JP2007319179A - Cushion body and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To make a cushion body improved in body pressure dispersibility and air permeability, simple in structure and easy in cleaning. <P>SOLUTION: The air mattress 1 comprises a three-dimensional net-like structure 2 whose raw material or a main raw material is a thermoplastic resin or a thermoplastic elastic resin and which is a spring structure composed of a plurality of hollow continuous wires 3 irregularly entangled in a loop shape by extrusion molding and thermally bonded partially, and a closed part 4 and a closed part 5 respectively formed at both end parts in the longitudinal direction of the three-dimensional net-like structure 2. The closed part 5 is provided with a filling part 6 where the end part of the hollow continuous wire 3 is filled with a resin, an air amount adjusting part 7 connected with the filling part 6 and communicating with one end part of the hollow continuous wire 3 for adjusting the gas pressure of a gas enclosed inside the hollow continuous wire 3, and a valve 8 for supplying air to the air amount adjusting part 7. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  TECHNICAL FIELD The present invention relates to a cushion body that is capable of optimal hardness adjustment from a care recipient to a healthy person regardless of a user's weight and body shape, and realizes optimal body pressure distribution and is difficult to stand.

The air mattress of Patent Document 1 is formed in a substantially rectangular plate shape and is expanded to a predetermined height by being supplied with compressed air, and is laminated in the middle in the longitudinal direction of the upper surface of the main air mat. It is an invention comprising an auxiliary air mat that expands to a predetermined height on the upper surface of the main air mat by being supplied, and an exterior body that covers the main air mat and the auxiliary air mat. The air mattress of Patent Document 2 is an air bed device including three independent airtight segments that are linearly fixed to form an air mattress, and each segment of the air mattress can be inflated independently of each other. In this invention, the sleeper can adjust the level of support given to his / her head, waist and feet by changing the air pressure in each segment. Furthermore, the air mattress of Patent Document 3 includes an air tube, a mattress main body that holds the air tube and is covered with an exterior, and an air supply pump that is provided in the mattress main body and supplies compressed air to the airbag. It is an invention provided.
Japanese Patent Laid-Open No. 10-327986 Japanese Patent Application Laid-Open No. 11-188793 JP 2000-189288 A

  However, in the conventional air mattress, the core itself is excellent in dispersion of body pressure, but since the air tube is thick and each core is formed in a columnar shape, the gap between the cores is wide and a step is formed. . Therefore, it is the same state as sleeping on a round tree, and the weight is received linearly only at the top of the round tree, the weight cannot be received in the valley portion, and the body pressure dispersion is deteriorated. In addition, since the body of the air mat sinks, it is difficult for the care recipient to turn over and wake up. If you can't roll over or wake up, your muscles will weaken and recovery will be difficult. There is a need for independence support for care recipients. The air mattress seems to be floating above the air for the user and is unstable. When a caregiver moves a person requiring care, such as when the knee is placed on the mat, the posture of both the caregiver and the care recipient becomes unstable, which is inconvenient. Also, it is uncomfortable. In addition, sweating from the human body increases and air permeability is lost. This is the main cause of stuffiness and floor slippage. It is structurally complex. Since there is usually an air generator, cleaning can only be performed by wiping and cleaning for waterproof reasons. Air mattresses are usually equipped with a compressor and a power source, but they do not function when moving the bed if the supply of electricity stops due to an earthquake or the like. If the air escapes, the body pressure dispersibility of the air mattress deteriorates and a bottomed state is obtained.

  Therefore, in view of the above problems, the air mattress's body pressure dispersibility is improved, it is easy to turn over and wake up, the stability of the user's posture is ensured, the sleeping comfort is improved, the air permeability is improved, and the steam and floor The purpose is to prevent misalignment, simplify the structure, and facilitate cleaning.

  In order to achieve this object, the invention according to claim 1 is a three-dimensional network structure having a spring structure formed by irregularly heat-bonding or heat-welding hollow continuous filaments, and the three-dimensional network structure. One of the closed portions formed respectively at both end portions and the closed portion is connected to the filled portion in which a gap between the hollow continuous filaments is filled with a filler, and the hollow continuous filament is connected to the filled portion. And a fluid amount adjusting unit that adjusts the pressure of the gas and / or the liquid pressure of the liquid enclosed in the hollow continuous filament. The cushion body here includes an air mattress, a seat, a pillow, a cushion, a bed cushion, a playground equipment, an exercise device (see JP 2005-224453), a medical device (dementia prevention device), etc., and the body pressure of the human body. What is necessary is just to disperse | distribute.

  In the three-dimensional structure according to a second aspect of the present invention, it is preferable that the fluid amount adjusting portions are formed at both ends in the longitudinal direction.

  According to a third aspect of the present invention, it is preferable that the fluid amount adjusting unit is divided into upper and lower parts, and the respective adjusting units are connected by a communication valve.

  According to the invention of claim 4, a thermoplastic continuous resin or a thermoplastic elastic resin is used as a raw material or a main raw material, and is composed of hollow continuous filaments that are irregularly entangled in a loop shape by extrusion and partially heat-bonded or heat-welded. A filling portion forming step for forming a filling portion in which a gap between the hollow continuous filaments is filled with a filler by solidifying one end portion of a three-dimensional network structure having a spring structure with a resin; A fluid amount for connecting an opening end forming step for forming the opening end of the hollow continuous filament by cutting the fluid, and a fluid amount adjusting unit communicating with the opening end for adjusting the amount of fluid connected to the filling unit An adjustment part forming step. A cushion body manufacturing method comprising:

  According to the cushion body according to claims 1 to 4, since the internal gas pressure can be freely adjusted by the fluid amount adjustment unit, the degree of freedom in designing the cylindrical thick portion of the hollow continuous filament increases, Convenience of handling is also increased. Moreover, the adjustment of the body pressure dispersion is excellent due to the pressure of the air sealed in the hollow continuous filament, and the adjustment of the hardness of the spring is easy by the fluid amount adjustment unit. In addition, the hollow continuous filaments with increased pressure are molded in a three-dimensional entanglement manner, each of which can be a spring, and the inside of the hollow continuous filament is pressurized air, It becomes a spring. Therefore, body pressure can be received in a planar manner, and body pressure dispersion is improved. In addition, the care recipient can easily turn over or wake up by the repulsive force of the cushion body. The care recipient's muscles prevent weakness and facilitate recovery, enabling independence support. Stabilize the posture of the caregiver and the person requiring care. For example, when the caregiver moves the care recipient, when the knee is placed on the cushion body, the posture of both the caregiver and the care recipient is stable. So it is convenient. In addition, the sleeping comfort is improved. Furthermore, by improving air permeability, it is possible to reduce sweating from the human body and prevent stuffiness and floor slippage. Furthermore, the cushioning property is improved, it is difficult to sag, and the data can be greatly improved even in the repeated load resistance test. In addition, the structure is simple, easy to clean, and easy to disinfect and wash. Furthermore, since the three-dimensional network structure is a simple structure, it can be easily recycled after use.

  According to the second aspect, the fluid amount can be quickly adjusted.

  According to the third aspect, the fluid can be circulated, which can contribute to health promotion such as blood flow promotion of the human body.

  Hereinafter, as an example of a cushion body of the present invention, an air mattress 1 according to an embodiment will be described with reference to the drawings. As shown in FIGS. 1 and 2, the air mattress 1 is a three-dimensional network structure 2 made of a thermoplastic resin or a thermoplastic elastic resin as a raw material or a main raw material, and is entangled irregularly in a loop shape by extrusion molding. It is a spring structure composed of a plurality of hollow continuous filaments 3 that are partially thermally bonded, and includes a closed portion 4 and a closed portion 5 that are respectively formed at both ends in the longitudinal direction of the three-dimensional network structure 2. ing. The closed portion 5 is connected to the filling portion 6 in which the end of the hollow continuous filament 3 is filled with resin, and to the filling portion 6, and communicates with one end of the hollow continuous filament 3, and the inside of the hollow continuous filament 3 The air amount adjusting unit 7 that adjusts the atmospheric pressure of the gas sealed in the air and the valve 8 for supplying air to the air amount adjusting unit 7 are provided. Details will be described below.

  The bulk specific gravity of the three-dimensional network structure 2 is 0.007 to 0.01, the hollowness is 30 to 95%, and the pressure of air enclosed in the hollow continuous filament 3 is 101 to 304 kPa (1.0 to 3 atm). It is preferable that it is set to. The three-dimensional network structure 2 is manufactured by extrusion molding. As the raw material or main raw material which is a thermoplastic resin, a flaky or chip-shaped resin raw material is used. It may be a recycled resin or a virgin resin. For example, as thermoplastic resins, polyolefins such as polyethylene and polypropylene, polyesters such as polyethylene terephthalate, polyamides such as nylon 66, polyvinyl chloride, polystyrene, copolymers and elastomers based on the above resins, and blends of the above resins Etc. A polyethylene resin mixed with vinyl acetate resin and rubber is preferable. If the raw material is thermoplastic urethane, elasticity can be maintained with low resilience.

  As shown in FIG. 2A, the closing part 4 closes each of the open ends at the end of the tube 30 of the hollow continuous filament 3. Or the obstruction | occlusion part 4 may obstruct | occlude the whole end surface like a film | membrane, for example. The closed portion 4 prevents air from leaking from the hollow portion 31 of the hollow continuous filament 3. The blocking unit 4 does not include the filling unit 6 and the air amount adjusting unit 7.

  The closing part 5 is formed on the opposite side of the pushing direction from the closing part 4. The filling portion 6 is filled with a resin or the like in the gap between the hollow continuous filaments 3 so that the hollow continuous filaments 3 are embedded therein. The end of the hollow continuous filament 3 has an open end 32 as shown in FIG. The open end 32 communicates the hollow continuous wire 3 with the air amount adjusting unit 7.

  The filling part 6 is made of resin. The filling part 6 includes an opening 61, a resin solidifying part 62, and a peripheral part 63 (see FIG. 5B). Resin is adhered or welded to the outer surface of the tube 30 so as to fill the outer region of the tube 30.

  The air amount adjusting unit 7 is a case having an open end surface, the opening of the air amount adjusting unit 7 and the end surface in the longitudinal direction of the three-dimensional network structure 2 are abutted, and the opening end 70 of the air amount adjusting unit 7 is a filling unit. 6 is connected to the peripheral edge 63 (see FIG. 6), and air is sealed inside the hollow portion 31 of the hollow continuous filament 3 and the air amount adjusting portion 7. A valve 8 is formed on the side surface of the air amount adjusting unit 7. By supplying air to the air amount adjusting unit 7, the air in the hollow portion 31 of the hollow continuous filament 3 can be pressurized. Therefore, as shown in FIG. 2 (c), the internal atmospheric pressure becomes high, so that the thickness of the tube 30 can be designed to be thin. Conventionally, as indicated by a dotted line 35, since the inside is atmospheric pressure, in order to prevent the three-dimensional network structure from sagging, the tube had to be thick, but in this respect, in this embodiment, As indicated by the solid line from the dotted line 35, the diameter of the hollow portion 31 can be increased and the thinning of the tube 30 can be realized. Therefore, the cost can be reduced and the degree of design freedom is increased.

  The valve 8 is a cylindrical metal part provided with a valve for preventing a reverse flow of the blown air when air is supplied to the air amount adjusting unit 7. When there is a pressure difference of a predetermined atmospheric pressure, air flows only in a certain direction. An air pump (not shown) can be attached to the valve 8.

  According to the air mattress 1 of the present embodiment, the internal gas pressure can be freely adjusted by the air amount adjusting unit 7, so that the degree of freedom in designing the cylindrical thick portion of the hollow continuous filament 3 is increased. Moreover, the adjustment of the body pressure dispersion is excellent due to the pressure of the air sealed in the hollow continuous filament 3, and the spring amount can be easily adjusted by the air amount adjusting unit 7. Further, since the hollow continuous filament 3 has a spring function by being molded in a three-dimensional entanglement manner, and since it has an air spring function by the inside of the hollow continuous filament 3 being pressurized air, it has cushioning properties. As a result, it becomes difficult to sag and the data can be greatly improved even in a repeated load resistance test. In addition, the structure is simple, easy to clean, and easy to disinfect and wash. Furthermore, since the three-dimensional network structure 2 is a simple structure, it can be easily recycled after use. Furthermore, since the thickness of the air mattress 1 can be reduced, the convenience of handling is enhanced. For example, when it is used while being laid on a chair for an elderly person, by reducing the thickness, there are advantages that the elderly person's feet can easily land and care can be facilitated.

  The manufacturing method of the air mattress 1 of this embodiment is demonstrated with reference to FIGS. As shown in FIG. 3, the method for manufacturing the air mattress 1 according to the present embodiment first uses a thermoplastic resin or a thermoplastic elastic resin as a raw material or a main raw material, and is entangled irregularly in a loop shape by extrusion and partially heats up. The three-dimensional network-structured main body 20 having a spring structure composed of hollow continuous filaments that are bonded or heat-welded and opened by cutting or the like at both ends is held by holding portions 35 and 36, and an end face region 38 is formed by a hot plate 37. By pressing, the open end of the hollow continuous filament in one end face region 38 of the three-dimensional network main body 20 is melted by heat and closed (step 1). The three-dimensional network-structure main body 20 is manufactured by spinning a thermoplastic resin with a large number of hollow continuous filaments from a downward nozzle, fusing each hollow continuous filament randomly, and solidifying by cooling. . The production method thereof is described in JP-B-50-39185, JP-A-55-17527, JP-A-58-149362, JP-A-1-207463, JP-A-1-314771, and the like. Since this is a technology, the description is incorporated.

  Next, as shown in FIG. 4, the three-dimensional network-structure main body 20 in which the open end of the end surface region 38 is closed in Step 1, with the end surface region 39 on the side opposite to the end surface region 38 facing down, as shown in FIG. As shown, the lower end is immersed in a treatment tank 51 containing a molten resin 50 and taken out as shown in FIG. 4B (step 2). As a result, the outer periphery of the hollow continuous filament (the gap between the hollow continuous filaments) is solidified and filled with resin, and the resin penetrates from the open end of the continuous hollow filament 3 into the inside of the inlet and is solidified. A filling portion 60 in which continuous filaments are embedded is formed.

  Next, as shown by an arrow C in FIG. 5A, the filling portion 60 is cut perpendicularly in the short direction from the middle to form the filling portion 6 (step 3). As shown in FIG. 5 (b), a plurality of openings 61 are formed at the ends of the hollow continuous filaments closed in Step 2. The opening 61 includes end portions of the tube 30 and the hollow portion 31.

  Next, the peripheral edge part 63 of the filling part 6 and the opening end part 70 of the air amount adjusting part 7 are connected by adhesion or welding (step 4). For example, there are methods such as adhering a film to the end face region with an adhesive, or welding by melting the end of a hollow continuous filament with heat. The valve 8 may be provided in the air amount adjusting unit 7 in a step before step 4 in advance, or the air amount adjusting unit 7 may be provided with the valve 8 after the connection. The air mattress 1 is manufactured as described above.

  When adjusting the pressure of the air mattress 1, as shown in FIG. 7, an air container 81 is inserted into the valve 8, and air is supplied into the air amount adjusting unit 7, thereby passing through the hollow continuous filaments in the filling unit 6. Thus, air is supplied from the filling unit 6 to the continuous hollow continuous filament. This adjustment may be performed during the manufacturing process of the air mattress 1 or may be performed by the user after the manufacturing.

  According to the manufacturing method of the air mattress 1 described above, one end portion of the three-dimensional network structure body 20 is immersed in resin and solidified to form the filling portion 60, which is cut, and the cut filling portion 6 is replaced with the amount of air. Since it is only necessary to connect to the adjusting unit 7, the manufacturing is extremely easy. Further, the pressure can be adjusted simply by inserting the air supply 81 into the valve 7 and supplying the air. Therefore, the spring hardness can be easily adjusted and the settling can be effectively prevented.

  As a modification of the above embodiment, the air mattress 1 shown in FIG. 8 has a filling portion 6 that is not a rectangular parallelepiped and an open end that is an inclined surface. The area to be connected is increased, and the cushioning property is enhanced by covering the surface side more widely with the hollow continuous filament. In addition, about the common structure, description of the said embodiment mentioned already is used.

  Further, as a different modification, the air mattress 1 shown in FIG. 9 has the air amount adjusting portions 7 formed at both ends in the longitudinal direction. Thereby, adjustment of air quantity can be performed rapidly. One or more valves 8 may be provided. For example, you may provide the valve | bulb 8 in each air quantity adjustment part 7 of both ends. In addition, about the common structure, description of the said embodiment mentioned already is used.

  Further, as a different modification, in the air mattress 1 shown in FIGS. 10A and 10B, the fluid amount adjusting unit 7 is divided into two upper and lower chambers, and each adjusting unit 7a, 7b is a communication valve. They are connected by 9a and 9b, respectively. The valve 9a distributes air from the upper air amount adjusting unit 7a to the lower air amount adjusting unit 7b, and the valve 9b distributes air from the lower air amount adjusting unit 7b to the upper air amount adjusting unit 7a. It is something to be made. FIG. 10A shows a structure in which the pump 10 is built in, and FIG. 10B shows the structure in which the pump 10 is externally connected to the lower air amount adjusting unit 7 b through the pipe 11. The valves 9a and 9b are preferably check valves through which air flows in one direction. In this structure, air is circulated in the air mattress 1. In addition, the temperature can be adjusted by installing the heater 12 in an appropriate place such as the pressure adjusting unit 7a and / or 7b. For example, natural vibrations can be generated by circulating hot water. Thereby, the blood flow of the human body is promoted, floor slippage prevention, and improvement of coldness can be achieved. By installing a cooling device (not shown) instead of the heater 12, cold water can be flowed in summer. In the above-described step 4, the air amount adjusting parts 7a and 7b that are divided in advance and formed into valves 9a and 9b, respectively, may be attached to the filling part 6 respectively. A structure in which the three-dimensional network structure body 20 is divided in advance by a sheet in advance in correspondence with the air amount adjusting units 7a and 7b is preferable. For the common structure, the description of the above-described embodiment is cited. To do.

  The present invention is not limited to the above-described embodiment, and modifications and the like can be made without departing from the technical idea of the present invention. It will be included in the technical scope of the present invention. For example, the implementation of step 1 of the manufacturing process does not necessarily have to be performed before step 2, and may be performed simultaneously with step 2 or after step 2. Further, in the embodiment shown in FIG. 10, a liquid may be used instead of air. Further, the liquid amount adjusting unit and the gas amount adjusting unit may be separately provided so that the liquid is circulated on the upper side and the gas is circulated on the lower side.

  According to the cushion body of the present invention, the spring of the cushion can be freely adjusted, and it can be washed and dried quickly, so it is clean and easy to use air mattress, pillow, bed cushion, seat cushion, play equipment, exercise equipment, medical equipment (cognition Disease prevention device).

1 is a perspective view of an air mattress 1 according to an embodiment of the present invention. (A) is a longitudinal sectional view in the axial direction of one end portion of the continuous hollow wire 3, (b) is a longitudinal sectional view in the axial direction of the other end portion, and (c) is a radial direction of the continuous hollow wire 3 in the radial direction. It is a longitudinal cross-sectional view. It is explanatory drawing which shows step 1 of the manufacturing process of an air mattress. It is explanatory drawing which shows the same step 2. FIG. (A) (b) is explanatory drawing which shows the same step 3. FIG. It is explanatory drawing which shows the same step 4. FIG. It is a perspective view which shows the air supply to the air mattress 1 by air filling. It is a perspective view which shows the air mattress 1 of a change form. It is a perspective view which shows the air mattress 1 of another modification. Furthermore, it is a perspective view which shows the air mattress 1 of another modified form.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Air mattress 2 ... Three-dimensional network-like structure 3 ... Hollow continuous filament 4 ... Blocking part 5 ... Blocking part 6 ... Filling part 7 ... Air quantity adjustment part 8, 9 ... Valve 10 ... Pump 11 ... Heater 30 ... Pipe 31 ... Hollow part 32 ... Open end 20 ... Three-dimensional network-structure body 35, 36 ... Holding part 37 ... Hot plate 38, 39 ... End face region 50 ... Resin 51 ... Treatment tank 60 ... Filling part 61 ... Opening part 62 ... Resin solidifying part 63 ... peripheral part 70 ... open end 81 ... pneumatic

Claims (4)

A three-dimensional network structure of a spring structure formed by irregularly heat-bonding or heat-welding hollow continuous filaments;
A closed portion formed in the three-dimensional network structure,
It has a structure in which liquid or gas is sealed inside,
The blocking part is
A filling portion in which a gap between the hollow continuous filaments is filled with a filler, and
A fluid amount adjusting unit that is connected to the filling unit, communicates with one end of the hollow continuous filament, and adjusts a fluid amount of the fluid enclosed in the interior;
A cushion body comprising:   The cushion body according to claim 1, wherein the fluid amount adjusting portions are formed at both ends in the longitudinal direction.   The cushion body according to claim 1, wherein the fluid amount adjusting part is divided into upper and lower parts, and each adjusting part is connected by a communication valve. A three-dimensional network structure with a spring structure composed of hollow continuous filaments that are made of thermoplastic resin or thermoplastic elastic resin as a raw material or main raw material and are entangled irregularly in a loop shape by extrusion and partially heat-bonded or heat-welded. A filling portion forming step of forming a filling portion in which a gap between the hollow continuous filaments is filled with a filler by hardening one end portion of the resin with a resin;
An opening end forming step for forming an opening end of the hollow continuous filament by cutting the filling part in the middle;
A fluid amount adjusting unit forming step of connecting a fluid amount adjusting unit communicating with the opening end and adjusting a fluid amount to the filling unit;
A method for manufacturing a cushion body, comprising:

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