JP6682264B2 - mattress - Google Patents

Description

  The present invention relates to a mattress in which both widthwise end portions of the mattress are harder than a central portion sandwiched between the both end portions.

BACKGROUND ART Conventionally, as a mattress used for a bed, there is a mattress in which members at both ends in the width direction of a mattress and a member at a central portion sandwiched between the members at both ends are separately manufactured and bonded. The members on both ends of the mattress in the width direction are greatly elastically deformed when the user or caregiver of the mattress sits on or leans against both ends of the mattress in the width direction, which makes the posture unstable and comfortable. It is made of a material that is harder than the member in the central part in order to prevent the deterioration of the posture and the difficulty in carrying out nursing work due to a collapsed posture.
In the case of hospitals and nursing beds, the central member is made of a material with high body pressure dispersal to prevent pressure ulcers, but the members at the widthwise ends should not fall from the bed after being rolled over. It is preferable that the member is harder than the central member.

  However, the mattress in which the members at both ends in the width direction of the mattress and the member at the central portion are separately manufactured and adhered to each other, the members at the both ends in the width direction and the member at the central portion are bonded by adhesion, and thus the bonding strength is not sufficient. It is hard to say that if a large force is repeatedly applied to both ends of the mattress in the width direction due to nursing care or the like, the members at both ends may be separated from the member at the center. Also, when raising the upper body side of the bed, a large bending force is applied to the mattress, but since the hardness of the adhered members at both ends in the width direction and the member at the center are different, Is easily separated from the central member.

JP, 2014-212848, A

  The present invention has been made in view of the above points, and an object of the present invention is to provide a mattress in which both widthwise end portions of the mattress are harder than the central portion and both widthwise end portions are difficult to separate from the central portion.

The invention according to claim 1 is a mattress comprising end portions located at both ends of the mattress in the width direction and a central portion located between the end portions, wherein the end portion is harder than the central portion, parts and the central portion is Ri coupled sequentially with urethane foam, the said end portion characterized in that the hardness increased core material is embedded.

According to a second aspect of the present invention, in the first aspect , a plurality of protrusions are formed on the upper surface of the mattress.

According to a third aspect of the present invention, in the second aspect , the protrusion is formed on the upper surface of the central portion and is not formed on the upper surface of the end portion.

According to a fourth aspect of the present invention, in any one of the first to third aspects, the mattress is composed of a plurality of mattress divided bodies in a length direction, and the mattress divided body is a molded product. .

According to the first aspect of the present invention, since the end portions at both ends in the width direction that are harder than the central portion are continuously connected to the central portion by the urethane foam, the end portions are difficult to separate from the central portion.
According to the invention of claim 1, by selecting the hardness-increasing core material to be embedded in the end portions at both ends in the width direction, the end portions at both ends in the width direction can be made to have the required hardness.

According to the second aspect of the present invention, since the plurality of protrusions are formed on the upper surface of the mattress, the body pressure dispersibility is enhanced and the feeling of use is improved.

According to the third aspect of the present invention, when the mattress of the bed is seated or leaned against the widthwise end of the mattress, there is no protrusion on the upper surface of the hard end, so that the hard protrusion hits during care work or the like. No discomfort.

According to the invention of claim 4 , when raising a part of the mattress, the force for bending the mattress is relaxed by the portion between the mattress divided bodies, and the bending force applied to each mattress divided body is reduced, and the width direction is reduced. The ends of both ends can be made difficult to separate from the central part.

It is a perspective view of the mattress of 1st Embodiment. It is a mattress division body and AA sectional view of a 1st embodiment. It is a perspective view and BB sectional view of a mattress of a 2nd embodiment. It is a perspective view and CC sectional view of a mattress of a 3rd embodiment. It is a perspective view and DD sectional view of a mattress of a 4th embodiment. It is sectional drawing of the shaping | molding die used for manufacture of the mattress division body of 1st Embodiment. It is sectional drawing which shows the time of arrangement | positioning of a masking plate. It is sectional drawing which shows the injection | pouring of the 1st urethane foam raw material. It is sectional drawing which shows the injection | pouring of the 2nd urethane foam raw material. It is sectional drawing of the shaping | molding die and masking plate used for manufacture of the mattress division body of 2nd Embodiment. It is sectional drawing of the shaping | molding die used for the mattress division body of 3rd Embodiment, and the core material for hardness increase. It is sectional drawing of the shaping | molding die used for the mattress division body of 4th Embodiment, and the core material for hardness increase.

  Hereinafter, embodiments of the mattress of the present invention will be described. The mattress of the present invention is suitable for being placed on a bed and used. The mattress 10A of the first embodiment shown in FIG. 1 is composed of mattress divided bodies 11a, 11a, 11a which are divided into three in the length direction. The mattress 10A may be composed of one undivided mattress instead of being composed of a plurality of mattress divided bodies. The mattress 10A is used by being housed in a bag-shaped cover (not shown). Reference symbol L is the length direction, and W is the width direction.

  Depending on the size of the mattress, the mattress divided body 11a may be formed by dividing the mattress into two or four or more in the length direction. The mattress divided body 11a is made of a molded product obtained by injecting a foaming raw material into a molding die (foaming) and foam-molded, and as shown in FIG. 2, ends 12a and 12a located at both ends in the width direction W, and The central portion 13a is sandwiched between the end portions 12a and 12a.

  The end portions 12a, 12a and the central portion 13a are each made of soft urethane foam and are continuously connected. The widths of the ends 12a, 12a are appropriately determined, but as an example, about 50 mm to 200 mm is given.

  A plurality of protrusions 15a are formed on the upper surfaces of the end portions 12a, 12a and the central portion 13a. The protrusions 15a have an appropriate shape, size, and number (or intervals). Examples of the shape of the projection 15a include a quadrangular pyramid shape, a shape in which a cone is placed on the upper end of a pillar (the shape shown in the drawing), and a pillar shape. In addition, as an example of the size of the protrusion 15a, when the shape of the protrusion 15a is such that a square pyramid is placed on a regular square prism, one side of the base of the regular square prism is 10 to 30 mm, and a height is 10 to 15 mm. The case where the height of the pyramid is set to 5 to 10 mm will be described. In addition, 0.5 mm to 15 mm is given as an example of the interval between the protrusions 15a. Due to the projections 15a, the body pressure dispersibility of the mattress 10A becomes good, and the feeling of use becomes good.

The central portion 13a is composed of two layers, an upper layer 131a and a lower layer 132a, and the lower layer 132a is made of a harder material than the upper layer 131a. As an example of the ratio of the thicknesses of the upper layer 131a and the lower layer 132a, the thickness of the upper layer 131a: the thickness of the lower layer 132a = 1: 9 to 9: 1.
The end portions 12a, 12a are continuously formed of the same urethane foam as the lower layer 132a of the central portion 13a, and are harder than the upper layer 131a of the central portion 13a.

An example of the hardness of the upper layer 131a of the central portion 13a is 30N to 200N (JIS K6400-2 6.7D method), and an example of the hardness of the lower layer 132a of the central portion 13a and the end portions 12a and 12a is 100N to 500N ( JIS K6400-2 6.7D method).
Due to the presence of the upper layer 131a, which is softer than the ends 12a, 12a, the central portion 13a is softer than the ends 12a, 12a in hardness.

  The upper layer 131a and the lower layer 132a of the central portion 13a, and the upper layer 131a and the end portions 12a, 12a of the central portion 13a are foamed at respective portions when the mattress divided body 10A is molded as described below. Due to the self-adhesiveness when urethane foams and hardens, it adheres firmly.

  In the mattress divided body 11a having the above structure, the lower layer 132a of the central portion 13a and the end portions 12a, 12a are continuously formed, and the upper layer 131a of the central portion 13a and the end portions 12a, 12a are foamed. Since urethane is strongly adhered by self-adhesiveness when foaming and hardening, as shown in FIG. 1, when the mattress 10A is arranged in the length direction and accommodated in a cover (not shown) and used, the width Even if a large force is applied to the ends 12a, 12a at both ends in the direction, the central part 13a and the ends 12a, 12a can be prevented from being separated from each other.

  The mattress 10B of the second embodiment shown in FIG. 3 is composed of mattress divided bodies 11b, 11b, 11b which are divided into three in the length direction. In each mattress divided body 11b, a protrusion 15b is formed only on the upper surface of the central portion 13b. In this example, the upper surfaces of the end portions 12b, 12b at both ends in the width direction have no protrusion. Other configurations are similar to those of the mattress 10A of the first embodiment, the central portion 13b is composed of two layers of an upper layer 131b and a lower layer 132b, and the lower layer 132b is composed of a harder material than the upper layer 131b. It is formed continuously with the end portions 12b, 12b at both ends in the width direction.

  As in the first embodiment, the mattress 10B of the second embodiment can prevent the central portion 13b and the end portions 12b, 12b from being separated from each other even when a large force is applied to the end portions 12b, 12b at both ends in the width direction. it can. Furthermore, the mattress 10B of the second embodiment has no protrusions on the upper surfaces (surfaces) of the end portions 12b, 12b at both ends in the width direction that are harder than the central portion 13b, so that the mattress 10B can be seated or leaned at the time of care. The hard protrusions do not make you feel uncomfortable.

The mattress 10C of the third embodiment shown in FIG. 4 is composed of mattress divided bodies 11c, 11c, 11c which are divided into three in the length direction.
In each mattress divided body 11c, a core material 17c for increasing hardness is embedded in the end portions 12c, 12c at both ends in the width direction along the length direction L, and is sandwiched between the end portions 12c, 12c at the both ends in the width direction. The portion 13c and the end portions 12c, 12c are continuously formed of the same urethane foam. 100N to 300N (JIS K6400-2 6.7D method) is given as an example of the hardness of the urethane foam forming the central portion 13c and the end portions 12c, 12c. Reference numeral 15c is a protrusion.

  The hardness increasing core material 17c is made of a material harder than the urethane foam forming the central portion 13c and the end portions 12c, 12c, and in the illustrated example, has a square bar shape. The hardness-increasing core material 17c is not particularly limited, and examples thereof include soft foam urethane, hard foam urethane, and polystyrene foam having a high density.

  In the mattress 10C of the third embodiment, the end portions 12c and 12c at both ends in the width direction and the central portions 13c and 13c are continuously formed, so that the central portion 13c is separated from the end portions 12c and 12c. Can be reliably prevented.

  In the mattress 10D of the fourth embodiment shown in FIG. 5, the hardness-increasing core material 17d embedded in the end portions 12d, 12d at both ends in the width direction of the mattress divided body 11d has the end portions 12d, 12d at both ends in the width direction. It is different from the mattress 10C of the third embodiment in that it is exposed on the upper surface, and the other configurations are the same as the mattress 10C of the third embodiment. The reference numeral 13d is a central portion sandwiched between the end portions 12d, 12d at both ends in the width direction, and is continuously formed of the same urethane foam as the end portions 12d, 12d. Reference numeral 15d is a protrusion.

  In the mattress 10D of the fourth embodiment, the end portions 12d and 12d at both ends in the width direction and the central portions 13d and 13d are continuously formed, so that the central portion 13d is separated from the end portions 12d and 12d. The same can be surely prevented as in the third embodiment.

A method of manufacturing the mattress divided bodies 10a to 10d of the first to fourth embodiments will be described.
FIG. 6 shows a molding die (mold) 50A used for manufacturing the mattress divided body 11a of the first embodiment. The molding die 50A includes a lower die 51A and an upper die 57A. The cavity 52A of the lower mold 51A has a shape adapted to the mattress division body to be manufactured, and a plurality of recesses 54A for forming the protrusions 15a of the mattress division body 11a are formed on the cavity bottom surface 53A.

  First, as shown in FIG. 7, in the cavity bottom surface 53A of the lower mold 51A, masking plates 631 and 631 are formed on the portions 531A and 531A that form the upper surfaces of the end portions 12a and 12a at both ends in the width direction of the mattress division body 11a. Place it.

  The masking plates 631 and 631 have flat surfaces 632 and 632 and flat surfaces 632 and 632 that cover portions 531A and 531A that form the upper surfaces of the end portions 12a and 12a of the mattress divided body 11a at the widthwise ends of the cavity bottom surface 53A. It is composed of upright surfaces 633, 633 which are upright from the inner end of the cavity. The widths of the flat surfaces 632 and 632 are equal to the widths of the end portions 12a and 12a at both ends in the width direction of the mattress divided body 11a. The height of the upright surfaces 633, 633 is smaller than the thickness of the central portion 13a of the mattress divided body 11a by a predetermined amount. The masking plates 631 and 631 are made of an appropriate material such as metal or plastic, and a mold release agent is applied to the masking plates 631 and 631 in the same manner as the mold cavity surface.

  Next, as shown in FIG. 8, on the cavity bottom surface 53A of the lower mold 51A exposed between the upright surfaces 633 and 633 of the masking plates 631 and 631, the upper layer 131a of the central portion 13a of the mattress divided body 10a is formed. For this purpose, the first urethane foam raw material P1 is injected and foamed to form the upper layer 131a. The injection amount of the urethane foam raw material P1 is an amount for forming the upper layer 131a of the central portion 13a. Reference numeral N1 is a nozzle of an injection device for injecting the first urethane foam P1.

  Next, after removing the masking plates 631 and 631 from the bottom surface 53A of the cavity of the lower mold 51A, as shown in FIG. 9, the lower layer 132a of the central portion 13a of the mattress split body 10a and the end portions 12a and 12a at both ends in the width direction. In the lower mold 51A, the second urethane foam raw material P2 is used for the upper layer 131a of the central portion 13a formed from the first urethane foam raw material P1 and the flat surfaces 632 of the masking plates 631, 631. It is injected on the cavity bottom surfaces 531A and 531A covered with 632. The second urethane foam raw material P2 forms urethane foam that is harder than the first urethane foam raw material P1. Reference numeral N2 is a nozzle of an injection device for injecting the second urethane foam P2.

Then, the lower mold 51A is covered with the upper mold 57A to foam the second urethane foam P2 in the molding mold 50A, and the lower layer 132a of the central portion 13 of the mattress divided body 11a and the widthwise both ends. The end portions 12a, 12a are continuously formed. Further, due to the self-adhesiveness of the second urethane foam P2 during foaming, the lower layer 132a and the upper layer 131a of the central portion 13a of the mattress divided body 11a, and the central portion 13a and the end portions 12a, 12a at both ends in the width direction are formed. Firmly adheres and integrates.
After the foaming is completed, the molding die 50A is opened and the mattress divided body 11a is demolded.

  FIG. 10 shows a molding die (mold) 50B used for manufacturing the mattress divided body 11b of the second embodiment. The molding die 50B is composed of a lower die 51B and an upper die 57B, and in the cavity bottom surface 53B, portions 531B and 531B forming the upper surfaces of the end portions 12b and 12b at both ends in the width direction of the mattress division body 11b are flat. In addition, the molding die 50A has the same configuration as that of the molding die 50A except that the concave portions 54B for projection are not formed in the portions 531B and 531B forming the upper surfaces of the end portions 12b and 12b. Reference numeral 52B indicates a cavity.

  The method of manufacturing the mattress divided body 11b of the second embodiment using the molding die (mold) 50B is the same as the method of manufacturing the mattress divided body 11a of the first embodiment using the molding die 50A. is there.

  FIG. 11 shows a molding die (mold) 50C used for manufacturing the mattress divided body 11c of the third embodiment. The molding die 50C is composed of a lower die 51C and an upper die 57C, and in the cavity bottom surface 53C, portions 531C and 531C forming the upper surfaces of the end portions 12c and 12c of the mattress divided body 11b in the width direction are flat. In addition, hardness increasing core material support pins 513C are erected at predetermined intervals. The hardness increasing core material support pin 513C is for supporting the hardness increasing core material 17c embedded in the end portions 12c, 12c at both ends in the width direction of the mattress divided body 11c of the third embodiment. Reference numeral 52C is a cavity, and reference numeral 54C is a concave portion for projection.

A method of manufacturing the mattress divided body 11c of the third embodiment using the molding die (mold) 50C will be described.
First, the hardness increasing core materials 17c and 17c are arranged on the hardness increasing core material support pins 513C and 513C. The hardness increasing cores 17c, 17c may have a length in which both ends in the length direction are in close contact with the cavity side surface of the lower mold 51C, and the hardness increasing cores 17c, 17c may be prevented from being displaced due to the close contact.

  Next, urethane foam raw materials for the ends 12c, 12c and the central portion 13c at both ends in the width direction of the mattress divided body 11c of the third embodiment are injected into the cavity 52C of the lower mold 51C, and the molding die 50C is closed. After the foaming is completed, the molding die 50C is opened to release the mattress divided body 11c of the third embodiment.

  FIG. 12 shows a molding die (mold) 50D used for manufacturing the mattress divided body 11d of the fourth embodiment. The molding die 50D includes a lower die 51D and an upper die 57D, and in the cavity bottom surface 53D, portions 531D and 531D that form the upper surfaces of the end portions 12b and 12b of the mattress divided body 11d in the width direction are flat. The molding die 50C has the same structure as that of the molding die 50C except that the hardness increasing core material support pins 513C and 513C of the molding die 50C shown in FIG. 11 are not provided in the portions 531D and 531D. Reference numeral 52D is a cavity, and reference numeral 54D is a concave portion for projection.

A method of manufacturing the mattress divided body 11d of the fourth embodiment using the molding die (mold) 50D will be described.
First, the hardness increasing core materials 17d and 17d are arranged on the portions 531D and 531D forming the upper surfaces of the end portions 12d and 12d of the mattress divided body 11d in the width direction on the cavity bottom surface 53D of the lower mold 51D. The hardness increasing cores 17d and 17d may have a length in which both ends in the length direction are in close contact with the side surfaces of the cavity of the lower mold 51D, and the hardness increasing cores 17d and 17d may not be easily displaced by the contact. .

  Next, into the cavity 52D of the lower mold 51D, urethane foam raw materials for the end portions 12d, 12d and the central portion 13d at both ends in the width direction of the mattress divided body 11d of the fourth embodiment are injected to form the molding die 50D. After closing and foaming, the molding die 50D is opened after the foaming is completed, and the mattress divided body 11d of the fourth embodiment is demolded.

  In the above embodiment, the mattress is divided into a plurality of mattress divided bodies, but the mattress of the present invention may be formed by molding one without dividing the mattress in the length direction. .

  As described above, in the mattress of the present invention, since the central portion and the end portions at both ends in the width direction that are harder than the central portion are continuously connected by the urethane foam, even if a large force is applied to both end portions in the width direction, The ends are difficult to separate from the center.

10A, 10B, 10C, 10D Mattress 11a, 11b, 11c, 11d Mattress division bodies 12a, 12b, 12c, 12d Ends 13a, 13b, 13c, 13d at both ends in the width direction Central portion 15a, 15b, 15c, 15d Protrusion 17c, 17d Hardness increasing core material 50A, 50B, 50C, 50D Mold 51A, 51B, 51C, 51D Lower mold 52A, 52B, 52C, 52D Cavity 53A, 53B, 53C, 53D Cavity bottom 57A, 57B, 57C, 57D Upper mold

Claims (4)

In a mattress composed of end portions located at both ends in the width direction of the mattress and a central portion located between the end portions,
The end portion is harder than the central portion, and the end portion and the central portion are continuously connected by urethane foam,
A mattress, wherein a core material for increasing hardness is embedded in the end portion. The mattress according to claim 1 , wherein a plurality of protrusions are formed on an upper surface of the mattress. The mattress according to claim 2 , wherein the protrusion is formed on an upper surface of the central portion and is not formed on an upper surface of the end portion . The mattress according to any one of claims 1 to 3, wherein the mattress is composed of a plurality of mattress divided bodies in the length direction, and the mattress divided body is a molded product .

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