JP2005211602A - Core material for futon quilt - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a core material for Futon quilt, which has an excellent productivity, air-permeability, and foldability, and further has a reduced weight. <P>SOLUTION: The core material for the Futon quilt is composed of a woven fabric made of resin foam strips 1. The core material composed of the woven fabric prevents the generation of punched waste and has the excellent productivity, different from a conventional core material of Futon quilt, in which air vents and folding holes are bored by punching. Gaps 4 at intersection parts of the resin foam strips, which uniformly exist all over the core material, provide a good air-permeability to the whole of the body thereon. The gaps facilitates the folding thereof. The core material has the reduced weight due to the resin foam material. A resin foam with closed cells is rich in elasticity and small in deterioration of elasticity with time accompanying the use. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a lightweight futon core material that is excellent in productivity, breathability, and foldability.

Futons such as mattresses are required not to give a feeling of bottoming to the person who lies on the mattress, but to provide a comfortable sleep by demonstrating appropriate air permeability. Further, it is required that the folding property is good when stored, and that both side end portions (both end portions in the width direction) after folding are easily bent and excellent in storing property.

2. Conventionally, a futon core material is formed by punching a vent hole 7 and a hole (folding hole) 8 for facilitating folding at a required portion of a profiled foam sheet 6 as shown in FIG. (For example, Patent Document 1) and a plurality of independent notches having a linear shape in plan view penetrating from the front surface to the back surface in the center portion in the width direction of the foam sheet 6 as shown in FIG. What formed No. 9 was used (for example, patent document 2).

Japanese Patent Laid-Open No. 9-272166 JP 2001-186964 A

However, the former (Patent Document 1) is inferior in productivity because punching waste is generated because a vent hole and a folding hole are formed in the foam sheet by punching, and the processing is troublesome. Further, if the ventilation holes and the folding holes are reduced in consideration of the productivity, there is a problem that sufficient ventilation and folding properties cannot be obtained.

  In the latter (Patent Document 2), punching scraps are not generated, but the cut portion is opened only when weight is applied. Therefore, the cut portion is difficult to open in a lightweight portion such as below the knee. In some cases, it was difficult to obtain sufficient breathability throughout the lying body.

The air permeability was inferior particularly when the foam sheet was formed from a closed cell resin foam. In addition, when the air permeability is poor, it causes discomfort to the person lying on the futon and causes mold, and when the folding property is poor, it is difficult to carry and store.

  An object of this invention is to provide the core material for duvets which is excellent in productivity, air permeability, and foldability, and is lightweight.

  A first aspect of the present invention is a futon core material comprising a woven fabric of a strip-shaped resin foam.

  A second aspect of the present invention is the futon core material according to the first aspect, wherein the resin foam is a closed cell type resin foam.

Since the futon core material of the present invention is made of a woven fabric, unlike the futon core material in which the vent holes and the folding holes are formed by punching, punching dust is not generated and the productivity is excellent. Further, there are gaps at the intersecting portions of the belt-shaped resin foams, and the gaps exist uniformly over the entire core material for the duvet, so that good air permeability can be obtained over the entire lying body. Furthermore, folding can be easily performed due to the presence of the gap.
The futon core material of the present invention is lightweight because the material is a resin foam. Also, those using closed cell type resin foams are rich in elasticity, and the deterioration over time of the elasticity due to use is small.

Hereinafter, the present invention will be specifically described with reference to the drawings.
FIG. 1 is a plan view showing an embodiment of the present invention.
This core material for futon consists of a plain fabric woven by crossing every other horizontal band 2 and vertical band 3 of a strip-shaped resin foam 1 having a rectangular cross section. There is a gap 4 at a portion where the horizontal band 2 and the vertical band 3 intersect, and this gap 4 serves as a vent.

This core material for futon is formed by using a wide band-shaped resin foam on the outer frame 5 and the horizontal band 2 to form a strong skeleton and weaving a narrow band-shaped resin foam as a vertical band 3 there. . Since the vertical belt 3 is narrow, weaving can be easily performed.
Thus, in the present invention, the cross-sectional shapes of the outer frame 5, the horizontal band 2, and the vertical band 3 can be arbitrarily selected according to the purpose.
In the present invention, if the outer frame 5 and the horizontal band 2 are bonded together by heat fusion or the like, the shape is stably maintained, so that air permeability is improved.

In the present invention, any resin foam such as a polyolefin foam, a polyurethane foam, a polystyrene foam, a vinyl acetate foam, or those obtained by subjecting these foams to crosslinking treatment can be used as the strip-shaped resin foam.

The expansion ratio can be appropriately selected, but is preferably 10 to 50 times. If the expansion ratio is less than 10 times, the sheet itself is hard and uncomfortable, and the folding property is also deteriorated. On the other hand, if the expansion ratio is greater than 50, not only is it too soft and the durability is inferior, but permanent distortion remains or a feeling of bottoming occurs, resulting in poor sleeping comfort.

In the present invention, the closed cell resin foam means a resin foam in which 60% of the total thickness of the foam is a closed cell resin foam. For example, an open-cell resin foam itself based on polyolefin or the like, or an open-cell resin foam on at least one side of the closed-cell resin foam, for example, less than 40% of the thickness of the entire foam is open-cell This is a foam sheet made of the above rubber as a base resin.

The cross-sectional shape of the strip-shaped resin foam is arbitrary, such as a rectangle, a square, a rhombus, an ellipse, and a circle.
The cross-sectional dimension of the belt-shaped resin foam is not particularly limited, but the smaller the gap, the greater the gap between the fabrics and the better the air permeability.

  In the present invention, any fabric such as plain weave, oblique weave, and satin weave can be applied to the fabric of the strip-shaped resin foam.

  Increasing the weave density of the belt-shaped resin foam improves cushioning and heat retaining properties, and decreasing the weave density improves air permeability and reduces weight. In particular, when the weaving density is reduced, it is desirable to maintain the air permeability and shape by joining the intersecting portions of the horizontal band and the vertical band by heat fusion or the like.

The futon core material of the present invention may be used singly or in a plurality of layers.
When a plurality of sheets are used in a stacked manner, it is desirable to maintain the shape by joining the edges of the futon core material to each other by heat fusion or the like.

  The core material for a futon according to the present invention is used as a mattress, a comforter, a cushion, a cushion or the like with a cover.

The core material having the structure shown in FIG. 1 was manufactured using a closed-cell-type band-like polyethylene foam (apparent density 32 kg / m ³ , foaming ratio 30 times), and this was covered with a cover and used as a mattress. The cross-sectional dimensions of the strip-like polyethylene foam were 10 mm thick and 60 mm wide for the frame and horizontal strip, and 10 mm thick and 30 mm wide for the vertical strip.
As a result of use, there was no deterioration in elasticity over time, and the entire lying body was breathable and comfortable. In addition, it is easy to carry and store because it is foldable and lightweight. Furthermore, manufacturing was also easy because almost no waste was generated.

It is plane explanatory drawing which shows embodiment of the core material for futons of this invention. It is plane explanatory drawing of the core material for conventional futons. It is an isometric view explanatory drawing of the other conventional core material for futons.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Band-shaped resin foam 2 Horizontal band 3 Vertical band 4 Crevice 5 Outer frame 6 Foam sheet 7 profile-processed 7 Vent hole 8 Folding hole 9 Notch

Claims (2)

  A futon core material comprising a belt-shaped resin foam woven fabric.   2. The futon core material according to claim 1, wherein the resin foam is a closed cell resin foam.

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