JP2006158563A - Mattress core material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a mattress core material having a superior texture, being comfortable to sleep, having superior air permeability, hygroscopicity, and heat retaining property, preventing settling (lowering of cushioning property) of a part mainly receiving the body pressure, and especially suited for a nursing care. <P>SOLUTION: This mattress core material is formed of two-layer structure of a hard layer 1 formed of highly elastic cotton where polyester staples are three-dimensionally fixed at intersections, and a soft layer 1; the hard layer 1 has a basis weight of 1.8-2.5 kg/m<SP>2</SP>; the soft layer 2 has a basis weight of 1.4 to less than 1.8 kg/m<SP>2</SP>; and a reinforcing layer 3 formed of the highly elastic cotton with a basis weight of 0.4-0.8 kg/m<SP>2</SP>is press-fitted and highly densified across the whole width near the central part in the longitudinal direction of the hard layer 1 and/or the soft layer 2. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a core material for a mattress, and more specifically, feel and sleeping comfort are excellent, breathability, hygroscopicity, heat retention, and prevention of settling (decrease in cushioning properties) of a portion where a large body pressure is applied, More particularly, the present invention relates to a mattress core material suitable for nursing care.

Conventionally, as this kind of core material for mattresses, those made of futon cotton such as cotton and feathers, those made of plastic foam such as polyurethane foam and polyethylene foam, and those made of a combination of futon cotton and plastic foam, Etc. have been proposed.
A common problem among these is that the use of the product for a long time causes settling, and as a result, the appropriate cushioning property is lost, the comfortable touch and the sleeping comfort are lost, and the air permeability and the hygroscopic property are lowered.

  In particular, the area near the buttocks where the body pressure is high is large and the cushioning properties of this area are lost, not only the functions such as the above-mentioned touch are lost, but also the sinking of the buttocks is increased, and an appropriate lying posture is achieved. As a result, it becomes impossible to hold, and as a result, a good sleep cannot be obtained, and in some cases, the spine is adversely affected and health may be impaired.

  Moreover, in the case of a bed for nursing care, the person often sits near the center to eat and change clothes, and often gets on and off or sits down near the center of the bed. For this reason, there is a problem that the settling near the center becomes large.

  In order to solve such a problem, for example, it has an upper layer futon part, a lower layer futon part, and a futon core material arranged between the upper layer futon part and the lower layer futon part. The cloth and the lower cloth are connected to each other with gusseted tape, and the inside of the cloth is divided into a plurality of spherical body filling chambers by a partitioning tape, and the spherical body filled in the wool ball filling chamber of the futon cloth is provided. A mattress is proposed (for example, see Patent Document 1).

  In addition, to prevent settling, to maintain a correct sleeping posture, and to obtain a proper massage effect, a filling material for a duvet having an upper layer cotton part, a middle core material, and a lower layer cotton part was encapsulated with a bag-like duvet cloth. In the mattress, there is proposed a mattress in which the core material is configured by arranging unit core materials in which a winding material is wrapped in a rod shape with a cloth having rigidity in a row (see, for example, Patent Document 2). ).

In addition, the mattress body is suitable for both heavy and light people, providing a suitable softness that does not easily cause pressure ulcers, and that does not impair the resilience of caregivers sitting on the edge of the mattress. One of the front and back sides is a low hardness side foam layer and the other is a term hardness side foam layer, with the front and back foam layers laminated, with a frame-like edge and can be used with the front and back reversed There has been proposed a mattress for a bed (see, for example, Patent Document 3).
JP 2001-104110 A JP 2001-112585 A JP 2002-223901 A

  However, the mattress of Patent Document 1 is a futon core material, in which the upper and lower fabrics are connected with a gusseted tape and the interior is partitioned into a plurality of spherical body filling chambers by a partition tape, Since it has a very complicated structure of having a spherical body filled in the wool ball filling chamber, it is inevitable that the cost will be increased, and in addition, if the mattress is soiled by incontinence or food, washing is not easy. Contains.

  In addition, Patent Document 2 also uses a structure in which unit core materials in which a winding material is wrapped in a rod shape with a rigid cloth arranged in a row as an intermediate core material, and thus has an extremely complicated structure. Similarly, the cost is inevitably increased, and if water gets into the entrainment material during washing, it cannot be easily dried. After drying, it is necessary to wind up again in a paste form, and tedious work is inevitable.

  Furthermore, in Patent Document 3, it is said that a soft urethane foam is suitable as the high-hardness side foam layer and the low-hardness side foam layer, but compared to cotton, it is inferior in touch, sleeping comfort, and moisture absorption, Moreover, when it is contaminated by incontinence or food, it is trapped in the soft urethane foam, so it is unhygienic, and even when it is washed, the washing water is trapped and cannot be easily dried.

  The present invention solves the above-described problems of the prior art, makes use of the unique touch, comfort, breathability, moisture absorption, and heat retention properties of cotton, prevents settling, is easy to wash and is quick to dry. An object of the present invention is to provide a mattress core material suitable for use.

The present invention has been made to solve the above problems, and the invention of claim 1 is based on a two-layer structure of a hard layer and a soft layer made of high-elasticity cotton in which polyester short fibers are sterically fixed at intersections. becomes, the rigid layer is a basis weight 1.8~2.5kg / m ^2, soft electrolyte layer is basis weight from 1.4 to 1.8 less than kg / m ^2, of the hard layer and / or the soft layer A core material for a mattress, characterized in that a reinforcing layer made of the high elastic cotton having a weight per unit area of 0.4 to 0.8 kg / m ² is press-fitted and densified in the vicinity of a central portion in the longitudinal direction. Content.

The invention of claim 2 is characterized in that the hard layer has a basis weight of 1.85 to 2.5 kg / m ² and the soft layer has a basis weight of 1.4 to 1.8 kg / m ^2. The content is the core material for mattress described.

  The invention according to claim 3 is characterized in that each length of the hard layer and the soft layer is 1900 to 2200 mm, each width is 800 to 1000 mm, and each thickness is 30 to 60 mm. The core material for mattress is included.

  In addition, the invention according to claim 4 includes the core material for mattress according to any one of claims 1 to 3, wherein the vicinity of the central portion in the longitudinal direction is 500 to 700 mm.

  The invention of claim 5 is characterized in that the surface of the hard layer and / or the soft layer is processed into a corrugated shape in which arcs are connected in the longitudinal direction. The core material for mattress described in the above is included.

  The invention of claim 6 is characterized in that the core material for mattress according to any one of claims 1 to 5 is antibacterial processed.

  The invention according to claim 7 includes the core material for mattress according to claim 6, wherein the antibacterial processing is a coating treatment of a lava solution.

  Moreover, invention of Claim 8 is an object for nursing care, The content is the core material for mattresses of any one of Claims 1-7.

  The core material for mattresses of the present invention is densified by pressing a reinforcing layer made of polyester cotton over the entire width in the vicinity of the central portion in the longitudinal direction. The posture can be maintained, a good sleep can be obtained, and the health problems caused by an inappropriate lying posture can be removed.

  When used in a nursing bed, the area around the center where the sick person gets up, gets on, gets off, or sits down to eat or change clothes is dense with a reinforcing layer. Can be prevented.

  In addition, since the core material for mattress of the present invention uses a high-elasticity cotton in which polyester short fibers are three-dimensionally fixed at the intersection, the fiber connection is strong and flexible compared to conventional nonwoven fabrics and hard cottons. It responds flexibly to compression from all directions, does not cause stickiness even when used for many years, and can maintain excellent elasticity. As a result, the core material for mattresses excellent in the touch, sleeping comfort, breathability, moisture absorption, and heat retaining properties of the high elastic cotton is provided.

  Moreover, since the core material for mattresses of the present invention has a two-layer structure of a hard layer and a soft layer, a hard mattress and a soft mattress can be selectively used as desired.

  By processing the surface of the hard layer and / or the soft layer into a corrugated shape in which the arc shape is connected in the longitudinal direction, an acupressure effect from the corrugated portion can be obtained, and a concave groove formed between the corrugated portions can be ventilated. It plays the role of a road and can get a pressure ulcer prevention effect.

  Further, by applying antibacterial processing, an antibacterial effect against MRSA, Pseudomonas aeruginosa, Escherichia coli, etc. can be obtained, and it is particularly useful as a core material for mattresses used in home care and hospitals.

  Further, the core material for mattress of the present invention is excellent in breathability and water permeability because it is made of highly elastic cotton having a structure in which fibers are intertwined three-dimensionally. Therefore, even if it is contaminated by incontinence, etc. immediately. It does not stuffy or sticky, and can be easily washed by spraying water (hot water) or water (hot water) containing a detergent, and dries in a short time.

  Furthermore, since the core material for mattresses of the present invention can be obtained simply by laminating and compressing a hard layer, a soft layer, and a reinforcing layer, a mattress core material that is easy to manufacture and inexpensive can be provided.

The core material for mattresses of the present invention has a two-layer structure of a hard layer and a soft layer made of highly elastic cotton in which polyester short fibers are three-dimensionally fixed at the intersections, and the hard layer has a basis weight of 1.8-2. 5 kg / m ² , the soft layer has a basis weight of 1.4 to less than 1.8 kg / m ² , and the weight per unit area of the hard layer and / or the soft layer near the center in the longitudinal direction is 0 over the entire width. The reinforcing layer made of the high elastic cotton of 4 to 0.8 kg / m ² is press-fitted and densified.

  As the high-elasticity cotton in which polyester short fibers are three-dimensionally fixed at the intersection, for example, trade name “Elk” manufactured by Teijin Limited is preferably used.

The hard layer has a basis weight of 1.8 to 2.5 kg / m ² , the soft layer has a basis weight of 1.4 to less than 1.8 kg / m ² , preferably, the hard layer has a basis weight of 1.85 to 2.5 kg / m ² , The soft layer has a basis weight of 1.4 to 1.8 kg / m. When the hard layer exceeds 2.5 kg / m ² , it tends to be too hard, and when the hard layer is less than 1.8 kg / m ² , the difference from the soft layer is reduced, thereby providing a mattress core material for both soft use. The object of the present invention will not be fully achieved.

On the other hand, if the soft layer is less than 1.4 kg / m ² , it tends to be too soft, and if it is greater than 1.8 kg / m ² , the difference from the hard layer becomes small, and the core material for mattresses for both hard and soft use can be obtained. The object of the present invention to be provided is not fully achieved.

  The size of the core material for mattress of the present invention is not particularly limited, but usually the lengths of the hard layer and the soft layer are 1900 to 2200 mm, the widths are 800 to 1000 mm, and the thicknesses are 30 to 60 mm.

A reinforcing layer made of the above highly elastic cotton having a basis weight of 0.4 to 0.8 kg / m ² is press-fitted and densified in the vicinity of the central portion in the longitudinal direction of the hard layer or the soft layer or both the hard layer and the soft layer. . The vicinity of the central portion in the longitudinal direction is preferably about 500 to 700 mm in the vicinity of the central portion in the size described above, that is, about 250 to 350 mm on the left and right from the center line in the longitudinal direction. The width into which the highly elastic cotton is press-fitted is the entire width of the hard layer and the soft layer. In this way, high-elasticity cotton is press-fitted over the entire width to increase the density, so that, for example, even when sitting on the edge of the mattress during nursing care, no settling occurs. Further, if necessary, high-elasticity cotton is pressed into a width of about 10 to 20 cm from the end in the width direction to increase the density, and it is possible to more effectively prevent settling when sitting on the waist.

  When the surface of the hard layer or the soft layer or both the hard layer and the soft layer is processed into a corrugated shape in which the arc shape is connected in the longitudinal direction, a finger pressure effect is obtained, and a concave groove formed between the corrugated portions. Plays a role of airway and prevents pressure ulcers. Furthermore, if necessary, it is possible to further improve the air permeability by providing a vent hole in the concave groove portion.

The mattress core material of the present invention comprising the hard layer, soft layer and reinforcing layer can be made into a mattress core material particularly suitable for home care and hospital use by applying antibacterial processing. The antibacterial processing referred to in the present invention is used as a term including antibacterial processing.
Antibacterial processing includes the case where an antibacterial agent is kneaded in advance in the fiber, the case where the fiber is subjected to antibacterial treatment by post-processing, the case where the cotton is subjected to antibacterial treatment, and the like. Although it does not restrict | limit especially as an antibacterial agent, from the surface of safety, the Hiba liquid permitted as a food additive is preferable, for example, sprays the aqueous solution which diluted 100 milliliters of Hiba stock solution into 16 L of water on 300 kg cotton. Thus, an antibacterial effect against MRSA, Pseudomonas aeruginosa, and Escherichia coli (O157) can be obtained, and further, an insecticidal effect and a deodorizing effect can be obtained.

  An example of a method for producing a core material for a mattress according to the present invention will be described in the case where a reinforcing layer is press-fitted and densified into a hardened layer. A high-elastic cotton in which polyester short fibers are three-dimensionally fixed at an intersection is carded and molded. By using a machine, each cotton (thickness of about 80 to 90 mm) of a hard layer, a soft layer, and a reinforcing layer is obtained.

  Next, the hard layer and the soft layer are overlaid, in particular, the reinforcing layer is drawn out near the center of the hard layer, and compressed between rollers so that the total thickness is about 60 to 120 mm. Press into the hard layer to increase the density. When the surface is corrugated, after heat-treating the core material for the mattress with a high density at about 210 ° C., the temperature is maintained at about 180 ° C., and is provided at predetermined intervals so as to rotate on the shaft. Passing under a roller heated to a certain degree, a corrugated shape having a wavelength of approximately the roller interval is connected in the longitudinal direction, and a core material for a mattress is obtained in which concave grooves between the corrugated portions are formed in the width direction. The wave shape wavelength is preferably about 50 to 150 mm, and the wave height (height from the bottom surface of the groove portion to the wave shape center portion (top portion)) is preferably about 10 to 30 mm.

  In the above production method, when antibacterial processing is applied to cotton, a method of applying by spraying before leaving the carding and entering the molding machine is preferable. For the detailed apparatus and method, for example, the apparatus and method described in Japanese Patent No. 3443256 can be used.

  The core material for mattresses obtained as described above is accommodated in the side ground after being accommodated in the inner bag, thereby forming a mattress. As the inner bag, for example, a polyester mesh fabric is preferable. By storing it in the inner bag in this way, the core material can be easily handled during maintenance such as washing of the core material. Troubles such as loosening the square cotton are prevented. For example, polyester knitted fabric is preferable from the viewpoint of being gentle to the skin, and a flame-treated one is preferable.

Comparative Examples 1-4
As shown in FIG. 1 to FIG. 4, a high-elasticity cotton “Elk” (trade name of Teijin Ltd.) in which polyester short fibers are three-dimensionally fixed at an intersection, has a thickness of 1910 mm, a width of 900 mm, and a thickness of 40 mm. Four types of core materials A to D for mattresses were produced.
A is a core material for a mattress of a hard layer 1 having a basis weight of 2.0 kg / m ² , B is a core material for a mattress of a soft layer 2 having a basis weight of 1.5 kg / m ² , and C is a central portion of the core material of B ( A core material for a mattress in which a reinforcing layer 3 having a basis weight of 500 g / m ² is press-fitted and densified in a width of 600 mm, and D is a mattress core in which the reinforcing layer 3 is press-fitted and densified in the vicinity of the center in the core material A. It is a material.

Comparative Example 5
As shown in FIG. 5, a mattress core material in which a core material A (upper side) and a core material B (lower side) were laminated was manufactured.

  As shown in FIG. 6, in Comparative Example 5, the core material for mattress in which the upper and lower core materials A and B were reversed and the core material B (upper side) and the core material A (lower side) were laminated was manufactured.

Examples 1-3
As shown in FIGS. 7-9, the core material for mattresses (Example 1) which laminated | stacked the core material D (upper side) and the core material B (lower side), the core material D (upper side), and the core material C (lower side) ) And a mattress core material (Example 3) in which a core material C (upper side) and a core material D (lower side) are stacked.

[Physical properties of core material for mattress]
The physical properties of the core materials for mattresses of Comparative Examples 1 to 4, Comparative Examples 5 to 6, and Examples 1 to 3 were evaluated.
The basis weight, density, thickness, and compression characteristics were evaluated as basic physical properties of the mattress. The results are shown in Table 1.
Moreover, about the core material for mattresses of Comparative Examples 5-6 and Examples 1-3, the strong compression test was done on the following conditions as anti-stickiness evaluation. That is, after repeating compression (0.8 kg / m ² × 15 seconds) and release (10 seconds) 360 times, the residual strain is calculated from the thickness change before and after the compression test, and what percentage of the hardness before compression is The hardness was measured or the retention rate (25% stress) was obtained. The results are shown in Table 2. In addition, about the thing in which the reinforcement layer was press-fitted and densified, the physical property of the said densified part was measured and evaluated.

  From the results of Table 1 above, as is clear from the comparison between Comparative Example 5 and Example 1 having the same basis weight combination, the reinforcing layer of Comparative Example 5 was replaced with the core material A that was not press-fitted and densified, and the reinforcing layer was By using the core material D that has been press-fitted and densified, the compression characteristics are greatly improved. From the results of Table 2, the core material for the mattress of Example 1 remains as compared with the core material for the mattress of Comparative Example 5. It can be seen that the strain is small and the retention rate is greatly improved, that is, the sag resistance is greatly improved.

  Furthermore, instead of the core material B of the comparative example 5, the core material C of the embodiment 2 in which the reinforcing layer is press-fitted and densified, and the reinforcing layer is press-fitted and densified on both the upper side and the lower side is used. The compression characteristics are further improved, and the results shown in Table 2 indicate that the residual strain is further reduced, the retention rate is further improved, and the sag resistance is further significantly improved.

  Furthermore, in Example 2, the core material for mattress of Example 3 in which the upper core material D and the lower core material C are turned upside down and the upper core material C and the lower core material D are laminated. It can also be seen that, compared with the mattress core material of Comparative Example 6, the compression characteristics are improved, the residual strain is small, the retention rate is large, and the settling resistance is improved.

Example 4
Spray high-elastic cotton (hard layer, soft layer, reinforcing layer) by spraying at a rate of processing an aqueous solution obtained by diluting 50 ml of Hiba stock solution (manufactured by Maki Shoji Co., Ltd.) into 8 liters of water to a cotton processing amount of 150 kg. A mattress core was manufactured in the same manner as in Example 2 except that the antibacterial treatment was performed.
The obtained mattress core material was subjected to an antibacterial test and an acaricidal test by the following methods.

[Antimicrobial test]
About the core material for mattresses obtained in Example 2, MRSA (Methicillin Resistant Staphylococcus Aureus IID 1677), Pseudomonas aeruginosa (NBRC 3080) and Escherichia coli O157 (H7. Escherichia coli O157: H7 ATCC 43888) was tested for antibacterial properties. The results are shown in Table 3, and an excellent antibacterial (bacteriostatic) action was observed against any bacteria.

[Tick-proof test]
Mite prevention (repellency test) was tested by the invasion prevention method.
That is, a sample is spread on a petri dish having a diameter of 4 cm, and 50 mg of food is placed thereon. This is placed in the center of a petri dish having a diameter of 9 cm. Ten thousand mites [Dermatophagoides pteronyssinus (Tokyo Women's Medical University)] are introduced between these two petri dishes. Similarly, the same set is prepared for antibacterial untreated samples, and the samples are bred in a container at a temperature of 25 ° C. and a humidity of 75%. Twenty-four hours later, the food on the sample was collected by a saturated saline suspension method, and the sample and petri dish were washed out by a water washing method. As a result, the repelling rate was 95%.
Number of living mites in antibacterial untreated samples-Number of live mites repelled in antibacterial treated samples (%) = ──────────────────────────── × 100
Number of live mites in antibacterial untreated samples

Example 5
As shown in FIG. 10, in the core material for mattresses of Example 1, the surface of the core material D has a wavelength of about 100 mm, the width of the groove between the wave portions is about 10 mm, and the wave height (from the bottom of the groove portion to the wave shape center). The core material for mattresses was manufactured by applying a waveform processing of about 20 mm (height to the top (top)). A comfortable acupressure effect is obtained from the corrugated portion 4, and the concave groove portion 5 between the corrugated portions 4 functions as an air passage, has excellent air permeability, and is a sanitary core material for mattresses. This core material for mattress has a core D surface when it is desired to obtain a shiatsu effect with a hard texture and sleeping comfort, and a core B surface when it is desired to obtain a soft, flat texture and sleeping comfort. Can be used, and can be used according to preference.

Example 6
As shown in FIG. 11, in the core material for mattresses of Example 2, the surface of the core material D (upper side) and the surface of the core material C (lower side) were subjected to corrugated processing in the same manner as in Example 5 and the mattress. A core material was manufactured. A comfortable acupressure effect is obtained from the corrugated portion 4, and the concave groove portion 5 between the corrugated portions 4 functions as an air passage, has excellent air permeability, and is a sanitary core material for mattresses. This core material for mattresses can use the core material D surface if you want to get a hard texture and sleep, while you can use the core material C surface if you want a soft texture and comfort. It is possible to use properly according to.

Example 7
As shown in FIG. 12, in the core material for a mattress of Example 3, the surface of the core material C (upper side) and the surface of the core material D (lower side) are subjected to corrugated processing in the same manner as in Example 5 for mattress use. A core material was produced. A comfortable acupressure effect is obtained from the corrugated portion 4, and the concave groove portion 5 between the corrugated portions 4 functions as an air passage, has excellent air permeability, and is a sanitary core material for mattresses. This core material for mattresses can use the core material C surface for hard texture and sleeping comfort, while the core material D surface can be used for soft texture and sleeping comfort. It is possible to use properly according to.

  As described above, according to the present invention, the touch and the sleeping comfort are good, the breathability, the hygroscopic property and the heat retaining property are excellent, and the portion where the body pressure is greatly applied is prevented from being loosened (decrease in cushioning properties). A mattress core material useful as a mattress core material suitable for use is provided. In addition, since the core material for mattress of the present invention is composed of a hard layer and a soft layer, according to preference, it is possible to use properly a hard texture, a comfortable feeling, and a soft texture, a comfortable feeling, A bed life that is rich in change and interesting.

It is a perspective view which shows the core material for mattresses in the comparative example 1. It is a perspective view which shows the core material for mattresses in the comparative example 2. It is a perspective view which shows the core material for mattresses in the comparative example 3. It is a perspective view which shows the core material for mattresses in the comparative example 4. It is a perspective view which shows the core material for mattresses in the comparative example 5. It is a perspective view which shows the core material for mattresses in the comparative example 6. It is a perspective view which shows the core material for mattresses in Example 1. FIG. It is a perspective view which shows the core material for mattresses in Example 2. FIG. 6 is a perspective view showing a core material for mattresses in Example 3. FIG. It is a perspective view which shows the core material for mattresses in Example 5. FIG. It is a perspective view which shows the core material for mattresses in Example 6. FIG. It is a perspective view which shows the core material for mattresses in Example 7. FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Hard layer 2 Soft layer 3 Reinforcement layer 4 Waveform part 5 Groove part

Claims (8)

It has a two-layer structure of a hard layer and a soft layer made of highly elastic cotton in which polyester short fibers are three-dimensionally fixed at an intersection, and the hard layer has a basis weight of 1.8 to 2.5 kg / m ^2. layer is basis weight from 1.4 to 1.8 less than kg / m ^2, the hard layer and / or over the entire width in the longitudinal direction in the vicinity of the center portion of the soft layer basis weight 0.4~0.8kg / m ² A core material for a mattress, wherein the reinforcing layer made of the high elastic cotton is press-fitted and densified. Hard layer is basis weight 1.85~2.5kg / m ^2, claim 1 mattress core material according to the soft layer is characterized by a basis weight 1.4~1.8kg / m ^2.   The core material for a mattress according to claim 1 or 2, wherein each length of the hard layer and the soft layer is 1900 to 2200 mm, each width is 800 to 1000 mm, and each thickness is 30 to 60 mm.   The core material for a mattress according to any one of claims 1 to 3, wherein the vicinity of the central portion in the longitudinal direction is 500 to 700 mm.   The core material for a mattress according to any one of claims 1 to 4, wherein the surface of the hard layer and / or the soft layer is processed into a corrugated shape in which arc shapes are connected in the longitudinal direction.   The core material for mattresses according to any one of claims 1 to 5, which is antibacterial processed.   The mattress core material according to claim 6, wherein the antibacterial processing is a coating treatment with a lava solution. The core material for mattresses according to any one of claims 1 to 7, wherein the core material is for nursing care.

Images