cushion

Abstract

Provided is a cushion having a unique design quality not found in conventional cushions by making a three-dimensional net-like structure visible to a user. The cushion has: a three-dimensional net-like structure that has a three-dimensional random loop bonded structure formed of a continuous linear resin, has an apparent density of 0.005 g / cm3 to 0.30 g / cm3 inclusive and a thickness of 5 mm to100 mm inclusive, contains a pigment or a dye, and exhibits a color having an L* value of 60 or less according to the L*a*b* color system; and a cover material that covers the three-dimensional net-like structure and has a see-through prevention index (Nt) of 90 or less according to the JIS L 1923 B method.

Description

cushion

[0001] This invention relates to a cushion.

[0002] Traditionally, cushions with a three-dimensional mesh structure have been widely used in furniture, bedding such as beds, and seats in vehicles such as trains, automobiles, and motorcycles, due to their excellent breathability and recyclability.

[0003] Since the three-dimensional mesh structure itself is merely a functional component and not necessarily aesthetically pleasing, it has conventionally been covered with a cover material so that it is not visible to the user, similar to the coil springs in a mattress. For example, Patent Document 1 discloses a cushion in which the cushioning material is covered with a cover, and the cushioning material includes a three-dimensional mesh structure in which multiple filaments made of thermoplastic resin as a raw material or as the main raw material are randomly intertwined in a spiral and heat-fused together. Patent Document 2 discloses a laminated mattress comprising a three-dimensional mesh structure made of thermoplastic resin, a soft urethane foam laminated on the three-dimensional mesh structure, and a storage body that houses the three-dimensional mesh structure and the soft urethane foam.

[0004] International Publication No. 2015 / 125497, Japanese Patent Publication No. 2015-211703

[0005] In the cushion described in Patent Document 1, a three-dimensional mesh structure formed from undyed filaments is covered with a cover material that has excellent opacity, and the three-dimensional mesh structure inside the cushion cannot be seen by the user. In addition, in the mattress disclosed in Patent Document 2, the three-dimensional mesh structure is surrounded by urethane foam or a storage body, making it invisible from the outside.

[0006] However, the three-dimensional mesh structure has a unique shape, and the inventors have found that by deliberately making this visible to the user, a unique design can be added to the cushion product. This invention was made in view of the above circumstances, and its purpose is to provide a cushion with a unique design that was not found in conventional cushions, by making the three-dimensional mesh structure visible to the user.

[0007] The cushion according to the present invention is as follows: [1] It has a three-dimensional random loop joint structure formed of a continuous linear resin, and has an apparent density of 0.005 g / cm³. ３ 0.30g / cm or more ３ The following are the thicknesses of 5 mm to 100 mm, and contain pigments or dyes, L ＊ a ＊ b ＊ L by color system ＊ [1] A cushion having a three-dimensional mesh structure exhibiting a color value of 60 or less, and a cover material covering the three-dimensional mesh structure and having an opacity index (Nt) of 90 or less according to the JIS L 1923 B method. [2] The cushion according to [1], wherein the wire diameter of the continuous linear resin is 0.1 mm or more and 5 mm or less. [3] The cushion according to [1] or [2], wherein the continuous linear resin is a polyester elastomer and the three-dimensional mesh structure contains a disperse dye. [4] The cushion according to [3], wherein the cover material is composed of a fibrous structure made of a polyester polymer. [5] The cushion according to any one of [1] to [4] above, wherein the three-dimensional mesh structure has a lightfastness of grade 3 or higher according to JIS L 0842 third exposure method, at least one of discoloration and staining is grade 3 or higher in the wash fastness according to JIS L 0844 A method A-2, and at least one of discoloration and staining is grade 2 or higher in the sublimation fastness according to JIS L 0854. [6] The cushion according to any one of [1] to [5] above, wherein the continuous linear resin has a hollow cross-sectional shape.

[0008] In this invention, by deliberately coloring the three-dimensional mesh structure with pigments or dyes and using a cover material that is rather opaque, the three-dimensional mesh structure inside the cushion can be seen, giving it a unique design that was not present in conventional cushions. This expands the applications of cushions to include fixtures in art museums and model homes, cafes and bars, and outdoor equipment.

[0009] The cushion of the present invention comprises a three-dimensional mesh structure and a cover material that covers the three-dimensional mesh structure.

[0010] <Three-dimensional mesh structure> The three-dimensional mesh structure used in the present invention has a three-dimensional random loop joint structure formed from a continuous linear resin. Specifically, a continuous linear resin formed from a thermoplastic resin is bent to form random loops, and each loop is brought into contact with the others in a molten state to form a three-dimensional random loop joint structure. The three-dimensional mesh structure used in the present invention can be manufactured by known manufacturing methods.

[0011] A continuous linear resin is a linear filament having a continuous portion of at least 5 mm or more. The presence of adhesive portions at the intersections of the continuous filaments facilitates the formation of a three-dimensional network structure. Therefore, it is preferable that the three-dimensional network structure of the present invention has adhesive portions where the intersections of the continuous filaments are bonded together.

[0012] The continuous linear resin preferably has a hollow cross-sectional shape. A hollow cross-sectional shape allows for weight reduction. The cross-sectional shape of the continuous linear resin is not particularly limited; it may be a substantially circular cross-section, or an irregularly shaped cross-section that is not substantially circular.

[0013] The thermoplastic resin is not particularly limited, but is preferably at least one selected from thermoplastic elastomers and biodegradable thermoplastic resins, and is more preferably a thermoplastic elastomer from the viewpoint of cushioning properties. Examples of thermoplastic elastomers include polyester elastomers, polyolefin elastomers, styrene elastomers, polyurethane elastomers, polyamide elastomers, and ethylene vinyl acetate copolymer elastomers, but is most preferably a polyester elastomer.

[0014] The thickness of the three-dimensional network structure used in the present invention is 5 mm or more and 100 mm or less. If the thickness is less than 5 mm, the three-dimensional network structure itself becomes difficult to see, and an improvement in designability cannot be achieved. In addition, if the thickness is less than 5 mm, it is difficult to use the three-dimensional network structure as a cushioning material or the like. On the other hand, if the thickness exceeds 100 mm, the wire rods appear crowded, making it difficult to visually recognize the shape of the three-dimensional network structure. The thickness of the three-dimensional network structure is defined as follows: cut the three-dimensional network structure into a size of 10 cm × 10 cm in the vertical and horizontal directions, measure the height at one central location of the three-dimensional network structure using a test piece thickness gauge (Model FD-80N manufactured by Kobunshi Keiki Co., Ltd.), and take the measured height as the thickness of the three-dimensional network structure.

[0015] The apparent density of the three-dimensional network structure used in the present invention is 0.005 g / cm ３ or more and 0.30 g / cm ３ or less. If the apparent density is less than 0.005 g / cm ３ , the linear resin itself constituting the three-dimensional network structure becomes difficult to see, and a substantial improvement in the designability of the cushion cannot be achieved. In addition, if the apparent density is less than 0.005 g / cm ３ , the hardness of the three-dimensional network structure is insufficient, resulting in a cushion that gives a feeling of bottoming out. On the other hand, if the apparent density exceeds 0.30 g / cm ３ , the linear resins are crowded, making it difficult to visually recognize the shape of the three-dimensional network structure. In addition, if the apparent density exceeds 0.30 g / cm ３ , flexibility becomes insufficient. The apparent density can be calculated by measuring the thickness of the three-dimensional network structure according to the method described above, and then placing the three-dimensional network structure on an electronic balance to measure the weight of the sample.

[0016] It is preferable that the wire diameter (average fiber diameter) of the continuous linear resin constituting the three-dimensional network structure used in the present invention is 0.1 mm or more and 5 mm or less. By setting the wire diameter within the above range, it becomes easy to ensure cushioning performance while securing the hardness required for a three-dimensional network structure. The wire diameter (average fiber diameter) is determined as follows: focus an optical microscope at an appropriate magnification on the fiber diameter measurement site of the collected continuous linear resin, measure the thickness viewed from the side surface of the continuous linear resin, and take the average value of the thicknesses of 10 continuous linear resins as the wire diameter (average fiber diameter).

[0017] The three-dimensional network structure used in this invention contains a pigment or dye.

[0018] The pigments are not particularly limited and can include yellow pigments, black pigments, magenta pigments, cyan pigments, white pigments, green pigments, orange pigments, glossy pigments such as gold and silver, and metallic pigments. They may be used individually or in combination of two or more.

[0019] The dyes used are not particularly limited and can include disperse dyes, acid dyes, direct dyes, reactive dyes, and basic dyes. They may be used individually or in combination of two or more. When selecting dyes, it is desirable to choose dyes with excellent colorfastness when combined with the continuous linear resin (thermoplastic resin) that constitutes the three-dimensional network structure.

[0020] In particular, since disperse dyes can dye various thermoplastic resins, it is preferable to use disperse dyes as dyes, that is, it is preferable that the three-dimensional network structure used in the present invention contains a disperse dye.

[0021] The stainability of the three-dimensional network structure was determined by measuring the color of the stained three-dimensional network structure using a spectrophotometer (Konica Minolta CM-3500d), with a field of view of 10°, using a D65 light source, and the SCI method. ＊ a ＊ b ＊ The color of the three-dimensional network structure is determined by the color system (CIE 1976). ＊ It is quantitatively evaluated by expressing it as a value. Specifically, the three-dimensional mesh structure is cut into small pieces with a width of 0.3 to 1.0 cm, and tightly packed into a black plastic case (4 cm in diameter, 2 cm in height) that is cylindrical and has a transparent measuring surface, which is made for hue measurement. A black cardboard is placed on the opposite side of the measurement to adjust, and the L of the three-dimensional mesh structure is measured through the transparent plastic using a spectrophotometer. ＊ Measure the value.

[0022] The three-dimensional mesh structure used in the present invention is L ＊ a ＊ b ＊ L by color system ＊ It exhibits a color with a value of 60 or less. L ＊By combining a colored or low-luminosity three-dimensional mesh structure with a value of 60 or less, such as gray or black, with a cover material that has poor opacity, the user can perceive the shape of the three-dimensional mesh structure inside the cushion.

[0023] The three-dimensional mesh structure used in the present invention preferably has a lightfastness rating of 3 or higher according to JIS L 0842:2004 Third Exposure Method. The lightfastness test is a test that evaluates discoloration and fading caused by irradiation with light such as sunlight, and a rating of 3 or higher is preferable because it indicates less discoloration and fading caused by light irradiation.

[0024] The three-dimensional mesh structure used in this invention preferably has a wash fastness rating of 3 or higher for at least one of discoloration and staining according to JIS L 0844:2011 Method A, No. A-2. The wash fastness test evaluates the fastness to color transfer and fading caused by washing. A rating of 3 or higher is preferable because it reduces color transfer and fading to covers and other products washed together, allowing the cushion to be washed with other products. It is even more preferable that both discoloration and staining are rated 3 or higher.

[0025] The three-dimensional mesh structure used in this invention preferably has a sublimation fastness rating of 2 or higher for at least one of discoloration and staining according to JIS L 0854:2013. The sublimation fastness test is a test that evaluates color changes and color transfer due to the sublimation phenomenon of dyes. A rating of 2 or higher is preferable because it reduces color changes due to the sublimation phenomenon of dyes and color transfer to the cover material during prolonged use, thus maintaining a good appearance. It is even more preferable that both discoloration and staining be rated 3 or higher.

[0026] <Cover Material> The cover material used in this invention has an opacity index (Nt) of 90 or less according to JIS L 1923:2017 Method B. By using a cover material with poor opacity, the shape of the three-dimensional mesh structure inside the cushion can be seen by the user.

[0027] When the continuous linear resin is a polyester elastomer, the three-dimensional network structure is composed of a polyester elastomer, so it is preferable that the cover material is also composed of a fibrous structure made of a polyester polymer, similar to the continuous linear resin.

[0028] This application claims the benefit of priority based on Japanese Patent Application No. 2025-052523, filed on 26 March 2025. The entire specification of Japanese Patent Application No. 2025-052523, filed on 26 March 2025, is incorporated herein by reference.

[0029] The cushion of the present invention can be given a unique design that was not possible with conventional cushions using a three-dimensional mesh structure, and can be used, for example, as fixtures in art museums and housing exhibitions, fixtures in cafes and bars, and outdoor equipment.

Claims

1. It has a three-dimensional random loop joint structure formed from continuous linear resin, with an apparent density of 0.005 g / cm³. ３ 0.30g / cm or more ３ The following are the thicknesses of 5 mm to 100 mm, and contain pigments or dyes, L ＊ a ＊ b ＊ L by color system ＊ A cushion comprising a three-dimensional mesh structure exhibiting a color value of 60 or less, and a cover material that covers the three-dimensional mesh structure and has an opacity index (Nt) of 90 or less according to the JIS L 1923 B method.

2. The cushion according to claim 1, wherein the wire diameter of the continuous linear resin is 0.1 mm or more and 5 mm or less.

3. The cushion according to claim 1, wherein the continuous linear resin is a polyester elastomer and the three-dimensional network structure contains a disperse dye.

4. The cushion according to claim 3, wherein the cover material is composed of a fibrous structure made of a polyester polymer.

5. The cushion according to claim 1, wherein the three-dimensional mesh structure has a lightfastness of grade 3 or higher according to JIS L 0842 third exposure method, at least one of discoloration and staining is grade 3 or higher in the wash fastness according to JIS L 0844 A method A-2, and at least one of discoloration and staining is grade 2 or higher in the sublimation fastness according to JIS L 0854.

6. The cushion according to claim 1, wherein the continuous linear resin has a hollow cross-sectional shape.