JP6228463B2 - mattress - Google Patents

Description

  The present invention relates to a mattress formed by laminating elastic foams.

  Some mattresses are formed by laminating elastic urethane foam. Such a mattress uses urethane foam having different physical properties for each layer, thereby improving body pressure dispersibility, ease of turning over, eliminating the feeling of bottoming, and the like. Here, the closed-cell structure urethane foam in which fine bubbles are separated from each other by the wall is advantageous in obtaining moderate elasticity and hardness, but has poor air permeability and is difficult to peel off. doing. Therefore, a mattress with a three-layer structure in which a gap for ventilation leading to the side surface is formed between the blocks that function as pillars that support the user's load by configuring the intermediate layer with a plurality of blocks spaced apart from each other. Has been proposed (see Patent Document 1).

JP 2003-144273 A

  As described above, the air permeability is improved to some extent by forming a gap for ventilation in the intermediate layer, but the lump that is arranged in the intermediate layer is made of metal, a solid resin molded product (elastomer) having elasticity, Further, it is pointed out that the air flow is hindered by using a material having poor air permeability such as a bag-like body enclosing a gel.

  That is, the present invention has been proposed in order to suitably solve these problems inherent in the mattresses according to the prior art, and is a mattress that has good air permeability and can reduce heat accumulation. The purpose is to provide.

In order to overcome the above-mentioned problems and achieve the intended object, the mattress of the invention according to claim 1 of the present application is
Consists of a flexible foam and a base layer on the floor side, a support layer provided above the base layer and made of a flexible foam, and an intermediate layer provided between the base layer and the support layer A mattress with a layer,
The intermediate layer is composed of a foam, and
A plurality of space portions formed to be spaced apart from each other in the horizontal direction;
A communication path that connects the space portions adjacent to each other in the horizontal direction;
It is a summary to provide.
The invention according to claim 2 further includes a connecting portion formed adjacent to each other across the communication path,
The gist is that the connecting portion extends between a lower layer and an upper layer.
In the invention according to claim 3, the base layer is made of an elastic foam and is a floor side, the support layer is provided on the upper side of the base layer and is made of an elastic foam, and the base layer and In a mattress provided with an intermediate layer provided between support layers,
The intermediate layer is made of a foam having an open-cell structure that has been subjected to film removal, and extends from a layer positioned below the intermediate layer to a layer positioned above and is dispersed in the horizontal direction. The gist is to have a plurality of connecting portions to be arranged, and to provide a space portion between the plurality of connecting portions.
According to the invention which concerns on Claim 3 , it can be made to ventilate with the foam itself laminated | stacked between the base layer and the support layer by comprising an intermediate | middle layer with the foam of the open cell structure by which the film removal process was carried out. . Moreover, since the space part which does not have a foam is formed between the some connection parts disperse | distributed and arrange | positioned in the intermediate | middle layer, the fluidity | liquidity of the air in an intermediate | middle layer can be improved. As a result, heat, moisture and the like can be made difficult to stay inside the mattress, and a comfortable feeling of use can be obtained.

The gist of the invention according to claim 4 is that the base layer includes a concave portion that is formed in conformity with the space portion penetrating vertically between the connecting portions and opens into the space portion.
According to the invention which concerns on Claim 4 , by providing the recessed part opened to the space part of an intermediate | middle layer in a base layer, a space part becomes wide with a recessed part and the fluidity | liquidity of the air in an intermediate | middle layer can be improved more.

In the invention according to claim 5 , the base layer is set to be harder than the support layer,
The support layer is characterized in that the resilience is set larger than that of the base layer.
According to the invention which concerns on Claim 5 , while producing favorable body pressure dispersibility, generation | occurrence | production of a feeling of bottom can be prevented.

The gist of the invention according to claim 6 is that the intermediate layer is formed such that adjacent connecting portions are connected at least on the lower layer side.
According to the invention which concerns on Claim 6 , it can prevent that an intermediate | middle layer becomes too flexible.

  According to the mattress according to the present invention, the air permeability can be improved and the heat accumulation can be reduced by the intermediate layer having excellent air fluidity.

1 is a schematic perspective view showing a mattress according to a preferred embodiment of the present invention. It is a schematic perspective view shown in the state which decomposed | disassembled each layer of the mattress of an Example. It is the sectional view on the AA line of FIG. It is the BB sectional view taken on the line of FIG. BRIEF DESCRIPTION OF THE DRAWINGS It is explanatory drawing which shows an example of the manufacturing method of the mattress of an Example, (a) profile-processed the laminated body which laminated | stacked the foam for intermediate | middle layers which forms an intermediate | middle layer, and the foam for base layers which form a base layer. (B) shows the cut position when forming the intermediate layer by cutting the divided laminate obtained by profile processing, and (c) shows the support layer bonded to the intermediate layer. Indicates the situation.

  Next, a preferred embodiment of the mattress according to the present invention will be described below with reference to the accompanying drawings.

  As shown in FIGS. 1 and 2, the mattress 10 according to the embodiment is made of an elastic foam, and is provided with a base layer 12 on the floor side and an upper side of the base layer 12, and is elastic. And a support layer 14 made of a foam. The mattress 10 includes an intermediate layer 16 that is provided between the base layer 12 and the support layer 14 and is formed of a foam having an open cell structure that has been subjected to film removal (see FIGS. 3 and 4). The mattress 10 of the embodiment is a plate-like body formed in a rectangular shape in a plan view, and is a laminate in which the base layer 12, the intermediate layer 16, and the support layer 14 are stacked in the thickness direction of the mattress 10 in this order from the bottom (floor side). It has a structure. The mattress 10 is configured to be elastically deformable in the thickness direction, which is the stacking direction of the base layer 12, the intermediate layer 16, and the support layer 14, and has flexibility that can be bent to some extent. In the mattress 10, 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 10 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 the like of the mattress 10, or as it is. . The characteristic values of the layers 12, 14, and 16 described below are values according to a test method based on JIS K 6400-2 and rebound resilience based on a test method based on JIS K 6400-3 unless otherwise specified. The density is a value according to a test method based on JIS K7222.

The base layer 12 is made of a foamed material such as a flexible urethane foam or a polyolefin-based foam, and a flexible urethane foam is preferable among the foamed materials. As the foam constituting the base layer 12, a closed cell structure in which fine bubbles are separated from each other by a film, or a continuous cell structure in which adjacent bubbles are connected as a space by having a through-hole in the bubble film is used. Can be used. Like the base layer 12 of the embodiment, the base layer 12 is preferably composed of a foam having an open cell structure. By using the foam having an open cell structure for the base layer 12, the amount of compression during use can be increased. The base layer 12 of the embodiment is a rectangular plate-like body having a flat bottom surface facing the floor side, and mainly plays a role of supporting the load on the mattress 10 so that the user does not bottom out. ing. The base layer 12 uses a foam whose hardness is classified as “hard” in a display style based on the household goods quality labeling method. In the embodiment, a foam having a hardness in the range of 215N to 275N is used. ing. Moreover, it is preferable that the base layer 12 sets the resilience of the foam to be smaller than 35%. Incidentally, the base layer 12 of the embodiment uses a foam density in the range of ^{23kg / m 3 ~27kg / m 3} . And it is preferable to set the thickness of the base layer 12 in the range of 25 mm-45 mm, and the base layer 12 of an Example has set thickness to 35 mm.

The support layer 14 is made of a foamed material such as a flexible urethane foam or a polyolefin-based foam, and a flexible urethane foam is preferable among the foamed materials. In addition, as a foam which comprises the support layer 14, the thing of a closed cell structure or an open cell structure can be used like the base layer 12, and it is a foam of an open cell structure like the support layer 14 of an Example. It should be configured. The support layer 14 of the embodiment is a rectangular plate-like body having a flat lower surface facing the intermediate layer 16 side. The support layer 14 softens the contact with the user and distributes the load applied to the mattress 10. Is responsible for. The support layer 14 can be used in any of the categories “hard”, “normal”, and “soft” in the display style based on the household goods quality labeling method. A foam having a hardness in the range of 60N is used. Here, the mattress 10 desirably sets the base layer 12 to be harder than the support layer 14. The support layer 14 preferably has a foam rebound resilience of 35% or more, and the mattress 10 desirably has a support layer 14 rebound resilience higher than the base layer 12 rebound resilience. Further, the support layer 14 of the embodiment uses a foam density in the range of ^{34kg / m 3 ~43kg / m 3} . And it is preferable to set the thickness of the support layer 14 in the range of 20 mm-50 mm, and the support layer 14 of an Example has set thickness to 40 mm.

  As shown in FIGS. 1 and 2, the support layer 14 has a plurality of irregularities on the upper side on which the user rests. The uneven shape of the support layer 14 is formed such that the convex portions 14a and the concave portions 14b are arranged in a regular or irregular pattern. In the support layer 14 of the example, the irregular pattern with a regular pattern is formed by profile processing. As for the uneven shape of the support layer 14 of the embodiment, the convex portions 14a are arranged at regular intervals in the horizontal and vertical directions, and the concave portions 14b are provided between the four convex portions 14a adjacent in the vertical and horizontal directions, and are arranged in the horizontal direction. The row of the convex portions 14a and the convex portions 14a of the rows adjacent in the vertical direction with respect to this row are shifted from each other. The convex portion 14a is formed so as to be tapered toward the protruding end (upper side). Further, the concave portion 14b is formed so as to become narrower toward the closed end (bottom) side, and the concave portion 14b of the embodiment is opened in substantially the same shape as the outer shape of the convex portion 14a.

The intermediate layer 16 is made of a foamed material such as a flexible urethane foam or a polyolefin-based foam, and a flexible urethane foam is preferable among the foamed materials. Here, as the foam constituting the intermediate layer 16, an open cell structure in which the film separating the bubbles is removed and only the resin skeleton is left is used. That is, the intermediate layer 16 is made of a foam having higher air permeability than the base layer 12 and the support layer 14, and air can flow in the vertical direction and the horizontal direction through the foam forming the intermediate layer 16. ing. Intermediate layer 16 of the embodiment uses a foam density in the range of ^{27kg / m 3 ~33kg / m 3} . The foam forming the intermediate layer 16 is not particularly limited as long as it does not hinder the properties such as elasticity and the like that the base layer 12 and the support layer 14 develop. In the embodiment, the foam is more than the base layer 12 and the support layer 14. A foam having low density and softness and low rebound resilience is used for the intermediate layer 16. And it is preferable to set the thickness of the intermediate | middle layer 16 in the range of 10 mm-30 mm, and the intermediate | middle layer 16 of an Example has set thickness to 15 mm.

  As shown in FIGS. 2 and 3, the intermediate layer 16 is made of the foam having the open cell structure, and extends from the base layer 12 positioned below the intermediate layer 16 to the support layer 14 positioned above. And a plurality of connecting portions 18 that are distributed in the horizontal direction. Further, the intermediate layer 16 is provided with a space 20 between the plurality of connecting portions 18. The intermediate layer 16 may be formed so that the plurality of connecting portions 18 are independent from each other, but is preferably formed so that the adjacent connecting portions 18 are connected at least on the lower base layer 12 side. In the intermediate layer 16 of the embodiment, the connecting portion 18 is formed in a substantially truncated quadrangular pyramid shape with a wide sectional area on the lower side, and the lower portions of the adjacent connecting portions 18 are connected to each other, while the adjacent connecting portions 18 The upper parts are separated from each other (see FIG. 2). And between the connection parts 18, the space part 20 penetrated to an up-down direction is provided, and the adjacent space part 20 is connected to the horizontal direction via the connection part upper part which the lower parts of the adjacent connection part 18 connected. (See FIG. 4). That is, in the mattress 10 of the embodiment, not only the space portion 20 penetrates vertically in the intermediate layer 16 between the connecting portions 18, but also the space portion 20 communicates in the horizontal direction through the communication path 22 in the intermediate layer 16. The air circulation space is connected so as to open to the side surface of the mattress 10.

  As shown in FIG. 2, the intermediate layer 16 is formed so that the connecting portions 18 and the space portions 20 are arranged in a regular pattern (almost lattice shape in the embodiment). In the embodiment, the uneven shape formed by the connecting portion 18 and the space portion 20 in the intermediate layer 16 is formed by profile processing as will be described later. The concave-convex shape of the intermediate layer 16 of the embodiment is such that the connecting portions 18 are arranged at regular intervals in the horizontal and vertical directions, and a space portion 20 penetrating vertically is provided between the four connecting portions 18 adjacent in the vertical and horizontal directions. The row of connecting portions 18 arranged in the horizontal direction and the connecting portions 18 in rows adjacent to the row in the vertical direction are arranged so as to be shifted. In the mattress 10 of the embodiment, the connecting portion 18 of the intermediate layer 16 is disposed below the convex portion 14a of the support layer 14, and the connecting portion between the convex portion 14a of the support layer 14 and the intermediate layer 16 is thus related. 18 is preferable because the load received on the support layer 14 can be appropriately dispersed in the base layer 12 via the intermediate layer 16.

  As shown in FIGS. 3 and 4, the base layer 12 includes a concave portion 24 that is formed in accordance with the space portion 20 that penetrates vertically between the connecting portions 18 and opens into the space portion 20. The concave portion 24 is formed so as to become narrower toward the closed end (bottom) side, and the wall defining the concave portion 24 is formed so as to be continuously connected from the peripheral surface of the connecting portion 18. . In the embodiment, when forming an uneven shape formed by the connecting portion 18 and the space portion 20 in the intermediate layer 16, profile processing is performed on a laminate in which the foam forming the intermediate layer 16 and the foam forming the base layer 12 are stacked. Thus, the concave portion 24 of the base layer 12 is formed in conjunction with the formation of the connecting portion 18 and the space portion 20 of the intermediate layer 16.

  Note that the roles of the base layer 12, the support layer 14, and the intermediate layer 16 described above are main, and the mattress 10 is aimed as a whole when the characteristics of the base layer 12, the support layer 14, and the intermediate layer 16 are combined. It sets so that various characteristics, such as body pressure dispersibility to express.

  Next, an example of a method for manufacturing the mattress 10 according to the embodiment will be described with reference to FIG. A plate-like laminate 30 is prepared by bonding the base layer foam 32 with an adhesive or the like on both surfaces of the intermediate layer foam 34. The laminate 30 is passed between the pair of opposed rolls 36, 36, and the laminate 30 is laminated by the cutter 38 in a state where the laminate 30 is deformed so as to be waved by the projections 36a projecting on the outer peripheral surfaces of the rolls 36, 36. By performing profile processing for cutting the intermediate portion of the object 30 by a plane, two divided laminates 40 having an uneven shape on the cut surface can be obtained (see FIG. 5A). In the split laminate 40, the tip end portion of the protruding portion 40a is constituted by one base layer foam 32, and the recessed portion 40b passes through the intermediate layer foam 34 and reaches the other base layer foam 32. (See FIG. 5B). The protruding portion 40a of the divided laminate 40 is cut by a plane from the base layer foam 32 at the base side of the protruding portion 40a. As a result, the connecting portion 18 having a flat upper surface is formed from the protruding portion 40a whose upper portion is cut, and the intermediate layer 16 in which the space portion 20 is provided between the connecting portions 18 by the recessed portion 40b is obtained. In addition, the base layer 12 in which the concave portion 24 communicating from the bottom portion of the concave portion 40 b to the space portion 20 is formed is obtained in a state of being bonded to the intermediate layer 16.

  In addition, a plate-like support layer foam (not shown) is passed through a laminate between opposed rolls, and the support layer foam is deformed so as to be undulated by a protrusion protruding from the outer peripheral surface of the roll. In this state, by performing profile processing that cuts the intermediate portion of the foam for the support layer with a cutter with a flat surface, two support layers 14 having an uneven shape on the cut surface can be obtained. And the mattress 10 which concerns on an Example is obtained by joining the flat lower surface of the support layer 14, and the upper surface of the flat connection part 18 in the intermediate | middle layer 16 with an adhesive agent etc. (refer FIG.5 (c)). ). Here, by forming the split laminate 40 and the support layer 14 using the same roll 36, the profile from the peripheral surface of the coupling portion 18 to the concave portion 24 of the base layer 12 in the intermediate layer 16 and the convex portion of the support layer 14. The profile from the lower part of 14a to the recessed part 40a can be made substantially the same. Moreover, the uneven | corrugated shape of the support layer 14 and the pattern of the connection part 18 in the intermediate | middle layer 16, and the space part 20 penetrated to an up-down direction can also be made substantially the same.

(Effects of Example)
Next, the operation of the mattress 10 according to the embodiment will be described. Since the mattress 10 is formed of a foam having an open cell structure in which the intermediate layer 16 is subjected to film removal treatment, the mattress 10 can be ventilated also in the connecting portion 18 that connects the base layer 12 and the support layer 14. Moreover, since the space part which does not have a foam is formed in the intermediate | middle layer 16 by the some space part 20 disperse | distributed and provided between the connection parts 18, the fluidity | liquidity of the air in the intermediate | middle layer 16 is formed. Can be increased. Thereby, heat, moisture, etc. can be made hard to stay inside the mattress 10, and a comfortable feeling of use can be obtained. Moreover, by providing the base layer 12 with the recess 24 that opens in the space 20 provided in the intermediate layer, the space formed by the space 20 is widened by the recess, and the air fluidity in the intermediate layer 16 is further improved. be able to. The intermediate layer 16 communicates in the horizontal direction with the space portion 20 via the communication path 22 and is connected to the air circulation space so as to open to the side surface of the mattress 10. The fluidity of air can be further improved. Thus, according to the mattress 10 of the embodiment, the air permeability can be improved by the intermediate layer 16 having excellent air fluidity.

  In the mattress 10, the base layer 12 is set to be harder than the support layer 14, and the rebound resilience of the support layer 14 is set to be larger than that of the base layer 12, so that good body pressure dispersibility can be obtained and a bottoming feeling can be obtained. Occurrence can be prevented. Since the intermediate layer 16 is formed so that adjacent connecting portions 16 are connected at least to the lower base layer 12 side, the intermediate layer 16 may be provided even if the communication path 22 connecting the space portions 20 between the connecting portions 18 is provided. Can be prevented from becoming too flexible.

(Example of change)
The present invention is not limited to the configuration described above, and can be modified as follows, for example.
(1) In the embodiment, a mattress having a three-layer structure including a base layer, an intermediate layer, and a support layer has been described. However, another functional layer is provided between the base layer and the intermediate layer or between the support layer and the intermediate layer. It may be a multilayer structure of four or more layers provided.
(2) For example, in the mattress, the layer structure may be changed for each part of the mattress, such as softening the part corresponding to the user's waist while setting the part corresponding to the user's head to be hard. Note that changing the layer structure includes not only changing the number of layers but also changing the hardness, rebound resilience, shape, and the like of each layer. That is, the characteristics of each layer are appropriately changed depending on the application.
(3) The mattress according to the present invention can be used as a rug not only for sleeping, but also for medical purposes such as sitting and surgery.
(4) The base layer and / or the support layer may be provided with holes penetrating vertically so as to further improve the ventilation toward the intermediate layer.
(5) The shape of the connecting portion in the intermediate layer may be a truncated cone shape such as a substantially truncated cone shape or a substantially truncated triangular pyramid shape, or a columnar shape. In addition, when forming the connection part of an intermediate | middle layer by the profile process demonstrated in the Example, a connection part can be made into a substantially truncated cone shape by cut | disconnecting a protrusion part at the front end side.
(6) The mattress manufacturing method according to the present invention is not limited to the method of the embodiment described above. For example, the connecting portion and the space portion may be formed by punching the intermediate layer foam.

  12 base layers, 14 support layers, 16 intermediate layers, 18 connecting portions, 20 spaces, 24 recesses

Claims (3)

Consists of a flexible foam and a base layer on the floor side, a support layer provided above the base layer and made of a flexible foam, and an intermediate layer provided between the base layer and the support layer A mattress with a layer,
The intermediate layer is made of a foam having an open-cell structure that has been subjected to film removal, and extends from a layer positioned below the intermediate layer to a layer positioned above and is dispersed in the horizontal direction. A plurality of connecting portions disposed, and a space portion is provided between the plurality of connecting portions ;
The mattress according to claim 1, wherein the base layer includes a concave portion that is formed in accordance with the space portion penetrating vertically between the connecting portions and opens into the space portion . The base layer is set to be harder than the support layer,
The support layer mattress of claim 1, wherein the rebound resilience is greater than the base layer. The intermediate layer, the mattress according to claim 1 or 2, wherein connecting portion adjacent is formed so as to be connected with at least the lower layer side.

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