例１）
平均カット長が５１ｍｍである１３デニールのポリエチレンナフタレート（以下「ＰＥＮ」と略称する）からなる繊維Ａ［中実断面］８０重量％と、１３デニールの繊維Ｂ［芯成分：ＰＥＮ、鞘成分：共重合ポリエステル（ＰＥＴ／ＰＥＮ＝４０／６０）、軟化点：１７０℃］２０重量％から構成されるステープル混合原料をカードレイヤー方式にてウエブを形成し、規定の厚みに圧縮した後２００℃に加熱することにより、平均見かけ密度０．０２５ｇ／ｃｍ^３のポリエステル繊維集合体よりなるクッション材を得た。
【００８３】
（実施例２）
平均カット長を２０ｍｍとした他は、実施例１と全く同様にしてクッション材を得た。
【００８４】
（実施例３）
平均カット長を１００ｍｍとした他は、実施例１と全く同様にしてクッション材を得た。
【００８５】
（実施例４）
平均見かけ密度を０．０１ｇ／ｃｍ^３とした他は、実施例１と全く同様にしてクッション材を得た。
【００８６】
（実施例５）
平均見かけ密度を０．２ｇ／ｃｍ^３とした他は、実施例１と全く同様にしてクッション材を得た。
【００８７】
（実施例６）
繊維Ｂを［芯成分：ＰＥＮ、鞘成分：共重合ポリエステル（ＰＥＴ／ＰＥＮ＝８０／２０）、軟化点：２００℃］とした以外は、実施例１と全く同様にしてクッション材を得た。
【００８８】
（実施例７）
繊維Ｂを［芯成分：ＰＥＮ、鞘成分：共重合ポリエステル（ＰＥＴ／ＰＥＮ＝２０／８０）、軟化点：２２０℃］とした以外は、実施例１と全く同様にしてクッション材を得た。
【００８９】
（実施例８）
繊維Ａおよび繊維Ｂの繊度を１．５デニールとした他は、実施例１と全く同様にしてクッション材を得た。
【００９０】
（実施例９）
繊維Ａおよび繊維Ｂの繊度を１００００デニールとした他は、実施例１と全く同様にしてクッション材を得た。
【００９１】
（実施例１０）
繊維Ａを９５重量％、繊維Ｂを５重量％とした他は、実施例１と全く同様にしてクッション材を得た。
【００９２】
（実施例１１）
繊維Ａを０重量％、繊維Ｂを１００重量％とした他は、実施例１と全く同様にしてクッション材を得た。
【００９３】
（実施例１２）
繊維ＡをＰＥＴとした他は、実施例１と全く同様にしてクッション材を得た。
【００９４】
（実施例１３）
繊維Ｂを［芯成分：ＰＥＮ、鞘成分：共重合ポリエステル（ＰＥＴ／ＰＥＩ＝７０／３０）、軟化点：１４０℃］とした他は、実施例１と全く同様にしてクッション材を得た。
【００９５】
（実施例１４）
繊維Ｂを［芯成分：ＰＥＮ、鞘成分：共重合ポリエステル（ＰＥＴ／ＰＥＩ＝２０／８０）、軟化点：１６０℃］とした他は、実施例１と全く同様にしてクッション材を得た。
【００９６】
（実施例１５）
繊維Ｂを［芯成分：ＰＥＮ、鞘成分：共重合ポリエステル（ＰＥＴ／ＰＥＩ＝８０／２０）、軟化点：１８０℃］とした他は、実施例１と全く同様にしてクッション材を得た。
【００９７】
（実施例１６）
繊維Ｂを［芯成分：ＰＥＮ、鞘成分：共重合ポリエステル（ＰＥＴ／ＰＥＩ＝４０／６０）、軟化点：１００℃］とした他は、実施例１と全く同様にしてクッション材を得た。
【００９８】
（実施例１７）
繊維Ｂを［芯成分：ＰＥＮ、鞘成分：共重合ポリエステル（ＰＥＴ／ＰＥＩ＝５０／５０）、軟化点：９０℃］とした他は、実施例１と全く同様にしてクッション材を得た。
【００９９】
（実施例１８）
繊維Ｂを［芯成分：ＰＥＮ、鞘成分：共重合ポリエステル（ＰＢＴ／ＰＣＬ＝５０／５０）、軟化点：１７０℃］とした他は、実施例１と全く同様にしてクッション材を得た。
【０１００】
（実施例１９）
繊維Ｂを［芯成分：ＰＥＮ、鞘成分：共重合ポリエステル（ＰＢＴ／ＰＣＬ＝２０／８０）、軟化点：９０℃］とした他は、実施例１と全く同様にしてクッション材を得た。
【０１０１】
（実施例２０）
繊維Ｂを［芯成分：ＰＥＮ、鞘成分：共重合ポリエステル（ＰＢＴ／ＰＣＬ＝８０／２０）、軟化点：２００℃］とした他は、実施例１と全く同様にしてクッション材を得た。
【０１０２】
（実施例２１）
繊維Ａの断面を５％の中空断面とした他は、実施例１と全く同様にしてクッション材を得た。
【０１０３】
（実施例２２）
繊維Ａの断面を１５％の中空断面とした他は、実施例１と全く同様にしてクッション材を得た。
【０１０４】
（実施例２３）
繊維Ｂを［芯成分：ＰＥＮ、鞘成分：共重合ポリエステル（ＰＥＴ／ＰＥＮ＝４０／６０）］のサイドバイサイド型複合繊維とした他は、実施例１と全く同様にしてクッション材を得た。
【０１０５】
（実施例２４）
繊維Ｂを共重合ポリエステル（ＰＥＴ／ＰＥＮ＝４０／６０）の単一成分からなる全融型繊維とした他は、実施例１と全く同様にしてクッション材を得た。
【０１０６】
（実施例２５）
繊維Ａを実施例１と同じＰＥＮとこれより分子量の低いＰＥＮとのサイドバイサイド型の繊維にした他は、実施例１と全く同様にしてクッション材を得た。
【０１０７】
（実施例２６）
繊維Ａを実施例１と同じＰＥＮと実施例１２と同じＰＥＴとのサイドバイサイド型の繊維にした他は、実施例１と全く同様にしてクッション材を得た。
【０１０８】
（実施例２７）
繊維Ａを実施例１と同じＰＥＮとこれより分子量の低いＰＥＮとのサイドバイサイド型の繊維にし、さらに１５％の中空断面形状にした他は、実施例１と全く同様にしてクッション材を得た。
【０１０９】
（実施例２８）
実施例１の繊維配合で自動車用シート形状のクッション材を成形し、発泡ウレタン製の自動車用シートと比較を行った（図４）。
【０１１０】
（実施例２９）
実施例１の繊維配合で自動車用シートの座面、背当て面を成形し、発泡ウレタン製の自動車用シートの座面、背当て面と置換し、発泡ウレタン製の自動車用シートと比較を行った（図２，３）。
【０１１１】
（参考例１）
平均カット長が５１ｍｍである１３デニールのＰＥＴからなる繊維Ａ［中実断面］８０重量％と１３デニールの繊維Ｂ［芯成分：ＰＥＴ、鞘成分：共重合ポリエステル（ＰＥＴ／ＰＥＩ＝７０／３０）、軟化点：１５０℃］２０重量％から構成されるステープル混合原料をカードレイヤー方式にてウエブを形成し、規定の厚みに圧縮した後１８０℃に加熱することにより、平均見かけ密度０．０２５ｇ／ｃｍ^３のポリエステル繊維集合体よりなるクッション材を作製したところ、熱時のへたりが大きく、また、反発力の小さい不織布であった。
【０１１２】
（比較例１）
平均カット長を１５ｍｍとした他は、実施例１と全く同様にしてクッション材の作製を試みたところ、繊維のカット長が短いため凝集性が低く、また、綿埃の発生も多く、不織布化が不可能であった。
【０１１３】
（比較例２）
平均カット長を１５０ｍｍとした他は、実施例１と全く同様にしてクッション材の作製を試みたところ、繊維のカット長が長すぎるため繊維同士の絡み付きが強く、開繊ができず作製不可能であった。
【０１１４】
（比較例３）
平均見かけ密度を０．００７ｇ／ｃｍ^３とした他は、実施例１と全く同様にしてクッション材の作製を試みたところ、密度が低すぎるため形状保持性がなく、クッション材になり得ないものであった。
【０１１５】
（比較例４）
平均見かけ密度を０．３ｇ／ｃｍ^３とした他は、実施例１と全く同様にしてクッション材の作製を試みたところ、密度が高すぎるため、クッション感がないものであった。
【０１１６】
（比較例５）
繊維Ｂを［芯成分：ＰＥＮ、鞘成分：共重合ポリエステル（ＰＥＴ／ＰＥＮ＝９０／１０）、軟化点：２４５℃］とした他は、実施例１と全く同様にしてクッション材の作製を試みたところ、軟化点が高すぎ、成形不可能であった。
【０１１７】
（比較例６）
繊維Ｂを［芯成分：ＰＥＮ、鞘成分：共重合ポリエステル（ＰＥＴ／ＰＥＮ＝１０／９０）、軟化点：２８０℃］とした他は、実施例１と全く同様にしてクッション材の作製を試みたところ、軟化点が高すぎ、成形不可能であった。
【０１１８】
（比較例７）
繊維Ｂの繊度を１デニールとした他は、実施例１と全く同様にしてクッション材の作製を試みたところ、繊維径が小さいため繊維が密につまり、成型時に送り込む熱風が通りにくく、成形不可能であった。
【０１１９】
（比較例８）
繊維Ｂの繊度を１０００００デニールとした他は、実施例１と全く同様にしてクッション材の作製を試みたところ、接着本数が少ないため、凝集性が低く不織布にならなかった。
【０１２０】
（比較例９）
繊維Ａを９７重量％、繊維Ｂを３重量％とした他は、実施例１と全く同様にしてクッション材の作製を試みたところ、繊維Ｂの本数が少ないため接着点が減少し、凝集性が低く不織布にならなかった。
【０１２１】
（比較例１０）
繊維Ｂを［芯成分：ＰＥＮ、鞘成分：共重合ポリエステル（ＰＥＴ／ＰＥＩ＝９０／１０）、軟化点：２５０℃］とした他は、実施例１と全く同様にしてクッション材の作製を試みたところ、軟化点が高すぎ、成形不可能であった。
【０１２２】
（比較例１１）
繊維Ｂを［芯成分：ＰＥＮ、鞘成分：共重合ポリエステル（ＰＥＴ／ＰＥＩ＝１０／９０）、軟化点：２４５℃］とした他は、実施例１と全く同様にしてクッション材の作製を試みたところ、軟化点が高すぎ、成形不可能であった。
【０１２３】
（試験例）
上記実施例１〜２４、参考例１および比較例１〜１１において得られたクッション材について、以下の実験を行った。なお、表中において、「軟化点」は、ＪＩＳ Ｋ ７２０２で制定する「熱可塑性プラスチックのビカット軟化温度試験方法」に基づいて、試験荷重：５ｋｇｆ、昇温速度：５０℃／ｈで測定したものを記載した。
【０１２４】
また、「反発力」の測定は、上記の各実施例、参考例および比較例によって得られたクッション材について、ＪＩＳ Ｋ ７２２０で制定する「硬質発泡プラスチックの圧縮試験方法」に基づいて、幅および長さ：１００ｍｍ、高さ：５０ｍｍの試験片に対して圧縮強さを測定した。
【０１２５】
さらに、「へたり」は、上記の各実施例、参考例および比較例によって得られたクッション材について、ＪＩＳ Ｋ ７２２０で制定する「硬質発泡プラスチックの圧縮試験方法」に基づいて、幅および長さ：１００ｍｍ、高さ：５０ｍｍの試験片に対して圧縮強さを測定した。
【０１２６】
表中に記載した評価記号は、参考例１の値を基準とし、これより著しく優れたもの、優れたもの、同程度のもの、劣ったものについて、それぞれ、◎、○、△、×で相対的に評価した。なお、表中に「−」としたものは、他の測定項目に著しく劣ったものが有り、測定が不可能だったものである。
【０１２７】
また、綿埃については、吸音材製造工程中に著しく作業環境を悪化させる量の綿埃を発生させたものにのみ「有」と付した。
【０１２８】
【表２】

【０１２９】
【表３】

【０１３０】
【表４】

【０１３１】
【表５】

【０１３２】
【表６】

【０１３３】
【表７】

【０１３４】
表に示すように、本発明実施例のクッション材では、いずれも、凝集性が良く、綿埃の発生がなく、反発力が大きいと共に熱へたりの少ない特性の優れたクッション材となっていることが認められた。
【図面の簡単な説明】
【図１】繊維集合体からなるクッション材の成形要領を（Ａ）（Ｂ）（Ｃ）に分けて順次示す説明図である。
【図２】本発明に係わるクッション材を自動車用シートに適用した例を示す側面説明図（図２の（Ａ））および正面説明図（図２の（Ｂ））である。
【図３】本発明に係わるクッション材を自動車用シートに適用した他の例を示す側面説明図（図３の（Ａ））および正面説明図（図３の（Ｂ））である。
【図４】本発明に係わるクッション材を自動車用シートに適用したさらに他の例を示す側面説明図（図４の（Ａ））および正面説明図（図４の（Ｂ））である。
【符号の説明】
１１ 繊維集合体の積層体
１２ 成形用上型
１３ 成形用下型
１４ 繊維集合体の成形体
２１，３１，４１ 自動車用シート
２２，３２，４２ 座面用クッション材
２３，３３，４３ 背当て用クッション材[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a cushion material with high sag resistance used for automobile seats and the like, and a method for producing the same.
[0002]
[Prior art]
Conventionally, polyurethane (PU) foam has been mainly used for cushion materials such as cushion materials for automobile seats, mat materials for bedding, and cushions.
[0003]
However, this material has started to point out problems from the standpoint of environmental protection due to the generation of nitrogen-containing gas during combustion and the use of chlorofluorocarbon gas during production.
[0004]
Therefore, as an alternative material of this material, a material using polyethylene terephthalate (PET) fiber is disclosed in Japanese Patent Application Laid-Open No. 57-35047. Further, as a material for further additional functions, a cushion material using a fiber assembly has been studied.
[0005]
However, the cushion material made of a fiber assembly has a drawback that it is easy to sag against compression in a high-temperature atmosphere, and that a repulsive force is small, particularly when a PET fiber is used.
[0006]
Causes of the occurrence of sag in this case include thermal shrinkage of the main fiber, thermal deformation of the binder bonding point, re-adhesion due to binder re-softening, lack of elastic recovery force, and the like.
[0007]
For this reason, as means for making it difficult to sag, a polyester short fiber using a urethane binder (JP-A-4-84906), or a polyester short fiber using a polyamide binder fiber (JP-A-4-309398). No.), those using polyphenylene sulfide (PPS) fibers as binders for aromatic polyamide (aramid) fibers (Japanese Patent Laid-Open No. 2-2975), and polyester bicopolymers for polybismethylenecyclohexane terephthalate (PCT) fibers. Those using united fibers as a binder (JP-A-7-54253) have been devised.
[0008]
[Problems to be solved by the invention]
However, the use of urethane, amide, and PPS does not eliminate the drawbacks in terms of recycling, while the use of PCT does not reach the glass transition point of PCT at 90 ° C. It ’s not a radical solution to heat fever.
[0009]
In addition, in the case of a material having a small repulsive force, methods such as an increase in density and an increase in the amount of binder fibers have been taken in order to eliminate the disadvantage of a small repulsive force. However, this method causes an increase in cost and an increase in weight. End up. For example, since the elastic modulus of the fiber is similar to that of PET, PCT has a defect that the feeling of rigidity is insufficient like the PET fiber.
[0010]
OBJECT OF THE INVENTION
The present invention eliminates the drawbacks of such conventional cushion materials such as ease of holding, low recyclability, lack of rigidity, etc., and in applications such as cushion materials for automobile seats, mat materials for bedding, and cushions. An object of the present invention is to provide an all-polyester cushioning material that can be suitably used, is difficult to sag, is recyclable, and can easily obtain sufficient rigidity.
[0011]
[Means for Solving the Problems]
The inventors of the present invention have intensively studied the mechanism of the cushion material sag due to the fiber assembly, and have studied in detail the materials and configurations for solving the conventional problems, and found the materials for solving these problems. As a result, the present invention has been reached.
[0012]
That is, as described in claim 1, the cushion material according to the present invention is a cushion material including part or all of the fiber assembly, and the fibers constituting the fiber assembly have a fineness of 1.5 to 10,000. A denier high softening point synthetic fiber staple (fiber A) and a low softening point synthetic fiber staple (fiber B) having a fineness of 1.5 to 10,000 denier and at least 30 ° C. lower than fiber A on the fiber surface. In which the average apparent density of the fiber assembly is 0.01 to 0.2 g / cm. ³ And the average cut length of the constituent fibers is 20 to 100 mm, and the fibers A or B or both the fibers A and B contain polyethylene 2,6-naphthalate (PEN), and the fibers A PEN / polyethylene terephthalate (PET) copolymer in which A is mainly composed of PEN, fiber B has PEN as a core component, and has a softening point 30 to 180 ° C. lower than the softening points of the core components of fibers A and B The core-sheath type composite fiber is characterized in that the fiber B contains 5 to 100% by weight with respect to the total amount of the fiber A and the fiber B.
[0014]
Further, as described in claim 2, the cushion material according to the present invention is a cushion material including part or all of the fiber assembly, and the fibers constituting the fiber assembly have a fineness of 1.5 to 10,000. A denier high softening point synthetic fiber staple (fiber A) and a low softening point synthetic fiber staple (fiber B) having a fineness of 1.5 to 10,000 denier and at least 30 ° C. lower than fiber A on the fiber surface. In which the average apparent density of the fiber assembly is 0.01 to 0.2 g / cm. ³ And the average cut length of the constituent fibers is 20 to 100 mm, and the fibers A or B or both the fibers A and B contain polyethylene 2,6-naphthalate (PEN), and the fibers Side-by-side type comprising a PEN / PET copolymer in which A is mainly composed of PEN, fiber B has PEN as a core component, and has a softening point 30 to 180 ° C. lower than the softening point of the core components of fibers A and B It is a composite fiber and is characterized in that the fiber B contains 5 to 100% by weight with respect to the total amount of the fiber A and the fiber B.
[0015]
Further, as described in claim 3, the cushion material according to the present invention is a cushion material including part or all of the fiber assembly, and the fibers constituting the fiber assembly have a fineness of 1.5 to 10,000. A denier high softening point synthetic fiber staple (fiber A) and a low softening point synthetic fiber staple (fiber B) having a fineness of 1.5 to 10,000 denier and at least 30 ° C. lower than fiber A on the fiber surface. In which the average apparent density of the fiber assembly is 0.01 to 0.2 g / cm. ³ And the average cut length of the constituent fibers is 20 to 100 mm, and the fibers A or B or both the fibers A and B contain polyethylene 2,6-naphthalate (PEN), and the fibers A is composed of PEN as a main component, and fiber B is a single-component fiber composed of a PEN / PET copolymer having a softening point 30 to 180 ° C. lower than that of fiber A. Fiber B is composed of fibers A and B. It is characterized by having a constitution containing 5 to 100% by weight with respect to the total amount.
[0016]
And in the cushioning material of the said Claim 1 thru | or 3, as described in Claim 4, the fiber A is side-by-side type | mold crimp fiber of PEN and this and PEN or PET from which this has a different shrinkage | contraction rate. It can be comprised with.
[0017]
Further, as described in claim 5, the cushion material according to the present invention is a cushion material including part or all of the fiber assembly, and the fibers constituting the fiber assembly have a fineness of 1.5 to 10,000. A denier high softening point synthetic fiber staple (fiber A) and a low softening point synthetic fiber staple (fiber B) having a fineness of 1.5 to 10,000 denier and at least 30 ° C. lower than fiber A on the fiber surface. In which the average apparent density of the fiber assembly is 0.01 to 0.2 g / cm. ³ And the average cut length of the constituent fibers is 20 to 100 mm, and the fibers A or B or both the fibers A and B contain polyethylene 2,6-naphthalate (PEN), and the fibers A core sheath comprising a PEN / PET copolymer in which A is mainly composed of PET, fiber B has PET as a core component, and has a softening point 30 to 160 ° C. lower than the softening points of the core components of fibers A and B The type composite fiber is characterized in that the fiber B contains 5 to 100% by weight with respect to the total amount of the fiber A and the fiber B.
[0018]
Moreover, the cushion material concerning this invention is a cushion material which contains a fiber assembly in part or all as described in Claim 6, The fiber which comprises a fiber assembly is fineness 1.5-10000. A denier high softening point synthetic fiber staple (fiber A) and a low softening point synthetic fiber staple (fiber B) having a fineness of 1.5 to 10,000 denier and at least 30 ° C. lower than fiber A on the fiber surface. In which the average apparent density of the fiber assembly is 0.01 to 0.2 g / cm. ³ And the average cut length of the constituent fibers is 20 to 100 mm, and the fibers A or B or both the fibers A and B contain polyethylene 2,6-naphthalate (PEN), and the fibers Side-by-side type comprising a PEN / PET copolymer in which A is mainly composed of PET, fiber B has PET as a core component, and has a softening point 30 to 160 ° C. lower than the softening point of the core components of fibers A and B It is a composite fiber and is characterized in that the fiber B contains 5 to 100% by weight with respect to the total amount of the fiber A and the fiber B.
[0019]
Further, as described in claim 7, the cushion material according to the present invention is a cushion material including part or all of the fiber assembly, and the fibers constituting the fiber assembly have a fineness of 1.5 to 10,000. A denier high softening point synthetic fiber staple (fiber A) and a low softening point synthetic fiber staple (fiber B) having a fineness of 1.5 to 10,000 denier and at least 30 ° C. lower than fiber A on the fiber surface. In which the average apparent density of the fiber assembly is 0.01 to 0.2 g / cm. ³ And the average cut length of the constituent fibers is 20 to 100 mm, and the fibers A or B or both the fibers A and B contain polyethylene 2,6-naphthalate (PEN), and the fibers A is a single component fiber composed mainly of PET, and fiber B is composed of a PEN / PET copolymer having a softening point 30 to 160 ° C. lower than that of fiber A. Fiber B is composed of fibers A and B. It is characterized by having a constitution containing 5 to 100% by weight based on the total amount.
[0020]
And in the cushion material of the said Claim 5 thru | or 7, as described in Claim 8, the fiber A is a side-by-side type | mold crimp fiber of PET and PET which has a different shrinkage | contraction rate from this. It can be configured.
[0021]
In the cushion material according to any one of claims 1 to 8, as described in claim 9, the molar fraction of the monomer constituting the PEN / PET copolymer is 20/80 to 80/20. There can be.
[0022]
Further, as described in claim 10, the cushion material according to the present invention is a cushion material including part or all of the fiber assembly, and the fibers constituting the fiber assembly have a fineness of 1.5 to 10,000. A denier high softening point synthetic fiber staple (fiber A) and a low softening point synthetic fiber staple (fiber B) having a fineness of 1.5 to 10,000 denier and at least 30 ° C. lower than fiber A on the fiber surface. In which the average apparent density of the fiber assembly is 0.01 to 0.2 g / cm. ³ And the average cut length of the constituent fibers is 20 to 100 mm, and the fibers A or B or both the fibers A and B contain polyethylene 2,6-naphthalate (PEN), and the fibers PET / polyethylene isophthalate (PEI) co-weight, in which A is mainly composed of PEN, and fiber B has PEN as a core component and has a softening point 30 to 180 ° C. lower than the softening points of the core components of fibers A and B A core-sheath type composite fiber made of a coalescence or polybutylene terephthalate (PBT) / polyε caprolactone (PCL) copolymer, and fiber B is contained in an amount of 5 to 100% by weight based on the total amount of fiber A and fiber B It is characterized by having a configuration to do.
[0023]
In the cushion material according to the present invention, as described in claim 11, in the cushion material including part or all of the fiber assembly, the fibers constituting the fiber assembly have a fineness of 1.5 to 10,000. A denier high softening point synthetic fiber staple (fiber A) and a low softening point synthetic fiber staple (fiber B) having a fineness of 1.5 to 10,000 denier and at least 30 ° C. lower than fiber A on the fiber surface. In which the average apparent density of the fiber assembly is 0.01 to 0.2 g / cm. ³ And the average cut length of the constituent fibers is 20 to 100 mm, and the fibers A or B or both the fibers A and B contain polyethylene 2,6-naphthalate (PEN), and the fibers A PET / PEI copolymer in which A is composed mainly of PEN, and fiber B has PEN as a core component and has a softening point 30 to 180 ° C. lower than the softening points of the core components of fibers A and B, or PBT This is a side-by-side type composite fiber made of a / PCL copolymer, and is characterized in that the fiber B contains 5 to 100% by weight with respect to the total amount of the fiber A and the fiber B.
[0024]
Further, as described in claim 12, the cushion material according to the present invention is a cushion material including part or all of the fiber assembly, and the fibers constituting the fiber assembly have a fineness of 1.5 to 10,000. A denier high softening point synthetic fiber staple (fiber A) and a low softening point synthetic fiber staple (fiber B) having a fineness of 1.5 to 10,000 denier and at least 30 ° C. lower than fiber A on the fiber surface. In which the average apparent density of the fiber assembly is 0.01 to 0.2 g / cm. ³ And the average cut length of the constituent fibers is 20 to 100 mm, and the fibers A or B or both the fibers A and B contain polyethylene 2,6-naphthalate (PEN), and the fibers A is composed of PEN as a main component, and fiber B is a single component fiber composed of a PET / PEI copolymer having a softening point lower by 30 to 180 ° C. than fiber A, or a PBT / PCL copolymer, It is characterized in that the fiber B contains 5 to 100% by weight with respect to the total amount of the fiber A and the fiber B.
[0025]
And in the cushion material of the said Claims 10 thru | or 12, as described in Claim 13, the fiber A is a side-by-side type | mold crimp fiber of PEN and PEN which has a different shrinkage | contraction rate from this. It can be configured.
[0026]
In the cushion material according to any one of claims 10 to 13, as described in claim 14, the molar fraction of the monomer constituting the PET / PEI copolymer or PBT / PCL copolymer is 20 / 80 to 80/20.
[0027]
Furthermore, in the cushioning material according to any one of claims 1 to 14, as described in claim 15, the cross-sectional shape of the fiber A is a hollow cross-sectional shape fiber having a hollowness of 5% or more. can do.
[0028]
As described in claim 16, the automotive seat component according to the present invention uses the cushion material according to any one of claims 1 to 15 on at least a seat surface or a backrest surface. It is characterized by that.
[0029]
The method for manufacturing a cushion material according to the present invention is, as described in claim 17, when producing the cushion material according to any one of claims 1 to 16, and at least one of a card layer method and an air layer method. After being laminated by the above, after heating at a temperature of 10 ° C. or more higher than the softening point of the fiber B and lower than the softening point of the fiber A, pressing, or pressing while heating and cooling to a desired shape It is characterized by having a saddle shape.
[0030]
[Effects of the Invention]
The cushion material and the manufacturing method thereof according to the present invention have the above-described configuration, and the formed fiber aggregate is a low softening point synthetic fiber staple having a softening point that is at least 30 ° C. lower than that of the fiber A. The adhesion points between the constituent fibers due to the fusion of B are substantially uniformly dispersed in the molded body. In this specification, the “softening point” refers to a temperature at which the resin constituting the fiber is softened by heating to develop adhesiveness. Further, the fiber A may be a mixture of two or more kinds within a range of fineness of 1.5 to 10000 denier. Furthermore, the fiber B may also be a mixture of two or more types having a fineness in the range of 1.5 to 10000 denier.
[0031]
As described above, the fineness of the fibers A and B needs to be in the range of 1.5 to 10000 denier. In this case, when the fineness is less than 1.5 denier, the rigidity of the fiber itself is small, so that it is difficult to obtain sufficient cohesiveness of the fiber assembly. This is not preferable because the fiber fly soars and the yield decreases and contamination of the working environment by cotton dust becomes serious. Further, since the entanglement between the fibers increases, there is a possibility that the fiber is not sufficiently opened at the time of web formation, the density distribution of the aggregate becomes excessive, and the thickness is not constant. On the other hand, when the fineness exceeds 10,000 denier, the ratio of the number of fibers in the fiber assembly decreases, so that sufficient adhesion points between the constituent fibers cannot be secured, and the cohesiveness and moldability of the fiber assembly are reduced. Since it decreases, it is not preferable.
[0032]
The fiber B has a softening point lower than that of the fiber A because the fiber B bears a repulsive force due to the cohesiveness and bonding structure of the fiber assembly. This is because the fiber B is selectively softened and has adhesiveness when heated at a temperature lower than the softening point of the fiber A during manufacture. However, the softening point of the fiber B needs to be lower than that of the fiber A by 30 ° C. or more due to the molecular weight reduction and alteration of the fiber A during heating, and the adhering to the apparatus and the capacity of heating.
[0033]
The average apparent density of the fiber aggregate molded according to the present invention is 0.01 to 0.2 g / cm. ³ It is necessary to be in the range. And the average apparent density is 0.01 g / cm ³ This is because the ratio of fibers in the same volume decreases when the ratio is less than 1, so that it is difficult to provide sufficient cohesiveness as a fiber assembly. On the other hand, the average apparent density is 0.2 g / cm ³ This is because the fiber aggregate is too hard and the hardness does not hold as a cushioning material.
[0034]
The average cut length of the fibers A and B needs to be in the range of 20 to 100 mm. And when the average cut length is less than 20 mm, the entanglement between the fibers decreases, and therefore the cohesiveness deteriorates due to the decrease in the contact point with the fusion fiber, and further, it becomes difficult to maintain the shape at the time of molding. This is because, when attached to a building or the like, short fibers may fly and fall out of the fiber assembly during transportation or the like, which may deteriorate shape retention. On the other hand, when the length exceeds 100 mm, the entanglement between the fibers becomes large, so that there is a possibility that the spread of the fibers is insufficient at the time of web formation, the density distribution of the aggregate becomes excessive, and the thickness does not become constant. .
[0035]
In order to obtain the performance in the present invention, the fiber A or the fiber B or both the fiber A and the fiber B must contain polyethylene 2,6-naphthalate (PEN). This is because PEN has a modulus of elasticity about 3 times that of PET and can provide a cushion material with a large repulsive force, and the glass transition point (Tg) is the same as that of PET. This is because PEN has a temperature of about 110 ° C. or higher while it is about 65 ° C., and is an effective material for heat settling.
[0036]
The chemical formulas of PET and PEN are shown in Formula (1) and Formula (2), respectively, and their characteristics are shown in Table 1.
[0037]
[Chemical 1]

[0038]
[Chemical formula 2]

[0039]
[Table 1]

[0040]
With the above-described configuration, a cushioning material having a high repulsive force and a small amount of heat sag can be obtained. More preferably, the fiber A is mainly composed of PEN homopolymer, and the fiber B is It consists of a PEN / PET copolymer. The fiber A is preferably made of PEN because of the above heat resistance and high elastic modulus, and the adhesiveness between the fiber B and the fiber A and the operation of the softening point can be adjusted by the copolymerization ratio. The softening point of the fiber B varies depending on the copolymerization ratio, but since the melting point of PEN is 270 ° C., the softening point lower by 180 ° C. becomes the lower limit when the ambient temperature at the place of use is taken into consideration. Therefore, the above-mentioned fiber B is softened selectively and has good adhesiveness, and a fiber having a temperature of 30 ° C. or higher obtained from heating, heating, and molecular weight reduction and alteration of the fiber A. Along with the need to make it lower than the softening point of A, the softening point of the fiber B needs to be inductively lower than the fiber A within the range of 30 to 180 ° C.
[0041]
Furthermore, the content of the fiber B is 5 to 100% by weight with respect to the total amount of the fiber A and the fiber B. Since this fiber B has a binder function in the fiber assembly, when the content of the fiber A is 95% by weight or more, the bonding points in the fiber assembly are reduced, and the unit as the fiber assembly is lost and scattered. This is because the amount of fibers is remarkably increased.
[0042]
Since the cross-sectional shape of the fiber B is desirably bonded only to the surface, a core-sheath type composite fiber having a PEN having a high repulsive force at the core is particularly desirable. Side-by-side composite fibers are desirable. Further, as a more inexpensive method, it is possible to produce a fully melted fiber with a single component that can use a single-component spinning die.
[0043]
In addition, by using fiber A as PET, fiber A can be made into PET and fiber B can be made into a PEN / PET copolymer as an inexpensive method with a small repulsive force. In this case, since the melting point of PET is 250 ° C., the softening point of the surface layer of the fiber B needs to be lowered by 30 to 160 ° C. Moreover, the ratio for which the fiber B occupies needs to be 5 to 100 weight% from the reason mentioned above. The cross-sectional shape of the fiber B in this case is also desirably bonded only to the surface, so that a core-sheath type composite fiber having PET as the core is particularly desirable. Side-by-side composite fibers are desirable. Further, as a more inexpensive method, it is possible to produce a fully melted fiber with a single component that can use a single-component spinning die.
[0044]
More preferably, the copolymerization ratio of the PEN / PET copolymer is such that the molar fraction of the constituent monomers is in the range of 20/80 to 80/20. In this PEN / PET copolymer, the glass transition point varies from 65 ° C. of homo-PET to 113 ° C. of homo-PEN depending on the molar fraction, but in the range of the molar fraction of 20/80 to 80/20, Amorphous. And this amorphous material changes viscosity linearly with respect to the heating temperature at the time of molding, and density unevenness hardly occurs. For this reason, the molar fraction of the monomer which makes manufacture easy is desirable in the range of 20/80 to 80/20.
[0045]
For the same reason, it was confirmed that even when the fiber A is PEN and the fiber B is a polyester-based copolymer not containing PEN, a fiber assembly can be obtained that can provide sufficient performance. In this case, the fiber B needs to be a polyester type in order to improve the adhesiveness with the PEN. From this point, PET / polyethylene isophthalate (PEI) copolymer or polybutylene terephthalate (PBT) / polyε caprolactone (PCL) copolymer, which is well distributed and easily available in the market, is desirable, but softening As long as it is within the range where the adhesiveness to the fiber A is not impaired, other fiberizable polyester copolymers may be used.
[0046]
For example, the ethylene glycol component of PET replaced with another different glycol component (eg, polyhexamethylene terephthalate (PHT)) and / or the terephthalic acid component replaced with another different dibasic acid component (eg, A copolymer of polybutylene isophthalate (PBI)) and PET, or a copolymer of substituted ones may be used. Besides the above-mentioned substitutes, poly δ valerolactone (PBL), etc. Or a polymer of an aliphatic lactone having 4 to 11 carbon atoms, or a copolymer of polydiol and the above-described substituted product or PET.
[0047]
That is, such copolymers include PET, PBT, PHT, PEI, PBI, PHI (polyhexamethylene isophthalate), PEN (polyethylene naphthalate), PBN (polybutylene naphthalate), PHN (polyhexamethylene naphthalate). Phthalate), PCL, PBL, PEG (polyethylene glycol), PTMG (polytetramethylene glycol) and the like as constituent units.
[0048]
However, even if the surface layer of the fiber B is any polyester copolymer, since the fiber A is PEN, the softening point is required to be 30 to 180 ° C. lower than that of PEN.
[0049]
In addition, since the copolymerization ratio is desirably a region close to amorphous, the PET / PEI or PBT / PCL copolymer requires the monomer mole fraction to be in the range of 20/80 to 80/20.
[0050]
Thus, according to the present invention, it is possible to provide a cushion material having a high repulsive force and a small amount of sag when heated. In particular, application to an automobile seat, which is an application in which the ambient temperature becomes high, is effective. In particular, when applied to the seat surface and backrest surface that are most likely to sag, it uses a fiber assembly that has a high repulsive force and a small sag when heated, so it is possible to provide a comfortable seat with good breathability. It becomes possible.
[0051]
In the production of the cushioning material according to the present invention, among the constituent fibers, the softening point of the fiber B is set lower than the softening point of the fiber A, so that, for example, FIG. After the laminate 11 of the fiber assembly as shown in FIG. 1 is manufactured, after heating at a temperature higher than the softening point of the fiber B by 10 ° C. or more and lower than the softening point of the fiber A, for example, FIG. For example, as shown in FIG. 1C, by pressing between the upper mold 12 for molding and the lower mold 13 for molding as shown in FIG. It can be formed into a shape of a molded body 14 of a fiber assembly having a desired shape. And in order to raise the coupling | bonding between constituent fibers, it is possible to manufacture a cushioning material simply by making temperature into 10 degreeC or more from the softening point of the fiber B. FIG.
[0052]
And the cushioning material obtained in this way is, for example, a cushioning material 22 for the seating surface that constitutes a part of the seating surface over the upper and lower parts like the automobile seat 21 shown in FIGS. 2 (A) and 2 (B). A part of the back surface can be used as a cushioning material 23 for the back surface that covers the front and back portions, and a part of the seat surface can be used as in the car seat 31 shown in FIGS. 3 (A) and 3 (B). 4A and 4B can be used as the cushioning material 32 for the seating surface formed only at the upper surface side portion or the cushioning material 33 for the back surface that is configured only at the front surface side portion. Like the automobile seat 41 shown in B), it can be used as the cushioning material 42 for the seating surface that constitutes the entire seating surface or the cushioning material 43 for the back surface that constitutes the entire back surface.
[0053]
In general, as a means for imparting cohesiveness and shape stability to the fiber assembly, a method of imparting a heat-fusible resin powder, a method of imparting or impregnating a solution type resin, etc. are common. Used for. However, when resin powder or solution-type resin is used, the resin powder tends to aggregate locally, and there is a risk of performance variations due to products.
[0054]
On the other hand, in the fiber aggregate in which the binder fiber is mixed into the main fiber, it becomes easy to uniformly mix the binder fiber into the fiber aggregate, and heat treatment is performed at a temperature between the softening points of the main fiber and the binder fiber. Thus, if the heat sagability is not taken into consideration, the morphological stability between the constituent fibers by the fusion of the binder is obtained.
[0055]
However, if the main fiber and the binder fiber are made of different chemical compositions, it becomes difficult to recycle, and in the case of using PET as the main fiber and a PET copolymer as the binder fiber, the heat resistance of PET is low. , Had increased the sag during heat.
[0056]
However, when PEN is used for the fiber A and / or fiber B, the heat resistance is remarkably improved and high sag resistance performance is exhibited. PEN is also a material having a higher elastic modulus than PET, and can obtain a high repulsive force without increasing the density or increasing the amount of binder fibers that have been used to solve the shortage of repulsive force. .
[0057]
Further, the repulsive force can be increased by using side-by-side crimped fibers made of polymers having different shrinkage rates. In this case, the combination of PET, PEN, or a combination of PET and PEN is desirable from the viewpoint of the adhesiveness between them and the availability.
[0058]
Improvement of the repulsive force can also be obtained by making the cross-sectional shape of the fiber A into a hollow cross-sectional shape having a hollow ratio of 5% or more. However, in this case, if the hollowness is less than 5%, the effect of the hollow cross section is not exhibited, so that a hollowness of at least 5% is required. And by making it a hollow cross-sectional shape, the bending rigidity of the fiber A increases, the rebound resilience higher than the fiber assembly of the same fineness can be obtained, and the cushioning material advantageous from the surface of weight and material cost can be produced.
[0059]
More desirably, side-by-side crimped fibers made of polymers having different shrinkage rates are made with a hollow cross section and used. At this time, the repulsive force increases dramatically and is very effective.
[0060]
When manufacturing such a cushioning material, more specifically, the fiber A having a predetermined cut length and a predetermined fineness, staple cotton, fleece, wrap, etc. of the fiber B are opened and mixed at an appropriate mixing ratio, and then the card It is jetted onto the conveyor by the layer method or air layer method, sucked as necessary to form a web on the conveyor, further compressed to a predetermined apparent density, and molded with hot air or heated steam at a predetermined temperature. Solidify. Alternatively, the web on the conveyor is finished to a specified thickness and a specified apparent density by needle punching, and similarly heat-treated.
[0061]
In the cushion material according to the present invention, for example, a tricot, a nonwoven fabric, a woven fabric, or the like can be laminated on at least one surface of the fiber assembly. In this case, the material of the epidermis is not particularly limited. The card layer method and the air layer method are used for forming a web and are not particularly limited with respect to subsequent post-processing steps.
[0062]
【The invention's effect】
In the cushion material according to the present invention, as described in claim 1, in the cushion material including the fiber assembly in part or in whole, the fibers constituting the fiber assembly have a fineness of 1.5 to 10000 denier. Main composition of softening point synthetic fiber staple (fiber A) and low softening point synthetic fiber staple (fiber B) having a fineness of 1.5 to 10000 denier and at least 30 ° C. lower than fiber A on the fiber surface A fiber assembly comprising fibers, and the average apparent density of the fiber assembly is 0.01 to 0.2 g / cm ³ And the average cut length of the constituent fibers is 20 to 100 mm, and both fiber A or fiber B or both fiber A and fiber B contain polyethylene 2,6-naphthalate (PEN), and the fiber A PEN / polyethylene terephthalate (PET) copolymer in which A is mainly composed of PEN, fiber B has PEN as a core component, and has a softening point 30 to 180 ° C. lower than the softening points of the core components of fibers A and B It is a core-sheath type composite fiber, and the fiber B is contained in an amount of 5 to 100% by weight with respect to the total amount of the fiber A and the fiber B. Therefore, it is light in weight and has high sag resistance and high repulsive force. It is possible to provide a cushioning material having excellent characteristics, and is an all polyester suitable for uses such as cushioning materials for automobile seats, mat materials for bedding, and cushions. PEN can be provided, especially PEN's good heat resistance and high elastic modulus can be utilized, and PEN having a high repulsive force is preferable for bonding only on the surface. By using the core-sheath-type composite fiber, it is possible to provide a remarkably excellent effect that it is possible to provide a cushioning material having a high repulsive force and a small sag when heated.
[0064]
In the cushion material according to the present invention, as described in claim 2, in the cushion material including part or all of the fiber assembly, the fibers constituting the fiber assembly have a fineness of 1.5 to 10000 denier. Main composition of softening point synthetic fiber staple (fiber A) and low softening point synthetic fiber staple (fiber B) having a fineness of 1.5 to 10000 denier and at least 30 ° C. lower than fiber A on the fiber surface A fiber assembly comprising fibers, and the average apparent density of the fiber assembly is 0.01 to 0.2 g / cm ³ And the average cut length of the constituent fibers is 20 to 100 mm, and both fiber A or fiber B or both fiber A and fiber B contain polyethylene 2,6-naphthalate (PEN), and the fiber Side-by-side type comprising a PEN / PET copolymer in which A is mainly composed of PEN, fiber B has PEN as a core component, and has a softening point 30 to 180 ° C. lower than the softening point of the core components of fibers A and B Since it is a composite fiber and the fiber B is contained in an amount of 5 to 100% by weight with respect to the total amount of the fiber A and the fiber B, it is lightweight and has excellent characteristics of having high sag resistance and high resilience. A cushion made of all polyester that can provide cushion materials and is suitable for uses such as cushion materials for automobile seats, mat materials for bedding, and cushions. In particular, it is possible to take advantage of the good heat resistance and high elastic modulus of PEN, and make use of the ease of obtaining a spinneret for melt spinning by using side-by-side type composite fibers with PEN. This is a remarkable effect that is possible.
[0065]
In the cushion material according to the present invention, as described in claim 3, in the cushion material including part or all of the fiber assembly, the fibers constituting the fiber assembly have a fineness of 1.5 to 10000 denier. Main composition of softening point synthetic fiber staple (fiber A) and low softening point synthetic fiber staple (fiber B) having a fineness of 1.5 to 10000 denier and at least 30 ° C. lower than fiber A on the fiber surface A fiber assembly comprising fibers, and the average apparent density of the fiber assembly is 0.01 to 0.2 g / cm ³ And the average cut length of the constituent fibers is 20 to 100 mm, and both fiber A or fiber B or both fiber A and fiber B contain polyethylene 2,6-naphthalate (PEN), and the fiber A is composed of PEN as a main component, and fiber B is a single-component fiber composed of a PEN / PET copolymer having a softening point 30 to 180 ° C. lower than that of fiber A. Fiber B is composed of fibers A and B. Since it is contained in an amount of 5 to 100% by weight with respect to the total amount, it is possible to provide a cushioning material having excellent characteristics having light weight and high sag resistance and high repulsive force. It is possible to provide cushion materials made of all polyester suitable for applications such as cushion materials, mat materials for bedding, cushions, etc. You can take advantage of sex ratio, by as a single component fiber, significantly better effect that it is possible to achieve cost reduction by using a die for monocomponent spinning is provided.
[0066]
And as described in claim 4, the fiber A is composed of side-by-side-type crimped fibers of PEN and PEN or PET having a different shrinkage rate, thereby achieving high heat resistance. A remarkable effect that it is possible to provide a lightweight all-polyester cushioning material having high elasticity and high resilience is provided.
[0067]
In the cushion material according to the present invention, as described in claim 5, in the cushion material including part or all of the fiber assembly, the fibers constituting the fiber assembly have a fineness of 1.5 to 10000 denier. Main composition of softening point synthetic fiber staple (fiber A) and low softening point synthetic fiber staple (fiber B) having a fineness of 1.5 to 10000 denier and at least 30 ° C. lower than fiber A on the fiber surface A fiber assembly comprising fibers, and the average apparent density of the fiber assembly is 0.01 to 0.2 g / cm ³ And the average cut length of the constituent fibers is 20 to 100 mm, and both fiber A or fiber B or both fiber A and fiber B contain polyethylene 2,6-naphthalate (PEN), and the fiber A core sheath comprising a PEN / PET copolymer in which A is mainly composed of PET, fiber B has PET as a core component, and has a softening point 30 to 160 ° C. lower than the softening points of the core components of fibers A and B Because it is a type composite fiber and the fiber B contains 5 to 100% by weight with respect to the total amount of the fiber A and the fiber B, it is lightweight and has excellent characteristics of having high sag resistance and high resilience Cushion materials made of all polyester suitable for uses such as automotive seat cushion materials, bedding mat materials, and cushions. In particular, the repulsive force is slightly smaller than that of PEN, but the advantage of being inexpensive can be utilized, and by using a core-sheath type composite fiber having PET as a core part that is preferable for adhesion only on the surface. Thus, it is possible to provide a cushioning material that is cheaper and has less sag when heated and has a good repulsive force.
[0068]
In the cushion material according to the present invention, as described in claim 6, in the cushion material including the fiber assembly in part or in whole, the fibers constituting the fiber assembly have a fineness of 1.5 to 10000 denier. Main composition of softening point synthetic fiber staple (fiber A) and low softening point synthetic fiber staple (fiber B) having a fineness of 1.5 to 10000 denier and at least 30 ° C. lower than fiber A on the fiber surface A fiber assembly comprising fibers, and the average apparent density of the fiber assembly is 0.01 to 0.2 g / cm ³ And the average cut length of the constituent fibers is 20 to 100 mm, and both fiber A or fiber B or both fiber A and fiber B contain polyethylene 2,6-naphthalate (PEN), and the fiber Side-by-side type comprising a PEN / PET copolymer in which A is mainly composed of PET, fiber B has PET as a core component, and has a softening point 30 to 160 ° C. lower than the softening point of the core components of fibers A and B Since it is a composite fiber and the fiber B is contained in an amount of 5 to 100% by weight with respect to the total amount of the fiber A and the fiber B, it is lightweight and has excellent characteristics of having high sag resistance and high resilience. A cushion made of all polyester that can provide cushion materials and is suitable for uses such as cushion materials for automobile seats, mat materials for bedding, and cushions. In particular, the repulsive force is slightly smaller than that of PEN, but the advantage of being inexpensive can be utilized. By using side-by-side type composite fibers, the ease of obtaining the spinneret for melt spinning is utilized. The result is a remarkable effect.
[0069]
In the cushion material according to the present invention, as described in claim 7, in the cushion material including part or all of the fiber assembly, the fibers constituting the fiber assembly have a fineness of 1.5 to 10000 denier. Main composition of softening point synthetic fiber staple (fiber A) and low softening point synthetic fiber staple (fiber B) having a fineness of 1.5 to 10000 denier and at least 30 ° C. lower than fiber A on the fiber surface A fiber assembly comprising fibers, and the average apparent density of the fiber assembly is 0.01 to 0.2 g / cm ³ And the average cut length of the constituent fibers is 20 to 100 mm, and both fiber A or fiber B or both fiber A and fiber B contain polyethylene 2,6-naphthalate (PEN), and the fiber A is a single component fiber composed mainly of PET, and fiber B is composed of a PEN / PET copolymer having a softening point 30 to 160 ° C. lower than that of fiber A. Fiber B is composed of fibers A and B. Since it is contained in an amount of 5 to 100% by weight with respect to the total amount, it is possible to provide a cushioning material having excellent characteristics having light weight and high sag resistance and high repulsive force. It is possible to provide cushion materials made of all polyester suitable for cushioning materials, mat materials for bedding, cushions, etc., and the repulsive force is slightly smaller than that of PEN. It is possible to take advantage of the inexpensiveness of the material, and by making it a single component fiber, it is possible to reduce the cost by using a base for single component spinning, which has a remarkably excellent effect. Brought about.
[0070]
And as described in claim 8, the fiber A is made of side-by-side crimped fibers of PET and PET having a shrinkage ratio different from that of PET. It is possible to provide a lightweight and inexpensive all-polyester cushioning material having a good elasticity and a good repulsive force.
[0071]
Further, as described in claim 9, by setting the molar fraction of the monomer constituting the PEN / PET copolymer to 20/80 to 80/20, the heating temperature at the time of molding can be increased. On the other hand, the viscosity can be changed linearly, and it is possible to make the density unevenness less likely to occur, and it is possible to improve the manufacturability.
[0072]
In the cushion material according to the present invention, as described in claim 10, in the cushion material including part or all of the fiber assembly, the fibers constituting the fiber assembly have a fineness of 1.5 to 10000 denier. Main composition of softening point synthetic fiber staple (fiber A) and low softening point synthetic fiber staple (fiber B) having a fineness of 1.5 to 10000 denier and at least 30 ° C. lower than fiber A on the fiber surface A fiber assembly comprising fibers, and the average apparent density of the fiber assembly is 0.01 to 0.2 g / cm ³ And the average cut length of the constituent fibers is 20 to 100 mm, and both fiber A or fiber B or both fiber A and fiber B contain polyethylene 2,6-naphthalate (PEN), and the fiber PET / polyethylene isophthalate (PEI) co-weight, in which A is mainly composed of PEN, and fiber B has PEN as a core component and has a softening point 30 to 180 ° C. lower than the softening points of the core components of fibers A and B A core-sheath type composite fiber made of a coalescence or polybutylene terephthalate (PBT) / polyε caprolactone (PCL) copolymer, and fiber B is contained in an amount of 5 to 100% by weight based on the total amount of fiber A and fiber B Therefore, it is possible to provide a cushioning material with excellent characteristics that is lightweight and has high sag resistance and high resilience. It is possible to provide cushioning materials made of all polyester suitable for applications such as automotive seat cushioning materials, bedding mat materials, and cushions, especially utilizing the good heat resistance and high elastic modulus of PEN. It is possible to provide a cushioning material having a high repulsive force and a small sag at the time of heating by using a core-sheath type composite fiber having a core having PEN having a high repulsive force, which is preferable for bonding only on the surface. This is a remarkable effect that is possible.
[0073]
In the cushion material according to the present invention, as described in claim 11, in the cushion material including the fiber assembly in part or in whole, the fibers constituting the fiber assembly have a fineness of 1.5 to 10000 denier. Main composition of softening point synthetic fiber staple (fiber A) and low softening point synthetic fiber staple (fiber B) having a fineness of 1.5 to 10000 denier and at least 30 ° C. lower than fiber A on the fiber surface A fiber assembly comprising fibers, and the average apparent density of the fiber assembly is 0.01 to 0.2 g / cm ³ And the average cut length of the constituent fibers is 20 to 100 mm, and both fiber A or fiber B or both fiber A and fiber B contain polyethylene 2,6-naphthalate (PEN), and the fiber A PET / PEI copolymer in which A is composed mainly of PEN, and fiber B has PEN as a core component and has a softening point 30 to 180 ° C. lower than the softening points of the core components of fibers A and B, or PBT / Side-by-side type composite fiber made of PCL copolymer, and fiber B contains 5 to 100% by weight with respect to the total amount of fiber A and fiber B, so it is lightweight and has high sag resistance. It is possible to provide a cushioning material with high resilience and excellent characteristics, and suitable for applications such as automotive seat cushioning materials, bedding mat materials, and cushions. It is possible to provide a cushioning material made of polyester polyester, and in particular, the good heat resistance and high elastic modulus of PEN can be utilized. By using side-by-side type composite fibers with PEN, A remarkably excellent effect that it is possible to make use of the simplicity of obtaining the die is brought about.
[0074]
In the cushioning material according to the present invention, as described in claim 12, in the cushioning material including part or all of the fiber assembly, the fibers constituting the fiber assembly have a fineness of 1.5 to 10000 denier. Main composition of softening point synthetic fiber staple (fiber A) and low softening point synthetic fiber staple (fiber B) having a fineness of 1.5 to 10000 denier and at least 30 ° C. lower than fiber A on the fiber surface A fiber assembly comprising fibers, and the average apparent density of the fiber assembly is 0.01 to 0.2 g / cm ³ And the average cut length of the constituent fibers is 20 to 100 mm, and both fiber A or fiber B or both fiber A and fiber B contain polyethylene 2,6-naphthalate (PEN), and the fiber A is composed of PEN as a main component, and fiber B is a single component fiber composed of a PET / PEI copolymer having a softening point lower by 30 to 180 ° C. than fiber A, or a PBT / PCL copolymer, Since the fiber B is contained in an amount of 5 to 100% by weight with respect to the total amount of the fiber A and the fiber B, a lightweight cushioning material having excellent sag resistance and high resilience is provided. It is possible to provide cushion materials made of all polyester suitable for applications such as cushion materials for automobile seats, mat materials for bedding, and cushions. In particular, the good heat resistance and high elastic modulus of PEN can be utilized, and by using a single component fiber, it is possible to reduce the cost by using a single component spinning die. This is a remarkable effect.
[0075]
And, as described in claim 13, the fiber A is composed of side-by-side crimped fibers of PEN and PEN having a different shrinkage rate, so that high heat resistance can be obtained. It is possible to provide a lightweight all-polyester cushioning material having a high resilience and a high repulsive force.
[0076]
Further, as described in claim 14, the molar fraction of the monomer constituting the PET / PEI copolymer or PBT / PCL copolymer is 20/80 to 80/20. The viscosity can be changed linearly with respect to the heating temperature at the time of molding, and it is possible to make the density unevenness less likely to occur, and it is possible to improve the productivity. The effect is brought about.
[0077]
Furthermore, as described in claim 15, the bending rigidity of the fiber A can be increased by making the cross-sectional shape of the fiber A a hollow cross-sectional shape fiber having a hollowness of 5% or more. In this case, the repulsive force can be further improved.
[0078]
The automotive seat component according to the present invention uses the cushion material according to any one of claims 1 to 15 on at least a seating surface or a backrest surface, as described in claim 16. Because it is the seat surface and backrest surface that are most prone to sag, it has high repulsive force, small sag during heat, can exhibit good cushioning properties over a long period of time, and uses a fiber assembly In addition, it is possible to provide an automotive seat component having good air permeability.
[0079]
In the method for manufacturing a cushion material according to the present invention, as described in claim 17, when the cushion material according to any one of claims 1 to 16 is manufactured, at least one of a card layer method and an air layer method is used. After laminating, it is heated at a temperature of 10 ° C. or more higher than the softening point of the fiber B and lower than the softening point of the fiber A, and then pressed, or pressed while being heated, and then cooled to obtain a desired shape. Since the mold is formed, it is possible to produce a cushioning material that is excellent in sag resistance at the time of heating and can maintain a high repulsive force over a long period of time with a high productivity.
[0080]
It is characterized by that.
[0081]
【Example】
Hereinafter, examples of the present invention will be described in more detail with reference examples and comparative examples, but the present invention is not limited to such examples.
[0082]
(Example 1)
80% by weight of fiber A [solid cross-section] consisting of 13 denier polyethylene naphthalate (hereinafter abbreviated as “PEN”) having an average cut length of 51 mm, and 13 denier fiber B [core component: PEN, sheath component: A staple mixed raw material composed of 20% by weight of a copolyester (PET / PEN = 40/60), softening point: 170 ° C. is formed into a web by a card layer method, compressed to a specified thickness, and then heated to 200 ° C. By heating, the average apparent density 0.025 g / cm ³ The cushion material which consists of a polyester fiber aggregate was obtained.
[0083]
(Example 2)
A cushion material was obtained in the same manner as in Example 1 except that the average cut length was 20 mm.
[0084]
(Example 3)
A cushion material was obtained in the same manner as in Example 1 except that the average cut length was 100 mm.
[0085]
(Example 4)
Average apparent density of 0.01 g / cm ³ Except for the above, a cushioning material was obtained in exactly the same manner as in Example 1.
[0086]
(Example 5)
Average apparent density is 0.2 g / cm ³ Except for the above, a cushioning material was obtained in exactly the same manner as in Example 1.
[0087]
(Example 6)
A cushion material was obtained in exactly the same manner as in Example 1, except that the fiber B was [core component: PEN, sheath component: copolymerized polyester (PET / PEN = 80/20), softening point: 200 ° C.].
[0088]
(Example 7)
A cushion material was obtained in exactly the same manner as in Example 1, except that the fiber B was [core component: PEN, sheath component: copolymerized polyester (PET / PEN = 20/80), softening point: 220 ° C.].
[0089]
(Example 8)
A cushion material was obtained in the same manner as in Example 1 except that the fineness of the fibers A and B was 1.5 denier.
[0090]
Example 9
A cushion material was obtained in the same manner as in Example 1 except that the fineness of the fibers A and B was 10,000 denier.
[0091]
(Example 10)
A cushion material was obtained in the same manner as in Example 1 except that the fiber A was 95% by weight and the fiber B was 5% by weight.
[0092]
(Example 11)
A cushion material was obtained in the same manner as in Example 1 except that the fiber A was 0% by weight and the fiber B was 100% by weight.
[0093]
(Example 12)
A cushion material was obtained in the same manner as in Example 1 except that the fiber A was PET.
[0094]
(Example 13)
A cushioning material was obtained in the same manner as in Example 1 except that the fiber B was [core component: PEN, sheath component: copolymerized polyester (PET / PEI = 70/30), softening point: 140 ° C.].
[0095]
(Example 14)
A cushion material was obtained in exactly the same manner as in Example 1, except that the fiber B was [core component: PEN, sheath component: copolymerized polyester (PET / PEI = 20/80), softening point: 160 ° C.].
[0096]
(Example 15)
A cushioning material was obtained in the same manner as in Example 1 except that the fiber B was [core component: PEN, sheath component: copolymerized polyester (PET / PEI = 80/20), softening point: 180 ° C.].
[0097]
(Example 16)
A cushion material was obtained in exactly the same manner as in Example 1 except that the fiber B was [core component: PEN, sheath component: copolymerized polyester (PET / PEI = 40/60), softening point: 100 ° C.].
[0098]
(Example 17)
A cushion material was obtained in exactly the same manner as in Example 1, except that the fiber B was [core component: PEN, sheath component: copolymerized polyester (PET / PEI = 50/50), softening point: 90 ° C.].
[0099]
(Example 18)
A cushion material was obtained in exactly the same manner as in Example 1 except that the fiber B was [core component: PEN, sheath component: copolymerized polyester (PBT / PCL = 50/50), softening point: 170 ° C.].
[0100]
(Example 19)
A cushion material was obtained in exactly the same manner as in Example 1 except that the fiber B was [core component: PEN, sheath component: copolymerized polyester (PBT / PCL = 20/80), softening point: 90 ° C.].
[0101]
(Example 20)
A cushion material was obtained in exactly the same manner as in Example 1 except that the fiber B was [core component: PEN, sheath component: copolymerized polyester (PBT / PCL = 80/20), softening point: 200 ° C.].
[0102]
(Example 21)
A cushion material was obtained in the same manner as in Example 1 except that the cross section of the fiber A was changed to a hollow cross section of 5%.
[0103]
(Example 22)
A cushion material was obtained in the same manner as in Example 1 except that the cross section of the fiber A was changed to a 15% hollow cross section.
[0104]
(Example 23)
A cushion material was obtained in exactly the same manner as in Example 1 except that the fiber B was a side-by-side type composite fiber of [core component: PEN, sheath component: copolymer polyester (PET / PEN = 40/60)].
[0105]
(Example 24)
A cushioning material was obtained in exactly the same manner as in Example 1 except that the fiber B was a fully fused fiber composed of a single component of copolymerized polyester (PET / PEN = 40/60).
[0106]
(Example 25)
A cushioning material was obtained in exactly the same manner as in Example 1, except that the fiber A was a side-by-side type fiber of the same PEN as in Example 1 and PEN having a lower molecular weight.
[0107]
(Example 26)
A cushion material was obtained in exactly the same manner as in Example 1, except that the fiber A was a side-by-side fiber of the same PEN as in Example 1 and the same PET as in Example 12.
[0108]
(Example 27)
A cushioning material was obtained in exactly the same manner as in Example 1 except that the fiber A was made into side-by-side fibers of the same PEN as in Example 1 and PEN having a lower molecular weight than that, and the hollow cross-sectional shape was 15%.
[0109]
(Example 28)
A cushion material in the form of a car seat was molded with the fiber blend of Example 1 and compared with an automobile seat made of urethane foam (FIG. 4).
[0110]
(Example 29)
The seat and back support surfaces of the automobile seat are molded with the fiber blend of Example 1, and replaced with the seat surface and back support surface of the urethane foam automobile seat, and compared with the urethane foam automobile seat. (Figs. 2 and 3).
[0111]
(Reference Example 1)
Fiber A consisting of 13 denier PET with an average cut length of 51 mm [solid cross section] 80% by weight and fiber B of 13 denier [core component: PET, sheath component: copolymer polyester (PET / PEI = 70/30) , Softening point: 150 ° C.] A staple mixed raw material composed of 20% by weight is formed into a web by a card layer method, compressed to a specified thickness, and then heated to 180 ° C., whereby an average apparent density of 0.025 g / cm ³ When the cushion material which consists of the polyester fiber aggregate of this was produced, it was a nonwoven fabric with a large settling at the time of a heat | fever, and a small repulsive force.
[0112]
(Comparative Example 1)
Except that the average cut length was set to 15 mm, an attempt was made to produce a cushioning material in the same manner as in Example 1. As the cut length of the fibers was short, the cohesiveness was low, and there was a lot of dust generation, making it a nonwoven fabric. Was impossible.
[0113]
(Comparative Example 2)
Except for setting the average cut length to 150 mm, an attempt was made to produce a cushioning material in the same manner as in Example 1. As the cut length of the fibers was too long, the fibers were strongly entangled and could not be opened and could not be produced. Met.
[0114]
(Comparative Example 3)
Average apparent density 0.007 g / cm ³ The cushion material was tried in exactly the same way as in Example 1, but the density was too low, so that the shape retention was not possible and the cushion material could not be obtained.
[0115]
(Comparative Example 4)
Average apparent density of 0.3 g / cm ³ The cushion material was tried in the same manner as in Example 1 except that the density was too high and there was no cushion feeling.
[0116]
(Comparative Example 5)
Except that the fiber B was [core component: PEN, sheath component: copolymer polyester (PET / PEN = 90/10), softening point: 245 ° C.], a cushioning material was prepared in exactly the same manner as in Example 1. As a result, the softening point was too high and molding was impossible.
[0117]
(Comparative Example 6)
Except that the fiber B was [core component: PEN, sheath component: copolymerized polyester (PET / PEN = 10/90), softening point: 280 ° C.], a cushioning material was prepared in exactly the same manner as in Example 1. As a result, the softening point was too high and molding was impossible.
[0118]
(Comparative Example 7)
Except that the fineness of the fiber B was set to 1 denier, an attempt was made to produce a cushioning material in the same manner as in Example 1. It was possible.
[0119]
(Comparative Example 8)
Except that the fineness of the fiber B was set to 100000 denier, an attempt was made to produce a cushioning material in the same manner as in Example 1. As the number of adhesions was small, the cohesiveness was low and the nonwoven fabric was not formed.
[0120]
(Comparative Example 9)
Except that the fiber A was 97% by weight and the fiber B was 3% by weight, an attempt was made to produce a cushioning material in the same manner as in Example 1. As the number of the fibers B was small, the adhesion point decreased, and the cohesiveness. Was low and did not become a non-woven fabric.
[0121]
(Comparative Example 10)
Except that the fiber B was [core component: PEN, sheath component: copolymer polyester (PET / PEI = 90/10), softening point: 250 ° C.], a cushioning material was prepared in exactly the same manner as in Example 1. As a result, the softening point was too high and molding was impossible.
[0122]
(Comparative Example 11)
Except that the fiber B was [core component: PEN, sheath component: copolymer polyester (PET / PEI = 10/90), softening point: 245 ° C.], a cushioning material was prepared in exactly the same manner as in Example 1. As a result, the softening point was too high and molding was impossible.
[0123]
(Test example)
The following experiments were conducted on the cushion materials obtained in Examples 1 to 24, Reference Example 1 and Comparative Examples 1 to 11. In the table, “softening point” is measured at a test load of 5 kgf and a heating rate of 50 ° C./h based on the “Vicat softening temperature test method for thermoplastics” established in JIS K 7202. Was described.
[0124]
In addition, the measurement of “repulsive force” is performed on the cushion materials obtained in the above Examples, Reference Examples, and Comparative Examples based on the “Compression Test Method for Hard Foamed Plastic” established in JIS K 7220. The compressive strength was measured on a test piece having a length of 100 mm and a height of 50 mm.
[0125]
Furthermore, “edge” is the width and length of the cushion material obtained in each of the above Examples, Reference Examples and Comparative Examples, based on “Compression test method of rigid foam plastic” established in JIS K 7220. : Compressive strength was measured on a test piece of 100 mm and height: 50 mm.
[0126]
The evaluation symbols described in the table are based on the values in Reference Example 1, and are markedly superior, superior, comparable, and inferior in terms of ◎, ○, Δ, and ×, respectively. Evaluated. In addition, in the table, “−” indicates that the measurement items were extremely inferior to other measurement items, and measurement was impossible.
[0127]
In addition, as for the cotton dust, “Yes” is attached only to the dust that has generated an amount of dust that significantly deteriorates the working environment during the sound absorbing material manufacturing process.
[0128]
[Table 2]

[0129]
[Table 3]

[0130]
[Table 4]

[0131]
[Table 5]

[0132]
[Table 6]

[0133]
[Table 7]

[0134]
As shown in the table, each of the cushion materials according to the examples of the present invention has excellent cohesiveness, no generation of cotton dust, high repulsive force, and excellent cushioning properties with little heat sink. It was recognized that
[Brief description of the drawings]
BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is an explanatory view sequentially showing a molding procedure of a cushion material made of a fiber assembly divided into (A), (B), and (C).
FIG. 2 is a side explanatory view (FIG. 2A) and a front explanatory view (FIG. 2B) showing an example in which the cushion material according to the present invention is applied to an automobile seat.
FIG. 3 is a side explanatory view (FIG. 3A) and a front explanatory view (FIG. 3B) showing another example in which the cushion material according to the present invention is applied to an automobile seat.
FIG. 4 is a side explanatory view (FIG. 4A) and a front explanatory view (FIG. 4B) showing still another example in which the cushion material according to the present invention is applied to an automobile seat.
[Explanation of symbols]
11 Laminated body of fiber assembly
12 Upper mold for molding
13 Lower mold for molding
14 Molded product of fiber assembly
21, 31, 41 Car seat
22, 32, 42 Seat cushion
23, 33, 43 Back cushion material

Claims (17)

In the cushion material including the fiber aggregate in part or in whole, the fibers constituting the fiber aggregate are high softening point synthetic fiber staple (fiber A) having a fineness of 1.5 to 10000 denier and a fineness of 1.5 to 10,000 denier. And a low-softening-point synthetic fiber staple (fiber B) having a softening point at least 30 ° C. lower than that of the fiber A on the fiber surface as a main constituent fiber, the average appearance of the fiber assembly The density is 0.01 to 0.2 g / cm ³ and the average cut length of the constituent fibers is 20 to 100 mm. Polyethylene 2,6-naphthalate (PEN) is used for fiber A or fiber B or both fiber A and fiber B. )
PEN / polyethylene terephthalate (PET) co-polymerization, in which fiber A is mainly composed of PEN, fiber B has PEN as a core component, and has a softening point 30 to 180 ° C. lower than the softening point of the core components of fibers A and B A cushioning material, which is a core-sheath type composite fiber made of a coalescence, wherein fiber B is contained in an amount of 5 to 100% by weight based on the total amount of fiber A and fiber B. In the cushion material including the fiber aggregate in part or in whole, the fibers constituting the fiber aggregate are high softening point synthetic fiber staple (fiber A) having a fineness of 1.5 to 10000 denier and a fineness of 1.5 to 10,000 denier. And a low-softening-point synthetic fiber staple (fiber B) having a softening point at least 30 ° C. lower than that of the fiber A on the fiber surface as a main constituent fiber, the average appearance of the fiber assembly The density is 0.01 to 0.2 g / cm ³ and the average cut length of the constituent fibers is 20 to 100 mm. Polyethylene 2,6-naphthalate (PEN) is used for fiber A or fiber B or both fiber A and fiber B. )
Side-by-side made of PEN / PET copolymer in which fiber A is mainly composed of PEN, fiber B has PEN as a core component, and has a softening point 30 to 180 ° C. lower than the softening point of the core components of fibers A and B A cushioning material characterized in that it is a type composite fiber, and the fiber B is contained in an amount of 5 to 100% by weight based on the total amount of the fiber A and the fiber B. In the cushion material including the fiber aggregate in part or in whole, the fibers constituting the fiber aggregate are high softening point synthetic fiber staple (fiber A) having a fineness of 1.5 to 10000 denier and a fineness of 1.5 to 10,000 denier. And a low-softening-point synthetic fiber staple (fiber B) having a softening point at least 30 ° C. lower than that of the fiber A on the fiber surface as a main constituent fiber, the average appearance of the fiber assembly The density is 0.01 to 0.2 g / cm ³ and the average cut length of the constituent fibers is 20 to 100 mm. Polyethylene 2,6-naphthalate (PEN) is used for fiber A or fiber B or both fiber A and fiber B. )
The fiber A is composed of PEN as a main component, the fiber B is a single component fiber composed of a PEN / PET copolymer having a softening point 30 to 180 ° C. lower than the fiber A, and the fiber B is the fiber A and the fiber B Cushioning material characterized by containing 5 to 100 weight% with respect to the total amount. The cushion material according to any one of claims 1 to 3, wherein the fiber A is composed of side-by-side crimped fibers of PEN and PEN or PET having a different shrinkage rate. In the cushion material including the fiber aggregate in part or in whole, the fibers constituting the fiber aggregate are high softening point synthetic fiber staple (fiber A) having a fineness of 1.5 to 10000 denier and a fineness of 1.5 to 10,000 denier. And a low-softening-point synthetic fiber staple (fiber B) having a softening point at least 30 ° C. lower than that of the fiber A on the fiber surface as a main constituent fiber, the average appearance of the fiber assembly The density is 0.01 to 0.2 g / cm ³ and the average cut length of the constituent fibers is 20 to 100 mm. Polyethylene 2,6-naphthalate (PEN) is used for fiber A or fiber B or both fiber A and fiber B. )
A core comprising a PEN / PET copolymer in which the fiber A is mainly composed of PET, the fiber B has PET as a core component, and has a softening point 30 to 160 ° C. lower than the softening point of the core component of the fibers A and B A cushioning material, wherein the cushion material is a sheath type composite fiber, and the fiber B is contained in an amount of 5 to 100% by weight based on the total amount of the fiber A and the fiber B. In the cushion material including the fiber aggregate in part or in whole, the fibers constituting the fiber aggregate are high softening point synthetic fiber staple (fiber A) having a fineness of 1.5 to 10000 denier and a fineness of 1.5 to 10,000 denier. And a low-softening-point synthetic fiber staple (fiber B) having a softening point at least 30 ° C. lower than that of the fiber A on the fiber surface as a main constituent fiber, the average appearance of the fiber assembly The density is 0.01 to 0.2 g / cm ³ and the average cut length of the constituent fibers is 20 to 100 mm. Polyethylene 2,6-naphthalate (PEN) is used for fiber A or fiber B or both fiber A and fiber B. )
Side-by-side made of PEN / PET copolymer in which fiber A is mainly composed of PET, fiber B has PET as a core component, and has a softening point 30 to 160 ° C. lower than the softening point of the core components of fibers A and B A cushioning material characterized in that it is a type composite fiber, and the fiber B is contained in an amount of 5 to 100% by weight based on the total amount of the fiber A and the fiber B. In the cushion material including the fiber aggregate in part or in whole, the fibers constituting the fiber aggregate are high softening point synthetic fiber staple (fiber A) having a fineness of 1.5 to 10000 denier and a fineness of 1.5 to 10,000 denier. And a low-softening-point synthetic fiber staple (fiber B) having a softening point at least 30 ° C. lower than that of the fiber A on the fiber surface as a main constituent fiber, the average appearance of the fiber assembly The density is 0.01 to 0.2 g / cm ³ and the average cut length of the constituent fibers is 20 to 100 mm. Polyethylene 2,6-naphthalate (PEN) is used for fiber A or fiber B or both fiber A and fiber B. )
Fiber A is composed of PET as a main component, Fiber B is a single component fiber composed of a PEN / PET copolymer having a softening point 30 to 160 ° C. lower than Fiber A, and Fiber B is Fiber A and Fiber B Cushioning material characterized by containing 5 to 100 weight% with respect to the total amount. The cushion material according to any one of claims 5 to 7, wherein the fiber A is composed of side-by-side crimped fibers of PET and PET having a different shrinkage rate. The cushion material according to any one of claims 1 to 8, wherein a molar fraction of a monomer constituting the PEN / PET copolymer is 20/80 to 80/20. In the cushion material including the fiber aggregate in part or in whole, the fibers constituting the fiber aggregate are high softening point synthetic fiber staple (fiber A) having a fineness of 1.5 to 10000 denier and a fineness of 1.5 to 10,000 denier. And a low-softening-point synthetic fiber staple (fiber B) having a softening point at least 30 ° C. lower than that of the fiber A on the fiber surface as a main constituent fiber, the average appearance of the fiber assembly The density is 0.01 to 0.2 g / cm ³ and the average cut length of the constituent fibers is 20 to 100 mm. Polyethylene 2,6-naphthalate (PEN) is used for fiber A or fiber B or both fiber A and fiber B. )
A PET / polyethylene isophthalate (PEI) copolymer in which fiber A is mainly composed of PEN, fiber B has PEN as a core component, and has a softening point 30 to 180 ° C. lower than the softening point of the core components of fibers A and B A core-sheath type composite fiber made of a polymer or a polybutylene terephthalate (PBT) / polyε caprolactone (PCL) copolymer, and the fiber B is 5 to 100% by weight based on the total amount of the fiber A and the fiber B A cushioning material characterized by containing. In the cushion material including the fiber aggregate in part or in whole, the fibers constituting the fiber aggregate are high softening point synthetic fiber staple (fiber A) having a fineness of 1.5 to 10000 denier and a fineness of 1.5 to 10,000 denier. And a low-softening-point synthetic fiber staple (fiber B) having a softening point at least 30 ° C. lower than that of the fiber A on the fiber surface as a main constituent fiber, the average appearance of the fiber assembly The density is 0.01 to 0.2 g / cm ³ and the average cut length of the constituent fibers is 20 to 100 mm. Polyethylene 2,6-naphthalate (PEN) is used for fiber A or fiber B or both fiber A and fiber B. )
PET / PEI copolymer in which fiber A is mainly composed of PEN, fiber B has PEN as a core component, and has a softening point 30 to 180 ° C. lower than the softening points of the core components of fibers A and B, or A cushioning material, which is a side-by-side type composite fiber made of a PBT / PCL copolymer, wherein the fiber B is contained in an amount of 5 to 100% by weight based on the total amount of the fiber A and the fiber B. In the cushion material including the fiber aggregate in part or in whole, the fibers constituting the fiber aggregate are high softening point synthetic fiber staple (fiber A) having a fineness of 1.5 to 10000 denier and a fineness of 1.5 to 10,000 denier. And a low-softening-point synthetic fiber staple (fiber B) having a softening point at least 30 ° C. lower than that of the fiber A on the fiber surface as a main constituent fiber, the average appearance of the fiber assembly The density is 0.01 to 0.2 g / cm ³ and the average cut length of the constituent fibers is 20 to 100 mm. Polyethylene 2,6-naphthalate (PEN) is used for fiber A or fiber B or both fiber A and fiber B. )
Fiber A is composed of PEN as a main component, and fiber B is a single component fiber composed of a PET / PEI copolymer or PBT / PCL copolymer having a softening point 30 to 180 ° C. lower than that of fiber A. Cushioning material, wherein fiber B is contained in an amount of 5 to 100% by weight based on the total amount of fiber A and fiber B. The cushion material according to any one of claims 10 to 12, wherein the fiber A is composed of side-by-side crimped fibers of PEN and PEN having a different shrinkage rate. The cushion material according to any one of claims 10 to 13, wherein a molar fraction of a monomer constituting the PET / PEI copolymer or the PBT / PCL copolymer is 20/80 to 80/20. The cushion material according to any one of claims 1 to 14, wherein the cross-sectional shape of the fiber A is a hollow cross-sectional shape fiber having a hollowness of 5% or more. An automotive seat component, wherein the cushion material according to any one of claims 1 to 15 is used at least on a seating surface or a back surface. When the cushion material according to any one of claims 1 to 16 is manufactured, after being laminated by at least one of the card layer method and the air layer method, the softening point of the fiber A is higher than the softening point of the fiber B by 10 ° C or more. A method for producing a cushioning material, comprising: heating at a temperature below a point and then pressing, or pressing while heating and then cooling to form a desired shape.

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