JP6150481B2 - Cushion material - Google Patents

Description

  The present invention relates to a cushion material suitable for bedding such as a mattress.

  As a cushion material used for bedding such as a mattress, a soft polyurethane foam has been conventionally used. For example, a cushion material having an uneven shape on the surface of the soft polyurethane foam is known. Cushioning material with uneven shape on the surface has excellent body pressure dispersibility by partially supporting the body etc. with the convex part, and can also ensure breathability because the concave part can escape the steamed air It becomes.

As a method for producing a flexible polyurethane foam having a concavo-convex shape on the surface, a profile processing and a method of processing with a two-dimensional cutter are known.
For example, Patent Document 1 discloses that a high-breathable flexible polyurethane foam is laminated on the upper and lower surfaces of a high-density flexible polyurethane foam to form a three-layer laminate, and then the profile is processed by profiling the laminate. Describes a method of simultaneously molding two cushion materials having a three-layer structure having an uneven shape. According to this method, since two cushion materials having the same layer structure can be formed simultaneously, the production efficiency can be improved. In addition, the cushion material described in Patent Document 1 has a highly permeable flexible polyurethane foam exposed in a part of the concave portion in the concave and convex shape formed on the surface, and improves the air permeability simultaneously with the formation of the concave and convex shape. I am letting.

  A cushioning material formed in the same manner as described in Patent Document 1, and Patent Document 2 discloses a soft polyurethane foam having a relatively low hardness on the upper and lower surfaces of a relatively high hardness polyurethane foam. A cushioning material having a three-layer structure obtained by profiling a laminated layer of three layers is disclosed. In the cushion material described in Patent Document 2, since the convex-concave convex middle portion formed on the surface is formed of a relatively high hardness soft polyurethane foam, the convex portion buckles even when receiving weight, It becomes a state where the sleeping person is pushed up without being able to do so, and it becomes possible to give a good massage effect.

  By the way, as shown in FIG. 4, the cushioning materials described in Patent Documents 1 and 2 have a concavo-convex shape on the surface, but the convex portion has a three-layer structure. In this way, when the convex portion has a multilayer structure, there is a risk of peeling between the layers due to long-term use, particularly when used in a portion that is easily worn, and an adhesive between the layers is intended to prevent delamination. When the coating amount is increased, the difference in hardness between the adhesive and the flexible polyurethane foam may cause an uncomfortable feeling when contacting the body.

  Furthermore, in the cushioning materials described in Patent Documents 1 and 2, since the layer forming the bottom portion is formed from a filmless foam or a soft polyurethane foam having a relatively low hardness, the foam becomes difficult when used for a long time. It was easy to be done and a feeling of bottoming occurred, leaving room for improvement.

JP 2000-166707 A JP 2010-148819 A

  The object of the present invention is to provide a cushioning material that can withstand a long-term use of the convex and concave portions provided on the surface of the cushioning material, and that does not feel uncomfortable when touching the body and provides a comfortable sleeping comfort. It is what.

  As a result of studying to solve the above problems, in the laminate of 5 or more layers of flexible polyurethane foam, the convex portion of the surface uneven shape of the cushion material obtained by profiling into only one of the intermediate layers and bisecting, Since the cushioning material that can be used for a long time and does not feel uncomfortable when coming into contact with the body is obtained, the present invention has been achieved.

  That is, the present invention profiled only the central layer of the laminate in a cushioning material having a concavo-convex shape on the surface formed by profiling into a laminate of 5 or more layers made of flexible polyurethane foam at the same time. By processing, the surface irregularity shape of the cushion material is formed only by the central layer.

  According to the invention of the present application, since the concavo-convex convex portion formed on the surface of the cushion material is formed only by the central layer to be profiled, it is more durable than the convex portion formed by two or more layers. In addition, a cushioning material that does not feel uncomfortable and has an excellent sleeping comfort can be obtained.

In the present invention, the central layer is a soft polyurethane foam having a density of 20 to 70 kg / m ³ and a 25% compression hardness of 100 to 400 N, or a highly elastic flexible polyurethane foam having at least a resilience of 50% or more. Preferably there is.

The center layer to be profiled will form an uneven surface shape that supports the body when used as a cushioning material. Therefore, the central layer is composed of a flexible polyurethane foam having a density of 20 to 70 kg / m ³ and a 25% compression hardness of 100 to 400 N, or at least a highly elastic flexible polyurethane foam having a rebound resilience of 50% or more. Then, the convex part is repelled moderately without being deformed too much, so that the body pressure dispersibility is further improved, and a cushioning material having a comfortable sleeping comfort can be obtained.
In addition, the density in this invention is measured based on JISK7222, and 25% compression hardness and impact resilience are measured based on JISK6400.

  Furthermore, the intermediate layer adjacent to the center layer to be profiled is preferably a highly breathable flexible urethane foam.

In the present invention, the highly breathable flexible polyurethane foam is one having an air permeability of 3.0 dm ³ / s or more based on JIS K 6400. If such a highly breathable flexible polyurethane foam and the center layer to be profiled are adjacent to each other, when used as a cushion material, the steamed air is transferred from the concave and convex shaped recesses formed by the profile processing. It moves to an intermediate layer composed of a highly breathable flexible polyurethane foam, and is easily discharged to the outside of the foam, improving the breathability and obtaining a cushioning material with less stuffiness.

  In the present invention, the base layer constituting the front and back surfaces of the laminate is a flexible polyurethane foam to which a ventilation means is applied, and the intermediate layer adjacent to the flexible polyurethane foam to which the ventilation means is applied has a high air permeability. It is characterized by being a flexible polyurethane foam.

  In the present invention, the ventilation means is, for example, forming a ventilation hole penetrating in the vertical direction, or forming a groove or a concavo-convex shape on the surface. The air permeability can be further improved by adjoining the flexible polyurethane foam.

  The cushion material of the present invention is obtained by profiling only the central layer of a laminate of five or more layers made of flexible polyurethane foam, and the surface unevenness shape of the cushion material is profile processed. Since it is formed of only the central layer, a cushion material that is superior in durability than the convex portion formed of two or more layers, has no sense of incongruity, and is excellent in sleeping comfort is obtained.

  Further, if the intermediate layer adjacent to the center layer to be profiled is a highly breathable flexible polyurethane foam, the breathability can be improved, and a cushion material with less stuffiness can be obtained.

It is sectional drawing explaining embodiment of this invention, Comprising: (a) is the laminated body before profile processing, (b) shows a cushioning material. It is sectional drawing of the cushioning material explaining another embodiment of FIG. It is sectional drawing explaining other embodiment of this invention, Comprising: (a) is the laminated body before profile processing, (b) shows a cushioning material. It is sectional drawing explaining the conventional cushion material.

  An embodiment of the present invention will be described based on the drawings. Note that the present invention is not limited to this embodiment.

  The present invention is a cushion material obtained by profiling only the central layer of a laminate in which five or more layers of flexible polyurethane foam are laminated.

  Profile processing is a method of forming a concavo-convex shape on the surface of a flexible polyurethane foam. By feeding the laminate between a pair of concavo-convex rolls and compressing it in the thickness direction, it follows the concavo-convex shape of the roll. If the central part of the thickness is cut with a cutting blade on the outlet side, the cut surface can be processed into an uneven shape.

In the present invention, profiling only the central layer means that the cut does not reach the other layers. That is, by adjusting the compressive force of the roll, the height of the unevenness of the cut surface can be adjusted, and therefore, the compressive force may be adjusted so that the height of the unevenness does not exceed the thickness of the center layer.
The convex part of the surface irregularity shape of the cushion material formed in this way is composed of a single layer, and has superior durability and no sense of incongruity compared to the convex part composed of two or more layers. A cushioning material with excellent sleeping comfort is obtained.

In the invention of the present application, for example, as shown in FIG. 1 (a), as a laminated body to be profile processed, a flexible polyurethane foam having different physical properties is made of a base layer 13, an intermediate layer 12, a profile processed center layer 11, and an intermediate layer. 12 and the base layer 13 can be used, and the laminated body 1 having a five-layer structure in which layers are laminated by bonding with an adhesive or the like can be used. In addition, the layer which attached | subjected the same code | symbol shows that it is a flexible polyurethane foam with the same physical property and the same thickness.
As shown in FIG. 1B, the concavo-convex shape formed on the surface is formed of only the center layer 11 by profile processing only the center layer 11 located at the center of the laminate 1. Two cushion materials 10 can be formed simultaneously.

  In the present invention, the profiled center layer 11 forms a concavo-convex shape formed on the surface of the cushion material, and the convex portion A is a portion that supports the body. Therefore, the flexible polyurethane foam that can be used as the center layer 11 to be profiled may be appropriately selected according to the user's preference, usage environment, and the like.

For example, the profile-processed center layer 11 has a density of 20 to 70 kg / m ³ , a flexible polyurethane foam having a relatively high hardness of 25% compression hardness of 100 to 400 N, or a highly elastic soft material having at least a rebound resilience of 50% or more. Polyurethane foam is preferable because the convex portion does not deform too much and repels moderately, so that the body pressure dispersibility becomes better and a cushion material having a comfortable sleeping comfort can be obtained.

Alternatively, a low resilience flexible polyurethane foam having a rebound resilience of 15% or less as the center layer 11 to be profiled can be used. If it is a low-resilience flexible polyurethane foam, a cushioning material that hardly rubs on the floor can be obtained.
In addition, a flexible polyurethane foam having a rebound resilience of 25% or less and a hysteresis loss rate of 35% or less can be used. This foam is preferable because it is a foam that can follow the sinking of the human body and can appropriately support the human body. Examples of such a flexible polytan foam include those described in JP 2010-189481 A.

  In the present invention, a highly breathable flexible polyurethane foam can be used as the center layer 11 to be profiled. However, when using a flexible polyurethane foam (film-free foam) from which the cell membrane has been removed, it is necessary to consider. is there. In general, a film-free foam tends to sag during long-term use, and the cushioning property tends to be impaired. Therefore, when using a filmless foam, for example, in the case of a mattress, it may be used only in a place where a load is difficult to be applied such as a head or a foot.

In the present invention, the intermediate layers 12 and 12 of the laminate 1 that are not subjected to profile processing may be any flexible polyurethane foam that can be used as bedding, and may be appropriately selected depending on the use environment and application.
For example, a flexible polyurethane foam having a density of 20 kg / m ³ or more and a 25% compression hardness of 100 N or more can be used.

Moreover, it is preferable to use a highly breathable flexible polyurethane foam as the intermediate layers 12 and 12.
The steamed air collected in the vicinity of the surface recess B of the cushioning material 10 is exhausted to some extent through the adjacent recess B, but if the intermediate layer 12 is a highly breathable flexible polyurethane foam, the steamed air However, since it becomes easy to be discharged | emitted from the recessed part through the intermediate | middle layer 12 of a highly air permeable foam and the foam exterior, air permeability improves and the cushioning material with little stuffiness is obtained.
The highly breathable flexible polyurethane foam as used in the present invention has an air flow rate of 3.0 dm ³ / s or more in accordance with JIS K 6400. Can be mentioned.

In the present invention, the base layers 13 and 13 of the laminate 1 are layers that come into contact with the installation surface when the cushion material 10 is used, and a highly elastic flexible polyurethane foam having a rebound resilience of 50% or more, or a 25% compression hardness of 100. A flexible polyurethane foam having a relatively high hardness of ˜400 N can be used. As described above, if a high elastic flexible polyurethane foam or a soft polyurethane foam having a relatively high hardness is used for the base layer, a cushion material with less feeling of bottom likeness can be obtained.
In addition, the base layers 13 and 13 and the above-described profile-processed center layer 11 may be made of a flexible polyurethane foam having the same physical properties.

Moreover, you may use the flexible polyurethane foam which gave the ventilation | gas_flowing means for the base layers 13 and 13. FIG. In the present invention, the ventilation means includes, for example, a ventilation hole penetrating in the vertical direction, or forming a groove or an uneven shape on the surface.
For example, as shown in FIG. 2, when a soft polyurethane foam having vent holes C penetrating vertically is used for the base layers 13 and 13, the obtained cushioning material 10 ′ has steamy air accumulated inside the foam. Since it becomes easy to be discharged to the outside of the foam through the vent hole C, the feeling of stuffiness can be reduced.
As described above, when the flexible polyurethane foam having the ventilation means is used for the base layers 13 and 13, the above-described highly breathable flexible polyurethane foam is used for the intermediate layers 12 and 12 adjacent to the base layers 13 and 13. In this case, the steamed air accumulated inside the cushion material is easily discharged to the outside, which is more preferable.
In addition, you may use the flexible polyurethane foam which gave the ventilation | gas_flowing means not only to the base layer but to other layers as needed.

  The thickness of the flexible polyurethane foam that can be profile-processed depends on the type of the profile processing machine and the flexible polyurethane foam, but is about 30 to 300 mm, and the height of the concavo-convex shape that can be formed is 5 mm or more. That is, the thickness of the laminated body 1 should just be about 30-300 mm, Preferably, it is 50-250 mm. When the thickness of the laminate 1 exceeds 250 mm, it becomes difficult to form a clear uneven shape on the surface, and when it is less than 50 mm, the thickness of the resulting cushion material is thin, and the sleeping comfort tends to be impaired.

Moreover, what is necessary is just to set the thickness of each layer suitably so that the thickness of the laminated body 1 may exist in the range of 30-300 mm.
For example, the thickness of the center layer 11 to be profiled determines the possible range of the height h of the convex portion A having the surface irregularity when the cushion material 10 is used, and is preferably 15 to 100 mm. When the thickness of the center layer 11 is less than 15 mm, the height h of the convex portion when used as a cushion material is low, and it becomes difficult to obtain air permeability. Moreover, when the thickness of the center layer 11 exceeds 100 mm, the ratio of the height d of the recesses increases. If the ratio of the height of the recesses is too large, depending on the flexible polyurethane foam constituting the center layer 11 to be profile-processed, there is a risk that it will be easily stuffy.
Therefore, it is preferable that the thickness of the center layer 11 to be profiled is set within the above range so that the height d of the recess is 5 to 20 mm, and the compressive force of the roll during profile processing is adjusted.

  Moreover, it is preferable that each thickness of the base layers 13 and 13 of the laminated body 1 is 5 mm or more. If it is less than 5 mm, it is difficult to eliminate the feeling of bottom likeness even if the above-described highly elastic flexible polyurethane foam or a soft polyurethane foam having a relatively high hardness is used. On the other hand, if it is too thick, profile processing becomes difficult, the weight increases, and handling as a cushioning material may be difficult, so 5 to 60 mm is more preferable.

  As other embodiment of this invention, as shown to Fig.3 (a), the laminated body 2 which laminated | stacked seven layers of the flexible polyurethane foam from which a physical property differs can be used. By processing only the central layer 21 located at the center of the laminate 2, two cushion materials 20 having a four-layer structure shown in FIG. 3B are formed at the same time.

  As the center layer 21 to be profile-processed of the laminate 2, the same flexible polyurethane foam as that of the center layer 11 described above can be used.

Moreover, about the intermediate | middle layers 22, 22, 23, and 23 which are not profile-processed of the laminated body 2, what is necessary is just a flexible polyurethane foam which can be used as bedding, and what is necessary is just to select suitably according to a use environment and a use. For example, a flexible polyurethane foam having a density of 20 kg / m ³ or more and a 25% compression hardness of 100 N or more can be used.

Further, as the intermediate layers 22, 22, 23, and 23, similarly to the above-described intermediate layer 12, it is preferable to use a highly breathable flexible polyurethane foam because a cushion material with less stuffiness can be obtained.
In particular, it is more preferable if the intermediate layers 22 and 22 adjacent to the center layer 21 to be profile processed are highly breathable flexible polyurethane foam. In the case of the cushion material, the steamed air accumulated in the concave and convex portions formed by profile processing is likely to be discharged to the outside of the foam through the intermediate layer 22 that is an adjacent highly breathable flexible polyurethane foam. This is because the feeling of stuffiness can be reduced more effectively.

When the base material 24, 24 of the laminate 2 is the cushion material 20, it becomes a layer that comes into contact with the installation surface. Like the base layers 13, 13, the highly elastic flexible polyurethane foam having a rebound resilience of 50% or more, A flexible polyurethane foam having a relatively high hardness of 25% compression hardness of 100 to 400 N can be used.
Moreover, although not shown in figure, the flexible polyurethane foam which gave ventilation means, such as a vent hole, a groove | channel, or uneven | corrugated shape can also be used.

About the thickness of the laminated body 2, it should just be about 30-300 mm like the laminated body 1 mentioned above, Preferably, it is 50-250 mm, and what is necessary is just to set the thickness of each layer suitably within this range.
At this time, the profile-processed center layer 21 and base layers 24 and 24 are the same as the above-described center layer 11 and base layers 13 and 13.
The other intermediate layers 22, 22, 23, and 23 can be set to arbitrary thicknesses.

  Although the present invention has been described with respect to the case where the five-layer laminate 1 and the seven-layer laminate 2 are used, it may be further multilayered as long as it has a thickness that can be profile processed. In that case, the thickness of the central layer to be profiled and the thickness range of the base layer are as described above.

The cushion material of the present invention is adjusted to an arbitrary hardness depending on physical properties such as density and hardness of the flexible polyurethane foam to be used.
For example, as the laminate 1, the central layer 11 and the base layers 13 and 13 are flexible polyurethane foam having a density of 32 kg / m ³ and 25% compression hardness of 185N, and the intermediate layer 12 is 25% compression hardness having a density of 30 kg / m ^3. Convex height is 210 N, and it is made of a non-foamed foam having an air flow rate of 3.0 dm ³ / s or more, the central layer 11 is 55 mm, the base layers 13 and 13 are 40 mm each, the intermediate layers 12 and 12 are each 10 mm, Only the center layer 11 of the laminated body 1 was profiled so that h was 25 mm to obtain a cushion material 10. The obtained cushion material 10 had a 25% compression hardness of 94N.
As another specific example, the cushion material 10 obtained in the same manner as described above except that the central layer 11 and the base layers 13 and 13 are made of a flexible polyurethane foam having a density of 32 kg / m ³ and a compression hardness of 215N. The 25% compression hardness was 124N.

  In addition, when the cushion material of the present invention is used as a mattress, the profile processing cut surface may have the same uneven shape, but considering the dispersibility of body pressure, for example, the head region, chest / waist region, leg portion It is also possible to divide into regions and vary the hardness by changing the uneven shape in each region. By making the chest / lumbar region with high body pressure relatively hard and the leg region with low body pressure relatively soft, the bedding can be made more comfortable.

  Moreover, you may use the cushion material of this invention for a tri-fold type mattress. For example, the cushion material corresponding to three parts corresponding to the human head, chest / waist and leg portions may be stored in the bag for a tri-fold mattress, respectively, and has an advantage of excellent storage properties. Is.

  The cushion material of the present invention is suitable for bedding such as a mattress.

1 Laminate 11 Central layer (profile processing)
12 Intermediate layer 13 Base layer 10 Cushion material 10 'Cushion material A Convex h Convex height B Concave d Concave height 2 Laminate 21 Central layer (profile processing)
22 Intermediate layer 23 Intermediate layer 24 Base layer 20 Cushion material 100 Cushion material

Claims (2)

In the cushioning material having a concavo-convex shape on the surface, two are formed simultaneously by profiling into a laminate of 5 or more layers made of flexible polyurethane foam,
By profile processing only the central layer of the laminate, the surface irregularity shape of the cushion material is formed only of the central layer,
The center layer has a density of 20 to 70 kg / m ³ and a 25% compression hardness of 100 to 400.
A flexible polyurethane foam of N, or a highly elastic flexible polyurethane foam having at least 50% impact resilience,
The intermediate layer adjacent to the center layer is a highly breathable flexible urethane foam,
At least repelling base layer constituting the front and back surfaces of the laminate is 25% compressive hardness that has been subjected to ventilation means leading to the intermediate layer that has been subjected to ventilation means leading to soft quality polyurethane foam 100～400N, or intermediate layer A cushioning material characterized by being a highly elastic flexible polyurethane foam having an elasticity of 50% or more . The cushioning material according to claim 1, wherein the breathable means applied to the base layer is a through hole.