JP7762434B2 - mattress - Google Patents

Description

The present invention relates to a mattress having a mattress body made of three-dimensionally bonded filaments that extend in the front-to-back direction, which corresponds to the height of a person lying down, as well as in the left-to-right and up-to-down directions.

Conventionally, the cushioning material inside mattresses has been a mattress body made of three-dimensionally bonded filaments that extend in the front-to-back direction (the same direction as the height of a person lying down), the left-to-right direction, and the up-to-down direction (see, for example, Patent Document 1).

In this conventional mattress, filaments made of multiple molten thermoplastic resin fibers are lowered from above, fused together to form a three-dimensional net, and then cooled to form the mattress body, ensuring that the density of the filaments in the vertical direction is consistent in the front-to-back and left-to-right directions.

Japanese Patent Application Laid-Open No. 2000-120743

However, in the above-mentioned conventional mattresses, the density of the filaments in the vertical direction of the mattress body is constant in the front-to-back and left-to-right directions, so the expansion and contraction in the vertical direction when lying down is monotonous, and sleeping comfort is not good.

Furthermore, when the above-mentioned conventional mattresses were used in reclining beds used in hospitals, nursing homes, etc., the mattress body did not flex flexibly when reclined, making it difficult to use.

Therefore, in the present invention according to claim 1, in a mattress having a mattress body made of a three-dimensional filament assembly extending in the front-to-back direction, which corresponds to the height direction of a person lying down, and in the left-to-right direction and up-to-down direction, the mattress body is formed with a plurality of support regions which support the person lying down from below and have different average filament densities in the up-to-down direction, and bending regions are formed between adjacent support regions which are lower in height than the support regions and have a lower average filament density in the up-to-down direction than the support regions, making the mattress body bendable at the bending regions, and edge regions are formed only at the left and right ends of the support regions, and the average filament density in the edge regions is higher than that of the support regions and the bending regions.

In addition, in the present invention according to claim 2 , in the present invention according to claim 1 , the support region is provided with an upper layer consisting of one or more layers and a lower layer consisting of one or more layers, and an intermediate layer is provided between the upper layer and the lower layer, and the density of the filaments in the intermediate layer is made higher than that of the upper layer and the lower layer, and the density of the filaments in the end region is made the same as that of the intermediate layer in the support region .

In addition, in the present invention according to claim 3 , in the present invention according to claim 2 , the filament density of each layer forming the upper layer or the lower layer of the support region consisting of multiple layers gradually increases toward the middle layer , and the end region is formed of a single layer having the same filament density as the middle layer of the support region .

The present invention achieves the following effects:

In other words, this invention provides a mattress having a mattress body made of three-dimensionally bound filaments extending in the front-to-back direction, which corresponds to the height of a person lying down, as well as in the left-to-right direction and up-to-down directions. The mattress body is formed with multiple support regions that support the person lying down from below and have different average filament densities in the up-to-down direction. Furthermore, bending regions are formed between adjacent support regions that are lower in height than the support regions and have a lower average filament density in the up-to-down direction than the support regions, allowing the mattress body to bend in the bending regions. This results in partially different cushioning in the up-to-down direction when lying down, improving sleeping comfort. Furthermore, even when used on a reclining bed, the mattress (mattress body) can be flexed flexibly when reclined, improving usability.

In particular, if the support area is formed by integrally laminating multiple layers with different filament densities one above the other, or if the mattress body has an upper layer consisting of one or more layers and a lower layer consisting of one or more layers, with an intermediate layer between the upper and lower layers and the intermediate layer having a higher filament density than the upper and lower layers, or if the filament density of each layer forming the upper layer consisting of multiple layers or the lower layer consisting of multiple layers gradually increases toward the intermediate layer, the cushioning in the vertical direction when lying down will be smooth in response to the load, further improving sleeping comfort.

1 is a perspective view illustrating a mattress according to the present invention. An explanatory plan view of the mattress body. Cross-sectional view of the mattress body ((a) A-A cross-sectional view, (b) B-B cross-sectional view). Cross-sectional explanatory diagrams of the mattress body ((a) CC cross-sectional view, (b) DD cross-sectional view, (c) EE cross-sectional view, (d) FF cross-sectional view). Cross-sectional explanatory diagram of the mattress body ((a) enlarged view of CC cross section, (b) enlarged view of DD cross section, (c) enlarged view of EE cross section).

The specific configuration of the mattress according to the present invention will be explained below with reference to the drawings.

As shown in Figures 1 to 5, the mattress 1 contains a mattress body 3 inside a rectangular box-shaped bag-like exterior material 2.

The mattress body 3 is integrally formed from three-dimensionally bonded filaments, and is shaped like a rectangular plate extending in the front-to-back direction (left-to-right in Figure 1), which corresponds to the height of a person lying down, as well as in the left-to-right and up-to-down directions perpendicular to the front-to-back direction. The three-dimensionally bonded filaments are formed by fusing together multiple molten filaments made of thermoplastic resin fibers into a three-dimensional net-like shape and then cooling them. Thermoplastic resin materials such as polyethylene and polypropylene are used for the filaments.

In plan view, this mattress body 3 has multiple end regions 4-8 formed at front-to-back intervals on the left and right end portions, multiple support regions 9-13 formed at front-to-back intervals in the central portion (the portion where the recumbent lies) that support the body of the recumbent from below, and multiple flex regions 14 formed at front-to-back intervals between adjacent end regions 4-8 and support regions 9-13 to improve the flexibility of the mattress body 3. The flex regions 14 are thinner in the vertical direction and lower in height than the other end regions 4-8 and support regions 9-13, creating recesses on both the top and bottom surfaces of the mattress body 3. Here, the end regions 4-8 are formed as a single layer (single layer) with a uniform filament density, while the support regions 9-13 and flex region 14 are formed by integrally laminating multiple layers (multi-layers) with different filament densities one on top of the other. The entire mattress body 3 (end regions 4-8, support regions 9-13, and bending region 14) may be formed in multiple layers, or the bending region 14 may be formed in a single layer.

The mattress body 3 may have support regions 9-13 and a bending region 14 without end regions 4-8. The mattress body 3 has three support regions 11 spaced apart from each other in the front and rear direction in the central portion (mainly supporting the lower back of a reclining person), two support regions 10 spaced apart from each other in the front portion (mainly supporting the upper body of a reclining person), two support regions 12 spaced apart from each other in the rear portion (mainly supporting the lower body of a reclining person), three support regions 9 spaced apart from each other in the front end portion, and three support regions 13 spaced apart from each other in the rear end portion. The number of each support region 9-13 may be one or more. While the order of front-to-back width increases in the order of support regions 9, 13, support region 11, and support regions 10, 12, this is not a limitation.

The multi-layered portions of the mattress body 3 (support regions 9-13 and bending region 14) are formed with an upper layer 15 formed on the upper side and a lower layer 16 formed on the lower side, with an intermediate layer 17 integrally and tightly bonded between the upper layer 15 and lower layer 16. The upper layer 15 and lower layer 16 may be formed as a single layer, or multiple layers. Here, a single intermediate layer 17 is provided between the two-layer upper layer 15 and the two-layer lower layer 16.

The upper layers 15 of the support regions 9-13 are composed of, from top to bottom, first and second upper layers 18, 19. The first upper layer 18, the top layer, has the lowest filament density of the upper layers 15, and the second upper layer 19, the bottom layer, has the highest filament density of the upper layers 15. The filament density of the first and second upper layers 18, 19 gradually increases (in steps) as they approach the middle layer 17.

Furthermore, among the upper layers 15 of the support regions 9-13, the first upper layer 18, which is the top layer, has the thickest vertical thickness of all the upper layers 15, and the second upper layer 19, which is the bottom layer, has the thinnest vertical thickness of all the upper layers 15. The first and second upper layers 18, 19 have the same or gradually (in steps) thicker vertical thickness in order as they approach the middle layer 17. It is also possible to have the first and second upper layers 18, 19 have gradually (in steps) thinner vertical thickness in order as they approach the middle layer 17.

In this way, in the mattress body 3, the upper layer 15 of the support areas 9-13 is formed from multiple layers (first and second upper layers 18, 19), and the filament density of each layer (first and second upper layers 18, 19) that makes up the upper layer 15 gradually increases toward the middle layer 17. Furthermore, the vertical thickness (height) of each layer (first and second upper layers 18, 19) that makes up the upper layer 15 is the same or gradually increases toward the middle layer 17.

The lower layers 16 of the support regions 9-13 are composed of, from bottom to top, first and second lower layers 20, 21. The first lower layer 20, the lowest layer, has the lowest filament density of the lower layers 16, and the second lower layer 21, the highest layer, has the highest filament density of the lower layers 16. The filament density of the first and second lower layers 20, 21 gradually increases (in steps) as they approach the middle layer 17.

Furthermore, among the lower layers 16 in the support regions 9-13, the bottommost first lower layer 20 has the thickest vertical thickness of the lower layers 16, and the topmost second lower layer 21 has the thinnest vertical thickness of the lower layers 16, with the first and second lower layers 20, 21 having the same or gradually (in steps) thinner in the vertical direction as they approach the middle layer 17 in that order. It is also possible for the first and second lower layers 20, 21 to have the same or gradually (in steps) thicker in the vertical direction as they approach the middle layer 17 in that order.

In this way, in the mattress body 3, the lower layer 16 of the support areas 9-13 is formed from multiple layers (first and second lower layers 20, 21), and the filament density of each layer (first and second lower layers 20, 21) that makes up the lower layer 16 gradually increases toward the middle layer 17. Furthermore, the thickness (height) of each layer (first and second lower layers 20, 21) that makes up the lower layer 16 is the same or gradually decreases toward the middle layer 17.

The intermediate layer 17 of the support regions 9-13 has a higher filament density and is the same or thinner in the vertical direction than the first and second upper layers 18, 19 that form the upper layer 15 of the support regions 9-13 and the first and second lower layers 20, 21 that form the lower layer 16 of the support regions 9-13. The intermediate layer 17 of the support regions 9-13 may be thicker in the vertical direction than the first and second upper layers 18, 19 that form the upper layer 15 of the support regions 9-13 and the first and second lower layers 20, 21 that form the lower layer 16 of the support regions 9-13. The intermediate layer 17 of the support regions 9-13 may also be formed from multiple layers.

In the mattress body 3, the support region 11 formed in the central portion (the portion that primarily supports the lumbar region of a reclining person) is formed by the first and second upper layers 18a, 19a, the middle layer 17a, and the first and second lower layers 20a, 21a, all of which are tightly joined together. In addition, in the mattress body 3, the support region 10 formed in the front portion (the portion that primarily supports the upper body of a reclining person) and the support region 12 formed in the rear portion (the portion that primarily supports the lower body of a reclining person) are formed by the first and second upper layers 18b, 19b, the middle layer 17b, and the first and second lower layers 20b, 21b, all of which are tightly joined together. Furthermore, in the mattress body 3, the support region 9 formed in the front end portion and the support region 13 formed in the rear end portion are formed by the first and second upper layers 18c, 19c, the middle layer 17c, and the first and second lower layers 20c, 21c, which are integrally and closely attached to one another.

The mattress body 3 has different average vertical densities for the support region 11 formed by the first and second upper layers 18a, 19a, the intermediate layer 17a, and the first and second lower layers 20a, 21a; the support region 10, 12 formed by the first and second upper layers 18b, 19b, the intermediate layer 17b, and the first and second lower layers 20b, 21b; and the support region 9, 13 formed by the first and second upper layers 18c, 19c, the intermediate layer 17c, and the first and second lower layers 20c, 21c. For example, the average density of the support region 11 is the highest, and the average density of the regions 9, 13 is the lowest. It is sufficient that some of the support regions 9-13 formed in multiple layers have a different vertical filament density compared to the others, or all of the regions 9-13 may have different vertical filament densities.

As a result, when lying down, the mattress body 3 has vertical cushioning that varies partially between support regions 9-13 (particularly regions 10-12 where the sleeper lies), improving sleeping comfort. The cushioning for each support region 10-12 can be set appropriately according to the sleeper's body type and preferences. For example, if the average vertical density of support region 11 is made the highest and firmest, it will support the lower back of the sleeper, making it easier for them to turn over in bed.

The upper layer 15, lower layer 16, and middle layer 17 in the bending region 14 of the mattress body 3 are each formed from a single layer (first upper layer 18d, first lower layer 20d, middle layer 17d), with the middle layer 17 having a higher filament density than the upper layer 15 and lower layer 16, and the vertical thickness being the same or thinner. The vertical thickness of the middle layer 17 in the bending region 14 may be thicker than the upper layer 15 and lower layer 16. The upper layer 15, lower layer 16, and middle layer 17 in the bending region 14 may also be formed from multiple layers. Furthermore, the average vertical filament density may be different for each bending region 14.

The end regions 4-8 of the mattress body 3 are formed from a single layer, and have a higher average density of filaments in the vertical direction than the other support regions 9-13 and the upper layer 15 and lower layer 16 of the bending region 14, preventing sinking at the left and right ends of the mattress body 3.

Furthermore, the end regions 4-8 of the mattress body 3 are designed to have the same average vertical filament density as the other support regions 9-13 and the middle layer 16 of the bending region 14. The upper layer 15, lower layer 16, and middle layer 17 of the end regions 4-8 may be formed from multiple layers. Furthermore, the average vertical filament density may be different for each of the end regions 4-8.

In the mattress body 3, the upper layer 15 of the support regions 9-13 and the bending region 14 and the upper portions 22 of the end regions 4-8, the lower layer 16 of the support regions 9-13 and the bending region 14 and the lower portions 23 of the end regions 4-8, and the middle layer 16 of the support regions 9-13 and the bending region 14 and the middle portions 24 of the end regions 4-8 are integrally formed by adhering them together.

In the mattress body 3 described above, the upper and lower layers 15 and 16 in each of the support areas 9 to 13 are made identical in number of layers, thickness, and average vertical filament density, so that they can be used upside down. However, this is not limited to this, and the upper and lower layers 15 and 16 in each of the support areas 9 to 13 may differ in number of layers, thickness, and average vertical filament density.

The mattress body 3 is constructed as described above, and when used as the mattress 1, the upper layer 15 of the support areas 9-13 receives the load (body weight) from the person lying down, causing the upper layer 15 to expand and contract, while the lower layer 16 receives the load (reaction force) from the bed base, causing the lower layer 16 to expand and contract.

As a result, in mattress 1, the upper layer 15 and lower layer 16 sandwiching the middle layer 17 expand and contract in response to the load of the person lying down, providing cushioning properties with an N value that changes smoothly in response to the load, similar to that of pocket coils, thereby improving the sleeping comfort of the person lying down.

In the mattress body 3, the average density of the filaments is determined by the weight of the filaments (resin) per unit volume, and can be changed by changing the diameter or material of the filaments. In a three-dimensional filament bonded structure, the higher the average density of the filaments in the vertical direction, the stiffer the stretchability in the vertical direction.

As explained above, the mattress 1 has a mattress body 3 made of a three-dimensional assembly of filaments that extend in the front-to-back direction, which corresponds to the height of a person lying down, as well as in the left-to-right and up-to-down directions. The mattress body 3 is formed with multiple support regions 9-13 that support the person lying down from below and have different average filament densities in the vertical direction. Furthermore, between adjacent support regions 9-13, bending regions 14 are formed that are lower in height than the support regions 9-13 and have a lower average filament density in the vertical direction than the support regions 9-13, allowing the mattress body 3 to bend at the bending regions 14.

As a result, with the mattress 1 configured as described above, the cushioning properties in the vertical direction when lying down are partially changed, improving sleeping comfort. Furthermore, even when used on a reclining bed, the mattress 1 (mattress body 3) can be flexed flexibly when reclined, improving usability.

The mattress 1 is also configured so that support areas 9-13 are formed by integrally stacking multiple layers (upper layer 15, middle layer 17, lower layer 16) with different filament densities.

As a result, with the mattress 1 configured as described above, the cushioning in the vertical direction when lying down becomes smooth in response to the load, further improving sleeping comfort.

The mattress 1 also has a mattress body 3 with an upper layer 15 consisting of one or more layers and a lower layer 16 consisting of one or more layers, and an intermediate layer 17 between the upper layer 15 and the lower layer 16, with the intermediate layer 17 having a higher filament density than the upper layer 15 and the lower layer 16.

As a result, with the mattress 1 configured as described above, the cushioning in the vertical direction when lying down becomes smooth in response to the load, further improving sleeping comfort.

The mattress 1 is also configured so that the filament density of each layer forming the upper layer 15 (first and second upper layers 18, 19) or the lower layer 16 (first and second lower layers 20, 21), which is made up of multiple layers, gradually increases toward the middle layer 17.

As a result, with the mattress 1 configured as described above, the cushioning in the vertical direction when lying down becomes smooth in response to the load, further improving sleeping comfort.

1 Mattress 2 Outer material 3 Mattress body 4-8 End regions 9-13 Support regions 14 Bending region
15 Upper layer 16 Lower layer
17,17a~17d Middle layer 18,18a~18d 1st upper layer
19, 19a to 19c: Second upper layer 20, 20a to 20d: First lower layer
21,21a~21c 2nd lower layer 22 Upper part
23 Lower part 24 Middle part

Claims (3)

A mattress having a mattress body made of a three-dimensional filament bonded body extending in the front-to-back direction, which corresponds to the height direction of a person lying down, the left-to-right direction, and the up-to-down direction,
The mattress body is formed with a plurality of support regions that support a person lying down from below and have different average filament densities in the vertical direction, and a bending region is formed between adjacent support regions that is lower in height than the support regions and has a lower average filament density in the vertical direction than the support regions, making the mattress body bendable at the bending regions ;
A mattress characterized in that end regions are formed only at the left and right end portions of a support region, and the average density of filaments in the end regions is higher than that in the support region and the bending region . The support region includes an upper layer consisting of one or more layers and a lower layer consisting of one or more layers, and an intermediate layer is provided between the upper layer and the lower layer, and the intermediate layer has a higher filament density than the upper layer and the lower layer ;
2. The mattress of claim 1 , wherein the end regions have a filament density equal to that of the middle layer of the support region . The filament density of each layer forming the upper layer or the lower layer of the support region is gradually increased toward the intermediate layer ,
3. The mattress of claim 2 , wherein the end regions are formed from a single layer having the same filament density as the middle layer of the support region .