JPS6145532B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to an improved cushion body,
More specifically, a plurality of convex bodies are formed of a plurality of layers including an upper layer of synthetic resin foam and a lower layer of synthetic resin foam, and are formed by being impregnated with the synthetic resin foam stock solution of the lower layer. The present invention relates to an improved cushion body that is built into the synthetic resin foam of the upper layer, has an acupressure effect, and is substantially free from problems such as deformation and falling of the convex body.

As is well known, typical examples of synthetic resin foams that make up cushion bodies are polyurethane foam and foam rubber, but it is possible to provide consumers with inexpensive cushion bodies that provide even greater cushioning effects and reduce the amount of synthetic resin foam used. In order to provide this, for example, a cushion body has been proposed in which one side of the cushion body is subjected to so-called profile processing to form a wave-shaped unevenness A consisting of peaks 1 and valleys 2 on the entire surface, as shown in Fig. 1. has been done. This cushion body not only provides cushioning properties that are characteristic of the synthetic resin foam material itself, but also provides cushioning effects from the structural aspect. Normally, profiled cushions, especially bedding, are used with the uneven profile side facing down and the smooth side facing up, with the sleeping position on this smooth side. ing. However, with this type of cushion body, it is difficult to apply sufficient finger pressure to the body.

Therefore, it has recently been proposed to use the cushion body as bedding with the uneven profile side facing upward and the smooth side facing downward, as shown in Fig. 2. The acupressure effect is influenced by the distance h between the peaks 1 and troughs 2 of the profiled unevenness, the distance p between the peaks 1 and the adjacent peaks 1', the material of the synthetic resin foam, etc. It is known that the interrelationship between the distance h and the interval p described above has a particularly large influence. In order to produce a sufficient acupressure effect, the distance h between the peak 1 and the valley 2 must be
It is said that the distance p between the peak 1 and the adjacent peak 1' should be approximately twice the distance p. However, if this is done, the base w is short relative to the distance h between the peak 1 and the valley 2, resulting in an unstable structure, and even if the synthetic resin foam has cushioning properties, the third
As shown in the figure, the peaks (projections) are extremely easily deformed, causing inconveniences such as falling down. in this way,
If you want to create a cushion body that has a great acupressure effect, the distance h between peak 1 and valley 2 should be set by changing the distance h between peak 1 and adjacent peak 1'.
It is necessary to make the distance between the shiatsu and the shiatsu about twice the distance p, but if this is done, the convex body will be deformed or fall down during use, making it impossible to obtain any acupressure effect. Defects arise.

This invention has been made to solve the above-mentioned drawbacks, and its purpose is to provide an improved acupressure effect that has a sufficient acupressure effect and substantially eliminates inconveniences such as deformation and collapse of the convex body. The objective is to provide a cushioning body.

The gist of this invention is as follows: (1) A plurality of foams are formed of a plurality of layers including an upper layer of synthetic resin foam and a lower layer of synthetic resin foam, and are formed by protrusion impregnation with the synthetic resin foam stock solution of the lower layer. (2) The improved cushion body according to the preceding item (1), wherein the synthetic resin foam is a polyurethane foam, and (3) The improved cushion body according to item (1) above, wherein the synthetic resin foam of the upper layer is a polyurethane foam without a reticulated film having a three-dimensional structure.

The improved cushion body according to the present invention will be explained in detail with reference to FIGS. 4 and 5.

The cushion body B is made of synthetic resin foam 3 of the upper layer.
The air-impermeable sheet 6 is not only composed of a plurality of layers including a synthetic resin foam 4 as a lower layer, but also has holes 5 formed at a predetermined distance apart from each other for the synthetic resin foam stock solution in the lower layer. A plurality of protrusions 7, which are raised by the foaming pressure and impregnated into the upper layer synthetic resin foam 3, are embedded and fixed in the upper layer synthetic resin foam 3. Although any synthetic resin foam can be used, it is preferable to use polyurethane foam, especially flexible polyurethane foam. Further, it is preferable to use a polyurethane foam without a reticulated film having a three-dimensional structure as the synthetic resin foam 3 of the upper layer. When this is used, the effect of good impregnation with the stock solution of synthetic resin foam such as polyurethane foam, which is foamed and raised from the lower layer, is produced.
It is preferable to use a polyurethane foam without a reticulated film having a three-dimensional structure with a cell number of 8 to 11 cells/25 mm; if the number of cells is too small, impregnation will not be carried out well, while if it is too large, convex structures will occur. is not formed. Furthermore, in order to obtain a convex body that exhibits a good acupressure effect, the upper layer may be composed of a plurality of layers each having a different number of cells.

The improved cushion body of the present invention is characterized in that the convex bodies 7 are built into the synthetic resin foam 3 of the upper layer, unlike the conventional convex bodies which are formed completely individually. This is what is happening. For this reason,
Synthetic resin foam 3 of the upper layer adjacent to the convex body 7
, even if used for a long period of time, the convex body 7 will not substantially deform or fall down. In addition, when the synthetic resin foam stock solution in the lower layer that is foamed and raised is impregnated into contact with the synthetic resin foam 3 in the upper layer, a part of it is not foamed but solidified into a resin, so that the raised bumps are relatively hard. 7 is formed, so that not only a sufficient acupressure effect is achieved, but also deformation and the like are less likely to occur. In particular, if the synthetic resin foams of the upper and lower layers are made of polyurethane foam, and the upper layer is made of a material without a reticulated film having a three-dimensional structure, it will not only prevent deformation and collapse. The convex body 7 that exhibits a very good acupressure effect without any problems can be obtained. Further, when a polyurethane foam without a reticulated film having a three-dimensional structure is used as the upper layer, a cushion body with good air permeability can be obtained.

Furthermore, since the improved cushion body of the present invention does not have the convex body 7 exposed to the outside, its appearance is the same as that of a conventional square cushion body, and the cushion body can be simply put in and taken out from the cover for the cushion body. Not only is it easy to store and replace, but unlike conventional profile-processed products with exposed unevenness, the cover does not come loose and can be stored in a very orderly manner.

Next, a fifth method for manufacturing the cushion body of this invention will be described.
This will be explained with reference to Figures a to g.

(a) First, a mold c having a desired shape as shown in FIG. Prepare.

(b) Next, open the top lid 10 and attach the upper layer of synthetic resin foam 3 that matches the mold dimensions to the locking fitting 1.
Lock at 1. This synthetic resin foam 3 is covered with an air-impermeable sheet 6 having holes 5 formed at a predetermined distance apart, and the ends of this sheet 6 are locked at the rising portion 12 of the mold body 8.
The shape of the hole 5 is preferably square; if it is round, a large base may be formed when the hole 5 is impregnated with the stock solution.

(c) Next, a predetermined amount of the synthetic resin foam stock solution 13 is poured into the mold body 8 and foamed. This stock solution may be of a conventional formulation, but it is preferable to formulate the stock solution so that the point at which foaming is highest is near the air-impermeable sheet 6.

(d) After the stock solution 13 reaches the air-impermeable sheet 6, it passes only through the holes 5 of the sheet 6 due to the foaming pressure.

(e) Due to the foaming pressure, the stock solution 13 that has passed through the holes 5 is high in the areas where the holes 5 are located, and in the areas where there are no holes 5, the stock solution spreads left and right to impregnate and swell low, resulting in a large number of convex bodies 7.
is formed, and a wavy shape is formed overall. The convex body 7 is embedded and solidified in the synthetic resin foam 3 of the upper layer. Note that the stock solution is formulated so that foaming stops before it comes into contact with the upper lid 10. The degree of foaming can be easily controlled by appropriately selecting the foaming temperature, the type of compounding agent, the amount thereof, etc. In addition, when the stock solution 13 impregnates the synthetic resin foam 3 of the upper layer by the foaming ridges and a convex body is formed, the surface solidifies in a resin state, and a hard convex body 7 is formed. It is formed.

(f) After foaming is completed, open the top cover 10 and attach the locking metal fitting 11.
is removed from the upper layer of synthetic resin foam 3.

(g) The improved cushion body B can be taken out from the mold C and then processed according to the purpose.

The method for manufacturing the improved cushion body of the present invention is not limited to the above-mentioned manufacturing method, and various manufacturing methods can be used. , a film can also be used instead of the sheet 6.

EXAMPLES Hereinafter, the present invention will be specifically explained with reference to Examples.

〔Example〕

(a) A mold C including an aluminum mold body 8 measuring 980 mm x 635 mm x 100 mm, a hinge 9, an upper lid 10, and 10 diamond-shaped locking fittings 11 was prepared.

(b) Next, the number of cells is 11 using the locking metal fitting 11.
pcs/25mm 980mm x 635mm x 50mm polyurethane foam 3 without reticulation film is fixed, 15mm x
The polyurethane foam 3 without a reticulation film is covered with a polypropylene sheet 6 having a thickness of 0.05 mm, in which approximately square holes 5 having a diameter of 15 mm are bored at equal intervals of 40 mm in the horizontal and vertical directions, and the ends of the polypropylene sheet 6 are was locked at the rising portion 12 of the mold C.

(c) Next, the following compounded polyol [Propylan 333 (manufactured by Daiichi Kogyo Seiyaku Co., Ltd.) 50 parts by weight #Sn3086 (manufactured by Sumika Bayer Co., Ltd.]) was added to the mold body 8. 50 〃 H ₂ O 4.0 〃 Trichloromonofluoromethane 5.0 Parts by weight Triethylenediamine (manufactured by Houdy Process, Dabco) 0.15 parts by weight N-methylmorpholine 0.5 〃 L-520 (Silicone dispersant manufactured by Union Carbide) 1.5 〃 Dioctyl phthalate (manufactured by Yoshitomi Pharmaceutical)
0.3 〃 Tolylene diisocyanate index
A polyurethane foam stock solution 13 having a TDI Index of 105 was injected and foamed at a mold temperature of 40° C. using a low-pressure foaming method with a discharge rate of 20 kg/min.

(d). (e) The injection amount is set to 1.0 kg so that foaming reaches its maximum at the height of the air-impermeable sheet 6, and the impregnated raised convex body 7 stops 15 mm before the upper lid 10. did.

(f) After foaming is completed, open the top cover 10 and attach the locking metal fitting 11.
was removed from the top layer of polyurethane foam 3.

(g) The obtained cushion body B was taken out from the mold C. The three cushion bodies thus taken out were housed in a continuous cover to produce a pinerest.

For comparison, a pine tress was manufactured using a conventional profile body made of soft polyurethane foam (specific gravity: 0.016) as shown in Figure 2. In the case of this conventional cushion body, the convex body was deformed in 24 hours as shown in FIG. 3, whereas in the case of the improved cushion body of the present invention, the convex body was substantially deformed. It did not deform or fall over. In addition, a hard convex body was formed, and an extremely good acupressure effect was achieved.

[Brief explanation of the drawing]

1 and 2 are schematic front views of conventional cushion bodies, FIG. 3 is a conceptual diagram showing a state in which the peaks of the cushion body in FIG. 2 are deformed, and FIG. 4 is a schematic partial vertical cross-section of the cushion body of the present invention. The top view and FIG. 5 are flow sheets for explaining one method of manufacturing the cushion body of the present invention. 3... Synthetic resin foam for upper layer, 4... Synthetic resin foam for lower layer, 5... Hole, 6... Air impermeable sheet, 7... Convex body, 13... Synthetic resin foam Body fluid, B...Cushion body.

Claims (1)

[Scope of Claims] 1. A plurality of convexities that are composed of a plurality of layers including an upper layer of synthetic resin foam and a lower layer of synthetic resin foam, and are formed by protrusion impregnation with the synthetic resin foam stock solution of the lower layer. An improved cushion body characterized in that the raised body is built into the synthetic resin foam of the upper layer. 2. The improved cushion body according to claim 1, wherein the synthetic resin foam is polyurethane foam. 3. The improved cushion body according to claim 1, wherein the synthetic resin foam of the upper layer is a polyurethane foam without a reticulated membrane having a three-dimensional structure.