JP7787575B2 - 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, ensuring that the density of the filaments is consistent in both the vertical and horizontal directions.

Japanese Patent Application Laid-Open No. 2000-120743

However, in the above-mentioned conventional mattresses, the density of the filaments is constant in the vertical direction, so the expansion and contraction in the vertical direction when lying down is monotonous, making it uncomfortable to sleep on.

Therefore, in the present invention according to claim 1, the mattress has 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, as well as in the left-to-right direction and the up-to-down direction, and the mattress body has an upper layer made up of multiple layers and a lower layer made up of one or more layers, and an intermediate layer is provided between the upper and lower layers, with the intermediate layer having a higher filament density than the upper layer, and each layer forming the upper layer having a gradually increasing filament density and thickness toward the intermediate layer .

In addition, in the present invention according to claim 2, in the present invention according to claim 1, the lower layer is formed of multiple layers, and each layer forming the lower layer has a gradually increasing filament density and a gradually increasing thickness toward the middle layer .

The present invention achieves the following effects:

In other words, this invention provides a mattress with a mattress body made of three-dimensionally bound filaments that extend in the front-to-back direction, which corresponds to the height of a person lying down, as well as the left-to-right and up-to-down directions. The mattress body has an upper layer made up of one or more layers and a lower layer made up of one or more layers, with an intermediate layer provided between the upper and lower layers. This allows for smooth cushioning in the up-to-down direction when lying down, in response to load, improving sleeping comfort.

In particular, if the filament density of the middle layer is made higher than that of the upper and lower layers, the cushioning in the vertical direction when lying down becomes smoother in response to the load, further improving sleeping comfort.

Furthermore, if the filament density of each layer forming the upper layer or lower layer gradually increases toward the middle layer, the cushioning in the vertical direction when lying down becomes smoother in response to load, further improving sleeping comfort.

1 is a perspective view illustrating a mattress according to the present invention. Cross-sectional view of the mattress body.

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 and 2, the mattress 1 contains a mattress body 3 inside a rectangular box-shaped bag-like exterior material 2.

The mattress body 3 is formed by three-dimensionally bonded filaments into a rectangular plate shape that extends 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 filaments made of multiple molten thermoplastic resin fibers into a three-dimensional net shape and then cooling them. Thermoplastic resin materials such as polyethylene and polypropylene are used for the filaments.

This mattress body 3 has an upper layer 4 formed on the upper side and a lower layer 5 formed on the lower side, with an intermediate layer 6 formed between the upper layer 4 and the lower layer 5 and attached to them. The upper layer 4 and the lower layer 5 may each be formed of a single layer, or multiple layers. In this example, a single intermediate layer 6 is provided between the upper layer 4, which consists of six layers, and the lower layer 5, which consists of two layers.

The upper layer 4 is composed of the first to sixth upper layers 7-12, from top to bottom. The first upper layer 7 has the lowest filament density of the upper layers 4, and the sixth upper layer 12 has the highest filament density of the upper layers 4. The filament density of the first to sixth upper layers 7-12 gradually increases (in stages) as they approach the middle layer 6.

Furthermore, the first upper layer 7 has the thinnest vertical thickness among the upper layers 4, and the sixth upper layer 12 has the thickest vertical thickness among the upper layers 4, with the first through sixth upper layers 7-12 having the same or gradually (in stages) thicker vertical thicknesses in that order as they approach the intermediate layer 6.

In this way, when the upper layer 4 is formed from multiple layers (first to sixth upper layers 7-12), the filament density of each layer (first to sixth upper layers 7-12) that makes up the upper layer 4 gradually increases toward the middle layer 6, and the vertical thickness (height) of each layer (first to sixth upper layers 7-12) that makes up the upper layer 4 is the same or gradually increases toward the middle layer 6.

The lower layer 5 is composed of, from bottom to top, the first and second lower layers 13 and 14. The first lower layer 13 has the lowest filament density of the lower layers 5, and the second lower layer 14 has the highest filament density of the lower layers 5. The filament density of the first and second lower layers 13 and 14 gradually increases (in stages) as they approach the intermediate layer 6.

Furthermore, the first lower layer 13 has the thinnest vertical thickness among the lower layers 5, and the second lower layer 14 has the thickest vertical thickness among the lower layers 5, with the vertical thicknesses of the first and second lower layers 13, 14 either being the same or gradually (in stages) thicker in order as they approach the intermediate layer 6.

In this way, when the lower layer 5 is formed from multiple layers (first and second lower layers 13, 14), the filament density of each layer (first and second lower layers 13, 14) that makes up the lower layer 5 gradually increases toward the middle layer 6, and the vertical thickness (height) of each layer (first and second lower layers 13, 14) that makes up the lower layer 5 is the same or gradually increases toward the middle layer 6.

The middle layer 6 has a higher filament density and is thicker in the vertical direction than the first to sixth upper layers 7 to 12 that form the upper layer 4 and the first and second lower layers 13, 14 that form the lower layer 5.

The mattress body 3 is constructed as described above, with the number of upper layers 4 being greater than the number of lower layers 5, and the thickness of the upper layer 4 being greater than the thickness of the lower layer 5. When used as the mattress 1, the upper layer 4 receives the load (body weight) of the person lying down, causing the upper layer 4 to expand and contract, while the lower layer 5 receives the load (reaction force) from the bed base, causing the lower layer 5 to expand and contract.

As a result, in mattress 1, the upper layer 4 and lower layer 5 sandwiching the middle layer 6 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 pocket coils, thereby improving the sleeping comfort of the person lying down.

As explained above, the mattress 1 has a mattress body 3 that includes one or more upper layers 4 and one or more lower layers 5, with an intermediate layer 6 provided between the upper layer 4 and the lower layer 5.

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, improving sleeping comfort.

Furthermore, the mattress 1 is configured so that the filament density in the middle layer 6 is higher than that in the upper layer 4 and lower layer 5.

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

Furthermore, the mattress 1 is configured so that the filament density of each layer (first to sixth upper layers 7-12, first and second lower layers 13, 14) that forms the upper layer 4, which is made up of multiple layers, or the lower layer 5, which is made up of multiple layers, gradually increases toward the middle layer 6.

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

1 Mattress 2 Outer material 3 Mattress body 4 Upper layer 5 Lower layer 6 Middle layer
7～12 1st to 6th upper layer 13,14 1st and 2nd lower layer

Claims (2)

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 has an upper layer made up of multiple layers and a lower layer made up of one or more layers, and an intermediate layer provided between the upper layer and the lower layer ;
The filament density in the middle layer is made higher than that in the upper layer,
The layers constituting the upper layer have gradually increasing filament density and thickness toward the middle layer . 2. The mattress of claim 1 , wherein the lower layer is formed of a plurality of layers, and the layers forming the lower layer have a filament density that gradually increases and a thickness that gradually increases toward the middle layer .