JPH08112168A - Mattress core and mattress - Google Patents

Abstract

(57) [Summary] [Purpose] Weight should be classified according to weight so that the person can feel the same when lying on their back regardless of weight. [Structure] The first support 1 and the second support 2, which are molded bodies made of foamed resin of the same material, are made to face each other with the projections 4 facing outward, and the first support 1 and the second support 2 A columnar body 3 made of a foamed resin made of the same material is sandwiched and fixed between them. The columnar body 3 is fixed to the first support body 1 and the second support body 2 by heat fusion. The foaming rate, the number, the cross-sectional area, etc. of the columnar bodies 3 are changed according to the weight.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a core material for a mattress used in beds and the like.

[0002]

2. Description of the Related Art The mattresses that have been conventionally used are made by uniformly spreading natural cotton, synthetic fibers, feathers or a mixture thereof and covering them with a protective covering layer. When you lie on your back, generally the heavy torso is depressed and the chest and legs rise, and the spine is forced to deform, which makes it uncomfortable to sleep, and in some cases, this often causes fatigue and pain. Are known.
This is due to the fact that the fibers of the futon filler are pulled horizontally to support the human body on the hammock.

In order to eliminate this drawback, it has long been known that the human body should be supported by a large number of vertical mechanical forces that are mechanically independent in the horizontal direction, and a spring mat having a large number of upright coil springs arranged in a matrix. Is being developed. However, since the spring mat is complicated to manufacture, it is not suitable for an automated manufacturing process and is expensive, and since it is heavy and inconvenient to transport, it can only be used as a base for a style bed. Further, the spring mat has a drawback that it has a great amount of lateral wobbling and its damping time is long. In addition, since the coil spring is generally formed of a piano wire, it buckles due to metal fatigue, produces a squeaking noise, and cannot be washed.

Therefore, in order to solve this, Japanese Patent Laid-Open No. 61-61
12 and FIG. 1 described in Japanese Patent Publication No. 232808.
The mattress shown in 3 has been proposed. As shown in FIG. 12, the core material housed in this mattress is a synthetic resin foam substrate 101 and a large number of cylindrical or frustoconical moldings arranged in a matrix on its surface. Body 1
It consists of 02. The base 101 and the molded body 102
The core material composed of and is covered with the composite non-woven fabric layer 103, further covered with the silk and cotton layer 104 and the nylon mesh layer 105, and finally covered with the upper layer 106 of cotton cloth to form a mattress.

As shown in FIG. 13, the molded body 102 has a first portion 121 made of a relatively flexible and elastic synthetic resin foam and a second portion 122 made of a relatively hard molded body. Are bonded to each other, and the molded body 102 thus configured is fixed to the base 101 by bonding. Further, the arrangement and distribution density of the molded bodies 102 may be changed according to the weight distribution and body shape.

[0006]

However, the mattresses classified by weight have not been known so far, and when a person with a light weight is hardly deformed on the conventional mattress, the person feels stiff and has a heavy weight. When I lie on my back, it deforms too much and feels soft, and there is the problem that the way of feeling changes depending on the weight.

If the arrangement and distribution density of the molded bodies are changed according to the weight distribution and body shape as in the core material of the conventional mattress, for example, the number of molded bodies in the portion where the weight is applied is increased and the portion where the weight is not applied is increased. Therefore, the number of the molded articles will be reduced. Then, in the portion where the number of the molded bodies is reduced, the spacing between the molded bodies contacting the human body may be too wide, and there is a problem that the sleeping comfort becomes extremely poor.

[0008] Therefore, an object of the present invention is to provide a mattress and a core material thereof, which are classified by weight so that they can be made to feel almost the same when lying down regardless of weight.

[0009]

In order to achieve the above-mentioned object, the core material of the mattress of the first embodiment of the present invention comprises a first support body and a second support body having a large number of protrusions on one surface. A body and a plurality of columnar bodies sandwiched between the first support and the second support, wherein the first support and the second support are the protrusions. In a state where the surface provided with is directed outward, the columnar bodies are fixed so as to face each other with a predetermined gap, and the first support body, the second support body, and the columnar body. The body and the body are made of synthetic resin foam.

Further, in the core material of the mattress of the first embodiment, the expansion ratio of the columnar body is lowered as the allowable load is increased. The number of columnar bodies is increased, and the cross-sectional area of the columnar body may be increased as the allowable load increases.

In the core material of the mattress of the first embodiment, the first support and the columnar body are fixed by heat fusion, and the second support and the columnar body are provided. Is fixed by heat fusion.

Further, in the core material of the mattress of the second embodiment of the present invention, a large number of protrusions are provided on one surface and a large number of fitting convex portions are integrally formed on the other surface of the first support. And a second support body having a large number of projections provided on one surface and a large number of fitting recesses integrally formed on the other surface, and the fitting convex portion of the first support body, By fitting in the fitting recess of the second support, the first support and the second support are fixed to each other, and the fitting projection and the fitting recess are formed. A columnar body is formed by fitting the above, and the first support and the second support are made of synthetic resin foam made of the same material.

In addition, in the core material of the mattress of the second embodiment, the number of the columnar bodies is increased as the allowable load is increased, and the columnar shape is increased as the allowable load is increased. The cross-sectional area of the body is made larger, and further, a ring-shaped engaging projection is provided near the tip of the fitting projection, and the engagement is provided near the end of the fitting recess. An engaging concave portion that engages with the convex portion is provided.

Furthermore, the mattress of the present invention using the core material is arranged on both sides of the core material of the mattress of the first embodiment or the core material of the mattress of the second embodiment. Further, it comprises a synthetic resin thin plate whose flexibility can be adjusted, and an outer cover which integrally covers the core material and the thin plate in a disassembleable manner.

[0015]

According to the present invention, the first support and the second support are fixed to each other by a large number of columnar bodies, and the number of the columnar bodies, the cross-sectional area, etc. are increased or decreased in accordance with the allowable load, that is, the weight. By doing so, it is possible to obtain a mattress core material classified by weight so that the user can feel the same when lying on his / her back regardless of weight. In this case, since the shape of the surface contacting the human body is the same for each body weight, the sleeping comfort does not deteriorate. In the core material of the mattress of the first embodiment, changing the foaming ratio of the column also
It is possible to obtain the core material of the mattress according to the allowable weight (weight).

According to the first embodiment of the present invention, since the first support, the second support and the columnar body are made of the same material, they can be fixed to each other by heat fusion. . Further, according to the second embodiment, the first support and the second support can be fixed to each other only by fitting them. Therefore, according to the present invention, an adhesive is not required, and the volatile component of the adhesive does not pollute the environment of the factory or pollute the environment. Furthermore, since the same material is fixed by heat fusion or fitting, and different materials are not mixed, there will be no residue when incinerated,
Or only a very small amount of residue is generated. Therefore,
The core material of the present invention is very useful for incineration when it is no longer needed or for recovering heat energy by incineration.

[0017]

1 is a perspective view showing the structure of a first embodiment of a core material of a mattress of the present invention, and FIG. 2 is a side view thereof. In this figure, 1 is a synthetic resin first support body having a large number of projections 4 formed on one surface, 2 is a synthetic resin second support body having the same structure as the first support body 1, and 3 is a first support body. The columnar body 4 made of synthetic resin, which is sandwiched between the support body and the second support body 2 and is fixed so that the first support body 1 and the second support body face each other with a predetermined gap therebetween, First support 1 and second support 2
The protrusions 5 formed on the one surface are groove portions formed between the protrusions 4.

As described above, a large number of protrusions 4 are formed on the surfaces of the first support 1 and the second support 2. The protrusions 4 disperse and support the weight of the human body, and the space between the protrusions 4 is increased. The formed groove portion 5 provides good air permeability. The first support 1 and the second support 2 are formed by foaming a polyolefin synthetic resin, for example, polyethylene or polypropylene, and foamed particles made of this polyolefin synthetic resin are put into a mold to foam. When this is done, the projection 4 and the groove portion 5 are simultaneously molded integrally to form the first support 1
Alternatively, the second support 2 is manufactured. In addition, the protrusion 4
Although the cross-sectional shape is rectangular, any shape may be used as long as it is easy to mold. The expansion ratio of the first support 1 and the second support 2 is, for example, 20 times when formed from a crosslinked foam of polyethylene resin. The expansion ratio means the density (g / cm ³ ) of the resin composition before foaming and the density of the foamed product (g / cm ³ ) after foaming.
It is a numerical value obtained by dividing by ³ ).

Further, the columnar body 3 is also formed by foaming the same polyolefin-based synthetic resin as the material of the first support 1 and the second support 2, such as polyethylene or polypropylene. When formed from the body, the expansion ratio is 26 times. The shape of the columnar body 3 is cylindrical as shown in the figure, but the columnar body 3 has a polygonal shape such as a square or hexagonal section, an ellipse, a half moon shape, a crescent shape, or a hollow structure. The columnar body 3 may be formed. As described above, the first support 1, the second support 2, and the columnar body 3 are made of the same material, so that the first support 1 or the second support 2 and the columnar body 3 are fixed to each other. In this case, a fixing method by heat fusion can be used. Therefore, it is not necessary to use an expensive adhesive unlike the case of fixing different kinds of materials, and it is possible to prevent the influence of the volatile solvent of the adhesive.
The core material of the three-layered mattress made of the same material as described above has a height of about 70 to 110 m.
m.

Next, a top view of the core material of the mattress of the three-layer structure of the first embodiment described above is shown in FIG. 3, in which a plurality of ventilation holes 6 are formed dispersed in the groove portion 5. The ventilation hole 6 reaches the gap where the columnar body 3 is located, and the air flowability is further improved in combination with the action of the groove portion 5. The process of heat-sealing the first support 1 and the columnar body 3 or heat-sealing the second support and the columnar body 3 is disclosed in JP-A-63-278.
It can be performed automatically by a special machine described in Japanese Patent No. 822.

The mattress core material classified according to the weight of the three-layer structure will be described below.
The structure or configuration of the columnar body 3 in which the second support body 2 and the second support body 2 are fixed so as to maintain a gap is changed according to the weight. For example, the number of columnar bodies 3 is changed according to the weight. That is, when the weight is heavy, the number is increased, and when the weight is light, the number is decreased. Alternatively, the expansion ratio of the material forming the columnar body 3 is changed according to the weight. That is, when the weight is heavy, the expansion ratio of the material is lowered, and when the weight is light, the expansion ratio of the material is increased. Furthermore, the cross-sectional area of the columnar body 3 is changed according to the weight. That is, for heavy weight, the cross-sectional area is large,
For lighter weight, reduce the cross-sectional area.

FIG. 6 shows the relationship between the foaming ratio of the material and the number of columnar bodies with respect to the body weight. As shown in this figure, the relationship between the expansion ratio and the number of the columnar bodies 3 classified by body weight is defined in a certain range, but in this case, the cross-sectional area and height of the columnar bodies have certain constant values. Has been done. In addition, when separating by weight, the place where the weight is most applied is the torso when the human body is supine, and since this part weighs about 1/2 or more of the total weight, the weight of this torso is supported. The structure and configuration of the above-mentioned columnar body 3 for each weight are determined on the assumption that the above-mentioned structure is performed.

By the way, the structure or configuration of the first support 1 or the second support 2 may be changed according to the weight, but the structure of the first support 1 or the second support 2 which is a human body or When the configuration is changed, the shape and structure hitting the human body is changed, and thus sleeping comfort may be changed. Therefore, it is optimal to change the configuration or structure of the columnar body 3 according to the weight. Further, since the columnar body 3 is manufactured by punching a molded plate, it is possible to easily change the expansion ratio and the shape thereof.

Next, FIG. 4 is a perspective view showing a developed part of the structure of the mattress 10 using the core material of the first embodiment.
A sectional view is shown in FIG. In this figure, the members having the same reference numerals as those in FIG. 1 are the same members, and the description thereof is omitted, but 7 is a large number of projections provided on the first support 1 and the second support 2. Reference numeral 8 denotes a thin plate placed on 4, and reference numeral 8 denotes an outer cover that covers the whole of the core material and the thin plate 7.

The thin plate 7 is made of urethane foam or polyester non-woven fabric, natural cotton fiber or the like, and the jacket 8 is made by sewing cotton cloth or the like. By the way, the sleeping comfort is very different among individuals, and is not so closely related to the body weight. In some cases, the person who prefers a comfortable thing regardless of the weight and the one who prefers a soft thing are preferred. However, basically, "stiffness" that reliably supports the weight is required in the distorted portion of the mattress 10 when lying down. Therefore, as described above, the core material is classified according to body weight, but this may not satisfy the sleeping comfort. Therefore, the thin plate 7 that comes into contact with the human body through the thin outer cover 8 is used.
Optimal sleeping comfort can be obtained by freely changing the thickness, the material, or the flexibility.

Therefore, in the above-described mattress 10 of the present invention, the thin plate 7 is placed on the above-mentioned core material having a three-layer structure and is covered with the outer cover 8. Since it is not glued or sewn, it can be disassembled and the thin plate 7 of your choice is flexible.
Can be freely selected. Therefore, the optimum sleeping comfort described above can be obtained. The outer cover 8 is sewn openably and closably by using a fastener or a magic fastener so that the thin plate 7 and the core material can be put in and out.

The mattress 10 as described above is combined with the bed 30 as a set of three pieces as shown in FIG. In this case, when the three mattresses are covered so as to be in close contact with each other by the bed pad 20 sewn with cotton cloth or the like so that the mattresses 10 are not displaced from each other, the bed pad 20 has a box shape, and thus the three mattresses are box-shaped. Mattress 1
The positions of 0 can be prevented from being displaced from each other. Furthermore, by covering the three mattresses 10 with the bed pad 20 so as to be in close contact with each other, it is possible to prevent the displacement of the mattress 10 not only in the bed 30 but also when the mattress 10 is directly spread on the tatami mat. The mattress 10 of the present invention is not limited to Western beds and can be used in place of a futon.

Incidentally, the mattress 10 is divided into three, but this is for facilitating the manufacture and for easy storage, and the bed 30 can be divided into one without being divided.
The mattress 10 for business use is also good.

Next, the core material of the mattress of the second embodiment of the present invention will be described with reference to FIG. 8. In the second embodiment, not only the adhesive but also the core material without heat fusion is used. It is configured to be able to manufacture. FIG.
A cross section of the first support 41 is shown in FIG.
The protrusion 43 is provided on one surface of the protrusion 1.
Reference numeral 3 corresponds to the protrusion 4 of the first embodiment, and although not shown, a groove portion and a ventilation hole are also provided. Then, on the other surface of the first support body 41, there are integrally formed a plurality of fitting protrusions 42 in the form of cones.

Further, FIG. 2B shows a cross section of the second support 44. A protrusion 46 is provided on one surface of the second support 44. The protrusion 46 is the protrusion of the first embodiment. Although not shown, a groove portion and a ventilation hole are also provided. Then, on the other surface of the second support 44,
A large number of fitting concave portions 45 into which a large number of fitting convex portions 42 formed on the first support body 41 are fitted are integrally formed. In such a structure, in order to make the core material of the mattress, the other surfaces of the first support body 41 and the second support body 44 are made to face each other so that the fitting convex portion 42 fits into the fitting concave portion 45. The first support 41 and the second support are pressed against each other.

As a result, a mattress core having a three-layer structure similar to that of the first embodiment can be obtained as shown in the cross section of FIG. In this case, the columnar body 50 is formed by fitting the fitting convex portion 42 into the fitting concave portion 45. In order to increase the fitting force, the shape of the fitting convex portion 42 is a cone shape such as a cone or a pyramid, and the fitting concave portion 4 is formed.
Reference numeral 5 has a shape adapted to the fitting convex portion 42. As a result, the first support 41 and the second support 44 can be firmly fixed to each other without heat fusion.

Further, a modification of the second embodiment is shown in FIG. In this modified example, a ring-shaped engagement projection 48 is further provided near the tip of the fitting projection 42 of the second embodiment, and a ring-shaped engagement recess 49 is further provided near the end of the fitting recess 45. It is the one. That is, FIG. 10 (a)
As shown in (b), a ring-shaped engagement protrusion 48 is provided in the vicinity of the tip of the fitting protrusion 42 formed on the first support 41. An enlarged view of the vicinity of the engaging convex portion 48 is shown in FIG. 7C. The protrusion length d is a few m which is removed from the molding die because the first support body 41 is integrally molded.
m, for example, about 3 mm. Further, in the vicinity of the end of the fitting recess 45, an engagement recess 49 that engages with the ring-shaped engagement projection 48 is provided as shown in an enlarged view in FIG.

Then, the fitting protrusion 42 formed on the first support 41 is replaced with the fitting recess 45 formed on the second support 44.
, The ring-shaped engagement protrusion 48 provided near the tip of the engagement protrusion 42 engages with the ring-shaped engagement recess 49 provided near the end of the engagement recess 45. Will come together. Thereby, the fitting convex portion 42 and the fitting concave portion 45
Will be fitted more firmly, and the first support 41 and the second support 44 will be more firmly fixed without heat fusion.

The core material of the mattress in the above-described second embodiment and its modification is formed by foaming a polyolefin-based synthetic resin such as polyethylene or polypropylene for both the first support 41 and the second support 44. The expansion ratio is, for example, 26 times (in the case of a crosslinked foam of polyethylene resin). The mattress 10 as shown in FIGS. 4 and 5 can be applied in the same manner as the first embodiment, and when applied, the same effect as the first embodiment can be obtained. It is a thing. When the core material of the mattress in the second embodiment and its modification is classified by weight, the number of columnar bodies 50, the cross-sectional area, the shape, etc. may be changed according to the weight. That is, the number of fitting protrusions 42 and fitting recesses 45, the cross-sectional area, the shape, etc. may be changed according to the weight.

Further, the expansion ratio of the columnar body 50, that is, the expansion ratios of the first support 41 and the second support 44 may be changed according to the body weight, but in this case, the rigidity when lying down Since there is a possibility of different feelings, it is preferable to change the number of the fitting protrusions 42 and the fitting recesses 45 and the cross-sectional area according to the weight.

The core material and the mattress of the mattress of the present invention are constructed as described above, and the mattress can be disassembled and decomposed into the outer cover, the thin plate and the core material independently for each material. As stated above, since one type of material is used and it is fixed by heat fusion or fitting instead of adhesion, when disposing of the mattress, it is possible to easily separate and dispose of the different materials. it can. Further, since the core material of the mattress is made of the same synthetic resin material and different kinds of materials are not mixed, no residue is generated even when incinerated, or an extremely small amount of residue is generated. Therefore, the core material of the present invention is incinerated when it is no longer needed,
It is very useful for incineration to recover heat energy.

Further, since the mattress of the present invention is lightweight, it is easy to carry and can be disassembled, so that it can be easily sterilized and washed by sunlight, etc. Etc. are suitable. It is possible to disinfect and wash mats using springs if the equipment is extremely large-scale, but this is not possible at home, hospitals, facilities, etc. In addition, the mattress of the present invention does not cause sideways shaking or vibration for a long time, and does not produce a squeaking noise even if it is used for a long period of time, and can be used comfortably for a long period of time. In addition,
The material for the foamed synthetic resin of the first support, the second support and the columnar body of the present invention is "Mirablock" (trade name of polyethylene resin crosslinked foam) 26S type manufactured by JSP Co., Ltd. Is preferably used.

[0038]

As described above, according to the present invention, since the first support and the second support are supported by a large number of columnar bodies, it is possible to change the number of columnar bodies, the expansion ratio, and the like. As a result, it is possible to obtain a mattress core material classified by weight so that the user can feel the same when lying on his / her back regardless of weight. In this case, since the shape of the surface contacting the human body is the same for each body weight, the sleeping comfort does not deteriorate.

Further, since the first support, the second support and the columnar body are made of the same material and are fixed to each other by heat fusion or fitting, they may depend on the volatile component of the adhesive. It will not pollute the environment of the factory or pollute the environment, and can be used as a mattress core material that is kind to nature. Furthermore, since the materials are the same, they can be fixed by heat fusion, and since different kinds of materials are not mixed, incineration becomes easy when they are no longer needed.

[Brief description of drawings]

FIG. 1 is a perspective view of a first embodiment of a core material of a mattress of the present invention.

FIG. 2 is a sectional view of the first embodiment of the core material of the mattress of the present invention.

FIG. 3 is a top view of the first embodiment of the core material of the mattress of the present invention.

FIG. 4 is a partially exploded perspective view of the first embodiment of the mattress of the present invention.

FIG. 5 is a cross-sectional view of the first embodiment of the mattress of the present invention.

FIG. 6 is a diagram showing the relationship between the weight of the core material of the mattress in the first example of the present invention-foaming ratio-the number of columnar bodies.

FIG. 7 is a diagram showing a state in which the mattress of the present invention is applied to a bed.

FIG. 8 is a cross-sectional view of a first support body and a second support body in a second embodiment of the core material of the mattress of the present invention.

FIG. 9 is a cross-sectional view of a second embodiment of the core material of the mattress of the present invention.

FIG. 10 is a cross-sectional view of a first support body and a second support body modification of the second embodiment of the core material of the mattress of the present invention.

FIG. 11 is a cross-sectional view of a modified example of the second embodiment of the core material of the mattress of the present invention.

FIG. 12 is a perspective view in which a part of a conventional mattress is developed.

FIG. 13 is a part of a cross-sectional view of a conventional mattress.

[Explanation of symbols]

 1,41 1st support body 2,44 2nd support body 3,50 Columnar body 4,43,46 Protrusion 5 Groove part 6 Vent hole 7 Thin plate 8 Outer jacket 10 Mattress 20 Bed pad 30 Bed 42 Fitting convex part 45 Fitting Recessed portion 48 Engagement protruding portion 49 Engagement recessed portion

 ─────────────────────────────────────────────────── ─── Continued Front Page (72) Inventor Masao Makino 2-1-1 Uchisaiwaicho, Chiyoda-ku, Tokyo Within JSP Corporation (72) Inventor Kazumasa Imai 2-57-10 Narashinodai, Funabashi, Chiba Prefecture Stock company Toyo Package

Claims (11)

[Claims] 1. A first support body and a second support body each having a plurality of protrusions on one surface, and a plurality of support bodies sandwiched between the first support body and the second support body. A columnar body, and the first support body and the second support body have a predetermined gap between the first support body and the second support body with the columnar body in a state in which a surface provided with the protrusion faces outward. A mattress core material, which is fixed so as to face each other, wherein the first support, the second support, and the columnar body are formed of a synthetic resin foam made of the same material. 2. The first support and the columnar body are fixed to each other by heat fusion, and the second support and the columnar body are fixed to each other by heat fusion. The mattress core material according to claim 1. 3. The core material for a mattress according to claim 1, wherein the expansion ratio of the columnar body is decreased as the allowable load is increased. 4. The core material for a mattress according to claim 1, wherein the number of the columnar bodies is increased as the allowable load is increased. 5. The core material for a mattress according to claim 1, wherein the cross-sectional area of the columnar body is increased as the allowable load is increased. 6. A first projection, wherein a large number of protrusions are provided on one surface, and a large number of fitting convex portions are integrally formed on the other surface.
And a second support body having a large number of projections provided on one surface and a large number of fitting recesses integrally formed on the other surface, and the fitting projection of the first support body. The first support body and the second support body to each other by fitting the portion into the fitting recess portion of the second support body, and at the same time, the fitting convex portion and the fit portion. A columnar body is configured by fitting with the fitting recess, and the first support body and the second support body are formed of synthetic resin foam made of the same material. Core material. 7. The number of the columnar bodies is increased as the allowable weight is increased.
Mattress core material described. 8. The core material for a mattress according to claim 6, wherein the cross-sectional area of the columnar body is increased as the allowable load is increased. 9. A ring-shaped engagement protrusion is provided near the tip of the fitting protrusion, and an engagement recess that engages with the engagement protrusion is provided near the end of the fitting recess. The core material for a mattress according to any one of claims 6 to 8, wherein 10. The core material of the mattress according to claim 1, a synthetic resin thin plate disposed on both sides of the core material, the flexibility of which is adjustable, and the core material and the thin plate. A mattress, which comprises an outer cover that covers the body in a disassembleable manner. 11. The core material of the mattress according to claim 6, a synthetic resin thin plate disposed on both sides of the core material, the flexibility of which is adjustable, and the core material and the thin plate. A mattress, which comprises an outer cover that covers the body in a disassembleable manner.