JP2011098125A - Pillow and method for manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a pillow having extremely excellent moisture absorption and water absorption properties which achieves efficient moisture absorption and deodorization by the whole cinder when used as the pillow, and achieves an optimal environment when used in a living environment or for medical purpose. <P>SOLUTION: In the pillow, a coal layer 30 is provided inside a surface layer 35 having air permeability. The coal layer 30 includes: a fiber elastic void mat 31 which elastically deforms by combining, in a three-dimensional and non-directional manner, curling fibers 32 formed in a curved shape into a predetermined thickness and joining the intersections; and granular coal 33 formed by being filled into a gap of the curling fibers 32 of the fiber elastic void mat 31. The granular coal 33 is charcoal cinder 3 made by burning a wood chip 2. The pillow is closed by bonding a surface layer 35 on the surface of the fiber elastic void mat 31 through which the cinder 3 does not pass the void of the fiber elastic void mat 31, and the fiber elastic void mat 31 is elastically deformed in the thickness direction to allow forced ventilation by passing air through the surface layer 35. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a pillow and a method for manufacturing the same, and more particularly, to a pillow excellent in deodorizing characteristics filled with granular charcoal and a method for manufacturing the same.

  Pillows have been developed in which charcoal grains and machined curl-shaped pieces of wood are mixed and filled into a breathable cloth bag. (See Patent Document 1)

Japanese Patent Laid-Open No. 11-76022

  The pillows of the above publications contain charcoal particles mixed with curled wood pieces and housed inside, so deodorization and moisture absorption can be achieved with the filled charcoal, and further, cushioning properties can be achieved with the curled wood pieces. Can be realized. However, since this pillow is mixed and filled with wood pieces and charcoal particles, it is difficult to keep the wood pieces and charcoal particles having different specific gravities in a uniformly dispersed state. For this reason, a piece of wood and a charcoal grain are separated according to use, and there is a fault that it is difficult to use the whole with uniform cushioning properties. In addition, since it is cut into a curled shape to obtain a piece of wood, there is also a drawback that it is easy to crack over time and cushioning cannot be realized over a long period of time.

  The present invention has been developed for the purpose of solving the above drawbacks. An important object of the present invention is to provide a pillow that can be comfortably used for a long period of time, in addition to realizing extremely excellent deodorization and moisture absorption by extinguishing charcoal, and a method for manufacturing the same. There is.

  Furthermore, another important object of the present invention is to provide a pillow capable of realizing excellent deodorization characteristics while reducing the raw material cost and the manufacturing cost and mass-producing it at low cost, and a method for manufacturing the pillow.

Means for Solving the Problems and Effects of the Invention

  In the pillow according to the present invention, the charcoal layer 30 is provided inside the breathable surface layer 35. The charcoal layer 30 gathers curl fibers 32 formed into a shape curved with a predetermined radius of curvature to a predetermined thickness with no three-dimensional orientation, and provides voids between the curl fibers 32, The fiber elastic gap mat 31 is elastically deformed in the thickness direction by a load acting on the surface by joining the intersections, and the granular charcoal 33 is formed by filling the gap of the curled fibers 32 of the fiber elastic gap mat 31. The granular charcoal 33 is a charcoal 3 made by burning wood chips 2 formed by crushing wood into chips. The surface layer 35 is air permeable and has fine gaps that do not allow the granular charcoal 33 to pass therethrough. The pillow adheres the surface layer 35 to the surface of the fiber elastic gap mat 31 and closes the gap of the fiber elastic gap mat 31 so that the charcoal 3 does not pass through. The fiber elastic gap mat 31 is elastic in the thickness direction. The air is passed through the surface layer 35 and forced ventilation is performed.

  The above pillow is characterized by realizing extremely excellent deodorizing properties and moisture absorption characteristics. This feature is achieved by using granular charcoal that achieves deodorizing and moisture absorption characteristics as extinguisher, filling the voids of the fiber elastic gap mat, and molding the fiber elastic gap mat into a shape that curves with a predetermined radius of curvature. The curled fibers are gathered in a predetermined thickness without any direction in three dimensions, a gap is provided between the curled fibers, the intersection points of the curled fibers are joined, and the thickness of the head acts on the surface in the thickness direction. This is because the structure is elastically deformed. The pillow with this structure can uniformly fill the entire surface of the fiber elastic gap mat with granular charcoal, and can connect the gaps filled with granular charcoal to each other. Because it is elastically deformed in the vertical direction and forced ventilation is performed, extremely excellent deodorization and moisture absorption characteristics are realized. Further, the extinguishment of granular charcoal formed by filling the voids of the fiber elastic void mat is not produced by dry distillation or activation of wood like charcoal or activated carbon. Charcoal extinction is produced by burning wood chips obtained by crushing wood into chips. This charcoal is produced by putting the whole wood chip into a burning state and then stopping the supply of oxygen. In addition to the extremely low cost of raw materials, the charcoal produced by this method can be produced in large quantities in a simple incinerator, so that, for example, a large amount of waste and thinned wood generated by breaking a building can be reused effectively as a raw material. it can. Since charcoal is produced with the whole wood chip burning, the volume of the resulting charcoal is considerably less than the raw material. For example, the charcoal produced by the following method is reduced to about half of the raw wood chips. However, since extremely cheap waste wood can be used for the wood chip, even if the volume of the charcoal is reduced by half, it is effective that the obtained charcoal characteristics are superior to those of charcoal and activated carbon. In addition to halving the volume in the manufacturing process, charcoal extinction is not excellent as a fuel because it generates less heat when used in fuel. However, compared to charcoal and activated carbon, the porosity is extremely high and light, so deodorization and hygroscopicity are superior to charcoal and activated carbon compared to charcoal and activated carbon. For this reason, the deodorization and moisture absorption are effectively used for a pillow, and the outstanding characteristic which can be used extremely comfortably is implement | achieved.

  Furthermore, the remarkable feature of the present invention is that the deodorizing / moisture absorption characteristics of the charcoal can be comfortably maintained while realizing a comfortable cushioning property over a long period of time. This is because the pillow according to the present invention collects curled fibers three-dimensionally without any direction, and provides a space having a cushioning property by joining the intersections of the fibers, and this space is filled with extinguisher. The charcoal filling the voids of the fiber elastic void mat has curled fibers disposed between the charcoal extinguishers. The charcoal filled in the fiber elastic gap mat in this state does not become a dense pressure state but is separated from each other, and a blower gap that allows air to be smoothly blown is formed between the charcoal and the charcoal. Furthermore, the ventilation gap formed during charcoal removal becomes a continuous state by the curled fibers and is opened to the outside. The pillow having this structure is elastically deformed by the cushioning property of the fiber elastic gap mat, forcibly blows air, and is uniformly blown to the inside of the charcoal. For this reason, all the charcoal filling between the curled fibers comes into contact with air, and each charcoal has an effect of absorbing air and deodorizing extremely efficiently.

  Furthermore, since charcoal extinction is made by burning wood into charcoal, there is a feature that various organic substances and germs contained in waste wood can be completely lost. For this reason, by using waste wood as charcoal extinction, a large amount of waste wood that is not effectively used can be effectively reused to realize a comfortable living environment for pets and users. In other words, the ideal property of making the living environment comfortable is realized by using the waste wood that is difficult to dispose of.

  The above-described extinguishing is produced, for example, in the incinerator 10 shown in FIGS. The incinerator 10 is filled with wood chips 2 obtained by crushing wood into chips. The upper wood chip 2 is ignited with the open / close lid 16 of the air hole 15 opened. The opening / closing lid 16 is pulled in a closing direction by a spring (not shown), but is opened by being stretched by a stretching rod 23 that fixes a wood rod 19 such as a split chopstick to the tip. When the wood rod 19 of the disposable chopsticks disappears, the air hole 15 is pulled by a spring and closed. The fire ignited on the wood chip 2 gradually burns the lower wood chip 2, and when the bottom wood chip 2 starts to burn, the wood rod 19 of the split chopsticks burns and the open / close lid 16 is closed. When the opening / closing lid 16 is closed, the supply of air is stopped. If it cools in this state, it can extinguish. Since the charcoal produced by the above method stops supplying oxygen in a burning state, it is softer and more porous than charcoal or activated carbon, realizing excellent moisture absorption and deodorizing characteristics.

  Furthermore, in addition to using extinguishers for the granular charcoal, the above pillow has a predetermined thickness without three-dimensionally directing the curled fibers formed into a shape that is curved with a predetermined radius of curvature. Then, a gap is provided between the curled fibers and the intersections of the curled fibers are combined to form a base material that is elastically deformed in the thickness direction by a load acting on the surface. Since this fiber elastic gap mat is in a state where the gaps communicate with each other, the water absorption rate of the charcoal filled in the gap does not become unbalanced. In particular, the fiber elastic gap mat is elastically deformed in the thickness direction. Because of the forced ventilation, the water absorption amount of the charcoal filled in the gaps of the fiber elastic gap mat is made uniform to eliminate the excessive moisture absorption of specific charcoal, and the water absorption amount of the entire charcoal is considerably increased. it can.

  In particular, since the fiber elastic gap mat of the above pillow can be elastically deformed in the thickness direction, it is always elastically deformed by the load of the user's head, realizing a comfortable environment for the user, and elastically deforming. Forced ventilation of the air in the air gap by pump action. Air forcedly ventilated inside and outside from the fiber elastic gap mat eliminates an imbalance in the water absorption rate of the charcoal filling the gap and also provides a comfortable cushioning for the user when used as a pillow.

  Therefore, the above pillow can reduce the imbalance of the water absorption rate of the charcoal filling in the gap of the fiber elastic gap mat, and can be controlled to an optimum environment effectively for all the charcoal filling in the gap. A comfortable pillow is obtained by placing the head on top and elastically deforming like a cushion. Further, the fiber elastic gap mat is elastically deformed uniformly by the curled fibers to realize a comfortable cushioning property.

The pillow of the present invention can be a synthetic fiber in which the thickness of the curled fiber 32 of the fiber elastic gap mat 31 is 0.2 mm to 1 mm.
The above pillow can elastically deform the fiber elastic gap mat in an ideal state by using the curled fiber as a synthetic fiber having a specific thickness. For this reason, this pillow can realize an effective deodorizing / moisture absorption characteristic by comfortably elastically deforming the fiber elastic gap mat and efficiently forcibly ventilating in the state of use.

The pillow of the present invention can form the curled fibers 32 of the fiber elastic gap mat 31 into a curved shape with a radius of curvature of 5 mm to 2 cm.
By specifying the radius of curvature of the curled fiber, this pillow can increase the void ratio formed between the curled fibers and can be filled with granular charcoal made of a large amount of charcoal to improve the deodorization and moisture absorption characteristics.

In the pillow according to the present invention, the surface layer 35 is composed of a cushion sheet 36 bonded to the surface of the fiber elastic gap mat 31 and a breathable surface sheet 37 bonded to the surface of the cushion sheet 36. Can do.
In the above pillow, a cushion sheet is provided on the surface of a fiber elastic gap mat made of curled fibers, so that the curved curled fibers do not come into direct contact with the surface sheet. The fibers can contact the topsheet. For this reason, the cushioning action of the cushion sheet realizes a uniform cushioning property on the surface of the surface layer. Further, it is possible to prevent the curled fibers from being locally pressed against the surface sheet and damaged.

In the pillow of the present invention, the cushion sheet 36 can be a soft plastic foam having open cells.
This pillow is a soft plastic foam cushion sheet having open cells, and can effectively prevent leakage of granular charcoal filled in the voids of the fiber elastic void mat while realizing air permeability. Moreover, comfortable cushioning on the pillow surface can also be realized by the open cell plastic foam.

  The pillow of the present invention can cover the surface of the charcoal 3 with the thin film coating layer 7 having air permeability made of an emulsion type connecting agent.

  In the above pillow, since the surface of the charcoal that is light and easily damaged is covered with a thin-film coating layer having air permeability, the charcoal surface can be prevented from being damaged without deteriorating the water absorption characteristics of the charcoal. In particular, it is possible to effectively prevent breakage of the charcoal in a state where the fiber elastic gap mat is elastically deformed and pressure is applied to the granular charcoal. Since the charcoal has a high porosity and is extremely flexible as a whole, it has excellent deodorizing characteristics and water absorption characteristics, but it tends to generate a large amount of powdery black powder cracked from the surface in the handling process. If the amount of broken black powder is large and very small, and if the voids of the fibrous material and the bubbles of the plastic foam are large, they easily pass through the fine voids of the surface layer and leak to the surface. Furthermore, when the charcoal is broken and powdered, and is filled in the voids of the fiber elastic void mat in a powdery state, the void ratio is reduced, and there is a detrimental effect that deodorization characteristics and water absorption characteristics are deteriorated. Thus, the charcoal-extinguishing which has a unique physical property can eliminate the defect of the charcoal which is easily damaged from the coating without deteriorating the deodorizing characteristic and the water-absorbing characteristic by coating the surface with a thin air-permeable coating layer. In addition, when the surface is covered with a thin film coating layer, the charcoal that has become difficult to break can be filled smoothly into the gaps between the curled fibers by vibrating the fiber elastic gap mat, etc. Can be filled.

  Furthermore, the charcoal obtained by burning wood chips obtained by crushing wood into chips of a specific size has fewer protruding corners in the process of extinction. When the fiber elastic gap mat is vibrated using granular charcoal as a granular charcoal and filled into the gap, it is unlikely to form a bridge like the charcoal with corners, and the gap between the curled fibers is smoothly filled, resulting in deodorizing characteristics and water absorption characteristics. It can be improved.

In the pillow of the present invention, the thin film coating layer 7 formed by coating the surface of the extinguisher 3 can be made of vinyl acetate resin.
This pillow is coated with a thin film coating layer made of an emulsion type vinyl acetate resin, so the surface of the extinguisher is soft and the surface is easily damaged. You can make an environmentally friendly and healthy pillow. Further, since the vinyl acetate resin of the thin film coating layer is water-soluble, the film thickness can be adjusted to be extremely thin by diluting with water and adhering to the surface of the charcoal. That is, by controlling the diluting ratio with water, the air permeability in the state of adhering to the surface of the charcoal can be optimized.

  The method for manufacturing a pillow according to the present invention is a method for manufacturing a pillow in which a charcoal layer 30 is provided inside a breathable surface layer 35, and the charcoal layer 30 is formed into a shape curved with a predetermined radius of curvature. The curled fibers 32 are gathered to a predetermined thickness without any direction in three dimensions, a gap is provided between the curled fibers 32, the intersections of the curled fibers 32 are joined, and elastic in the thickness direction by a load acting on the surface It is made of a deformable fiber elastic gap mat 31 and granular charcoal 33 formed by filling the voids of the curled fibers 32 of the fiber elastic gap mat 31. The granular charcoal 33 is manufactured as a wood chip 2 by crushing wood into chips, burning the wood chip 2, shutting off the air, and producing the charcoal 3. Further, in the pillow manufacturing method, the fiber elastic gap mat 31 is vibrated to fill the gaps between the curled fibers 32 of the fiber elastic gap mat 31 with the granular charcoal 33 made of the extinguisher 3. In the method of manufacturing the pillow, the surface layer 35 having a fine gap that is air permeable and does not allow the granular charcoal 33 to permeate is adhered to the surface of the fiber elastic gap mat 31 filled with the granular charcoal 33 of the extinguisher. With the surface layer 35, the surface is blocked so that the charcoal removal 3 does not leak from the gaps of the fiber elastic gap mat 31.

  The above-described pillow manufacturing method is characterized in that, in addition to the feature of the pillow of claim 1, mass production can be easily and easily performed at low cost while uniformly dispersing granular charcoal made of extinguisher on a fiber elastic gap mat. is there.

It is a perspective view of the pillow concerning one example of the present invention. It is an expanded view which shows the manufacturing process of the pillow shown in FIG. It is a vertical sectional view of the pillow shown in FIG. It is an enlarged photograph which shows an example of a fiber elastic space | gap mat | matte. It is an enlarged photograph which shows the state which filled the clearance gap between the fiber elastic space | gap mats shown in FIG. 4 with granular charcoal. It is a schematic process drawing which shows the manufacturing process of the charcoal used for the pillow shown in FIG. It is a perspective view which shows an example of the incinerator which manufactures charcoal extinction. It is a vertical sectional view of the incinerator shown in FIG. It is a schematic perspective view which shows a smooth process.

  Embodiments of the present invention will be described below with reference to the drawings. However, the Example shown below illustrates the pillow for actualizing the technical idea of this invention, Comprising: This invention does not specify a pillow as the following.

  Further, in this specification, in order to facilitate understanding of the scope of claims, numbers corresponding to the members shown in the examples are indicated in the “claims” and “means for solving problems” sections. It is added to the members. However, the members shown in the claims are not limited to the members in the embodiments.

  A pillow according to an embodiment of the present invention is shown in FIGS. The pillows shown in these drawings are provided with a charcoal layer 30 inside a breathable surface layer 35. The illustrated pillow has a charcoal layer 30 inside the upper and lower surface layers 35.

  The charcoal layer 30 is filled with granular charcoal 33 in the gaps between the fiber elastic gap mats 31. FIG. 4 shows an enlarged photograph of the fiber elastic gap mat 31, and FIG. 5 shows an enlarged photograph of the state in which the granular charcoal 33 is filled in the gaps of the fiber elastic gap mat 31 shown in FIG. 4. As shown in these photographs, the fiber elastic gap mat 31 is a curled fiber 32 formed by gathering curled fibers 32 formed into a shape curved with a predetermined radius of curvature into a predetermined thickness in three dimensions without directionality. A mat that elastically deforms in the thickness direction by a load acting on the surface is formed by joining the intersections of the curled fibers 32 while providing a gap therebetween. Granular charcoal 33 is filled in the gaps between the curled fibers 32 of the fiber elastic gap mat 31.

  The curled fiber 32 of the fiber elastic gap mat 31 is a synthetic fiber having a thickness of 0.5 mmφ. However, synthetic fibers having a thickness of 0.2 mm to 1 mm can be preferably used for the curled fiber 32. If the curled fibers are too thin, the cushioning properties will be flexible, and thinly deformed with the head placed on top, breaking the charcoal of the granular charcoal. Conversely, if the curled fibers are too thick, the cushioning properties will be low. Thus, the proportion of elastic deformation with the head placed on top is small, and the effect of forced air blowing due to elastic deformation is reduced. Therefore, the thickness of the curled fiber is set to an optimum value depending on the material and application of the fiber used. The curl fiber 32 is preferably as thin as 0.2 mm to 0.7 mm for a pillow for children, and is preferably as thick as 0.3 mm to 1 mm for a pillow for adults. Further, as the synthetic fiber of the curl fiber 32, any fiber that is elastically deformed, such as polypropylene fiber and polyethylene fiber, can be used.

  Further, the radius of curvature at which the curled fibers 32 of the fiber elastic gap mat 31 are curved is optimally 5 mm to 1 cm. The curled fibers 32 are not molded so that all portions are curved with the same radius of curvature. The curled fiber 32 is wound around, for example, a cylindrical core, heated, or formed into a shape that is curved without heating, or heated in a state where tension is applied, or 1/4 to 1 of the entire circumference of the roll that is not heated. It is a roll that is curved by passing through / 2 or has a corrugated surface, and can be formed into a shape that is curved by being transferred while being sandwiched between two heated or unheated rolls. The curled fiber 32 that has been curved does not bend all parts with the same radius of curvature. Therefore, in this specification, the radius of curvature of the curled fiber 32 means the average radius of curvature of the curved portion. The radius of curvature at which the curled fiber 32 is curved can be increased to increase the gap between the curled fibers 32 and can be decreased to decrease the gap between the curled fibers 32. The radius of curvature of the curled fiber 32 is set to an optimum value in consideration of the average particle diameter of the granular coal 33 filled in the gap. By setting the radius of curvature of the curled fibers 32 to be smaller than the average particle diameter of the granular charcoal 33, the granular charcoal 33 can be smoothly filled in the gaps of the curled fibers 32. The curvature radius of the curled fiber 32 is preferably 5 mm to 2 cm, and more preferably 5 mm to 1.5 cm in consideration of the average particle diameter of the granular charcoal 33.

  The fiber elastic gap mat 31 is manufactured by gathering curled fibers 32 in a predetermined thickness without three-dimensional orientation, and joining the intersections of the curled fibers 32 with an adhesive or by heat welding. . The adhesive that joins the intersections of the curled fibers 32 is applied by spraying in a state where the curled fibers 32 are assembled. Further, after the fiber elastic gap mat 31 is immersed in the adhesive liquid, the excess adhesive is removed by pressing and the intersections of the curled fibers 32 can be bonded with the adhesive. The fiber elastic gap mat 31 for heat-welding the intersection of the curled fibers 32 uses fibers whose surfaces are coated with a synthetic resin having a low melting point as the curled fibers 32, gathered to a predetermined thickness, and then heated. The surface coating is melted and welded.

  The thickness of the fiber elastic gap mat 31 is also set to an optimum value in consideration of the use, but is set to 3 cm to 8 cm, for example. A thick fiber elastic void mat can be used to fill a large amount of granular coal. Moreover, cushioning properties can also be improved. However, since the manufacturing cost increases when the fiber elastic gap mat is thickened, the thickness of the fiber elastic gap mat can be set to, for example, 1 cm to 15 cm, preferably 2 cm to 10 cm in consideration of the use and the manufacturing cost.

  Further, in the charcoal layer 30 shown in FIGS. 1 to 3, elastic side walls 39 are fixed to the inner surfaces of both side edges of the surface layer 35, and the fiber elastic gap mat 31 is disposed between the elastic side walls 39. In the pillow shown in FIG. 2, elastic side walls 39 that are inclined downward toward one end are fixed to both side edges of the surface layer 35. This pillow is made by bonding elastically deformable surface layers 35 to both upper and lower surfaces of an elastic side wall 39. As described above, the pillow formed by fixing the elastic side walls 39 on both sides of the fiber elastic gap mat 31 elastically supports the surface layer 35 also by the elastic side walls 39, so that the elastic restoring force of the fiber elastic gap mat 31 is increased. It is possible to weaken the elastic support force of the surface layer 35 and increase the elastic restoring force optimal as a pillow by both the elastic side wall 39 and the fiber elastic gap mat 31. Furthermore, the pillow is an inner surface of the surface layer, and an elastic side wall can also be provided between the elastic side walls provided on both sides. However, in the pillow of the present invention, it is not always necessary to provide elastic side walls on the inner surface of the surface layer, and the upper and lower surface layers can be elastically supported only by the fiber elastic gap mat.

  Granular charcoal 33 is a charcoal made by crushing wood into chips to make wood chips and burning the wood chips. The extinguishing of the granular charcoal 33 is manufactured by the process shown in FIG. The manufacturing process of FIG. 6 includes a crushing process in which wood 9 is processed into chips to make wood chips 2, a charcoal removing process in which crushed wood chips 2 are burned to make charcoal 3, and the burned charcoal 3 is used as a rotating container. , And turning to make a charcoal extinguisher by a smoothing process for smoothing the protrusion of the extinguishing charcoal 3 and a coating process for covering the smoothed smooth charcoal 3 'surface with the thin film coating layer 7.

  In the crushing step, wood 9 such as conifers, deciduous trees and bamboo is crushed with a blade and processed into chips. In this step, bark can be added in addition to wood. Further, as the wood 9, waste wood obtained by breaking a building can be used, or wood that has not been effectively used can be effectively used by using thinned wood. In the crushing step, the wood 9 is crushed into wood chips 2 of 5 mm or more and 2 cm or less. If a wood chip is crushed to 5 mm or less, the yield in the process of converting to charcoal will deteriorate. Conversely, if the wood chip is larger than 2 cm, it becomes difficult to fill the gaps between the curled fibers 32. Therefore, in the crushing step, the wood 9 is preferably crushed into wood chips 2 of about 1 cm.

  The charcoal removal process does not process wood into hard charcoal like Bincho charcoal. The wood chip 2 is made into the extinguisher 3 in the incinerator 10 shown in FIGS. The incinerator 10 has a metal cylinder 11 that opens at the top and closes the bottom, and the upper opening 12 is closed by a supply lid 13. The metal cylinder 11 is large enough to be filled with 100 to 1000 liters of wood chips 2 and has a height of 1 to 3 m. The incinerator 10 is provided with a chimney 14 at the upper end of the metal cylinder 11 and exhausts from the chimney 14 with the supply lid 13 closed. The supply lid 13 is opened and the wood chip 2 is filled in the metal cylinder 11.

  The incinerator 10 shown in the figure has an air inlet 27 on the side surface of the bottom of the metal tube 11 so that air can be supplied to the inside. A guide tool 17 for supplying air to the inside of the metal cylinder 11 is inserted into the intake port 27. The guide 17 shown in the figure includes an insertion portion 17 </ b> A that is inserted into the metal tube 11 and a tube portion 17 </ b> B that is disposed outside the metal tube 11. The insertion portion 17A is a groove type having an upper surface opened, and has an infinite number of holes of about 5 to 10 mm on both side surfaces and the bottom surface. As shown in FIG. 8, the insertion portion 17 </ b> A is inserted into the metal cylinder 11 from the air inlet 27, and the wood chip 2 filled in the metal cylinder 11 is supplied from above. The cylindrical portion 17B is a cylindrical body having an outer shape larger than that of the insertion portion 17A, and is connected to the rear end of the insertion portion 17A. The cylindrical portion 17 </ b> B has an air hole 15 in the rear end surface, and the air hole 15 can be opened and closed with an opening / closing lid 16. The opening / closing lid 16 is connected to the cylindrical portion 17B by a hinge 18 at the upper edge so that the opening / closing lid 16 is elastically closed by being pulled by a spring (not shown). The opening / closing lid 16 is opened by being stretched by a stretching rod 23 having a wood rod 19 connected to the tip. The strut rod 23 is a metal rod, and a wood rod 19 that burns like a split chopstick is inserted and connected to the tip. In the state where the wood rod 19 is inserted into the insertion portion 17A, the extension rod 23 stretches the distal end surface of the insertion portion 17A and the opening / closing lid 16 at both ends thereof, and the opening / closing lid 16 opens the air hole 15. State. In this state, as shown in FIG. 8, the wood chip 2 is filled and the insertion portion 17 </ b> A of the guide tool 17 is embedded in the bottom of the wood chip 2.

  Further, in the incinerator 10 shown in the figure, a porous plate 24 is disposed at a position slightly away from the bottom of the metal cylinder 11, and an air chamber 25 is provided at the bottom of the metal cylinder 11. The perforated plate 24 is formed by opening countless small holes in a metal plate so that wood chips do not fall. However, the perforated plate may be a wire mesh. The perforated plate 24 is disposed in a horizontal posture on the upper surface of the receiving member 26 disposed at the bottom of the metal cylinder 11, and an air chamber 25 is provided below the perforated plate 24. Further, an insertion portion 17 </ b> A of the guide tool 17 is disposed on the upper surface of the porous plate 24. This structure is characterized in that the air supplied from the air hole 15 can be supplied to the air chamber 25 via the guide 17 and supplied from the air chamber 25 to the whole wood chip 2 filled in the metal cylinder 11. is there.

  The above incinerator 10 is filled with the wood chip 2 and then ignites on the wood chip 2 to close the supply lid 13. Since the wood chip 2 is supplied with air flowing in from the air holes 15 from the air chamber 25, the wood chip 2 is ignited from the top to the bottom and ignited as a whole. When the entire wood chip 2 is ignited, the wood rod 19 inside the insertion portion 17A disappears, the projecting rod 23 cannot stretch the opening / closing lid 16, and the opening / closing lid 16 is closed by a spring. If it will be in this state, air will no longer be supplied to the metal cylinder 11, the fire of the ignited wood chip 2 will extinguish, and it will become charcoal-extinguishing. The incinerators shown in FIGS. 7 and 8 are completely ignited while supplying air to the wood chip 2, and then the supply of air is cut off to extinguish the fire. Therefore, the wood chip 2 becomes the charcoal 3 that is burnt.

  As shown in FIG. 9, in the smooth process, the extinguisher 3 produced in the extinguishing process is put into a rotating container 22 and rotated to smooth the protrusion of the charcoal 3. The rotary container 22 shown in the figure is a cylindrical metal cylinder 22A. The rotating container 22 that is the metal cylinder 22A is disposed, for example, in an inclined posture, and is rotated in a state where the charcoal extinguishing 3 is supplied inside. The charcoal 3 supplied to the rotary container 22 is transferred from the supply side to the discharge side while rolling inside the metal cylinder 22A, and the surface is smoothed. Although not shown, the metal cylinder 22A can be made of a porous metal plate. This metal cylinder can be transferred while discharging fine debris and small pieces scraped off from the charcoal through the holes on the surface. The charcoal removal 3 that rolls inside the metal cylinder 22A is in contact with the inner surface of the metal cylinder 22A, or a large number of the charcoal removals 3 are in contact with each other, and the protrusions on the surface are shaved and become smooth. The extinguisher obtained from the wood chip has fewer protruding corners in the process of burning and extinguishing, but the protruding part of the surface generated in the crushing process may remain after the extinction. In addition, charcoal may be in a state where its surface becomes brittle and tends to collapse. In this smoothing step, the protrusions remaining on the surface of the extinguisher 3 and the brittle portion of the surface are removed to make the surface of the extinguisher 3 smooth. Thus, the smooth charcoal 3 'having a smooth surface has a high filling efficiency in the gaps between the curled fibers 32, and can improve deodorization characteristics and water absorption characteristics. This is because the gap between the curled fibers 32 can be filled smoothly without becoming a bridge. However, in the case of extinguishing the charcoal, the corner is reduced in the process of burning the wood chips, so this smooth process is not always necessary, and this process can be omitted.

  The surface of the extinguisher 3 filled in the gaps between the curled fibers 32 is coated with the thin film coating layer 7 in a coating process while being separated from each other. In the coating step, smooth charcoal 3 'is dipped in an emulsion type adhesive diluted with water, drained with a colander and dried. This coating process uses a vinyl acetate resin for an emulsion type adhesive. The film thickness of the thin film coating layer 7 that coats the surface of the charcoal extinguisher 3 is controlled by the magnification at which the adhesive is diluted with water. Preferably, the emulsion type adhesive is diluted 25 to 30 times, that is, 25 to 30 times by weight of water is added to the adhesive and stirred, and the diluted adhesive solution is treated with a charcoal 3 After being soaked, the thin film coating layer 7 having air permeability can be provided by raising it to a colander, draining it, and drying it. The extinguisher 3 coated in this state is in a separated state. If the thin film coating layer 7 is too thick, the air permeability is deteriorated and the water absorption characteristics are deteriorated. Therefore, the diluted adhesive solution is provided with the air-permeable thin film coating layer 7 by, for example, diluting the adhesive 10 to 40 times, preferably 25 to 30 times by weight. A vinyl acetate resin can be used for the adhesive. However, any other adhesive of emulsion type can be used as the adhesive. Emulsion type adhesives use adhesives such as vinyl acetate resin that lose contact with water in a dry state and lose their adhesive strength, that is, contact with water in a dry state and dissolve in water. The thin film coating layer 7 made of this adhesive can prevent the surface of the charcoal from being damaged in the process until the gap between the curled fibers 32 is filled with the charcoal extinguishing 3. The surface of the extinguisher 3 filled in the gap between the curled fibers 32 is not damaged, and the thin film coating layer 7 does not need to protect the surface of the extinguisher 3 in this state. It is important that the charcoal removal 3 filled in the gaps between the curled fibers 32 is exposed to a wider area to improve water absorption characteristics. The emulsion-type adhesive that is dissolved in water is dissolved with water adhering to the surface of the extinguisher 3 to expose the surface of the extinguisher 3 in a wider area, thereby improving the water absorption characteristics of the extinguisher 3. Therefore, the thin film coating layer 7 is filled in the gaps of the curled fibers 32 while filling the gaps of the curled fibers 32 without damaging the charcoal 3 by using an emulsion type adhesive that is dissolved in water. Then, the water absorption characteristics of the extinguisher 3 can be improved.

  The pillow shown in FIG. 2 is manufactured by the above-described process, and the surface is covered with the thin film coating layer 7 so that the granular charcoal 3 is filled as granular charcoal 33 in the gaps of the curled fibers 32.

  Furthermore, the pillow can be filled with calcium carbonate in addition to the charcoal-free material 3 in the gaps between the curled fibers 32 of the fiber elastic gap mat 31. In this pillow, calcium carbonate is added to the extinguisher, so that the combustion of the extinguisher can be prevented by the calcium carbonate and the fire resistance and flameproof characteristics can be improved.

  After filling the gap between the curled fibers 32 of the fiber elastic gap mat 31 with the granular charcoal 33, the surface layer 35 is adhered to the surface of the fiber elastic gap mat 31, and the charcoal 3 does not pass through the gap of the fiber elastic gap mat 31 Block. The surface layer 35 shown in FIGS. 1 to 3 is formed by laminating a surface sheet 37 that is thinner than the cushion sheet 36 and has air permeability on the surface of the cushion sheet 36 that is bonded to the surface of the fiber elastic gap mat 31. is doing. In the surface layer 35, the cushion sheet 36 is a soft plastic foam such as urethane foam, and the surface sheet 37 is a non-woven fabric. However, a plastic foam having a smaller expansion ratio than a soft plastic foam can be used for the top sheet. The top sheet 37 of FIGS. 1 and 3 is provided with an opening window 37A in order to realize excellent air permeability. In this charcoal laid tool, the surface layer 35 has a two-layer structure, but the surface layer does not necessarily have a two-layer structure, and may have a single-layer structure or a three-layer structure. The surface layer having a single layer structure may be a plastic foam having open cells having fine bubbles, or a nonwoven fabric in which fine fibers are aggregated.

  The surface layer 35 is thinner than the charcoal layer 30, for example, 2 mm to 20 mm, preferably 5 mm to 15 mm. However, the surface layer 35 can be thickened to improve the flexible cushioning property. The surface layer 35 having a two-layer structure uses a nonwoven fabric having a thickness of 1 mm to 3 mm for the surface sheet 37 laminated on the cushion sheet 36. The surface layer 35 can prevent the granular charcoal 33 from leaking to the outside by both the cushion sheet 36 and the surface sheet 37.

  In the pillows of FIGS. 1 to 3, a breathable surface layer 35 is bonded to both surfaces of a fiber elastic gap mat 31, and a charcoal layer 30 is provided between the two surface layers 35. The pillow with this structure can be used in the same way with both sides upside down. However, although not shown in the drawings, the pillow can be bonded to a breathable surface layer on one side of the fiber elastic gap mat and a non-breathable back sheet can be bonded to one side.

The above pillow is manufactured in the following steps.
[Manufacture of granular coal]
Waste wood is crushed into chips of 1 cm, and this wood chip 2 is processed into an extinguisher 3 in an incinerator 10 shown in FIGS. 7 and 8, and the obtained extinguisher 3 is put in a rotating container 22 shown in FIG. And the protrusion of the charcoal 3 is smoothed. Further, the obtained charcoal 3 is dipped in an adhesive solution obtained by diluting a vinyl acetate resin 30 times, taken out from the solution, dried in a state of draining, and coated with a thin film coating layer 7 to form a granular charcoal 33 and To do.

[Filling of granular charcoal]
While supplying the granular charcoal 33 onto the fiber elastic gap mat 31 having a thickness of 4 cm and having a radius of curvature of about 8 mm, the fiber elastic gap mat 31 is vibrated so that the curl fibers 32 Fill the gap. At this time, the surface layer 35 is bonded to the lower surface of the fiber elastic gap mat 31 in advance. The surface layer 35 is obtained by laminating and bonding a non-woven surface sheet 37 on the surface of a cushion sheet 36 made of plastic foam, and the cushion sheet 36 is bonded to the fiber elastic gap mat 31.

[Closing the opening]
After filling the granular charcoal 33, the surface layer 35 is further bent along the elastic partition wall 39 and adhered to the outer periphery of the end of the elastic partition wall 39 to close the openings 38 of the upper and lower surface layers 35.

  Although the above pillow is provided with the elastic side wall 39, it can also be made into a pillow without providing the elastic side wall. Pillows without elastic side walls are filled with granular charcoal by connecting the outer periphery of the upper and lower surface layers by bending or curving them to make the inside a closed structure.

2 ... wood chip 3 ... charcoalizing 3 '... smooth charcoal 7 ... thin film coating layer 9 ... wood 10 ... incinerator 11 ... metal cylinder 12 ... opening 13 ... supply lid 14 ... chimney 15 ... air hole 16 ... opening / closing lid 17 ... guide 17A ... Insertion part
17B ... Cylinder part 18 ... Hinge 19 ... Wood rod 22 ... Rotary container 22A ... Metal cylinder 23 ... Strut rod 24 ... Perforated plate 25 ... Air chamber 26 ... Receiver 27 ... Suction port 30 ... Coal layer 31 ... Fiber elastic gap mat 32 ... Curl fiber 33 ... Granular charcoal 35 ... Surface layer 36 ... Cushion sheet 37 ... Surface sheet 37A ... Opening window 38 ... Opening 39 ... Elastic partition

Claims (8)

A pillow provided with a charcoal layer (30) inside a breathable surface layer (35),
The carbon layer (30) is a curled fiber (32) formed into a shape that is curved with a predetermined radius of curvature and gathers a predetermined thickness three-dimensionally without any direction, leaving a gap between the curled fibers (32). A fiber elastic gap mat (31) that is elastically deformed in the thickness direction by a load acting on the surface by connecting the intersections of the curled fibers (32), and a curled fiber (32) of the fiber elastic gap mat (31). ) And granular charcoal (33) filled in the voids,
The granular charcoal (33) is a charcoal (3) made by burning wood chips (2) obtained by crushing wood into chips, and the surface layer (35) is breathable and granular charcoal (33) A state in which the surface layer (35) is bonded to the surface of the fiber elastic gap mat (31), and the charcoal (3) does not pass through the gap of the fiber elastic gap mat (31). The pillow is characterized in that the fiber elastic gap mat (31) is elastically deformed in the thickness direction so that air is forced through the surface layer (35).   The pillow according to claim 1, wherein the curled fiber (32) of the fiber elastic gap mat (31) is a synthetic fiber having a thickness of 0.2 mm to 1 mm.   The pillow according to claim 1 or 2, wherein the curled fibers (32) of the fiber elastic gap mat (31) are formed into a curved shape with a curvature radius of 5 mm to 2 cm.   A cushion sheet (36) formed by bonding the surface layer (35) to the surface of the fiber elastic gap mat (31), and a breathable surface sheet bonded to the surface of the cushion sheet (36) ( 37. The pillow according to claim 1, comprising 37).   The pillow according to claim 4, wherein the cushion sheet (36) is a soft plastic foam having open cells.   The pillow according to claim 1, wherein the charcoal-extinguishing (3) is coated with a thin-film coating layer (7) having air permeability made of an emulsion type connecting agent.   The pillow according to claim 6, wherein the thin film coating layer (7) covering the surface of the charcoal extinguishing (3) is a vinyl acetate resin. A method for producing a pillow, wherein a charcoal layer (30) is provided inside a breathable surface layer (35),
Curled fibers (32) formed by shaping the charcoal layer (30) into a shape that is curved with a predetermined radius of curvature are gathered to a predetermined thickness with no three-dimensional orientation, and voids are formed between the curled fibers (32). A fiber elastic gap mat (31) that is elastically deformed in the thickness direction by a load acting on the surface by connecting the intersections of the curled fibers (32), and a curled fiber (32) of the fiber elastic gap mat (31). ) Produced with granular charcoal (33) filled in the voids,
Furthermore, the granular charcoal (33) is made as a wood chip (2) by crushing wood into chips, burn this wood chip (2), cut off the air and manufactured as a charcoal (3),
Vibrating the fiber elastic gap mat (31), filling the gap between the curled fibers (32) of the fiber elastic gap mat (31) with the granular charcoal (33) made of the charcoal (3), Adhering a surface layer (35) having a fine gap that has air permeability and does not allow the passage of granular charcoal (33) to the surface of the fiber elastic void mat (31) filled with the granular charcoal (33), A method for producing a pillow, characterized in that the surface of the fiber elastic gap mat (31) is clogged with the surface layer (35) so as not to leak the charcoal (3).