JP4715980B2 - Medium core material - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a core material applied to mattresses, mattresses, pillows, health bedding, cushions, cushions, and the like, and more particularly, to a lightweight, highly breathable and warm core material.
[0002]
[Prior art]
Conventionally, the core material of the mattress (made of polyurethane foam, etc.) has many vertical holes (holes that reach the back surface from the front surface of the core material), or many grooves on both sides of the core material. It is provided to improve air permeability.
[0003]
However, simply providing a large number of vertical holes in the core material will improve the air permeability because the vertical holes in the core material will be blocked by the floor and the human body when body pressure is applied to the mattress. Is difficult. Further, if only a large number of grooves are provided on both the front and back surfaces of the core material, a part of the grooves is blocked by body pressure, so that the air permeability is not sufficient.
[0004]
[Problems to be solved by the invention]
This invention is made | formed in view of the conventional problem which concerns, The place made into the objective is to provide the core material which is lightweight, and is excellent in air permeability and heat retention.
[0005]
[Means for Solving the Problems]
In the present invention, grooves are provided on the front surface and the back surface of a plate made of flexible polyurethane foam , and the sum of the depths h1 and h2 of both grooves is larger than the thickness H of the plate. In particular, the present invention relates to a core material in which a communication hole communicating with both grooves is formed at a location where the groove on the surface side and the groove on the back surface side intersect each other.
[0006]
The core material having the above structure is light in weight because it has a large number of grooves on both the front and back surfaces of the plate-like material. In addition, since the grooves on the front and back sides of the plate-like object communicate with each other through the communication hole, air permeability and heat retention can be maintained even when body pressure is applied .
[0007]
Further, the core material of the present invention is loaded with a foamed synthetic resin body made non-filmed in the grooves on both the front and back surfaces of the plate-like object communicating with each other through the communication hole.
In the core material with the above structure, the non-film foamed synthetic resin bodies loaded in the grooves on the front and back surfaces of the plate-like object communicate with each other through the communication holes, so that the air permeability and the heat retaining property may be impaired. Absent. Moreover, the settling of the core material can be suppressed by the non-film foamed synthetic resin body loaded in the groove.
[0008]
Here, there are two methods for producing a film-free foamed synthetic resin body: an explosion method and a chemical method. The explosion method is a method in which a cellular material such as polyurethane foam and a flammable gas are enclosed in an explosion-proof structure, and the film is made filmless by igniting and igniting (see Japanese Patent Publication No. 41-752). The chemical method is a method in which a cellular material such as polyurethane foam is immersed in an alkaline solution and hydrolyzed to make a film-free film (see Japanese Patent Publication No. 34-8137).
[0009]
Further, the core material of the present invention is loaded with a foamed synthetic resin body made non-filmed in grooves on both sides of the plate-like object communicating with each other through the communication hole, and made non-filmed foamed synthetic resin. An uneven portion is provided on one side of the plate-like object loaded with the body.
[0010]
The core material with the above structure is a non-foamed foam loaded in the groove of the plate-like material by providing an uneven portion on one side of the plate-like material loaded with the non-foamed foam synthetic resin body. The area of the outer surface of the synthetic resin body is increased, and air permeability and heat retention are further improved.
[0011]
Here, as a method of providing an uneven portion on one surface of a foamed synthetic resin plate-like material, profile processing, that is, compressing the plate-like material passing between them with upper and lower rolls having a predetermined uneven surface. At the same time, a method of dividing the compressed plate-like material into two by a blade provided between both rolls is preferable.
[0012]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings. In this embodiment, an intermediate core material for mattress is taken as an example.
[0013]
First embodiment Fig. 1 is a plan view showing a first embodiment of a core material for mattress, Fig. 2 is an enlarged cross-sectional view taken along the line A-A in Fig. 1, and Fig. 3 is a view in Fig. 1B. -B is an enlarged sectional view. As shown in FIG. 1, the core material 10a for mattresses is formed as a rectangular flat plate 11 having required vertical and horizontal dimensions and thickness by a flexible polyurethane foam. In addition, a large number of U-shaped lateral grooves 13 are provided on the front surface 12 of the flat plate 11 at regular intervals, and a large number of U-shaped vertical grooves 15 are provided on the back surface 14 of the flat plate 11 at regular intervals. It has been.
[0014]
As shown in FIG. 2 and FIG. 3, the horizontal groove 13 on the front surface side and the vertical groove 15 on the back surface side are the sum of the depths h <b> 1 and h <b> 2 of both the grooves 13 and 15, and the thickness H Since it is larger, a communication hole 16 that communicates with the grooves 13 and 15 is formed at a location where the lateral groove 13 on the front surface side and the vertical groove 15 on the back surface side intersect each other.
[0015]
As described above, the core member 10 a is light in weight because it has a large number of lateral grooves 13 on the front surface side of the flat plate 11 and a large number of vertical grooves 15 on the back surface side of the flat plate 11. . Further, since the lateral groove 13 on the front surface side and the vertical groove 15 on the rear surface side communicate with each other through the communication hole 16, even if body pressure is applied, air permeability and heat retention can be maintained.
[0016]
Second embodiment Fig. 4 is a plan view showing a second embodiment of the core material for mattress, Fig. 5 is an enlarged cross-sectional view taken along line A-A in Fig. 4, and Fig. 6 is a view in Fig. 4B. -B is an enlarged sectional view. As shown in FIG. 4, the core material 10b for mattress is formed as a rectangular flat plate 11 having required vertical and horizontal dimensions and thickness by a flexible polyurethane foam. In addition, a large number of U-shaped lateral grooves 13 are provided on the front surface 12 of the flat plate 11 at regular intervals, and a large number of U-shaped vertical grooves 15 are provided on the back surface 14 of the flat plate 11 at regular intervals. It has been.
[0017]
As shown in FIGS. 5 and 6, the horizontal groove 13 on the front surface side and the vertical groove 15 on the back surface side have a sum of depths h <b> 1 and h <b> 2 of both the grooves 13 and 15, and the thickness H of the flat plate 11. Since it is larger, a communication hole 16 that communicates with the grooves 13 and 15 is formed at a location where the lateral groove 13 on the front surface side and the vertical groove 15 on the back surface side intersect each other.
[0018]
Further, a foamed synthetic resin body (hereinafter referred to as “film-free foam”) 17 is loaded in the lateral groove 13 on the front surface side, and a film-free foam 18 is loaded in the vertical groove 15 on the back surface side. These filmless foams 17 and 18 communicate with each other through the communication hole 16.
[0019]
Since the non-core foams 17 and 18 loaded in the grooves 13 and 15 on both the front and back surfaces are communicated with each other through the communication holes 16, the inner core material 10b does not impair air permeability and heat retention. Further, the film-less foams 17 and 18 loaded in the grooves 13 and 15 on both the front and back surfaces can suppress the settling of the core material 10b.
[0020]
Third embodiment Fig. 7 is a plan view showing a third embodiment of the core material for mattress, Fig. 8 is an AA enlarged sectional view of Fig. 7, and Fig. 9 is B of Fig. 7. -B is an enlarged sectional view. As shown in FIG. 7, the mattress core 10c is formed as a rectangular flat plate 11 having required vertical and horizontal dimensions and thickness by a flexible polyurethane foam. In addition, a large number of U-shaped lateral grooves 13 are provided on the front surface 12 of the flat plate 11 at regular intervals, and a large number of U-shaped vertical grooves 15 are provided on the back surface 14 of the flat plate 11 at regular intervals. It has been.
[0021]
As shown in FIGS. 8 and 9, the front surface side lateral groove 13 and the back surface side longitudinal groove 15 have a thickness H of the flat plate 11 that is the sum of the depths h1 and h2 of both the grooves 13 and 15. Since it is larger, a communication hole 16 that communicates with the grooves 13 and 15 is formed at a location where the lateral groove 13 on the front surface side and the vertical groove 15 on the back surface side intersect each other.
[0022]
Further, the film-free foam 17 is loaded in the lateral groove 13 on the front surface side, and the film-free foam 18 is loaded in the vertical groove 15 on the back surface side. These filmless foams 17 and 18 communicate with each other through the communication hole 16.
[0023]
Further, the flat surface 11 of the flat plate 11 has a flat back surface 14 but is provided with an uneven portion 19 by profile processing on the front surface 12. The concavo-convex portion 19 has a shape in which peaks 20 and valleys 21 are alternately repeated to expand two-dimensionally.
[0024]
In addition to the advantages of the intermediate core material 10b described above, the intermediate core material 10c is provided with the uneven portion 19 on the front surface 12 of the flat plate 11 on which the non-film foam 17 is loaded. The area of the outer surface of 17 increases, and air permeability and heat retention are further improved.
[0025]
In the above description, although the core material for mattresses has been described, the present invention is not limited to this, and can be widely applied as a core material for mattresses, pillows, health bedding, cushions, cushions, and the like.
[0026]
Moreover, as long as a horizontal groove and a vertical groove mutually cross | intersect (plan view), you may arrange | position diagonally with respect to the axis line of a flat plate. Further, the cross-sectional shape of the horizontal groove and the vertical groove is not limited to the U shape, and may be, for example, a U shape.
[0027]
Furthermore, the above-mentioned film-less foamed synthetic resin sheet (film-free foam sheet) can be further laminated on the front surface and / or the back surface of the core material of the present invention.
[0028]
【Example】
A comparison of the air permeability [ml / (cm ² · sec)] of the core material for mattresses in FIG. 1 and the conventional core material for mattresses (no-groove free communication holes), results shown in “Table 1”. was gotten.
[0029]
From this “Table 1”, it was found that the core material for mattress of the present invention has higher air permeability than the conventional core material for mattress.
Test method;
A test piece having a diameter of 78 mm (sample thickness: 30 mm) was punched and cut from each sample.
-The test piece extract | collected to the steel pipe of internal diameter 78mm was set, and each air permeability was measured with the Frazier type air permeability tester. The results are shown in Table 1.
[0030]
[Table 1]
| ------------- | ----------- |
| Test No. ｜ Air permeability [ml / (cm ²・ sec)] ｜
| ------------- | ----------- |
| 1 | Conventional Example 1 (* 1) | 72.5 |
| ------------- | ----------- |
| 2 | Invention 1 (* 2) | 202 |
| ------------- | ----------- |
| 3 | Invention 2 (* 3) | 168.8 |
| ------------- | ----------- |
[0031]
* 1) Flat product without groove processing (Those that do not have communication holes and grooves in the test piece.)
* 2) Groove processing (having two communication holes and two grooves in the test piece)
* 3) Groove processing (having one communication hole and one groove in the test piece)
[0032]
【The invention's effect】
As described above, the present invention is light in weight because it has a large number of grooves on both the front and back sides of the plate-like object. Further, since the grooves on the both sides of the plate-like object communicate with each other through the communication hole, it is possible to retain air permeability and heat retention even when body pressure is applied.
[0033]
Further, according to the present invention, since the non-film foamed synthetic resin bodies loaded in the grooves on the front and back surfaces of the plate-like object communicate with each other through the communication holes, the air permeability and the heat retaining property are not impaired. In addition, it is possible to prevent the groove from being loosened by the non-film foamed synthetic resin body loaded in the groove.
[0034]
Furthermore, the present invention provides a film-free foamed synthetic resin loaded in a groove of a plate-like material by providing an uneven portion on one side of the plate-like material loaded with a film-free foamed synthetic resin body. The area of the outer surface of the body has increased, and breathability and heat retention have been improved.
[Brief description of the drawings]
FIG. 1 is a plan view showing a first embodiment of a core material according to the present invention.
2 is an AA enlarged cross-sectional view of FIG.
FIG. 3 is an enlarged cross-sectional view taken along the line BB of FIG.
FIG. 4 is a plan view showing a second embodiment of the core material according to the present invention.
5 is an AA enlarged cross-sectional view of FIG. 4. FIG.
6 is an enlarged cross-sectional view taken along the line BB in FIG.
FIG. 7 is a plan view showing a third embodiment of the core material according to the present invention.
8 is an AA enlarged cross-sectional view of FIG.
9 is an enlarged cross-sectional view taken along the line BB in FIG.
[Explanation of symbols]
11 Plate-like object made of foamed synthetic resin 12 Front surface 13, 15 Groove 14 Back surface 16 Communication hole

Claims (3)

A number of grooves are provided on the front and back surfaces of the plate made of flexible polyurethane foam , respectively, and the sum of the depths h1 and h2 of both of the grooves is made larger than the thickness H of the plate. A core material formed by forming a communication hole communicating with both grooves at a location where the groove on the front surface side and the groove on the back surface side intersect each other.   The core material according to claim 1, wherein a foamed synthetic resin body made non-filmed is loaded into the grooves on the front and back surfaces of the plate-like object communicating with each other through the communication hole.   The plate-like product communicated with each other through the communication holes is loaded with a foamed synthetic resin body made non-filmed in the grooves on both the front and back surfaces of the plate-like product, and the plate-like product loaded with the non-film-formed foam synthetic resin body is loaded. The core material according to claim 2, wherein an uneven portion is provided on one side.

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