JP6986396B2 - Mattress and mattress manufacturing method - Google Patents

Description

The present invention relates to a mattress using a core material and a method for manufacturing the mattress.

In recent years, as a mattress used for a bed, a mattress having a plurality of functions is known. As a mattress configuration, multiple functions are provided according to the part of the mattress so that the user can use it comfortably on the mattress, or as a nursing care mattress, the user's upper body is raised. At that time, various methods have been proposed in which the mattress is configured to be easily bent.

As a conventional technique, for example, a mattress core material composed of a plurality of urethane foams having different hardness so that the state of use can be changed according to the part of the mattress (see Patent Document 1). As a core (core material) of a mattress, a method has been proposed in which a plurality of foam blocks having different surface shapes are formed so that the usage state can be changed according to the part of the mattress (see Patent Document 2). ).

In addition, as another technique, for example, a mattress that is integrally configured, such as a mattress for long-term care, a bellows-shaped telescopic portion is provided in the middle of the longitudinal direction, and the mattress is used when raising the upper body of the user. Has been proposed so as to be easily bent (see Patent Document 3).

Japanese Unexamined Patent Publication No. 2005-641 Japanese Unexamined Patent Publication No. 2014-50687 Japanese Unexamined Patent Publication No. 11-89672

However, in the above-mentioned conventional mattresses of Patent Documents 1 and 2, it is necessary to form core material constituent members such as urethane foams and foam blocks having different functions, and the core material constituent members are integrated into a core material. In order to construct the core material, a box-shaped frame that surrounds a plurality of core material constituent members and converges integrally is required, which causes a problem that the process of forming the core material and the work of forming the core material become complicated. be.

Further, in the above-mentioned conventional patent document 3, the mattress is integrally configured, but as a function of the mattress, when the mattress is operated, the mattress is easily deformed to improve the function of the mattress. It was not intended to improve the usage condition for the user.

The present invention has been made in view of the above-mentioned conventional problems, and is a mattress and a mattress that can easily configure a plurality of areas having different functions in a mattress and can provide a mattress user with a good usage condition. The purpose is to provide a manufacturing method.

The mattress and the mattress manufacturing method according to the present invention for solving the above-mentioned problems are as follows.

INDUSTRIAL APPLICABILITY In a mattress, which is a mattress and includes a core material having an uneven cross section, a plurality of regions having a specific function according to the surface shape are formed on the surface of the core material along the longitudinal direction of the mattress. It is characterized by doing.

Further, the present invention is a method for manufacturing a mattress, in which a core material that can be compressed and restored of a mattress is sandwiched between a pair of rolls and conveyed while being compressed in the thickness direction, and is brought close to the rolls on the downstream side in the pair of rotation directions. In a mattress manufacturing method in which the core material is divided into two and molded into a predetermined shape by a cutter member provided therein.
A step of forming a plurality of molding regions of uneven portions having different surface shapes along the roll axis direction on the pair of rolls, and a step of sandwiching and transporting the core material between the pair of rolls along the longitudinal direction of the mattress. It is characterized by having a step of simultaneously and integrally molding a plurality of regions having different surface shapes with respect to the core material.

According to the mattress of the present invention, in a mattress provided with a core material having an uneven cross section, a plurality of regions having a specific function according to the surface shape are formed on the surface of the core material along the longitudinal direction of the mattress. As a result, a plurality of areas having different functions can be easily configured, and a good usage condition can be provided to the mattress user.

Further, according to the mattress manufacturing method of the present invention, the core material that can be restored by compression of the mattress is sandwiched between a pair of rolls and conveyed while being compressed in the thickness direction, and is brought close to the rolls on the downstream side in the pair of rotation directions. In a mattress manufacturing method in which the core material is divided into two by a provided cutter member and molded into a predetermined shape, a plurality of molding regions of uneven portions having different surface shapes are formed on the pair of rolls along the roll axis direction. It has a step of sandwiching and transporting the core material between the pair of rolls along the longitudinal direction of the mattress, and a step of simultaneously integrally molding a plurality of regions having different surface shapes with respect to the core material. As a result, a plurality of areas having different functions can be easily configured, and a good usage condition can be provided to the mattress user.

It is explanatory drawing which shows the whole structure of the laminated mattress which concerns on 1st Embodiment. It is a top view which shows the structure of the laminated mattress. It is a side sectional view in the longitudinal direction of a mattress which shows the structure of the core material which constitutes the laminated mattress. It is a side sectional view of the mattress in the lateral direction which shows the structure of the core material which constitutes the laminated mattress. It is explanatory drawing which shows the whole structure of the mattress which concerns on 1st Embodiment. It is explanatory drawing which shows the structure of the 3rd intermediate core material which constitutes the laminated mattress. It is explanatory drawing which shows the surface shape of the head side and the foot side of the 3rd intermediate core material. It is explanatory drawing which shows the surface shape of the bending part of the 3rd intermediate core material. It is explanatory drawing which shows the surface shape of the part of the 3rd intermediate core material corresponding to the waist part of the user of the laminated mattress. It is explanatory drawing which shows the relationship of the surface shape of the 3rd intermediate core material corresponding to the sacrum of the user of the laminated mattress. It is explanatory drawing which shows the state which the side edge member was arranged in the laminated mattress. It is explanatory drawing which shows the structure of the side edge member. (A) is a plan view showing the structure of the side edge member, and (b) is a side view showing the structure of the side edge member. It is explanatory drawing which shows the state which the side edge member is arranged in the laminated mattress 1. It is explanatory drawing which shows the structure of the laminated mattress which concerns on 2nd Embodiment. It is explanatory drawing which shows the processing direction of the core material used for the laminated mattress which concerns on 3rd Embodiment. It is explanatory drawing which shows the outline of the state which the core material is processed.

(First Embodiment)
Hereinafter, embodiments for carrying out the laminated mattress of the present invention will be described in detail with reference to the drawings.
FIG. 1 is an example of an embodiment of the present invention, an explanatory view showing the overall configuration of the laminated mattress according to the first embodiment, FIG. 2 is a plan view showing the configuration of the laminated mattress, and FIG. 3 is the laminated mattress. FIG. 4 is a side sectional view in the longitudinal direction of the mattress showing the configuration of the core material constituting the mattress, and FIG. 4 is a side sectional view in the lateral direction of the mattress showing the configuration of the core material constituting the laminated mattress.

(Mattress composition)
As shown in FIGS. 1 to 4, the laminated mattress 1 according to the first embodiment is a mattress in which the laminated mattress 1 is covered with a side surface 2, and a plurality of core materials are laminated in the vertical direction. There is.
Specifically, the laminated mattress 1 includes a first surface core material 11 constituting one side of the front and back surface layers, a second surface core material 12 constituting the other side, and a first surface core material 11 and a first surface core material 11. It is configured to include an intermediate core material 20 arranged between the surface core material 12 and the surface core material 12.

The intermediate core material 20 includes a first intermediate core material 21 adjacent to the inside of the first surface core material 11, a second intermediate core material 22 adjacent to the inside of the second surface core material 12, and a second. It includes a third intermediate core material 23 arranged between the intermediate core material 21 of 1 and the second intermediate core material 22.

Further, as shown in FIGS. 2 to 4, in the laminated mattress 1, side edge members 3 and 3 are arranged along the longitudinal direction of the mattress on both left and right edges of the mattress, and the head side and the foot side of the mattress are arranged. Stopper members 4 and 4 are arranged on both end edges along the lateral side of the mattress.

(Composition of core material)
Adjacent core materials have different functions.
In the first embodiment,
The first surface core material 11 is called an extra soft surface, and has a lower hardness than the second surface core material 12, and a urethane material having the lowest hardness among the core materials used in the laminated mattress is used. There is.
The second surface core material 12 is referred to as a soft surface, and a urethane material having a low hardness and a high resilience is used next to the first surface core material 11.
A high-resilience urethane material is used for the first intermediate core material 21.
As the second intermediate core material 22, for example, a three-dimensional net-like body is used as the core material having a water resistant function. The second intermediate core material 22 may be a core material having a function of breathability, heat resistance or chemical resistance.
As the third intermediate core material 23, a urethane material having the highest hardness as the other core materials is used.

Here, the characteristic configuration of the third intermediate core material 23 of the first embodiment will be described with reference to the drawings.
FIG. 5 is an explanatory view showing the configuration of a third intermediate core material constituting the laminated mattress according to the first embodiment, and FIG. 6 is an explanatory view showing the surface shapes of the head side and the foot side of the third intermediate core material. FIG. 7 is an explanatory view showing the surface shape of the bent portion of the third intermediate core material, and FIG. 8 shows the surface shape of the portion of the third intermediate core material corresponding to the waist portion of the user of the laminated mattress. The explanatory view and FIG. 9 are explanatory views showing the relationship between the surface shape of the third intermediate core material corresponding to the sacrum of the user of the laminated mattress.

The third intermediate core material 23 has a region having a plurality of functions having a surface shape that disperses a load according to a part of a mattress user and a concavo-convex cross-sectional shape that makes the core material itself easy to bend.

Specifically, as shown in FIG. 5, the third intermediate core material 23 includes a first region 23a corresponding to the head and back of the mattress user, a second region 23b including the lumbar region, and legs. A region having a concavo-convex cross-sectional shape including the third region 23c including the region is formed.

Further, a portion of the second region 23b adjacent to both sides in the longitudinal direction of the mattress, that is, a portion between the first region 23a and the second region 23b, and a second region 23b and a third region 23c. In the portion between them, a fourth region 23d is formed in which the core material is easily bent.

In the first region 23a, as shown in FIGS. 5 and 6, a plurality of rows of uneven portions 23a1 having a continuous wavy surface shape along the short side (width direction) of the mattress are formed in parallel with the longitudinal direction of the mattress. ing. As shown in FIGS. 5 and 6, the third region 23c has a concave-convex portion 23c1 having the same configuration as that of the first region 23a.

As shown in FIGS. 8 and 9, in the second region 23b, the uneven portion 23b1 having a wavy surface shape along the width direction of the mattress according to the shape of the sacrum of the user's hip is formed in the longitudinal direction of the mattress. Multiple rows are formed in parallel.
Reference numeral 23b2 in FIG. 9 is a pattern schematically showing the shape of the user's sacrum.

As shown in FIGS. 5 and 7, the fourth region 23d is formed in a predetermined range with the second region 23b interposed therebetween, and in each region, a straight line continuous along the short side (width direction) of the mattress. A plurality of rows of uneven portions 23d1 having a shape-like surface shape are formed parallel to the longitudinal direction of the mattress.

As described above, in the third intermediate core material 23, the uneven portions 23a1,23b1,23c1,23b1 are formed in the respective surface shapes symmetrically with respect to the length of the mattress with the second region 23b as the center.

In the first embodiment, the height (or depth) of the uneven portion of each region of the third intermediate core material 23 is not specified, but it is changed according to the support function, the cushion function, and the like by the uneven portion. It is possible to set.

Further, in the first embodiment, the second surface core material 12 has a shape similar to the surface shape of the third intermediate core material 23, as shown in FIGS. 3 and 5.
With this configuration, the low hardness and high repulsion urethane material of the second surface core material 12 can support the user in a soft and cushioning state according to each region. Further, since the third intermediate core material 23 can support the user in the central portion of the laminated mattress 1 with the same configuration, the function of the uneven portion of each region can be effectively performed.

(Structure of side edge member)
Next, the side edge member 3 provided on the laminated mattress 1 of the first embodiment will be described.
10 is an explanatory view showing a state in which the side edge member is arranged on the laminated mattress of the first embodiment, FIG. 11 is an explanatory view showing the configuration of the side edge member, and FIG. 12A is a configuration of the side edge member. The plan view shown, (b) is a side view showing the structure of the side edge member, and FIG. 13 is an explanatory view showing a state in which the side edge member is arranged on the laminated mattress 1.

As shown in FIGS. 10 and 11, the side edge member 3 is provided between the first surface core material 11 and the second surface core material 12 at both side ends of the laminated mattress 1 along the mattress longitudinal direction. Has been done.

Specifically, the side edge member 3 uses a core material having a high hardness, and as shown in FIGS. 10 and 11, a plurality of continuous convex portions 31 having a so-called semicircular cross-sectional shape having a substantially semicircular cross-sectional shape. The mattress is arranged integrally and integrally over almost the entire longitudinal direction of the mattress.

As shown in FIGS. 12 (a) and 12 (b), a slit 32 is formed in a part of the convex portion 31 so as to be inward from the surface side and cut along the lateral direction (width direction) of the mattress. ing.

As a configuration of the slit 32, a first slit 32a cut inward from the end in the width direction by a predetermined amount, and a second slit 32 cut in a predetermined range in the vicinity of the center of the convex portion 31 leaving the vicinity of the end. Slit 32b is formed. The first slit 32a and the second slit 32b are formed alternately in the longitudinal direction of the mattress in a so-called staggered shape.

In the side edge member 3 configured in this way, as shown in FIG. 13, the convex portion 31 on which the slit 32 is formed faces each other between the first surface core material 11 and the second surface core material 12. It is arranged in a state of being stacked one above the other so that it is arranged in a vertical manner.

The position of the slit 32 formed in the side edge member 3 is formed at a position shifted to the foot side from the portion where the side edge member 3 is bent and deformed in, for example, in the operation of bending the leg portion of the laminated mattress 1. .. As a result, the foot side of the laminated mattress 1 is easily bent because the slit 32 is deformed by the weight of the mattress itself.

(Structure of stopper member)
The stopper member 4 is arranged at both ends of the laminated mattress 1 in the longitudinal direction of the mattress as shown in FIGS. 2 and 11 by using a core material having a high hardness, and is a second surface as shown in FIG. As shown in FIG. 10, the second intermediate core material 22 is arranged between the core material 12 and the third intermediate core material 23 and between the side edge members 3 and 3. ing.

According to the first embodiment, in the laminated mattress 1, the first surface core material 11 constituting the surface layer on one side and the second surface constituting the surface layer on the other side are configured as described above. Between the core material 12, the first surface core material 11 and the second surface core material, a first intermediate core material 21 adjacent to the inside of the first surface core material 11 and a second surface. A second intermediate core material 22 adjacent to the inside of the core material 12 and a third intermediate core material 23 arranged between the first intermediate core material 21 and the second intermediate core material 22 are provided. By assuming that the adjacent core materials have different functions, when the front and back surfaces of the laminated mattress 1 are used properly, for example, a high hardness function, a low hardness function, a high repulsion function, and water permeability. The functions of each core material, such as the function of the above, the function of heat resistance, and the function of chemical resistance, can be effectively made to function, and different functions on the front and back surfaces can be effectively made to function.

Further, in the first embodiment, by providing the side edge member 3 and the stopper member 4 as the configuration of the laminated mattress 1, the core material constituting the laminated mattress 1 can be integrally and stably configured, and the user. Even when the mattress 1 sits on the edge of the laminated mattress 1, it does not sink significantly, so that it is easy to sit down, and the influence of the posture on the sleeping user can be reduced.

(Second Embodiment)
Next, the second embodiment will be described with reference to the drawings.
FIG. 14 is an explanatory diagram showing the configuration of the laminated mattress according to the second embodiment.
In the laminated mattress according to the second embodiment, the same components as those of the laminated mattress according to the first embodiment are designated by the same reference numerals, and the description thereof will be omitted.

As shown in FIG. 14, the laminated mattress 101 of the second embodiment includes a second surface core material 112 having a flat surface shape in place of the second surface core material 12 of the first embodiment. It is characterized by that.

With this configuration, when the laminated mattress 101 is reversible and the front and back surfaces are used, the function depending on the surface shape can be used without being significantly changed.

(Third Embodiment)
Next, the third embodiment will be described with reference to the drawings.
FIG. 15 is an explanatory diagram showing a direction in which the core material used for the laminated mattress according to the third embodiment is processed, and FIG. 16 is an explanatory diagram showing an outline of a state in which the core material is processed.
In the laminated mattress according to the third embodiment, the same components as those of the laminated mattress according to the first embodiment are designated by the same reference numerals, and the description thereof will be omitted.

A third embodiment relates to a characteristic mattress manufacturing method for processing a core material constituting the laminated mattress 1 of the first embodiment.

For the basic urethane material processing method, detailed description thereof will be omitted by referring to the steps and the like disclosed in Japanese Patent Application Laid-Open No. 2004-290386.

In the third embodiment, as shown in FIGS. 15 and 16, the core material 330 that can be compressed and restored of the mattress is sandwiched between a pair of rolls 310 and conveyed while being compressed in the thickness direction, and is conveyed on the downstream side of the pair of rotation directions. This is a mattress manufacturing method in which the core material is divided into two and molded into a predetermined shape by a cutter member 320 provided close to the rolls 310.

In the third embodiment, a case where the third intermediate core material 23 constituting the laminated mattress 1 of the first embodiment is processed will be described.

The pair of rolls 310 are formed with a plurality of molded regions of uneven portions having different surface shapes along the roll axis direction.
Specifically, as shown in FIG. 15, the roll 310 has a first region 23a, a second region 23b, a third region 23c, and a fourth region of the third intermediate core material 23. A first molding region 311a, a second molding region 311b, a third molding region 311c, and a fourth molding region 311d corresponding to 23d are formed.

The core material 330 is a core material capable of taking two third intermediate core materials 23.
When the core material 330 is molded, as shown in FIG. 15, the core material 330 is arranged so as to face the longitudinal direction of the roll 310 with respect to the axial direction, and is sandwiched between the pair of rolls 310 for transportation.

Then, as shown in FIG. 16, the core material 330 discharged from between the pair of rolls 310 is divided into two by the cutter member 320 from the center in the thickness direction, so that the third intermediate core material 23 is used. The core material of the shape of can be molded into two pieces.

Since it is configured as described above, according to the third embodiment, in the characteristic mattress manufacturing method, the pair of rolls 310 differ according to the surface shape of the third intermediate core material 23 along the roll axis direction. By forming a plurality of molded regions of the uneven portion and transporting the core material 330 by sandwiching the core material 330 with a pair of rolls 310 along the longitudinal direction of the mattress, a plurality of regions having different surface shapes are simultaneously integrated with the core material 330. Can be molded into. Thereby, by cutting the core material 330 into two parts in the thickness direction by the cutter member 320, it is possible to produce two third intermediate core materials 23 by one molding process.

The present invention is not limited to the above-described embodiments and modifications, and various modifications can be made within the scope of the claims. That is, an embodiment obtained by combining technical means appropriately modified within a range not deviating from the gist of the present invention is also included in the technical scope of the present invention.

The side land and mattress of the present invention can be used for mattresses used for medical, long-term care, home beds and the like.

1 Laminated mattress 2 Side ground 3 Side edge member (side core material)
4 Stopper member 11 1st surface core material 12,112 2nd surface core material 20 Intermediate core material 21 1st intermediate core material 22 2nd intermediate core material 23 3rd intermediate core material 23a 1st region 23a1 , 23b1,23c1,23d1 Concavo-convex part 23b Second area 23b2 Sacral shape 23c Third area 23d Fourth area 31 Convex part 32 Slit 32a First slit 32b Second slit 101 Laminated mattress 310 Roll 311a First Molding area 311b 2nd molding area 311c 3rd molding area 311d 4th molding area 320 Cutter member 330 Core material

Claims (8)

A mattress with a core material having an uneven cross section.
The core material has a first surface core material, an intermediate core material, and a second surface core material.
In the intermediate core material , a plurality of regions having a specific function according to the surface shape are formed on the surface of the intermediate core material along the longitudinal direction of the mattress.
A side edge member is further provided between the first surface core material and the second surface core material only at both ends along the longitudinal direction of the mattress .
The mattress is characterized in that the side edge member is a core material having a higher hardness than the surface core material. The shape of the side edge member is a substantially semicircular cross-sectional shape .
The mattress according to claim 1 , wherein a plurality of convex portions having a substantially semicircular cross-sectional shape are continuously and integrally arranged over the longitudinal direction of the mattress. The mattress according to claim 1 or 2 , wherein the side edge member has a slit formed inward from the surface side of the side edge member along the lateral direction of the mattress. One of claims 1 to 3 , wherein a stopper member is further provided between the first surface core material and the second surface core material at both side ends of the mattress along the lateral direction. The mattress described in the section. Claimed, wherein the region includes a first region including the back, a second region including the lumbar region, and a third region including the legs, depending on the site of the mattress user. The mattress according to any one of 1 to 4. Said second region claim wherein the uneven portion having a sacrum corrugated surface shape along the mattress width direction together of the waist are a plurality of rows formed along the mattress longitudinal direction 5 The mattress described in. In the first region and the third region, a plurality of rows of uneven portions having a wave-shaped surface shape different from the wave shape of the second region are formed along the mattress longitudinal direction along the short side of the mattress. The mattress according to claim 5 , wherein the mattress is provided. The region between the first region and the second region and the region between the second region and the third region have a substantially linear surface shape along the short side (width direction) of the mattress. The mattress according to any one of claims 5 to 7 , wherein a plurality of rows of uneven portions having the above-mentioned are formed along the longitudinal direction of the mattress.

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