JP6116498B2

JP6116498B2 - Mattress manufacturing method

Info

Publication number: JP6116498B2
Application number: JP2014036714A
Authority: JP
Inventors: 山倉　賢一; 賢一山倉
Original assignee: SHOWA NISHIKAWA. CO., LTD.
Current assignee: SHOWA NISHIKAWA. CO., LTD.
Priority date: 2014-02-27
Filing date: 2014-02-27
Publication date: 2017-04-19
Anticipated expiration: 2034-02-27
Also published as: JP2015159951A

Description

この発明は、弾力性を有する発泡体を積層して構成されるマットレスの製造方法に関するものである。 The present invention relates to a method for manufacturing a mattress formed by laminating foams having elasticity.

弾力性を有する発泡体を積層して構成されるマットレスとして、例えば、略矩形状の下層部と、下層部上に形成され、中層部上を略格子状に延びる通気用の空洞部（溝部）を有する中層部と、中層部上に形成され、複数の突起部を有する上層部とからなる三層構造としたものが提案されている（特許文献１，２参照）。 As a mattress configured by laminating elastic foams, for example, a substantially rectangular lower layer portion and a ventilation cavity portion (groove portion) formed on the lower layer portion and extending in a substantially lattice shape on the middle layer portion There has been proposed a three-layer structure including a middle layer portion having a plurality of protrusions and an upper layer portion formed on the middle layer portion (see Patent Documents 1 and 2).

特開２００２−１５９３７５号公報JP 2002-159375 A 特開２００２−３０６２８５号公報JP 2002-306285 A

しかし、上述の特許文献１，２に記載されたマットレスでは、中層部に通気用の空洞部を格子状に形成しているため、通気性は確保されているものの、中層部の空洞部は上層部または下層部の空洞部まで連通して深い溝部または凹部を形成している。そのため、このマットレスに人間が横たわった場合、その体重によりその空洞部近傍が変形して潰れ易く、人体を均等に支持できないという問題がある。 However, in the mattresses described in Patent Documents 1 and 2 described above, since the air cavities are formed in a lattice shape in the middle layer portion, the air permeability is ensured, but the middle layer cavities are the upper layer. A deep groove or recess is formed in communication with the cavity of the part or lower layer. Therefore, when a person lies on this mattress, there is a problem that the vicinity of the hollow portion is easily deformed and crushed due to its weight, and the human body cannot be supported uniformly.

また、上述の特許文献１，２に記載されたマットレスでは、中層部に形成した空洞部は、断面が円形状であり、上層部または下層部との境界における開口部分の幅が狭くなっているため、中層部に凸部および凹部を形成することが困難であるという問題もある。 Further, in the mattress described in Patent Documents 1 and 2 described above, the hollow portion formed in the middle layer portion has a circular cross section, and the width of the opening portion at the boundary with the upper layer portion or the lower layer portion is narrow. Therefore, there is also a problem that it is difficult to form convex portions and concave portions in the middle layer portion.

そこで、本発明は、このような問題点を解決するためになされたもので、中層部に通気用の空洞部を設けても中層部が潰れ難く人体を均等に支持でき、かつ、空洞部を有する中層部を容易に製造することができるマットレスの製造方法を提供することを目的とする。 Therefore, the present invention has been made to solve such problems, and even if a hollow portion for ventilation is provided in the middle layer portion, the middle layer portion is hardly crushed and can support the human body evenly. It is an object of the present invention to provide a method for manufacturing a mattress that can easily manufacture an intermediate layer portion.

前記課題を解決するため、請求項１の発明に係るマットレスの製造方法は、
下層部用発泡体で構成され、床側となる下層部と、
中層部用発泡体で構成され、前記下層部の上に設けられる中層部と、
上層部用発泡体で構成され、使用者の体を支持する上面側に複数の凸部および凹部を有する上層部とを備え、前記下層部における前記中層部に接する上面は凹部が形成されず平面形状であるマットレスの製造方法において、
対向配置された一対のロールの間に当該上層部の元になる前記上層部用発泡体を通して、両ロールの外周面それぞれに突設した複数の突起によって前記上層部用発泡体を波打つように変形させた状態でカッターにより切断するプロファイル加工を行うことで、その切断面に凸部および凹部を形成して前記上層部を製造する上層部製造工程と、
対向配置された一対のロールの間に当該中層部の元になる前記中層部用発泡体を通して、両ロールの外周面それぞれに突設した複数の突起によって前記中層部用発泡体を波打つように変形させた状態でカッターにより切断するプロファイル加工を行うことで、その切断面に凸部および凹部を形成し、その後、形成された複数の凸部を所定の高さで水平にカットすることにより前記中層部を製造する中層部製造工程と、
前記上層部製造工程によって製造された前記上層部の底面側と、前記中層部製造工程によって製造された前記中層部の上面側とを貼り付ける上中層部貼付け工程と、
を有することを特徴とする。
また、請求項２の発明に係るマットレスの製造方法は、請求項１に記載のマットレスの製造方法において、
前記上層部製造工程と前記中層部製造工程とでは、同一のプロファイル加工機械のカッターによりプロファイル加工を行うことにより、これらのプロファイル加工により形成される前記上層部用発泡体と前記中層部用発泡体の切断面に形成した凸部および凹部を同一形状に形成することを特徴とする。
また、請求項３の発明に係るマットレスの製造方法は、請求項１または請求項２に記載のマットレスの製造方法において、
前記中層部製造工程では、
対向配置された一対のロールの間に、前記下層部の元になる２枚の前記下層部用発泡体の間に前記中層部用発泡体を挟んで接着した３層構造の発泡体を通し、両ロールの外周面それぞれに突設した複数の突起によってその３層構造の発泡体を波打つように変形させた状態でカッターにより少なくとも中間層の前記中層部用発泡体を切断するプロファイル加工を行うことで、切断面に凸部および凹部を形成することを特徴とする。
また、請求項４の発明に係るマットレスの製造方法は、請求項１〜請求項３のいずれか一の請求項に記載のマットレスの製造方法において、
前記中層部製造工程では、
前記プロファイル加工により切断面に凸部および凹部が現れた中層部用発泡体を得て、その後、その中層部用発泡体の表面側に形成された複数の凸部の先端部を所定の高さで水平にカットする際、カットにより残った切頭凸部の切断面が隣接する他の突起部のカット面と連続するようにカットし、
前記上中層部貼付け工程では、
前記中層部の切頭凸部の切断面を前記上層部の底面側に貼り付けた際、前記中層部にプロファイル加工により形成された各凹部が隣接する他の凹部と連通部を介して連通するように形成することを特徴とする。
また、請求項５の発明に係るマットレスの製造方法は、
下層部用発泡体で構成され、床側となる下層部と、
中層部用発泡体で構成され、前記下層部の上に設けられる中層部と、
上層部用発泡体で構成され、使用者の体を支持する上面側に複数の凸部および凹部を有する上層部とを備えたマットレスの製造方法において、
対向配置された一対のロールの間に当該上層部の元になる前記上層部用発泡体を通して、両ロールの外周面それぞれに突設した複数の突起によって前記上層部用発泡体を波打つように変形させた状態でカッターにより切断するプロファイル加工を行うことで、その切断面に凸部および凹部を形成して前記上層部を製造する上層部製造工程と、
対向配置された一対のロールの間に当該中層部の元になる前記中層部用発泡体を通して、両ロールの外周面それぞれに突設した複数の突起によって前記中層部用発泡体を波打つように変形させた状態でカッターにより切断するプロファイル加工を行うことで、その切断面に凸部および凹部を形成し、その後、形成された複数の凸部を所定の高さで水平にカットすることにより前記中層部を製造する中層部製造工程と、
前記上層部製造工程によって製造された前記上層部の底面側と、前記中層部製造工程によって製造された前記中層部の上面側とを貼り付ける上中層部貼付け工程と、を有し、
前記中層部製造工程では、
前記プロファイル加工により切断面に凸部および凹部が現れた中層部用発泡体を得て、その後、その中層部用発泡体の表面側に形成された複数の凸部の先端部を所定の高さで水平にカットする際、カットにより残った切頭凸部の切断面が隣接する他の突起部のカット面と連続しないようにカットし、
前記上中層部貼付け工程では、
前記中層部の切頭凸部の切断面を前記上層部の底面に貼り付けた際、前記中層部にプロファイル加工により形成された各凹部が隣接する他の凹部と連続せず独立した空洞部を形成することを特徴とする。
また、請求項６の発明に係るマットレスの製造方法は、請求項５に記載のマットレスの製造方法において、
前記上層部製造工程と前記中層部製造工程とでは、同一のプロファイル加工機械のカッターによりプロファイル加工を行うことにより、これらのプロファイル加工により形成される前記上層部用発泡体と前記中層部用発泡体の切断面に形成した凸部および凹部を同一形状に形成することを特徴とする。
また、請求項７の発明に係るマットレスの製造方法は、請求項５または請求項６に記載のマットレスの製造方法において、
前記中層部製造工程では、
対向配置された一対のロールの間に、前記下層部の元になる２枚の前記下層部用発泡体の間に前記中層部用発泡体を挟んで接着した３層構造の発泡体を通し、両ロールの外周面それぞれに突設した複数の突起によってその３層構造の発泡体を波打つように変形させた状態でカッターにより少なくとも中間層の前記中層部用発泡体を切断するプロファイル加工を行うことで、切断面に凸部および凹部を形成することを特徴とする。
また、請求項８の発明に係るマットレスの製造方法は、請求項１〜請求項７のいずれか一の請求項に記載のマットレスの製造方法において、
前記上中層部貼付け工程では、
前記中層部の上面側と、前記上層部の底面側とを貼り付ける際、前記中層部にプロファイル加工により形成された各凹部と、前記上層部にプロファイル加工により形成された各凹部の中心位置が一致するように貼り付けることを特徴とする。 In order to solve the above problems, a method for manufacturing a mattress according to the invention of claim 1 includes:
Consists of a lower part for the foam, and a lower portion serving as a floor side,
Consists of a foam for the middle layer, and a middle layer provided on the lower layer,
The upper layer portion is composed of a foam for the upper layer portion, and includes an upper layer portion having a plurality of convex portions and concave portions on the upper surface side that supports the user's body, and the upper surface in contact with the middle layer portion in the lower layer portion is not formed with a concave surface. In the manufacturing method of the mattress which is a shape ,
The foam for the upper layer part is deformed so as to be waved by a plurality of projections projecting on the outer peripheral surfaces of both rolls through the foam for the upper layer part between the pair of opposed rolls. An upper layer manufacturing process for manufacturing the upper layer part by forming a convex part and a concave part on the cut surface by performing profile processing that is cut by a cutter in a state of being made ,
The foam for the middle layer part is deformed so as to be waved by a plurality of protrusions projecting from the outer peripheral surfaces of both rolls through the foam for the middle layer part that is the origin of the middle layer part between a pair of opposed rolls. By performing profile processing that cuts with a cutter in a state of being made, a convex portion and a concave portion are formed on the cut surface, and then the plurality of formed convex portions are horizontally cut at a predetermined height to form the middle layer A middle layer manufacturing process for manufacturing a part;
An upper middle layer portion pasting step for pasting the bottom surface side of the upper layer portion manufactured by the upper layer portion manufacturing step and the upper surface side of the middle layer portion manufactured by the middle layer portion manufacturing step;
It is characterized by having .
A method of manufacturing a mattress according to the invention of claim 2 is the mattress method according to claim 1,
And in the upper part manufacturing process and the middle layer portion manufacturing process, by performing profile machining of the same profile processing machinery of the cutter, the foaming middle portion and the upper portion foams formed by these profiles machining and forming a convex portion and a concave portion formed on the cut surface of the body in the same shape.
A method of manufacturing a mattress according to the invention of claim 3 is the mattress method according to claim 1 or claim 2,
In the middle layer manufacturing process ,
Between a pair of rolls arranged opposite to each other, a foam having a three-layer structure in which the foam for the middle layer part is sandwiched between the two foams for the lower part that are the basis of the lower layer part is passed, performing profile machining of cutting at least a middle layer wherein in layer unit for foam by a cutter in a state in which the foam is deformed as undulating of the three-layer structure by a plurality of projections projecting from the respective outer peripheral surfaces of the rolls Thus, a convex portion and a concave portion are formed on the cut surface.
A method of manufacturing a mattress according to the invention of claim 4 is the mattress method according to any one of claims 1 to claim 3,
In the middle layer manufacturing process,
By obtaining the foam for the middle layer part in which the convex part and the concave part appear on the cut surface by the profile processing, and then, the tip parts of the plurality of convex parts formed on the surface side of the foam for the middle layer part have a predetermined height. When cutting horizontally with, cut so that the cut surface of the truncated convex part remaining by cutting is continuous with the cut surface of the other adjacent protrusions,
In the upper middle layer pasting step,
When the cut surface of the truncated convex portion of the middle layer portion is attached to the bottom surface side of the upper layer portion, each concave portion formed by profile processing in the middle layer portion communicates with another adjacent concave portion via a communicating portion. It is formed as follows.
The mattress manufacturing method according to the invention of claim 5
It is composed of a foam for the lower layer, and the lower layer that becomes the floor side,
Consists of a foam for the middle layer, and a middle layer provided on the lower layer,
In a method for manufacturing a mattress comprising a foam for an upper layer portion and having an upper layer portion having a plurality of convex portions and concave portions on the upper surface side that supports the user's body,
The foam for the upper layer part is deformed so as to be waved by a plurality of projections projecting on the outer peripheral surfaces of both rolls through the foam for the upper layer part between the pair of opposed rolls. An upper layer manufacturing process for manufacturing the upper layer part by forming a convex part and a concave part on the cut surface by performing profile processing that is cut by a cutter in a state of being made,
The foam for the middle layer part is deformed so as to be waved by a plurality of protrusions projecting from the outer peripheral surfaces of both rolls through the foam for the middle layer part that is the origin of the middle layer part between a pair of opposed rolls. By performing profile processing that cuts with a cutter in a state of being made, a convex portion and a concave portion are formed on the cut surface, and then the plurality of formed convex portions are horizontally cut at a predetermined height to form the middle layer A middle layer manufacturing process for manufacturing a part;
An upper middle layer portion pasting step for pasting the bottom surface side of the upper layer portion manufactured by the upper layer portion manufacturing step and the upper surface side of the middle layer portion manufactured by the middle layer portion manufacturing step;
In the middle layer manufacturing process,
By obtaining the foam for the middle layer part in which the convex part and the concave part appear on the cut surface by the profile processing, and then, the tip parts of the plurality of convex parts formed on the surface side of the foam for the middle layer part have a predetermined height. When cutting horizontally with, cut so that the cutting surface of the truncated convex part remaining by cutting is not continuous with the cutting surface of the other adjacent protruding part,
In the upper middle layer pasting step,
When the cut surface of the truncated convex portion of the middle layer portion is attached to the bottom surface of the upper layer portion, each of the concave portions formed by profile processing in the middle layer portion is not continuous with other adjacent concave portions, and independent hollow portions are formed. It is characterized by forming .
A mattress manufacturing method according to the invention of claim 6 is the mattress manufacturing method according to claim 5,
In the upper layer part manufacturing step and the middle layer part manufacturing step, the upper layer part foam and the middle layer part foam formed by performing profile processing with a cutter of the same profile processing machine. The protrusions and recesses formed on the cut surface are formed in the same shape.
A mattress manufacturing method according to a seventh aspect of the present invention is the mattress manufacturing method according to the fifth or sixth aspect,
In the middle layer manufacturing process,
Between a pair of rolls arranged opposite to each other, a foam having a three-layer structure in which the foam for the middle layer part is sandwiched between the two foams for the lower part that are the basis of the lower layer part is passed, Perform profile processing to cut at least the intermediate layer foam of the intermediate layer with a cutter in a state in which the foam of the three-layer structure is deformed so as to be waved by a plurality of protrusions protruding from the outer peripheral surfaces of both rolls. Thus, a convex portion and a concave portion are formed on the cut surface.
Moreover, the manufacturing method of the mattress according to the invention of claim 8 is the manufacturing method of the mattress according to any one of claims 1 to 7,
In the upper middle layer pasting step,
When affixing the upper surface side of the middle layer portion and the bottom surface side of the upper layer portion, each concave portion formed by profile processing on the middle layer portion and the center position of each concave portion formed by profile processing on the upper layer portion are It is characterized by being pasted so as to match .

本発明に係るマットレスの製造方法によれば、上層部と中層部は、それぞれ、上層部製造工程と中層部製造工程とにおいて、対向配置された一対のロールの間それぞれの元になる発泡体を通し、両ロールの外周面それぞれに突設した複数の突起により各発泡体を波打つように変形させた状態でカッターにより切断するプロファイル加工を行うことにより製造して、上中層部貼付け工程において中層部の上面側を上層部の底面側に貼り付けた。そのため、中層部には、プロファイル加工により凹凸形状に形成された表面と上層部の底面とに囲まれた空洞部が形成され、特許文献１，２に記載された従来のマットレスとは異なり、中層部の空洞部が上層部または下層部の凹部まで開口した深い凹部（溝部）を構成しないので、中層部に通気用の空洞部を設けても中層部が潰れ難くなり、マットレス全体として人体を均等に支持することができる。
特に、中層部製造工程では、上層部に形成した凸部および凹部と同様に対向配置された一対のロールの間に中層部用発泡体を通し、両ロールの外周面それぞれに突設した複数の突起により各発泡体を波打つように変形させた状態でカッターにより切断するプロファイル加工を行うことにより中層部に凸部および凹部を設けるようにしたため、上層部に形成した凸部および凹部と同様に中層部に凸部および凹部を形成することが可能となり、空洞部を有する中層部を容易に製造することができる。
また、中層部製造工程では、プロファイル加工により形成された複数の凸部を所定の高さで水平にカットすることにより中層部を製造するため、その凸部をカットすることにより略四角錐形状の切頭凸部が形成され、上中層部貼付け工程ではその切頭凸部の切断面が上層部の底面側に貼り付けられることになるので、上層部の底面側と中層部の上面側との間に空洞部を確保しつつも、中層部の凸部をカットせずに上層部の底面側に貼り付ける場合と比較して、上層部の底面側と中層部の上面側との接触面積が増大し、上層部の底面側と中層部の上面側とを確実に貼り付けることができる。 According to the method for manufacturing a mattress according to the present invention, the upper layer portion and the middle layer portion are respectively the foams that are the originals between the pair of rolls arranged to face each other in the upper layer portion manufacturing step and the middle layer portion manufacturing step. The middle layer part is manufactured by performing profile processing that is cut by a cutter in a state where each foam is deformed so as to be waved by a plurality of protrusions projecting on the outer peripheral surfaces of both rolls. The upper surface side of was attached to the bottom surface side of the upper layer portion. Therefore, in the middle layer portion, a hollow portion surrounded by the surface formed in a concavo-convex shape by profile processing and the bottom surface of the upper layer portion is formed. Unlike the conventional mattress described in Patent Documents 1 and 2, the middle layer Since the hollow part of the part does not constitute a deep concave part (groove part) that opens to the concave part of the upper layer part or the lower layer part, even if a ventilating cavity part is provided in the middle layer part, the middle layer part is not easily crushed and the human body as a whole mattress is even Can be supported.
In particular, in the middle layer manufacturing process, the foam for the middle layer part is passed between a pair of rolls arranged opposite to each other in the same manner as the convex part and the concave part formed in the upper layer part, and a plurality of protruding parts are provided on the outer peripheral surfaces of both rolls. Protrusions and recesses are provided in the middle layer part by performing profile processing that is cut with a cutter in a state in which each foam is deformed so as to wave with the protrusions, so that the middle layer is similar to the projections and recesses formed in the upper layer part. A convex part and a concave part can be formed in the part, and an intermediate layer part having a hollow part can be easily manufactured.
Further, in the middle layer manufacturing process, the middle layer is manufactured by horizontally cutting a plurality of convex portions formed by profile processing at a predetermined height. Therefore, by cutting the convex portions, a substantially quadrangular pyramid shape is formed. A truncated convex part is formed, and the cutting surface of the truncated convex part is attached to the bottom surface side of the upper layer part in the upper middle layer attaching step, so the bottom surface side of the upper layer part and the upper surface side of the middle layer part Compared to the case where it is pasted on the bottom surface side of the upper layer portion without cutting the convex portion of the middle layer portion while securing the hollow portion in between, the contact area between the bottom surface side of the upper layer portion and the upper surface side of the middle layer portion is As a result, the bottom surface side of the upper layer portion and the upper surface side of the middle layer portion can be reliably attached.

本発明に係るマットレスの製造方法によって製造される実施形態１のマットレスの一部分を示す斜視図である。 It is a perspective view which shows a part of mattress of Embodiment 1 manufactured by the manufacturing method of the mattress which concerns on this invention . 本発明に係るマットレスの製造方法によって製造される実施形態１のマットレスの各層を分解した構造を示す分解斜視図である。 It is a disassembled perspective view which shows the structure which decomposed | disassembled each layer of the mattress of Embodiment 1 manufactured by the manufacturing method of the mattress which concerns on this invention . 本発明に係るマットレスの製造方法によって製造される実施形態１のマットレスにおける断面構成を示す断面図である。It is sectional drawing which shows the cross-sectional structure in the mattress of Embodiment 1 manufactured by the manufacturing method of the mattress which concerns on this invention . （ａ），（ｂ）それぞれ本発明に係るマットレスの製造方法によって製造される実施形態１のマットレスの上層部の表面に凸部および凹部を形成する製造過程の一例を示す図である。(A), (b) is a figure which shows an example of the manufacturing process which forms a convex part and a recessed part in the surface of the upper layer part of the mattress of Embodiment 1 manufactured by the manufacturing method of the mattress which concerns on this invention, respectively. （ａ）〜（ｃ）それぞれ本発明に係るマットレスの製造方法によって製造される実施形態１のマットレスの中層部の表面に凸部および凹部を形成する製造過程の一例を示す図である。(A)-(c) is a figure which shows an example of the manufacturing process which forms a convex part and a recessed part in the surface of the middle layer part of the mattress of Embodiment 1 manufactured by the manufacturing method of the mattress which concerns on this invention, respectively. （ａ），（ｂ）それぞれ本発明に係るマットレスの製造方法によって製造される実施形態１のマットレスの断面構成の他の例を示す断面図である。(A), (b) It is sectional drawing which shows the other example of the cross-sectional structure of the mattress of Embodiment 1 manufactured by the manufacturing method of the mattress which concerns on this invention, respectively. 本発明に係るマットレスの製造方法によって製造される実施形態２のマットレスにおける断面構成を示す断面図である。It is sectional drawing which shows the cross-sectional structure in the mattress of Embodiment 2 manufactured by the manufacturing method of the mattress which concerns on this invention . 本発明に係るマットレスの製造方法によって製造される実施形態３のマットレスにおける断面構成を示す断面図である。It is sectional drawing which shows the cross-sectional structure in the mattress of Embodiment 3 manufactured by the manufacturing method of the mattress which concerns on this invention . （ａ），（ｂ）それぞれ本発明に係るマットレスの製造方法によって製造される実施形態３のマットレスの断面構成の他の例を示す断面図である。(A), (b) It is sectional drawing which shows the other example of the cross-sectional structure of the mattress of Embodiment 3 manufactured by the manufacturing method of the mattress which concerns on this invention, respectively.

次に、本発明に係るマットレスの製造方法によって製造されるマットレスにつき、好適な実施形態１〜３を挙げて、添付図面を参照して以下に説明する。 Next, preferred embodiments 1 to 3 of the mattress manufactured by the mattress manufacturing method according to the present invention will be described below with reference to the accompanying drawings.

実施形態１．
図１〜図３に示すように、実施形態１のマットレス１は、弾力性を有する発泡体で構成された上層部１１、中層部１２および下層部１３が厚み方向に重なった３層構造で構成されており、平面視で長方形に形成されている。そのため、マットレス１は、上層部１１、中層部１２および下層部１３の積層方向である厚み方向に弾性変形可能に構成されると共に、ある程度曲げることができる可撓性を有している。マットレス１は、接着剤や、溶着や、一体成形で層を構成することによる発泡体自体の接着力などによって隣り合う層同士が接合される。なお、マットレス１は、布地からなるカバーで表側を覆ったり、当該マットレス１の弾力性等の特性を阻害しない別の敷物を載置したり、そのままの状態など、各種形態で利用に供される。以下に説明する上層部１１と、中層部１２と、下層部１３の特性値は、特に断りのない限り、硬さをＪＩＳＫ６４００−２に基づく試験方法による値で、密度をＪＩＳＫ７２２２に基づく試験方法による値で示す。 Embodiment 1. FIG.
As shown in FIGS. 1 to 3, the mattress 1 according to the first embodiment has a three-layer structure in which an upper layer portion 11, a middle layer portion 12, and a lower layer portion 13 made of a foam having elasticity are overlapped in the thickness direction. It is formed in a rectangle in plan view. Therefore, the mattress 1 is configured to be elastically deformable in the thickness direction, which is the stacking direction of the upper layer portion 11, the middle layer portion 12, and the lower layer portion 13, and has flexibility that can be bent to some extent. In the mattress 1, adjacent layers are bonded to each other by an adhesive, welding, adhesive force of the foam itself by forming the layers by integral molding, or the like. The mattress 1 is used in various forms, such as covering the front side with a cover made of fabric, placing another rug that does not impair the elasticity and other characteristics of the mattress 1, or as it is. . Unless otherwise specified, the characteristic values of the upper layer part 11, the middle layer part 12, and the lower layer part 13 described below are hardness values according to a test method based on JIS K 6400-2, and the density is JIS K 7222. Indicated by the value of the test method based on.

（上層部１１の構成）
上層部１１は、軟質ウレタンフォームやポリオレフィン系フォーム等の発泡体で構成され、発泡体の中でも軟質ウレタンフォームが好適である。なお、上層部１１を構成する発泡体としては、気泡同士が独立している独立気泡構造や、気泡同士が連続している連続気泡構造のものを用いることができるが、連続気泡構造の発泡体で構成するのがよい。 (Configuration of upper layer part 11)
The upper layer part 11 is comprised with foams, such as a flexible urethane foam and a polyolefin-type foam, and a flexible urethane foam is suitable among foams. In addition, as a foam which comprises the upper layer part 11, the thing of the closed-cell structure where bubbles are independent, or the open-cell structure where bubbles are continuing can be used, However, The foam of an open-cell structure It is good to comprise.

上層部１１は、中層部１２側に臨む下面が平坦に形成された長方形の板状体であり、使用者への当たりを柔らかくすると共に、このマットレス１にかかる荷重を分散させる役割を主に担っている。 The upper layer portion 11 is a rectangular plate-like body whose lower surface facing the middle layer portion 12 is formed flat, and mainly plays a role of softening the hitting to the user and dispersing the load applied to the mattress 1. ing.

上層部１１は、その硬さが家庭用品品質表示法に基づく表示様式で「かため」、「ふつう」および「やわらかめ」の何れの区分であっても用いることができ、実施形態１では、１２０Ｎ〜２００Ｎの範囲の硬さにある発泡体を用いている。ここで、マットレス１は、下層部１３を上層部１１より硬く設定するのが望ましい。また、下層部１３の反発弾性よりも上層部１１の反発弾性を高く設定するのが望ましい。また、実施形態１の上層部１１は、密度が例えば３５ｋｇ／ｍ^３〜４５ｇ／ｍ^３の範囲にある発泡体を用いている。 The upper layer part 11 can be used in any of the categories “hard”, “normal” and “soft” in the display style based on the household goods quality display method. A foam having a hardness in the range of 120N to 200N is used. Here, the mattress 1 desirably sets the lower layer portion 13 to be harder than the upper layer portion 11. Moreover, it is desirable to set the rebound resilience of the upper layer portion 11 higher than the rebound resilience of the lower layer portion 13. Further, the upper portion 11 of the first embodiment uses a foam in the density range of, for example, ^{^{35kg / m 3 ~45g / m 3}} .

上層部１１は、その厚みを例えば４０ｍｍ程度の高さの軟質ウレタンフォームを後述するプロファイル加工（凹凸加工）を施すことにより、図１〜図３に示すように、使用者が乗る側となる上面側に複数の凸部１１ａおよび凹部１１ｂを形成している。 The upper layer portion 11 has an upper surface on the side on which the user rides as shown in FIGS. 1 to 3 by applying profile processing (unevenness processing), which will be described later, to a flexible urethane foam having a thickness of about 40 mm, for example. A plurality of convex portions 11a and concave portions 11b are formed on the side.

具体的には、上層部１１の凹凸形状は、水平方向縦横に凸部１１ａが一定間隔で配列されると共に、縦横に隣り合う４つの凸部１１ａの間に凹部１１ｂが設けられ、横方向に並ぶ凸部１１ａの列と、この列に対して縦方向に隣り合う列の凸部１１ａをずらして、凸部１１ａと凹部１１ｂとが平面視（上から見た場合に）、いわゆるチェッカー模様（市松模様）に配置される。 Specifically, the concave-convex shape of the upper layer portion 11 is such that the convex portions 11a are arranged at regular intervals in the horizontal and vertical directions, and the concave portions 11b are provided between the four convex portions 11a adjacent in the vertical and horizontal directions. By shifting the row of the protruding portions 11a and the protruding portions 11a of the row adjacent to the row in the vertical direction, the protruding portions 11a and the recessed portions 11b are viewed in plan (when viewed from above), so-called checker pattern ( (Checkered pattern).

ここで、凸部１１ａは、突出端(上)側に向かうにつれて先細りになるよう形成されている。また、凹部１１ｂは、閉塞端(底)側に向かうにつれて狭くなるように形成されており、凹部１１ｂは凸部１１ａの外形形状とほぼ同一形状で開口している。 Here, the convex part 11a is formed so that it may taper off toward the protrusion end (upper) side. Moreover, the recessed part 11b is formed so that it may become narrow as it goes to the closed end (bottom) side, and the recessed part 11b is opened in the substantially same shape as the external shape of the convex part 11a.

（上層部１１のプロファイル加工方法）
次に、上層部１１のプロファイル加工方法について説明する。 (Profile processing method of upper layer part 11)
Next, the profile processing method of the upper layer part 11 is demonstrated.

図４（ａ），（ｂ）は、それぞれ、実施形態１のマットレス１の上層部１１の表面に凸部１１ａおよび凹部１１ｂを形成する製造過程の一例を示す図である。 FIGS. 4A and 4B are diagrams illustrating an example of a manufacturing process in which the convex portions 11a and the concave portions 11b are formed on the surface of the upper layer portion 11 of the mattress 1 of the first embodiment.

図４（ａ）に示すように、上層部１１は、対向配置された一対のロール２，２の間に上層部の元になる上層部用発泡体１０を通して、両ロール２，２の外周面それぞれに突設された複数の突起２１，２１，・・・によって上層部用発泡体１０を波打つように変形させた状態でカッター５２により切断するプロファイル加工（凹凸加工）を行うことで、その切頭凸部切断面１２ａ１’に凸部１１ａおよび凹部１１ｂが現れた２枚の上層部１１を製造する。 As shown in FIG. 4 (a), the upper layer portion 11 passes between the pair of rolls 2 and 2 arranged opposite to each other, and passes through the upper layer portion foam 10 serving as the base of the upper layer portion, so that the outer peripheral surfaces of both rolls 2 and 2 By performing profile processing (unevenness processing) by cutting with the cutter 52 in a state in which the foam 10 for the upper layer portion is deformed so as to be waved by a plurality of protrusions 21, 21,. The two upper layer parts 11 in which the convex part 11a and the concave part 11b appear on the head convex part cutting surface 12a1 ′ are manufactured.

図４（ｂ）は、図４（ａ）に示すようなプロファイル加工により上層部用発泡体１０から製造した切頭凸部切断面１２ａ１’側に凸部１１ａおよび凹部１１ｂが現れた上層部１１の断面構造を示している。図４（ａ）に示すようなプロファイル加工によって、図４（ｂ）に示すような断面構造を有する上層部１１が２枚製造できる。 FIG. 4B shows an upper layer part 11 in which convex parts 11a and concave parts 11b appear on the truncated convex part cutting surface 12a1 ′ side produced from the foam 10 for the upper layer part by profile processing as shown in FIG. 4A. The cross-sectional structure of is shown. Two upper layer portions 11 having a cross-sectional structure as shown in FIG. 4B can be manufactured by profile processing as shown in FIG.

（中層部１２の構成）
中層部１２は、軟質ウレタンフォームやポリオレフィン系フォーム等の発泡体で構成され、発泡体の中でも軟質ウレタンフォームが好適である。ここで、中層部１２を構成する発泡体としては、気泡を区切る膜が除去されて、樹脂骨格だけが残された除膜処理された連続気泡構造が用いられている。すなわち、中層部１２は、上層部１１や下層部１３よりも気泡の系が大きく通気性が高いフィルターフォーム等と俗称される発泡体で構成されており、中層部１２をなす発泡体を通って空気が上下方向および水平方向に流通可能になっている。 (Configuration of middle layer portion 12)
The middle layer portion 12 is made of a foam such as a flexible urethane foam or a polyolefin-based foam, and a flexible urethane foam is preferable among the foams. Here, as the foam constituting the middle layer portion 12, an open cell structure is used in which the film separating the bubbles is removed, and only the resin skeleton is left, and the film removal process is performed. That is, the middle layer portion 12 is formed of a foam commonly called a filter foam having a larger bubble system and higher air permeability than the upper layer portion 11 and the lower layer portion 13, and passes through the foam forming the middle layer portion 12. Air can flow vertically and horizontally.

また、中層部１２は、例えば、密度が約３０ｋｇ／ｍ^３〜４０ｋｇ／ｍ^３の範囲にある上層部１１よりも低密度で、かつ、２４０Ｎ〜３３０Ｎの範囲の硬さである上層部１１よりも高硬度の発泡体を用いる。ただし、中層部１２をなす発泡体は、上層部１１および下層部１３が発現する弾力性等の特性を妨げない硬さや反発弾性であれば特に限定されず、上層部１１よりも低密度で柔らかく、反発弾性が低い発泡体を使用しても良い。そして、中層部１２は、その厚みを、例えば、２０ｍｍに設定しているが、１０ｍｍ〜４０ｍｍとしても良い。 Also, the middle layer 12, for example, low density than the upper layer portion 11 having a density in the range of from about ^{^{30kg / m 3 ~40kg / m 3}} , and from the upper portion 11 is a hardness in the range of 240N~330N Also use a foam with high hardness. However, the foam forming the middle layer portion 12 is not particularly limited as long as it has hardness or rebound resilience that does not hinder the properties such as elasticity exhibited by the upper layer portion 11 and the lower layer portion 13, and is softer at a lower density than the upper layer portion 11. A foam having a low impact resilience may be used. And although the middle layer part 12 has set the thickness to 20 mm, for example, it is good also as 10 mm-40 mm.

（中層部１２のプロファイル加工）
次に、中層部１２のプロファイル加工について説明する。 (Profile processing of middle layer 12)
Next, profile processing of the middle layer portion 12 will be described.

図５（ａ），（ｂ）は、それぞれ、実施形態１のマットレス１の中層部１２の表面に凸部１２ａおよび凹部１２ｂを形成する製造過程の一例を示す図である。 FIGS. 5A and 5B are diagrams illustrating an example of a manufacturing process in which the convex portion 12a and the concave portion 12b are formed on the surface of the middle layer portion 12 of the mattress 1 of the first embodiment.

中層部１２では、図４（ａ）に示す上層部１１の表面に凸部１１ａおよび凹部１１ｂを形成するプロファイル加工を行う機械と同様にして中層部１２に凸部１２ａおよび凹部１２ｂを形成する。 In the middle layer portion 12, the convex portions 12 a and the concave portions 12 b are formed in the middle layer portion 12 in the same manner as a machine that performs profile processing for forming the convex portions 11 a and the concave portions 11 b on the surface of the upper layer portion 11 shown in FIG.

具体的には、図５（ａ）に示すように、まず、対向配置された一対のロール２，２の間に、２枚の下層部１３の元になる２枚の下層部用発泡体３０の間に中層部１２の元になる中層部用発泡体２０を挟んで接着した３層構造の発泡体を通す。 Specifically, as shown in FIG. 5A, first, two lower layer foams 30 that form the basis of the two lower layer parts 13 between a pair of opposed rolls 2, 2. A foam having a three-layer structure bonded with a middle layer part foam 20 as a base of the middle layer part 12 interposed therebetween is passed.

そして、図５（ａ）に示すように、両ロール２，２の外周面それぞれに突設した複数の突起２１，２１，・・・によってその３層構造の発泡体を波打つように変形させた状態でカッター５２により、２枚の下層部用発泡体３０の間に挟まれた中間層１２の元になる中層部用発泡体２０を切断するプロファイル加工（凹凸加工）を行うことで、切頭凸部切断面１２ａ１’に凸部１２ａおよび凹部１２ｂが現れた中層部１２と下層部１３との積層物を２枚製造する． Then, as shown in FIG. 5 (a), the foam of the three-layer structure was deformed so as to wave by a plurality of protrusions 21, 21,. In the state, by performing profile processing (unevenness processing) for cutting the middle layer foam 12 that is the base of the intermediate layer 12 sandwiched between the two lower layer foams 30 by the cutter 52, Two laminates of the middle layer portion 12 and the lower layer portion 13 in which the convex portion 12a and the concave portion 12b appear on the convex cutting surface 12a1 ′ are manufactured.

図５（ｂ）は、図５（ａ）に示すようなプロファイル加工により２枚の下層部用発泡体３０の間に中間層１２の元になる中層部用発泡体２０を挟んだ３層構造の発泡体から製造した切頭凸部切断面１２ａ１’側に凸部１２ａおよび凹部１２ｂが現れた中層部１２の中間品の断面構造を示している。図５（ａ）に示すようなプロファイル加工によって、図５（ｂ）に示すような断面構造を有する中層部１２と下層部１３との中間品である中層・下層積層体４０が２枚製造できる。 FIG. 5B shows a three-layer structure in which the intermediate layer foam 20 that is the base of the intermediate layer 12 is sandwiched between two lower layer foams 30 by profile processing as shown in FIG. The cross-sectional structure of the intermediate product of the middle layer part 12 in which the convex part 12a and the concave part 12b appeared on the truncated convex part cut surface 12a1 ′ side manufactured from the above foam is shown. By performing profile processing as shown in FIG. 5A, two intermediate layer / lower layer laminates 40, which are intermediate products of the intermediate layer part 12 and the lower layer part 13 having a cross-sectional structure as shown in FIG. .

そして、実施形態１のマットレス１では、図５（ｂ）に示すようにプロファイル加工により形成された凸部１２ａおよび凹部１２ｂを有する中層部１２と下層部１３との中層・下層積層体４０に対し、下層部１３の上面から２０ｍｍ程の高さｈで中層部１２の凸部１２ａを水平にカットすることにより、図５（ｃ）に示すような四角錐形状の切頭凸部１２ａ’を形成する。 And in the mattress 1 of Embodiment 1, as shown in FIG.5 (b), with respect to the middle layer and lower layer laminated body 40 of the middle layer part 12 and the lower layer part 13 which have the convex part 12a and the recessed part 12b formed by profile processing. Then, the convex portion 12a of the middle layer portion 12 is horizontally cut at a height h of about 20 mm from the upper surface of the lower layer portion 13 to form a quadrangular pyramid-shaped truncated convex portion 12a ′ as shown in FIG. To do.

そして、その後は、図５（ｃ）に示すように四角錐形状の切頭凸部１２ａ’を有する中層部１２と下層部１３とからなる中層・下層積層体４０の四角錐形状の切頭凸部１２ａ’の上面（切頭凸部切断面１２ａ１’）の上から、図４（ｂ）に示すようにプロファイル加工によりにプロファイル加工により形成された凸部１１ａおよび凹部１１ｂを有する上層部１１の底面を貼り付けることにより、実施形態１のマットレス１が完成する。 After that, as shown in FIG. 5C, the quadrangular pyramid-shaped truncated convex of the middle-layer / lower-layer laminate 40 composed of the middle layer portion 12 and the lower layer portion 13 having the quadrangular pyramid-shaped truncated convex portion 12a ′. The upper layer portion 11 having the convex portion 11a and the concave portion 11b formed by profile processing by profile processing as shown in FIG. 4 (b) from the upper surface of the portion 12a ′ (the truncated convex portion cutting surface 12a1 ′). By attaching the bottom surface, the mattress 1 of the first embodiment is completed.

（下層部１３の構成）
実施形態１の下層部１３は、例えば、上層部１１の上層部用発泡体１０や、中層部１２の中層部用発泡体２０のウレタンフォームよりも高硬質のウレタンフォームやポリオレフィン系フォーム等の発泡体で構成されている。 (Configuration of lower layer 13)
The lower layer portion 13 of the first embodiment is, for example, foamed urethane foam or polyolefin foam that is harder than the urethane foam of the upper layer portion foam 10 of the upper layer portion 11 or the middle layer portion foam 20 of the middle layer portion 12. Consists of the body.

ここで、下層部１３を構成する発泡体としては、細かい気泡が互いに膜で区切られた独立気泡構造のものや、気泡の膜に貫通孔があることで隣り合う気泡が空間として繋がった連続気泡構造のものを用いることができるが、連続気泡構造の発泡体で構成するのが好ましい。これは、下層部１３に連続気泡構造の発泡体を用いることで、ユーザ使用時の圧縮変形量を大きくできるからである。 Here, as the foam constituting the lower layer portion 13, a closed cell structure in which fine bubbles are separated from each other by a film, or an open cell in which adjacent bubbles are connected as a space by having a through hole in the bubble film Although a structure can be used, it is preferably composed of a foam having an open cell structure. This is because the amount of compressive deformation during user use can be increased by using a foam having an open cell structure for the lower layer portion 13.

下層部１３は、床側に臨む下面が平坦に形成された長方形の板状体であり、マットレス１にかかる荷重を受け止めて、使用者が底付きしないように支持する役割を主に担っている。下層部１３は、その硬さが家庭用品品質表示法に基づく表示様式で「かため」に区分される発泡体を用いており、例えば、２００Ｎ〜３００Ｎ程度の範囲の硬さにある発泡体を用いている。なお、下層部１３は、密度が２０ｋｇ／ｍ^３〜３０ｋｇ／ｍ^３の範囲にある発泡体を用いている。そして、下層部１３は、その厚みを１０ｍｍ〜３０ｍｍの範囲で設定することが好ましく、この実施形態１の下層部１３は厚みを例えば３０ｍｍに設定している。 The lower layer portion 13 is a rectangular plate-like body having a flat bottom surface facing the floor side, and mainly plays a role of receiving a load applied to the mattress 1 so that the user does not bottom out. . The lower layer portion 13 uses a foam whose hardness is classified as “hard” in a display style based on the household goods quality labeling method. For example, a foam having a hardness in the range of about 200N to 300N is used. Used. Incidentally, the lower portion 13, the density is using a foam in the range of ^{^{20kg / m 3 ~30kg / m 3}} . And it is preferable to set the thickness of the lower layer part 13 in the range of 10 mm-30 mm, and the lower layer part 13 of this Embodiment 1 has set thickness to 30 mm, for example.

そして以上のように構成された上層部１１の底面と、中層部１２の切頭凸部１２ａ’の切頭凸部切断面１２ａ１’とを貼り付ける際は、中層部１２にプロファイル加工により形成された各凹部１２ｂと、上層部１１にプロファイル加工により形成された各凹部１１ｂの中心位置がなるべく一致するように貼り付けると良い。 When the bottom surface of the upper layer portion 11 configured as described above and the truncated convex portion cut surface 12a1 ′ of the truncated convex portion 12a ′ of the middle layer portion 12 are attached, the middle layer portion 12 is formed by profile processing. The recesses 12b may be pasted so that the center positions of the recesses 11b formed in the upper layer portion 11 by profile processing coincide as much as possible.

（マットレス１の作用）
次に、以上のように構成された実施形態１のマットレス１の作用について説明する。 (Function of mattress 1)
Next, the operation of the mattress 1 of the first embodiment configured as described above will be described.

以上のように構成した実施形態１のマットレス１では、中層部１２は除膜処理された連続気泡構造の中層部用発泡体２０で構成してあるので、下層部１３と上層部１１とを繋ぐ連結部１８においても通気させることができる。 In the mattress 1 of the first embodiment configured as described above, the middle layer portion 12 is composed of the foam 20 for the middle layer portion of the open cell structure that has been subjected to film removal treatment, and thus connects the lower layer portion 13 and the upper layer portion 11. The connecting portion 18 can also be ventilated.

また、実施形態１のマットレス１では、上層部１１にプロファイル加工により形成した凸部１１ａおよび凹部１１ｂと同様に、中層部１２にもプロファイル加工により凸部１２ａおよび凹部１２ｂを形成した後、その凸部１２ａをカットして切頭凸部１２ａ’を形成し、その切頭凸部切断面１２ａ１’を上層部１１の底面に貼り付けることにより中層部１２の上面と上層部１１の底面との間に空洞部１２ｃを設けているので、中層部１２における空気の流動性を高めることができる。 Further, in the mattress 1 of the first embodiment, similarly to the convex portions 11a and the concave portions 11b formed on the upper layer portion 11 by profile processing, the convex portions 12a and the concave portions 12b are formed on the middle layer portion 12 by profile processing, and then the convex portions are formed. The portion 12 a is cut to form a truncated convex portion 12 a ′, and the truncated convex portion cut surface 12 a 1 ′ is attached to the bottom surface of the upper layer portion 11, so that the space between the upper surface of the middle layer portion 12 and the bottom surface of the upper layer portion 11 Since the hollow portion 12c is provided in the middle portion 12, air fluidity in the middle layer portion 12 can be improved.

これにより、マットレス１の内部に熱や湿気などがこもり難くすることができ、快適な使用感が得られる。 Thereby, heat, moisture, etc. can be made hard to stay inside the mattress 1, and a comfortable feeling of use can be obtained.

マットレス１は、下層部１３を上層部１１よりも硬く設定すると共に、上層部１１の反発弾性を下層部１３よりも大きく設定することで、良好な体圧分散性が得られると共に、底付き感の発生を防止し得る。中層部１２は、隣り合う連結部１６が少なくとも下側の下層部１３側で繋がるように形成されているので、連結部１８の間の空間部２０を繋ぐ連通路２２を設けても、中層部１２が柔軟になり過ぎることを防止できる。 The mattress 1 sets the lower layer portion 13 to be harder than the upper layer portion 11 and sets the rebound resilience of the upper layer portion 11 to be larger than that of the lower layer portion 13, thereby obtaining good body pressure dispersibility and feeling of bottoming. Can be prevented. Since the middle layer portion 12 is formed so that the adjacent connecting portions 16 are connected at least on the lower layer portion 13 side, even if the communication path 22 that connects the space portions 20 between the connecting portions 18 is provided, the middle layer portion 12 can be prevented from becoming too flexible.

従って、実施形態１のマットレス１によれば、上層部１１および中層部１２それぞれについて、図４（ａ）および図５（ａ）に示すように対向配置された一対のロール２，２の間にそれぞれの元になる発泡体を通し、両ロール２，２の外周面それぞれに突設した複数の突起２１，２１，・・・により各発泡体を波打つように変形させた状態でカッター５２により切断するプロファイル加工を行うことにより中層部１２の上面側にも、上層部１１の上面側と同様に凸部および凹部を形成するようにしたため、中層部１２の上面側と上層部１１の底面とを貼り付けると、中層部１２の上面側と上層部１１の底面との間に空洞部１２ｃが形成されることになる。 Therefore, according to the mattress 1 of the first embodiment, each of the upper layer portion 11 and the middle layer portion 12 is disposed between a pair of rolls 2 and 2 that are arranged to face each other as shown in FIGS. 4 (a) and 5 (a). Each foam is cut by a cutter 52 in a state where each foam is deformed so as to wave by a plurality of protrusions 21, 21,... By performing the profile processing, a convex portion and a concave portion are formed on the upper surface side of the middle layer portion 12 in the same manner as the upper surface side of the upper layer portion 11, so that the upper surface side of the middle layer portion 12 and the bottom surface of the upper layer portion 11 are formed. When affixed, a cavity portion 12 c is formed between the upper surface side of the middle layer portion 12 and the bottom surface of the upper layer portion 11.

その結果、実施形態１のマットレス１によれば、上述の特許文献１，２に記載された従来のマットレスとは異なり、中層部１２の空洞部１２ｃが上層部１１または下層部の凹部まで開口した深い凹部（溝部）を構成しないので、中層部１２に通気用の空洞部１２ｃを設けても中層部１２が潰れ難くなり、マットレス１全体として人体を均等に支持することができる。 As a result, according to the mattress 1 of the first embodiment, unlike the conventional mattress described in Patent Documents 1 and 2, the hollow portion 12c of the middle layer portion 12 opens to the concave portion of the upper layer portion 11 or the lower layer portion. Since no deep concave portion (groove portion) is formed, the middle layer portion 12 is not easily crushed even if the middle layer portion 12 is provided with a ventilation cavity portion 12c, and the human body can be evenly supported by the mattress 1 as a whole.

また、実施形態１のマットレス１では、中層部１２に設ける凸部１２ａおよび凹部１２ｂは、上層部１１に設ける凸部１１ａおよび凹部１１ｂを形成するプロファイル加工の機械（装置）と同じ機械（装置）により形成するようにしたため、上層部１１に形成した凸部１１ａおよび凹部１１ｂと同様に中層部１２に凸部１２ａおよび凹部１２ｂを形成することが可能となり、空洞部１２ｃを有する中層部１２を容易に製造することができる。 In the mattress 1 of the first embodiment, the convex portion 12a and the concave portion 12b provided in the middle layer portion 12 are the same machine (device) as the profile processing machine (device) for forming the convex portion 11a and the concave portion 11b provided in the upper layer portion 11. Therefore, the convex portion 12a and the concave portion 12b can be formed in the middle layer portion 12 similarly to the convex portion 11a and the concave portion 11b formed in the upper layer portion 11, and the middle layer portion 12 having the cavity portion 12c can be easily formed. Can be manufactured.

また、実施形態１のマットレス１では、上層部１１、中層部１２および下層部１３の高さ（厚さ）が、例えば、それぞれ４０ｍｍ、２０ｍｍ、３０ｍｍであり、プロファイル加工により中層部１２に凸部１２ａおよび凹部１２ｂを形成する際、図５（ａ）に示すように下層部１３の元になる２枚の下層部用発泡体３０の間に中層部用発泡体２０を挟んで接着した３層構造の発泡体を通してプロファイル加工することにより、切頭凸部切断面１２ａ１’に凸部１２ａおよび凹部１２ｂが現れた中層部１２と下層部１３との積層物を２枚製造するようにしたため、図５（ａ）〜（ｃ）などに示すように中層部１２の凹部１２ｂの深さを極限まで、すなわち中層部１２の底面や下層部１３に到達するまで深く生成することが可能となり、空洞部１２ｃを有する中層部１２を容易に製造することができる。 Moreover, in the mattress 1 of Embodiment 1, the height (thickness) of the upper layer part 11, the middle layer part 12, and the lower layer part 13 is, for example, 40 mm, 20 mm, and 30 mm, respectively, and is convex on the middle layer part 12 by profile processing. When forming 12a and the recessed part 12b, as shown to Fig.5 (a), 3 layers which pinched | interposed the foam 20 for intermediate | middle layers between two lower layer foams 30 used as the origin of the lower layer 13 Since profile processing is performed through the foam of the structure, two laminates of the middle layer portion 12 and the lower layer portion 13 in which the convex portion 12a and the concave portion 12b appear on the truncated convex portion cutting surface 12a1 ′ are manufactured. 5 (a) to 5 (c) and the like, the depth of the concave portion 12b of the middle layer portion 12 can be deeply generated until the depth reaches the limit, that is, until reaching the bottom surface or the lower layer portion 13 of the middle layer portion 12. 12 It is possible to easily manufacture a middle portion 12 having a.

また、実施形態１のマットレス１では、中層部１２に設ける空洞部１２ｃは、プロファイル加工により中層部１２の表面に設けた複数の凸部２１，２１，・・・の先端部を所定の高さｈで水平にカットして四角錐形状の切頭凸部１２ａ’を形成した後、その四角錐形状の切頭凸部１２ａ’を上層部１１の底面に貼り付けることにより形成するようにしたため、上層部１１に設ける凸部１１ａおよび凹部１１ｂを形成するプロファイル加工の機械（装置）と同じ機械（装置）を使用してプロファイル加工しても、中層部１２に所望の深さの空洞部１２ｃを形成することができ、空洞部１２ｃを有する中層部１２を容易かつ低コストに製造することができる。 Further, in the mattress 1 of the first embodiment, the hollow portion 12c provided in the middle layer portion 12 has a predetermined height at the tips of the plurality of convex portions 21, 21, ... provided on the surface of the middle layer portion 12 by profile processing. Since it is cut horizontally at h to form a quadrangular pyramid-shaped truncated convex portion 12 a ′, the quadrangular pyramid-shaped truncated convex portion 12 a ′ is pasted on the bottom surface of the upper layer portion 11, Even if profile processing is performed using the same machine (apparatus) as the profile processing machine (apparatus) for forming the convex portion 11a and the concave portion 11b provided in the upper layer portion 11, the cavity portion 12c having a desired depth is formed in the intermediate layer portion 12. Therefore, the middle layer portion 12 having the cavity portion 12c can be manufactured easily and at low cost.

なお、実施形態１のマットレス１では、プロファイル加工により中層部１２に凸部１２ａおよび凹部１２ｂを形成する際、図５（ａ）に示すように下層部１３の元になる２枚の下層部用発泡体３０の間に中層部用発泡体２０を挟んで接着した３層構造の発泡体を通してプロファイル加工することにより、切頭凸部切断面１２ａ１’に凸部１２ａおよび凹部１２ｂが現れた中層部１２と下層部との積層物を２枚製造するように説明したが、本発明では、これに限らず、下層部１３の元になる２枚の下層部用発泡体３０の間に中層部用発泡体２０を挟まずに、中層部用発泡体２０のみを一対のロール２，２の間に通してプロファイル加工を実行するようにしても勿論良い。 In the mattress 1 of the first embodiment, when forming the convex portion 12a and the concave portion 12b in the middle layer portion 12 by profile processing, as shown in FIG. The middle layer part in which the convex part 12a and the concave part 12b appear on the truncated convex part cut surface 12a1 ′ by profile processing through a foam having a three-layer structure in which the foam 20 for the middle layer part is bonded between the foams 30. However, in the present invention, the present invention is not limited to this, and the present invention is not limited to this. For the middle layer portion between the two lower layer portion foams 30 that form the lower layer portion 13. Of course, only the middle layer foam 20 may be passed between the pair of rolls 2 and 2 without sandwiching the foam 20 to execute the profile processing.

また、上記実施形態１のマットレス１では、図３（ｂ）に示すような断面構造に形成して説明したが、図５（ａ）に示すように下層部１３の元になる２枚の下層部用発泡体３０の間に中層部用発泡体２０を挟んで接着した３層構造の発泡体を通してプロファイル加工することにより図６（ａ）の断面構造に示すように下層部１３の中まで深く削って生成するようにしても良いし、図６（ｂ）の断面構造に示すように上層部１１に凹部１１ｂを中層部１２の四角錐形状の切頭凸部１２ａ’の切頭凸部切断面（上側面）１２ａ１’に達するようにプロファイル加工するようにしても勿論良い。前者のように形成すると、中層部１２に形成した凹部１２ｃは、下層部１３の中まで達するため、凹部１２ｃの表面積が増大するので、中層部１２における排熱効果や湿気排出効果をより向上させることができる。 Further, the mattress 1 of the first embodiment has been described with a cross-sectional structure as shown in FIG. 3B. However, as shown in FIG. Profile processing is performed through a three-layer structure foam in which the middle layer foam 20 is sandwiched between the partial foams 30 to deepen into the lower layer 13 as shown in the cross-sectional structure of FIG. As shown in the cross-sectional structure of FIG. 6B, the upper layer portion 11 has a concave portion 11b and the middle layer portion 12 has a quadrangular pyramid-shaped truncated convex portion 12a ′. Of course, the profile processing may be performed so as to reach the surface (upper side surface) 12a1 ′. When the former is formed as in the former, the recess 12c formed in the middle layer 12 reaches the lower layer 13, and the surface area of the recess 12c is increased. Therefore, the heat exhaust effect and the moisture exhaust effect in the middle layer 12 are further improved. be able to.

実施形態２．
上記実施形態１のマットレス１では、中層部１２を上層部１２と同様にプロファイル加工すると共に、さらに、下層部１３の上面から２０ｍｍ程の高さｈで中層部１２の凸部１２ａを水平にカットすることにより、図５（ｃ）に示すような四角錐形状の切頭凸部１２ａ’を形成して、最終的には、図２に示すように対角線上で隣接する四角錐形状の切頭凸部１２ａ’同士は切頭凸部切断面１２ａ１’が水平、すなわち面一に連続する一方、四角錐形状の切頭凸部１２ａ’に囲まれた凹部１２ｂは独立するように形成したため、この中層部１２の四角錐形状の切頭凸部１２ａ’の切頭凸部切断面１２ａ１’に上層部１１の底面を被せて貼り付けると、各凹部１２ｂは独立した空洞部１２ｃを形成することになる。 Embodiment 2. FIG.
In the mattress 1 of the first embodiment, the middle layer portion 12 is profiled in the same manner as the upper layer portion 12, and the convex portion 12a of the middle layer portion 12 is horizontally cut at a height h of about 20 mm from the upper surface of the lower layer portion 13. By doing so, a quadrangular pyramid-shaped truncated convex portion 12a ′ as shown in FIG. 5C is formed, and finally, as shown in FIG. The convex portions 12a ′ are formed so that the truncated convex portion cutting surfaces 12a1 ′ are horizontal, that is, flush with each other, while the concave portions 12b surrounded by the quadrangular pyramid-shaped truncated convex portions 12a ′ are independent. If the bottom surface of the upper layer part 11 is applied to the truncated convex part cut surface 12a1 ′ of the quadrangular pyramid-shaped truncated convex part 12a ′ of the middle layer part 12 and attached, each concave part 12b forms an independent cavity part 12c. Become.

これに対し、実施形態２のマットレス１では、図７に示すように実施形態１の場合よりも下層部１３の上面から高い高さで中層部１２の凸部１２ａを水平にカットして四角錐形状の切頭凸部１２ａ’を形成するか、あるいは中層部１２の凸部１２ａを水平にカットする処理を省略して、図２に示す実施形態１の中層部１２における四角錐形状の切頭凸部１２ａ’同士のように切頭凸部切断面１２ａ１’が水平に連続することなく、対角線の方向で隣接する空洞部１２ｃ同士が連通部１２ｄを介して連通するように構成しても良い。 On the other hand, in the mattress 1 of the second embodiment, as shown in FIG. 7, the convex portion 12a of the middle layer portion 12 is horizontally cut at a height higher than the upper surface of the lower layer portion 13 as compared with the case of the first embodiment. The truncated truncated convex portion 12a 'is formed, or the process of horizontally cutting the convex portion 12a of the middle layer portion 12 is omitted, and the truncated pyramid shaped truncated shape in the middle layer portion 12 of the first embodiment shown in FIG. Instead of the convex protrusion cutting surfaces 12a1 'being horizontally continuous like the convex parts 12a', the cavity parts 12c adjacent in the diagonal direction may communicate with each other via the communication part 12d. .

従って、実施形態２のマットレス１によれば、上述の実施形態１のマットレス１と同様の効果が得られると共に、さらに中層部１２において連通部１２ｄを介し対角線方向で隣接する空洞部１２ｃ同士が連通部１２ｄを介して連通し、対角線方向である水平方向にも人体から発せられる熱や湿気を排出するため、上述の実施形態１のマットレス１よりも排熱効果や湿気排出効果が高いマットレス１を提供することができる。 Therefore, according to the mattress 1 of the second embodiment, the same effect as that of the mattress 1 of the first embodiment described above can be obtained, and the cavity portions 12c adjacent in the diagonal direction in the middle layer portion 12 can communicate with each other via the communication portion 12d. In order to discharge heat and moisture emitted from the human body also in the horizontal direction that is the diagonal direction, the mattress 1 having higher exhaust heat effect and moisture discharge effect than the mattress 1 of the first embodiment described above is communicated via the portion 12d. Can be provided.

実施形態３．
上述の実施形態１，２のマットレス１では、下層部１３については凸部および凹部を設けずに説明したが、実施形態３のマットレス１では、下層部１３については凸部１３ａおよび凹部１３ｂを設けたものである。なお、実施形態３のマットレス１の上層部１１および中層部１２の構成は、上述した実施形態１，２のマットレス１の上層部１１および中層部１２の構成と同じである。 Embodiment 3. FIG.
In the mattress 1 of the first and second embodiments described above, the lower layer portion 13 has been described without providing the convex portion and the concave portion, but in the mattress 1 of the third embodiment, the lower layer portion 13 is provided with the convex portion 13a and the concave portion 13b. It is a thing. The configurations of the upper layer portion 11 and the middle layer portion 12 of the mattress 1 of the third embodiment are the same as the configurations of the upper layer portion 11 and the middle layer portion 12 of the mattress 1 of the first and second embodiments.

図８（ａ）に示す実施形態３のマットレス１は、下層部１３についても上層部１１や中層部１２と同様にプロファイル加工を施して凸部１３ａおよび凹部１３ｂを設けて、その凸部１３ａを中層部１２の底面に貼り付けて構成したものである。 In the mattress 1 of the third embodiment shown in FIG. 8A, the lower layer portion 13 is profiled in the same manner as the upper layer portion 11 and the middle layer portion 12 to provide the convex portion 13a and the concave portion 13b. It is configured by being affixed to the bottom surface of the middle layer portion 12.

また、図８（ｂ）に示すように、実施形態３のマットレス１では、下層部１３についても上層部１１や中層部１２と同様にプロファイル加工を施して凸部１３ａおよび凹部１３ｂを設けた後、下層部１３の凸部１３ａおよび凹部１３ｂを形成していない底面側を中層部１２の底面に貼り付けて構成するようにしても勿論良い。 Further, as shown in FIG. 8B, in the mattress 1 of the third embodiment, the lower layer portion 13 is subjected to profile processing similarly to the upper layer portion 11 and the middle layer portion 12 to provide the convex portions 13a and the concave portions 13b. Of course, the bottom surface side of the lower layer portion 13 where the convex portion 13a and the concave portion 13b are not formed may be attached to the bottom surface of the middle layer portion 12 for configuration.

また、図９（ａ），（ｂ）に示すように、下層部１３にはプロファイル加工を施さずに、円柱形状の打ち抜き加工等により中空部１３ｅを設けても良い。 Further, as shown in FIGS. 9A and 9B, the lower layer portion 13 may be provided with a hollow portion 13e by a cylindrical punching process or the like without performing profile processing.

従って、実施形態３のマットレス１によれば、上述の実施形態１，２のマットレス１と同様の効果が得られると共に、さらに下層部１３にもプロファイル加工を施して凸部１３ａおよび凹部１３ｂを設けたり、打ち抜き加工等により空洞部１３ｃを設けたため、中層部１２の空洞部１２ｃで滞留した人体から排出された熱や湿気を下層部１３に設けた凹部１３ｂや空洞部１３ｃからも逃げ易くなり、上述の実施形態１，２のマットレス１よりも排熱効果や湿気排出効果が高いマットレス１を提供することができる。 Therefore, according to the mattress 1 of the third embodiment, the same effect as the mattress 1 of the first and second embodiments can be obtained, and the lower layer portion 13 is further profiled to provide the convex portions 13a and the concave portions 13b. Since the cavity 13c is provided by punching or the like, heat and moisture discharged from the human body staying in the cavity 12c of the middle layer 12 can be easily escaped from the recess 13b and the cavity 13c provided in the lower layer 13, It is possible to provide the mattress 1 having higher exhaust heat effect and moisture exhaust effect than the mattress 1 of the first and second embodiments.

尚、上記実施懈怠１〜３のマットレス１の説明では、上層部１１、中層部１２および下層部１３からなる３層構造のマットレス１で説明したが、本発明ではこれに限らず、下層部１３と中層部１２との間や上層部１１と中層部１２との間等に、別の機能層を設けた４層以上の複層構造であっても勿論良く、要は、上層部１１と下層部１３との間の中層部１２にプロファイル加工を施すことにより空洞部１２ｃを設ける構成であれば良い。 In the description of the mattress 1 of the implementation failures 1 to 3 described above, the mattress 1 having the three-layer structure including the upper layer portion 11, the middle layer portion 12 and the lower layer portion 13 has been described. Of course, a multi-layer structure of four or more layers in which another functional layer is provided between the upper layer portion 11 and the middle layer portion 12 or the like may be used. Any structure may be used as long as the hollow portion 12c is provided by performing profile processing on the middle layer portion 12 between the portion 13 and the intermediate portion 12.

また、上記実施形態１〜３のマットレス１を構成する上層部１１、中層部１２および下層部１３それぞれの各層の硬さや素材、密度、形状などの特性はあくまで一例であり、各層の特性は、用途によって適宜変更することができる。 In addition, the characteristics such as hardness, material, density, and shape of each layer of the upper layer part 11, the middle layer part 12, and the lower layer part 13 that constitute the mattress 1 of the first to third embodiments are merely examples, and the characteristics of each layer are as follows. It can be appropriately changed depending on the application.

また、上記実施形態１〜３のマットレス１は、就寝時に用いるものだけでなく、着座時や手術などの医療用途、その他の用途における座布団やクッション、敷物等として用いることができる。 Moreover, the mattress 1 according to the first to third embodiments can be used not only for sleeping, but also as a cushion, a cushion, a rug, or the like for medical use such as sitting or surgery, and other uses.

１マットレス
１１上層部
１１ａ凸部
１１ｂ凹部
１２中層部
１２ａ凸部
１２ａ’ 切頭凸部
１２ａ１’ 切頭凸部切断面
１２ｂ凹部
１２ｃ空洞部
１２ｄ連通部
１３下層部
１３ａ凸部
１３ｂ凹部
１３ｅ中空部
１０上層部用発泡体
２０中層部用発泡体
３０下層部用発泡体
４０中層・下層積層体
５ロール
５１突起
５２カッター DESCRIPTION OF SYMBOLS 1 Mattress 11 Upper layer part 11a Convex part 11b Concave part 12 Middle layer part 12a Convex part 12a 'Fraction convex part 12a1' Fraction convex part cut surface 12b Concave part 12c Cavity part 12d Communication part 13 Lower layer part 13a Convex part 13b Concave part 13e Hollow part 10 Foam for upper layer portion 20 Foam for middle layer portion 30 Foam for lower layer portion 40 Middle layer / lower layer laminate 5 Roll 51 Projection 52 Cutter

Claims

Consists of a lower part for the foam, and a lower portion serving as a floor side,
Consists of a foam for the middle layer, and a middle layer provided on the lower layer,
The upper layer portion is composed of a foam for the upper layer portion, and includes an upper layer portion having a plurality of convex portions and concave portions on the upper surface side that supports the user's body, and the upper surface in contact with the middle layer portion in the lower layer portion is not formed with a concave surface. In the manufacturing method of the mattress which is a shape ,
The foam for the upper layer part is deformed so as to be waved by a plurality of projections projecting on the outer peripheral surfaces of both rolls through the foam for the upper layer part between the pair of opposed rolls. An upper layer manufacturing process for manufacturing the upper layer part by forming a convex part and a concave part on the cut surface by performing profile processing that is cut by a cutter in a state of being made ,
The foam for the middle layer part is deformed so as to be waved by a plurality of protrusions projecting from the outer peripheral surfaces of both rolls through the foam for the middle layer part that is the origin of the middle layer part between a pair of opposed rolls. By performing profile processing that cuts with a cutter in a state of being made, a convex portion and a concave portion are formed on the cut surface, and then the plurality of formed convex portions are horizontally cut at a predetermined height to form the middle layer A middle layer manufacturing process for manufacturing a part;
An upper middle layer portion pasting step for pasting the bottom surface side of the upper layer portion manufactured by the upper layer portion manufacturing step and the upper surface side of the middle layer portion manufactured by the middle layer portion manufacturing step;
A method for producing a mattress , comprising:

In the manufacturing method of the mattress according to claim 1,
And in the upper part manufacturing process and the middle layer portion manufacturing process, by performing profile machining of the same profile processing machinery of the cutter, the foaming middle portion and the upper portion foams formed by these profiles machining mattress manufacturing method characterized by forming the convex portion and concave portion formed on the cut surface of the body in the same shape.

In the manufacturing method of the mattress according to claim 1 or 2,
In the middle layer manufacturing process ,
Between a pair of rolls arranged opposite to each other, a foam having a three-layer structure in which the foam for the middle layer part is sandwiched between the two foams for the lower part that are the basis of the lower layer part is passed, performing profile machining of cutting at least a middle layer wherein in layer unit for foam by a cutter in a state in which the foam is deformed as undulating of the three-layer structure by a plurality of projections projecting from the respective outer peripheral surfaces of the rolls Thus, a method for manufacturing a mattress is characterized in that convex portions and concave portions are formed on the cut surface.

In the manufacturing method of the mattress according to any one of claims 1 to 3,
In the middle layer manufacturing process,
By obtaining the foam for the middle layer part in which the convex part and the concave part appear on the cut surface by the profile processing, and then, the tip parts of the plurality of convex parts formed on the surface side of the foam for the middle layer part have a predetermined height. When cutting horizontally with, cut so that the cut surface of the truncated convex part remaining by cutting is continuous with the cut surface of the other adjacent protrusions,
In the upper middle layer pasting step,
When the cut surface of the truncated convex portion of the middle layer portion is attached to the bottom surface side of the upper layer portion, each concave portion formed by profile processing in the middle layer portion communicates with another adjacent concave portion via a communicating portion. A method of manufacturing a mattress , characterized in that it is formed as follows .

It is composed of a foam for the lower layer, and the lower layer that becomes the floor side,
Consists of a foam for the middle layer, and a middle layer provided on the lower layer,
In a method for manufacturing a mattress comprising a foam for an upper layer portion and having an upper layer portion having a plurality of convex portions and concave portions on the upper surface side that supports the user's body,
The foam for the upper layer part is deformed so as to be waved by a plurality of projections projecting on the outer peripheral surfaces of both rolls through the foam for the upper layer part between the pair of opposed rolls. An upper layer manufacturing process for manufacturing the upper layer part by forming a convex part and a concave part on the cut surface by performing profile processing that is cut by a cutter in a state of being made,
The foam for the middle layer part is deformed so as to be waved by a plurality of protrusions projecting from the outer peripheral surfaces of both rolls through the foam for the middle layer part that is the origin of the middle layer part between a pair of opposed rolls. By performing profile processing that cuts with a cutter in a state of being made, a convex portion and a concave portion are formed on the cut surface, and then the plurality of formed convex portions are horizontally cut at a predetermined height to form the middle layer A middle layer manufacturing process for manufacturing a part;
An upper middle layer portion pasting step for pasting the bottom surface side of the upper layer portion manufactured by the upper layer portion manufacturing step and the upper surface side of the middle layer portion manufactured by the middle layer portion manufacturing step;
In the middle layer manufacturing process,
By obtaining the foam for the middle layer part in which the convex part and the concave part appear on the cut surface by the profile processing, and then, the tip parts of the plurality of convex parts formed on the surface side of the foam for the middle layer part have a predetermined height. When cutting horizontally with, cut so that the cutting surface of the truncated convex part remaining by cutting is not continuous with the cutting surface of the other adjacent protruding part,
In the upper middle layer pasting step,
When the cut surface of the truncated convex portion of the middle layer portion is attached to the bottom surface of the upper layer portion, each of the concave portions formed by profile processing in the middle layer portion is not continuous with other adjacent concave portions, and independent hollow portions are formed. A method of manufacturing a mattress , comprising: forming the mattress.

In the manufacturing method of the mattress according to claim 5,
In the upper layer part manufacturing step and the middle layer part manufacturing step, the upper layer part foam and the middle layer part foam formed by performing profile processing with a cutter of the same profile processing machine. A method of manufacturing a mattress, wherein the convex portion and the concave portion formed on the cut surface are formed in the same shape.

In the manufacturing method of the mattress according to claim 5 or 6,
In the middle layer manufacturing process,
Between a pair of rolls arranged opposite to each other, a foam having a three-layer structure in which the foam for the middle layer part is sandwiched between the two foams for the lower part that are the basis of the lower layer part is passed, Perform profile processing to cut at least the intermediate layer foam of the intermediate layer with a cutter in a state in which the foam of the three-layer structure is deformed so as to be waved by a plurality of protrusions protruding from the outer peripheral surfaces of both rolls. A method of manufacturing a mattress, wherein a convex portion and a concave portion are formed on the cut surface.

In the manufacturing method of the mattress according to any one of claims 1 to 7,
In the upper middle layer pasting step,
When affixing the upper surface side of the middle layer portion and the bottom surface side of the upper layer portion, each concave portion formed by profile processing on the middle layer portion and the center position of each concave portion formed by profile processing on the upper layer portion are A mattress manufacturing method, wherein the mattresses are attached so as to match .