JP7335146B2 - Mattress and cushion body cover - Google Patents

Description

The present invention relates to a cushion body cover in which a cushion body is housed, a cushion body with the cover, a mattress, and a method of manufacturing the mattress.

2. Description of the Related Art Conventionally, cushion bodies (cushion bodies that support upper users) used for mattresses, sofa cushions, etc. have been widely used. As such a cushion body, for example, as disclosed in Patent Document 1 and Patent Document 2, a filament three-dimensionally bonded body (three-dimensional net-like structure) obtained by three-dimensionally fusion-bonding filaments made of a thermoplastic resin is known. structure).

According to Patent Document 1, after a molten polyethylene resin is extruded vertically downward from a plurality of horizontally arranged nozzles, a molten filament with a diameter of about 1 mm is dropped into cooling water and melted by the buoyancy of the water. It is disclosed that a filament loop is formed and at the same time, a plurality of melted filaments are three-dimensionally fused and bonded to produce a highly airy filament three-dimensional bonded body with a porosity exceeding 90%. there is

In addition, when forming a mattress using a filament three-dimensionally bonded body, a cushion body of the filament three-dimensionally bonded body formed in a plate shape (usually a rectangular parallelepiped plate shape) is prepared, and the cushion body is used as a mattress cover. A mattress is formed by storing in (a bag). In addition, when forming one mattress using a plurality of smaller cushion bodies, each cushion body is stored in the mattress cover in order.

WO2017/122370 JP 2019-131950 A

The above-described three-dimensional filament assembly is formed by entangling the filaments, and may have a non-smooth surface portion (a portion of the surface where, for example, the tip of the filament protrudes). Therefore, in the process of storing the cushion body of the three-dimensional filament combination in a bag such as a mattress cover, the non-smooth surface portion may get caught in the bag, hindering the smooth execution of the process.

If the cushion body is stored in the inner cover in advance and the cushion body with the inner cover is stored in the bag body, the cushion body and the bag body do not rub directly against each other, and the step of storing the cushion body in the bag body is eliminated. It is possible to proceed smoothly. However, in this case, since the inner cover covers the surface of the cushion body, the original air permeability of the cushion body is impaired accordingly. The above can also be a problem when other types of cushions having non-smooth surface portions are accommodated in the bag.

In view of the above-mentioned problems, the present invention provides a cushion body that can easily store a cushion body having a non-smooth surface portion in a bag body while minimizing loss of air permeability of the cushion body. Intended to provide cover.

A cushion body cover according to the present invention is a cushion body cover that houses a substantially plate-shaped cushion body whose thickness direction is the top and bottom so as to cover at least the side surfaces of the cushion body. , all or part of which is exposed. According to this configuration, it is possible to prevent the air permeability of the cushion body from being impaired as much as possible, while making it easy to store the cushion body having a surface portion that is not smooth in the bag body.

More specifically, the above configuration includes an upper surface portion facing the upper surface of the cushion body and a lower surface portion facing the lower surface of the cushion body, each of which has an opening through which a part of the cushion body is exposed. may be

More specifically, the upper surface portion may cover the entire outer edge of the upper surface of the cushion body, and the lower surface portion may cover the entire outer edge of the lower surface of the cushion body. According to this configuration, it is possible to suppress unintended deviation of the cushion body from the cushion body cover, and to cover the vicinity of the corners of the cushion body to make the surface smooth.

Further, in the cushion body cover configured as described above and in which the cushion body formed by the three-dimensionally bonded filament is accommodated, the size of the opening of at least one of the upper surface portion and the lower surface portion is determined through the opening. The cushion body may be detachably accommodated. According to this configuration, the work of detachably accommodating the cushion body is facilitated.

Further, in the cushion body cover having the configuration described above, in which the side surface portion covering the side surface of the entire circumference of the cushion body is provided, and the upper surface portion and the lower surface portion are connected to the side surface portion, the upper surface portion and the lower surface portion The size of both openings may be set so that the cushion body can be detachably accommodated through the openings.

Further, a cushion body with a cover according to the present invention is configured to have the cushion body cover configured as described above and the cushion body housed in the cushion body cover. A mattress according to the present invention includes a plurality of cushion bodies with covers configured as described above, and a bag-like mattress cover in which the plurality of cushion bodies with covers are accommodated.

In addition, the method of manufacturing a mattress according to the present invention includes a first step of housing the cushion body in the cushion body cover having the above configuration, and a plurality of cushion bodies with the cover formed by the first step, each of which is packed into one bag. and a second step of enclosing the mattress cover in a shaped mattress cover.

According to the cushion body cover of the present invention, it is possible to easily store a cushion body having a non-smooth surface portion in a bag body while minimizing loss of air permeability of the cushion body.

1 is a schematic perspective view of a cushion body cover 20 according to this embodiment and a cushion body 10 housed therein. FIG. 1 is a schematic perspective view of a cushion body 100 with a cover according to this embodiment; FIG. FIG. 4 is a schematic perspective view of the cushion body 100 with cover from another viewpoint; 1 is a schematic perspective view of a mattress 110 according to this embodiment; FIG. It is explanatory drawing regarding the catching in a storage process.

An example of an embodiment of the present invention will be described below with reference to each drawing. The vertical, horizontal, and front/rear directions in the following description are as shown in FIG. 1 and the like. Here, the vertical direction is merely defined for the sake of convenience so as to coincide with the thickness direction of the cushion body.

FIG. 1 is a schematic perspective view of a cushion body cover 20 according to this embodiment and a cushion body 10 accommodated therein. The cushion body 10 is a three-dimensionally bonded body of filaments, and is formed in the shape of a rectangular parallelepiped plate whose thickness direction is the vertical direction. Since the vertical direction is the thickness direction, the upper and lower surfaces of the cushion body 10 are sufficiently wider than the front, rear, left, and right side surfaces. The method for manufacturing the three-dimensionally bonded filament is well known as disclosed in, for example, Patent Document 1 and Patent Document 2, and therefore detailed description thereof will be omitted here.

The cushion body cover 20 is formed of a smooth sheet material made of, for example, resin or various fibers. It is formed to have a portion 22 and side portions 23 corresponding to the front, rear, left, and right side surfaces. The front, rear, left, and right outer edges of the upper surface portion 21 and the lower surface portion 22 are connected to the outer edges of the front, rear, left, and right side portions 23 . That is, the cushion body cover 20 has a side surface portion 23 that covers the side surfaces of the entire circumference of the cushion body 10 , and the upper surface portion 21 and the lower surface portion 22 are connected to the side surface portion 23 .

More specifically, the outer edges of the upper surface portion 21 and the lower surface portion 22 of the cushion body cover 20 are formed in substantially the same shape and dimensions as the outer edges of the upper and lower surfaces of the cushion body 10 . In addition, the outer edges of the left and right side portions 23 of the cushion body cover 20 are formed in substantially the same shape and dimensions as the outer edges of the left and right surfaces of the cushion body cover 10, and the outer edges of the front and rear side portions 23 of the cushion body cover 20 are formed. are formed to have substantially the same shape and dimensions as the outer edges of the front and rear surfaces of the cushion body 10 .

Therefore, the cushion body 10 housed in the cushion body cover 20 is adapted to fit the inner surface of the cushion body cover 20 . In this state, the upper surface portion 21 faces the upper surface of the cushion body 10 and the lower surface portion 22 faces the lower surface of the cushion body 10 .

The upper surface portion 21 of the cushion body cover 20 is formed with an upper opening portion 21a, and the lower surface portion 22 of the cushion body cover 20 is formed with a lower opening portion 22a. The upper opening 21a is provided so as to open a region near the center of the upper surface portion 21, and expose a region near the center of the upper surface of the accommodated cushion body 10. As shown in FIG. The lower opening 22a is provided so as to open a region near the center of the lower surface portion 22, and expose a region near the center of the lower surface of the accommodated cushion body 10. As shown in FIG.

In the example of this embodiment, the upper and lower openings 21a and 22a have the same shape and size, and the outer edge shape of each opening 21a and 22a is substantially similar to the outer edge shape of the upper surface portion 21 or the lower surface portion 22. be. Furthermore, in the example of the present embodiment, the area of each of the upper and lower openings 21a and 22a is set to about 60 to 80% of the area of the upper surface portion 21 or the lower surface portion 22. It is arranged so that the center positions of the portion 21 or the lower surface portion 22 and the center positions thereof match each other.

Therefore, when the cushion body 10 is accommodated in the cushion body cover 20, the upper surface part 21 covers only the vicinity of the entire outer edge of the upper surface of the cushion body 10, and the lower surface part 22 covers only the vicinity of the entire outer edge of the lower surface of the cushion body 10. will cover. In addition, since the upper surface portion 21 and the lower surface portion 22 have large openings, the cushion body 10 can be accommodated inside the cushion body cover 20 through these openings, as indicated by the dashed arrows in FIG. It is possible.

When the cushion body 10 is accommodated in this manner, the cushion body 10 can be easily accommodated by slightly bending the cushion body 10 or by slightly stretching the cushion body cover 20 . In this embodiment, the cushion body 10 can be detachably accommodated through the opening in either the upper surface portion 21 or the lower surface portion 22. Such accommodation may be possible.

By housing the cushion body 10 inside the cushion body cover 20, a cushion body with a cover can be formed. FIG. 2 is a schematic perspective view of the cushion body 100 with cover, and FIG. 3 is a schematic perspective view of the cushion body 100 with cover from another viewpoint.

As shown in these figures, in the cushion body 100 with cover, most of the upper and lower central areas of the cushion body 10 are exposed, and the air permeability of the cushion body 10 is impaired in these exposed areas. do not have. Thus, even if the cushion body cover 20 is accommodated, the excellent air permeability of the cushion body 10, which is a three-dimensional filament combination, is hardly impaired, and the cushion body 100 with the cover maintains excellent air permeability.

On the other hand, in the cushion body 100 with cover, the cushion body cover 20 covers the entire front, rear, left, and right side portions 23 of the cushion body 10, and the vicinity of the entire outer edge of the upper surface portion 21 and the lower surface portion 22. Unintentional deviation of the cushion body 10 from the cushion body cover 20 is suppressed as much as possible. Furthermore, the surface of the cushion body 100 with cover is in a smooth state at least in the portion covered by the cushion body cover 20 .

The covered cushion body 100 can be suitably used as a cushion member for forming a mattress, for example. For example, as shown in FIG. 4, cushion members 100A to 100C are prepared as a plurality of (three in the example of FIG. 4) covered cushion bodies 100, and these are housed in one bag-like mattress cover 30. A mattress 110 is formed.

More specifically, each of the cushion member 100A, the cushion member 100B, and the cushion member 100C is placed inside the mattress cover 30 in this order via a storage opening 30a that can be opened and closed by a zipper provided on one side of the mattress cover 30. stored in. After completing the step of storing all the cushion members 100A to 100C, the mattress 110 is completed through the step of closing the zipper. As the mattress cover, for example, a series of zippers (zippers arranged in a "U" shape when viewed from above) are provided on the side surfaces of three connecting directions, and the upper surface can be freely opened and closed by opening these zippers. Anything may be adopted. In this case, each of the cushion member 100A, the cushion member 100B, and the cushion member 100C can be accommodated in the mattress cover from above with the upper surface opened.

The manufacturing method of such a mattress consists of a first step of housing the cushion body 10 in the cushion body cover 20, and a plurality of each of the cushion bodies 100 with the cover formed in the first step to form one bag-like mattress cover. and a second step of housing at 30 .

Here, in the above storage process, assuming that the non-smooth surface portion of the cushion member (for example, the portion of the surface where the tip of the filament protrudes) is caught on the mattress bar 30, the smooth progress of the storage process is hindered. there is a risk that When the cushion member X is stored in the mattress cover 30 in a slightly tilted state as shown in FIG. neighborhood).

However, in the cushion member (cushion body 100 with cover) according to the present embodiment, the cushion body 10 is housed in the cushion body cover 20 having a smooth surface. is suppressed. The cushion body cover 20 exposes the upper and lower central regions of the cushion body 10 from the viewpoint of not impairing breathability, but covers the corners of the cushion body 10 almost completely. The effect of suppressing the catching is high. Thus, the cushion body cover 20 serves as an inner cover for facilitating the housing of the cushion body 10 in the mattress cover 30 .

As described above, the cushion body cover 20 according to the present embodiment is a cushion body cover that houses the plate-like cushion body 10 whose thickness direction is the top and bottom so as to cover at least the side surfaces of the cushion body. A portion of each of the upper and lower surfaces of the body 10 is exposed. More specifically, the cushion body cover 20 has an upper surface portion 21 facing the upper surface of the cushion body 10 and a lower surface portion 22 facing the lower surface of the cushion body 10, respectively. department is provided. Therefore, the air permeability of the cushion body 10 can be kept as low as possible while the cushion body 10 having a non-smooth surface portion can be easily accommodated in the bag body.

The upper surface portion 21 covers the entire outer edge of the upper surface of the cushion body 10 , and the lower surface portion 22 covers the entire outer edge of the lower surface of the cushion body 10 . Therefore, it is possible to prevent the cushion body 10 from unintentionally deviating from the cushion body cover 20, and to cover the vicinity of the corners of the cushion body 10 to make the surface smooth.

In addition, in the cushion body cover 20 that accommodates the cushion body 10 formed by the three-dimensionally bonded filaments, the sizes of the upper opening 21a and the lower opening 22a are such that the cushion body 10 can be attached and detached through the openings. It is set up so that it can be accommodated freely. Therefore, the work of detachably accommodating the cushion body is facilitated.

When setting the size of the opening in this way, characteristics such as the size and bendability of the cushion body 10 (three-dimensionally combined filament) and characteristics such as the ease of expansion and contraction of the cushion body cover 20 are taken into account. preferably considered. In particular, in this embodiment, the cushion body 10 can be detachably accommodated in the cushion body cover 20 through either the upper opening 21a or the lower opening 22a, so convenience is excellent.

The cushion body cover 20 of this embodiment accommodates the cushion body 10 formed by the three-dimensional filament combination, but the cushion body cover according to the present invention accommodates other types of cushion bodies. good too. By storing various cushion bodies having uneven surface portions in advance in the cushion body cover according to the present invention, the air permeability of the cushion body is not impaired as much as possible while being easily housed in the bag body. can be

The cushion body cover according to the present invention is a cushion body cover that houses a substantially plate-shaped cushion body whose thickness direction is the top and bottom so as to cover at least the side surfaces of the housed cushion body. Alternatively, one of them may be entirely exposed. By covering at least the side surfaces of the cushion body with the cushion body cover, for example, a bag body whose upper surface can be opened and closed (as an example, the above-mentioned mattress cover provided with a series of zippers on the side surfaces of three contiguous directions) and a plurality of cushion bodies. When the cushions are stored side by side by being fitted from above, the interposition of the cushion body cover prevents the side surfaces of the cushion body from being caught with each other and the side surfaces of the cushion body and the inner surface of the bag body from being caught. As a result, the cushion body (cushion body housed in the cushion body cover) can be smoothly housed in the bag body.

Although the embodiments of the present invention have been described above, the configuration of the present invention is not limited to the above embodiments, and various modifications can be made without departing from the gist of the invention. That is, the above-described embodiments should be considered as examples in all respects and not restrictive. The technical scope of the present invention is defined by the scope of claims rather than the description of the above embodiments, and is understood to include all modifications within the scope and meaning equivalent to the scope of claims. should.

INDUSTRIAL APPLICABILITY The present invention can be used for a cushion body cover or the like in which a cushion body is housed.

REFERENCE SIGNS LIST 10 cushion body 20 cushion body cover 21 upper surface portion 21a upper opening portion 22 lower surface portion 22a lower opening portion 30 mattress cover (bag)
30a storage port 100 cushion body with cover 110 mattress

Claims (4)

A mattress in which a cushion body is stored in the mattress cover through a storage opening provided in the mattress cover,
The cushion body has a substantially plate-like shape with the thickness direction extending vertically, and is composed of a filament three-dimensionally bonded body having a porosity exceeding 90%, which is obtained by three-dimensionally fusion bonding filaments made of a thermoplastic resin. The upper and lower surfaces in the thickness direction are smooth, and the outer peripheral side surface is not smooth because the tip of the filament is exposed,
Further, the cushion body is detachably attached with a cushion body cover covering the outer peripheral edge part of the upper surface, the outer peripheral edge part of the lower surface, and the outer peripheral side surface of the cushion body, and the outer peripheral edge part covered with the cushion body cover is detachably attached. Except for the upper and lower surfaces of the cushion body are exposed,
A mattress , wherein the cushion body cover is formed of a smooth sheet material . 2. The mattress according to claim 1, wherein said sheet material is made of resin or fiber. 3. The mattress according to claim 1, wherein a plurality of cushion bodies having said cushion body covers are housed in one said mattress cover. A cushion body to be housed in a mattress cover, which is a substantially plate-like cushion body made of a filament three-dimensionally bonded body in which filaments made of a thermoplastic resin are three-dimensionally fused and bonded, and the porosity exceeds 90%. and a cushion body cover detachably attached to a cushion body having smooth top and bottom surfaces in the thickness direction and uneven peripheral side surfaces due to the exposing ends of the filaments,
It covers the outer peripheral edge of the upper surface of the cushion body, the outer peripheral edge of the lower surface, and the outer peripheral side surface of the cushion body, and has an opening that exposes other than the outer peripheral edge of the upper surface part and the lower surface part of the cushion body, and contains resin or fiber. A cushion body cover characterized by being formed from a smooth sheet material .