JP2017113362A - mattress - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a mattress in which width-directional both ends are harder than a central part and the width-directional both ends hardly separate from the central part.SOLUTION: The mattress is constituted of end parts 12a and 12a located at both ends in the width direction W of the mattress, and a central part 13a located between the end parts 12a and 12a. The end parts 12a and 12a located at both ends in the width direction W are formed harder than the central part 13a, the end parts 12a and 12a located at both ends in the width direction W and the central part 13a are continuously connected by urethane foam, and upper faces of the end parts 12a and 12a located at both ends in the width direction W and an upper face of the central part 13a include a plurality of projections 15a.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a mattress that is harder than a center portion in which both end portions in the width direction of the mattress are sandwiched between the both end portions.

Conventionally, as a mattress used for a bed, there is a mattress in which a member at both ends in the width direction of the mattress and a member at a central portion sandwiched between the members at both ends are separately manufactured and bonded. When the mattress user or caregiver sits down or leans on both ends of the mattress in the width direction, the posture of the mattress becomes unstable due to large elastic deformation. It is made of a material that is harder than the central member, for example, in order to prevent the posture from getting worse or the care work from becoming difficult.
In addition, in the case of hospitals and nursing beds, the central part is made of a material with high body pressure dispersibility to prevent pressure ulcers, but the members at both ends in the width direction do not fall off the bed after rolling over. It is preferable to be made of a material harder than the central member.

  However, mattresses produced by separately manufacturing and bonding members at both ends in the width direction of the mattress and the members at the center are bonded by bonding between the members at both ends in the width direction and the members at the center. It is difficult to say that if a large force is repeatedly applied to both ends of the mattress in the width direction due to care or the like, the members at both ends may be separated from the members at the center. In addition, when the upper body side of the bed is raised, a large bending force is applied to the mattress, but since the hardness of the bonded members at both ends in the width direction and the members at the center is different, the members at both ends in the width direction Becomes easy to separate from the central member.

Japanese Patent Laid-Open No. 2014-212848

  The present invention has been made in view of the above points, and an object of the present invention is to provide a mattress in which both end portions in the width direction of the mattress are harder than the center portion and both end portions in the width direction are difficult to separate from the center portion.

  The invention according to claim 1 is a mattress comprising end portions located at both ends in the width direction of the mattress and a central portion located between the end portions, the end portions being harder than the central portion, The portion and the central portion are continuously connected by urethane foam.

  According to a second aspect of the present invention, in the first aspect, the central portion includes two layers of an upper layer and a lower layer, and the lower layer and the end portion of the central portion are continuously formed of urethane foam that is harder than the upper layer of the central portion. It is characterized by being.

  The invention of claim 3 is characterized in that, in claim 1, a core material for increasing hardness is embedded in the end portion.

  According to a fourth aspect of the present invention, in any one of the first to third aspects, a plurality of protrusions are formed on the upper surface of the mattress.

  A fifth aspect of the present invention is characterized in that, in the fourth aspect, the protrusion is formed on the upper surface of the central portion and is not formed on the upper surface of the end portion.

  A sixth aspect of the present invention is characterized in that, in any one of the first to fifth aspects, the mattress is constituted by a plurality of mattress divided bodies in the length direction, and the mattress divided body is formed of a molded product. .

  According to invention of Claim 1, since the edge part of the width direction both ends harder than a center part is continuously connected by the center part and urethane foam, an edge part becomes difficult to isolate | separate from a center part.

  According to the invention of claim 2, since the lower layer of the central portion and the end portions of both ends in the width direction are continuously formed of urethane foam that is harder than the upper layer of the central portion, the end portions of both ends in the width direction are formed from the central portion. Can be hardened and difficult to separate from the center.

  According to the invention of claim 3, by selecting the core material for increasing hardness embedded in the end portions at both ends in the width direction, the end portions at both ends in the width direction can be set to the required hardness.

  According to the invention of claim 4, since the plurality of protrusions are formed on the upper surface of the mattress, the body pressure dispersibility is improved, and the usability is improved.

  According to the invention of claim 5, when the mattress in the bed in the width direction is seated or drooped, there is no projection on the upper surface of the hard end portion, so that the hard projection hits in the case of care work or the like. I do not feel uncomfortable.

  According to the invention of claim 6, when a part of the mattress is raised, the force for bending the mattress is relaxed at the portion between the mattress divided bodies, and the bending force applied to each mattress divided body is reduced. It is difficult to separate the end portions at both ends from the central portion.

It is a perspective view of the mattress of a 1st embodiment. It is the mattress division body of 1st Embodiment, and AA sectional drawing. It is the perspective view and BB sectional drawing of the mattress of 2nd Embodiment. It is the perspective view and CC sectional drawing of the mattress of 3rd Embodiment. It is the perspective view and DD sectional drawing of the mattress of 4th Embodiment. It is sectional drawing of the shaping | molding die used for manufacture of the mattress division body of 1st Embodiment. It is sectional drawing which shows the time of arrangement | positioning of a masking plate. It is sectional drawing which shows injection | pouring of the 1st foaming urethane raw material. It is sectional drawing which shows injection | pouring of the 2nd foaming urethane raw material. It is sectional drawing of the shaping | molding die and masking plate which are used for manufacture of the mattress division body of 2nd Embodiment. It is sectional drawing of the shaping | molding die used for the mattress division body of 3rd Embodiment, and the core material for hardness increase. It is sectional drawing of the shaping | molding die used for the mattress division body of 4th Embodiment, and the core material for hardness increase.

  Hereinafter, embodiments of the mattress of the present invention will be described. The mattress of the present invention is suitable for being used on a bed. A mattress 10A according to the first embodiment shown in FIG. 1 includes mattress divided bodies 11a, 11a, and 11a that are divided into three in the length direction. The mattress 10 </ b> A may be composed of a single mattress that is not divided, instead of being composed of a plurality of mattress divided bodies. Further, the mattress 10A is used by being accommodated in a bag-like cover (not shown). Reference symbol L denotes the length direction, and W denotes the width direction.

  The mattress divided body 11a may be configured by dividing the mattress into two in the length direction or dividing it into four or more depending on the size of the mattress. The mattress divided body 11a is made of a molded product obtained by injecting a foaming raw material into a mold (mold) and foam-molded. As shown in FIG. 2, the end portions 12a and 12a located at both ends in the width direction W, It consists of the center part 13a located between the edge parts 12a and 12a.

  The end portions 12a, 12a and the central portion 13a are each made of soft foamed urethane and are continuously connected. The widths of the end portions 12a and 12a are appropriately determined, and examples include about 50 mm to 200 mm.

  A plurality of protrusions 15a are formed on the top surfaces of the end portions 12a, 12a and the central portion 13a. The protrusions 15a have an appropriate shape, size, and number (or interval). Examples of the shape of the protrusion 15a include a quadrangular pyramid shape, a shape in which a pyramid is placed on the upper end of the column (the shape shown in the figure), a column shape, and the like. As an example of the size of the projection 15a, when the 15a has a shape in which a quadrangular pyramid is placed on a regular quadrangular prism, one side of the base of the regular quadrangular prism is 10 to 30 mm, a height is 10 to 15 mm, The case where the height of a pyramid shall be 5-10 mm is given. Moreover, 0.5-15 mm is mentioned as an example of the space | interval of the said protrusion 15a. The protrusion 15a improves the body pressure dispersibility of the mattress 10A and improves the feeling of use.

The central portion 13a is composed of two layers, an upper layer 131a and a lower layer 132a, and the lower layer 132a is made of a harder material than the upper layer 131a. As an example of the ratio of the thickness of the upper layer 131a and the lower layer 132a, the thickness of the upper layer 131a: the thickness of the lower layer 132a = 1: 9 to 9: 1.
The end portions 12a and 12a are continuously formed of the same urethane foam as the lower layer 132a of the central portion 13a, and are harder than the upper layer 131a of the central portion 13a.

30N to 200N (JIS K6400-2 6.7D method) as an example of hardness of the upper layer 131a of the central portion 13a, and 100N to 500N (example of hardness of the lower layer 132a and the end portions 12a and 12a of the central portion 13a) JIS K6400-2 6.7D method).
The central portion 13a is softer than the end portions 12a, 12a because the upper layer 131a is softer than the end portions 12a, 12a.

  The upper layer 131a and the lower layer 132a of the central portion 13a, and the upper layer 131a and the end portions 12a and 12a of the central portion 13a are foamed when the mattress divided body 10A is molded as described later. Due to the self-adhesiveness when urethane is foam-cured, it is firmly bonded.

  In the mattress divided body 11a having the above-described configuration, the lower layer 132a of the central portion 13a and the end portions 12a and 12a are continuously formed, and the upper layer 131a and the end portions 12a and 12a of the central portion 13a are foamed. Since the urethane is firmly bonded by self-adhesiveness when it is foam-cured, the mattress 10A is arranged side by side in the length direction as shown in FIG. Even if a large force is applied to the end portions 12a and 12a at both ends in the direction, it is possible to prevent the central portion 13a and the end portions 12a and 12a from being separated.

  The mattress 10B of the second embodiment shown in FIG. 3 is composed of mattress split bodies 11b, 11b, and 11b that are divided into three in the length direction. In each mattress split body 11b, a protrusion 15b is formed only on the upper surface of the central portion 13b. In this example, no protrusions are formed on the upper surfaces of the end portions 12b and 12b at both ends in the width direction. Other configurations are the same as the mattress 10A of the first embodiment, the central portion 13b is composed of two layers of an upper layer 131b and a lower layer 132b, and the lower layer 132b is composed of a material harder than the upper layer 131b. It is formed continuously with the end portions 12b and 12b at both ends in the width direction.

  The mattress 10B of the second embodiment prevents the central portion 13b and the end portions 12b, 12b from separating even when a large force is applied to the end portions 12b, 12b at both ends in the width direction, as in the first embodiment. it can. Furthermore, the mattress 10B according to the second embodiment has no protrusions on the upper surfaces (surfaces) of the end portions 12b and 12b at both ends in the width direction which are harder than the central portion 13b. In addition, it does not feel uncomfortable when it hits a hard protrusion.

The mattress 10C according to the third embodiment shown in FIG. 4 includes mattress divided bodies 11c, 11c, and 11c that are divided into three in the length direction.
Each mattress divided body 11c has a central portion 17c having a hardness increasing core 17c embedded in the longitudinal direction L at both ends 12c, 12c at both ends in the width direction, and sandwiched between the ends 12c, 12c at both ends in the width direction. The portion 13c and the end portions 12c and 12c are continuously formed of the same urethane foam. Examples of the hardness of the urethane foam constituting the central portion 13c and the end portions 12c and 12c are 100N to 300N (JIS K6400-2 6.7D method). Reference numeral 15c is a protrusion.

  The hardness increasing core material 17c is made of a material harder than urethane foam constituting the central portion 13c and the end portions 12c and 12c, and in the illustrated example, has a square bar shape. The core material 17c for increasing hardness is not particularly limited, and examples thereof include soft foamed urethane, hard foamed urethane, and polystyrene foam having high density.

  In the mattress 10C of the third embodiment, since the end portions 12c, 12c at the both ends in the width direction and the central portion 13c, 13c are formed continuously, the central portion 13c and the end portions 12c, 12c are separated. Can be surely prevented.

  In the mattress 10D of the fourth embodiment shown in FIG. 5, the core material 17d for increasing hardness embedded in the end portions 12d, 12d at both ends in the width direction of the mattress divided body 11d has the end portions 12d, 12d at both ends in the width direction. It differs from the mattress 10C of the third embodiment in that it is exposed on the upper surface, and the other configuration is the same as the mattress 10C of the third embodiment. Reference numeral 13d denotes a central portion sandwiched between the end portions 12d and 12d at both ends in the width direction, and is continuously formed of the same foamed urethane as the end portions 12d and 12d. Reference numeral 15d is a protrusion.

  In the mattress 10D of the fourth embodiment, since the end portions 12d and 12d at the both ends in the width direction and the central portions 13d and 13d are formed continuously, the central portion 13d and the end portions 12d and 12d are separated. Can be reliably prevented as in the third embodiment.

The manufacturing method of the mattress division bodies 10a-10d of the said 1st-4th embodiment is demonstrated.
FIG. 6 shows a mold 50A used for manufacturing the mattress divided body 11a of the first embodiment. The mold 50A includes a lower mold 51A and an upper mold 57A. The cavity 52A of the lower mold 51A has a shape matched to the mattress divided body to be manufactured, and a plurality of recesses 54A for forming the protrusions 15a of the mattress divided body 11a are formed on the cavity bottom surface 53A.

  First, as shown in FIG. 7, masking plates 631 and 631 are formed on portions 531A and 531A that form upper surfaces of end portions 12a and 12a at both ends in the width direction of the mattress divided body 11a on the cavity bottom surface 53A of the lower mold 51A. Place.

  The masking plates 631 and 631 are flat surfaces 632 and 632 that cover portions 531A and 531A that form the upper surfaces of the end portions 12a and 12a at both ends in the width direction of the mattress divided body 11a on the cavity bottom surface 53A. It consists of standing surfaces 633 and 633 that stand up from the end on the inner side of the cavity. The widths of the flat surfaces 632 and 632 are equal to the widths of the end portions 12a and 12a at both ends in the width direction of the mattress divided body 11a. Further, the heights of the upright surfaces 633 and 633 are set to be a predetermined amount smaller than the thickness of the central portion 13a of the mattress divided body 11a. The masking plates 631 and 631 are made of an appropriate material such as metal or plastic, and a release agent is applied similarly to the cavity surface of the mold.

  Next, as shown in FIG. 8, the upper layer 131a of the central portion 13a of the mattress divided body 10a is formed on the cavity bottom surface 53A of the lower mold 51A exposed between the upstanding surfaces 633 and 633 of the masking plate 631 and 631. For this purpose, the first urethane foam material P1 is injected and foamed to form the upper layer 131a. The injection amount of the urethane foam raw material P1 is an amount for forming the upper layer 131a of the central portion 13a. Reference numeral N1 denotes a nozzle of an injection device for injecting the first urethane foam P1.

  Next, after removing the masking plates 631 and 631 from the cavity bottom surface 53A of the lower mold 51A, as shown in FIG. 9, the lower layer 132a of the central portion 13a of the mattress divided body 10a and the end portions 12a and 12a at both ends in the width direction. The second foamed urethane raw material P2 is used in the lower mold 51A, on the upper layer 131a of the central portion 13a formed from the first foamed urethane raw material P1, and the flat surfaces 632 of the masking plates 631, 631. Injection is performed on the cavity bottom surfaces 531A and 531A covered with 632. The second foamed urethane raw material P2 forms a urethane foam that is harder than the first foamed urethane raw material P1. Reference N2 is a nozzle of an injection device for injecting the second urethane foam P2.

Thereafter, the lower mold 51A is covered with the upper mold 57A, and the second urethane foam P2 is foamed in the molding mold 50A, and the lower layer 132a of the central portion 13 of the mattress divided body 11a and the width direction both ends are formed. The end portions 12a and 12a are formed continuously. Further, due to the self-adhesiveness when the second urethane foam P2 is foamed, the lower layer 132a and the upper layer 131a of the central portion 13a of the mattress divided body 11a, and the central portion 13a and the end portions 12a and 12a at both ends in the width direction are provided. Strongly bonded and integrated.
After the foaming is finished, the mold 50A is opened to remove the mattress divided body 11a.

  FIG. 10 shows a mold 50B used for manufacturing the mattress divided body 11b of the second embodiment. The mold 50B includes a lower mold 51B and an upper mold 57B, and portions 531B and 531B forming the upper surfaces of the end portions 12b and 12b at both ends in the width direction of the mattress divided body 11b on the cavity bottom surface 53B are planar. Further, it has the same configuration as that of the molding die 50A except that the concave portions 54B for projection are not formed in the portions 531B and 531B forming the upper surfaces of the end portions 12b and 12b. Reference numeral 52B denotes a cavity.

  The method of manufacturing the mattress divided body 11b of the second embodiment using the mold 50B is the same as the method of manufacturing the mattress divided body 11a of the first embodiment using the forming mold 50A. is there.

  FIG. 11 shows a mold 50C used for manufacturing the mattress divided body 11c of the third embodiment. The molding die 50C includes a lower die 51C and an upper die 57C, and portions 531C and 531C forming the upper surfaces of the end portions 12c and 12c at both ends in the width direction of the mattress divided body 11b on the cavity bottom surface 53C are planar. In addition, hardness increasing core material support pins 513C are erected at predetermined intervals. The hardness increasing core material support pins 513C are for supporting the hardness increasing core material 17c embedded in the ends 12c and 12c at both ends in the width direction of the mattress divided body 11c of the third embodiment. Reference numeral 52C is a cavity, and reference numeral 54C is a recess for projection.

A method for manufacturing the mattress divided body 11c of the third embodiment using the mold 50C will be described.
First, the hardness increasing core materials 17c and 17c are arranged on the hardness increasing core material supporting pins 513C and 513C. The hardness increasing cores 17c and 17c may be configured such that both ends in the length direction thereof are in close contact with the cavity side surface of the lower mold 51C, so that the hardness increasing cores 17c and 17c are not easily displaced.

  Next, the foamed urethane material for the end portions 12c, 12c and the center portion 13c at both ends in the width direction of the mattress divided body 11c of the third embodiment is injected into the cavity 52C of the lower mold 51C, and the mold 50C is closed. After the foaming is completed, the mold 50C is opened, and the mattress divided body 11c of the third embodiment is removed from the mold.

  FIG. 12 shows a mold 50D used for manufacturing the mattress divided body 11d of the fourth embodiment. The molding die 50D includes a lower die 51D and an upper die 57D, and portions 531D and 531D forming the upper surfaces of the end portions 12b and 12b at both ends in the width direction of the mattress divided body 11d on the cavity bottom surface 53D are planar. The parts 531D and 531D have the same configuration as the mold 50C, except that the cores supporting pins 513C and 513C for increasing the hardness of the mold 50C shown in FIG. 11 are not provided. Reference numeral 52D is a cavity, and reference numeral 54D is a recess for projection.

A method of manufacturing the mattress divided body 11d of the fourth embodiment using the mold 50D will be described.
First, the hardness increasing core materials 17d and 17d are disposed on the portions 531D and 531D forming the upper surfaces of the end portions 12d and 12d at both ends in the width direction of the mattress divided body 11d in the cavity bottom surface 53D of the lower mold 51D. The hardness increasing cores 17d and 17d may be such that both ends in the length direction are in close contact with the cavity side surface of the lower mold 51D, and the hardness increasing cores 17d and 17d are not easily displaced by the contact. .

  Next, the foamed urethane raw material for the end portions 12d, 12d and the center portion 13d at both ends in the width direction of the mattress divided body 11d of the fourth embodiment is injected into the cavity 52D of the lower mold 51D, and the molding die 50D is inserted. The foam is closed and foamed. After the foaming is finished, the mold 50D is opened, and the mattress divided body 11d of the fourth embodiment is removed.

  In addition, although what comprised the mattress division body which divided | segmented the mattress into plurality was shown in the said embodiment, the mattress of this invention is good also as what molded one thing without dividing | segmenting in a length direction. .

  As mentioned above, since the mattress of the present invention is connected continuously with foamed urethane at the center and the ends of the width direction harder than the center, even if a large force is applied to the width direction ends, The end is difficult to separate from the center.

10A, 10B, 10C, 10D Mattresses 11a, 11b, 11c, 11d Mattress divided bodies 12a, 12b, 12c, 12d Ends 13a, 13b, 13c, 13d at both ends in the width direction Central portions 15a, 15b, 15c, 15d Projections 17c, 17d Hardness increasing core material 50A, 50B, 50C, 50D Mold 51A, 51B, 51C, 51D Lower mold 52A, 52B, 52C, 52D Cavity 53A, 53B, 53C, 53D Cavity bottom surface 57A, 57B, 57C, 57D Upper mold

Claims (6)

In the mattress composed of end portions located at both ends in the width direction of the mattress and a central portion located between the end portions,
The mattress is characterized in that the end portion is harder than the center portion, and the end portion and the center portion are continuously connected with urethane foam. The central part consists of two layers, an upper layer and a lower layer,
2. The mattress according to claim 1, wherein the lower layer and the end of the central portion are continuously formed of urethane foam that is harder than the upper layer of the central portion.   The mattress according to claim 1, wherein a core material for increasing hardness is embedded in the end portion.   The mattress according to any one of claims 1 to 3, wherein a plurality of protrusions are formed on an upper surface of the mattress.   The mattress according to claim 4, wherein the protrusion is formed on the upper surface of the central portion and is not formed on the upper surface of the end portion.   The mattress according to any one of claims 1 to 5, wherein the mattress is configured by a plurality of mattress divided bodies in a length direction, and the mattress divided body is formed of a molded product.

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