JP2020099567A - Mattress cover, mattress, and bed with ventilator - Google Patents

Abstract

To provide a mattress cover that can exhibit a humidity rise suppression effect in the sweating without impairing heat retention.SOLUTION: A mattress cover is provided in which a cushion is covered and a mattress is formed. The mattress cover is configured such that a heat insulation layer is provided in the upper surface part for covering the top of the cushion, and the heat insulation layer contains acrylate-based fiber in which the moisture content at the temperature of 20°C and the humidity of 65%RH becomes 30% or more and 50% or less.SELECTED DRAWING: Figure 2

Description

The present invention relates to a mattress cover, a mattress, and a bed with a ventilation device using the mattress cover.

The temperature difference (distal-proximal skin temperature gradient) between the skin temperature of a person's limbs (distal skin temperature) and the skin temperature near the chest (proximal skin temperature) increases during the day (the limbs become colder). ), it is known that the night gets smaller (limbs get warmer). Further, in recent sleep studies, it is known that a person feels drowsiness when the temperature difference becomes small, and the sleep depth is deepened by a decrease in the core body temperature after falling asleep.

In order to lower the distal-proximal skin temperature gradient and the core body temperature, a person unconsciously increases blood flow in the limbs and lowers the proximal skin temperature by sweating. It is said that the amount of perspiration after falling asleep is most immediately after falling asleep (the transition period from the first REM sleep to non-REM sleep), and thereafter it increases during the transition period from REM sleep to non-REM sleep according to the sleep cycle. ..

However, when the humidity in the bedding increases due to a large amount of perspiration, it becomes difficult for the sweat to evaporate, so the core body temperature may not fall sufficiently, and you may not be able to sleep deeply or you may wake up due to the heat and humidity. .. Therefore, as a mattress (laying bedding) capable of suppressing an increase in humidity due to perspiration, Patent Document 1 discloses a bedding provided with a hygroscopic exothermic cotton layer containing an acrylate fiber.

The acrylate fiber has a function of rapidly adsorbing water vapor in a high humidity environment by the highly polar ionic bond introduced into the acrylic fiber. By using acrylate fiber as a heat insulating material for the mattress (bedding), water vapor evaporated from the skin surface due to perspiration is quickly adsorbed on the acrylate fiber surface, so that the humidity inside the bedding can be maintained without impairing heat retention. It is possible to prevent it from rising excessively.

Utility model registration No. 3067814

However, in the mattress using the acrylate-based fiber described in Patent Document 1, the acrylate-based fiber has excellent hygroscopicity, but on the other hand, a level that cannot be ignored even when compared with the heat of vaporization of water (about 2300 J/g) that contributes to temperature decrease. Since the heat of adsorption (about 1000 to 2000 J/g) is generated, there is a problem that heat easily accumulates in the mattress.

In addition, it is known that, in the sleep of one night, when REM sleep and non-REM sleep are repeated many times, the transitional period to REM sleep and non-REM sleep, that is, sweating repeatedly at the timing when the sleep depth becomes deep, is known. However, there is a problem that the moisture absorption effect of the acrylate fiber is reduced by long-term use, and the effect of suppressing the increase in humidity during sweating is lost. Furthermore, since the acrylate fiber has a strong water vapor adsorption force, it is difficult to dry, and there is a problem that a long time use causes a large amount of water to be adsorbed to cause a dull feeling.

Especially in winter, it is necessary to increase the amount of heat insulating material used for mattresses to improve heat retention, but the higher the heat retention, the harder it becomes to dry the mattresses that have absorbed moisture, and the mattresses are regularly dried. However, there is a problem that it takes time and effort to maintain hygroscopicity. In view of the above problems, the present invention provides a mattress cover, a mattress, and a ventilated bed using the mattress that can exhibit a humidity increase suppressing effect during sweating for a long time without impairing heat retention. To aim.

The mattress cover according to the present invention is a mattress cover that covers a cushion to form a mattress, wherein a heat insulating layer is provided on an upper surface portion that covers an upper surface of the cushion, and the heat insulating layer has a temperature of 20° C. and a humidity of 65%. An acrylate-based fiber having a water content in RH of 30% or more and 50% or less is included. According to this configuration, it is possible to exert a humidity increase suppressing effect during sweating for a long time without impairing heat retention.

Further, as the above-described configuration, more specifically, the air permeability of the upper surface portion may be made larger than the air permeability of the side surface portion that covers the side surface of the cushion. According to this configuration, the upper surface portion supporting the user's body is preferentially ventilated by the ventilation device, so that the high-humidity air generated by sweating of the user can be efficiently used without excessively increasing the capacity of the ventilation device. It becomes possible to ventilate physically.

Further, more specifically as the above configuration, the air permeability of a region of the upper surface portion that supports the upper half of the user is set to be larger than the air permeability of the region of the upper surface portion that supports the lower half of the user. Good. According to this configuration, the flow of wind generated by the ventilation device is preferentially directed to the upper body, which tends to sweat more than the lower body, so that high-humidity air is kept while keeping the feet from getting too cold. It becomes possible to ventilate efficiently.

A mattress according to the present invention is a mattress including the mattress cover having the above-mentioned configuration and a cushion covered with the mattress cover, and has a connecting portion connectable to a ventilation device that generates an air flow. The inside of the mattress cover can be ventilated by using the ventilation device. According to this configuration, it is possible to stably ventilate the air inside the mattress cover 3, and it is possible to suppress the retention of moisture and heat inside the mattress.

Further, as the above-mentioned configuration, more specifically, the cushion may be provided with an air passage extending in a predetermined direction, and one end of the air passage may be connected to the connecting portion. According to this configuration, it is possible to more efficiently diffuse the water vapor adsorbed on the acrylate-based fibers of the heat insulating layer by passing the air passage.

Further, more specifically as the above-mentioned configuration, the cushion may be configured by a three-dimensional filament combination body. According to this configuration, the cushion can be made extremely well ventilated, and the ventilation device 7 can be used to easily generate an air flow in the cushion. The ventilated bed according to the present invention is configured to include the mattress having the above-described configuration, the ventilation device, and the bed supporting the mattress.

According to the mattress cover of the present invention, it is possible to exert a humidity increase suppressing effect during sweating for a long time without impairing heat retention. Further, according to the mattress and the bed with the ventilation device of the present invention, it is possible to enjoy the advantages of the mattress cover of the present invention.

It is a perspective view of bed 10 with a ventilation device concerning a 1st embodiment. It is sectional drawing of the mattress 1 used for the bed 10 with a ventilation device. It is sectional drawing of mattress 1S which concerns on 2nd Embodiment. It is a perspective view of cushion 2S concerning a 2nd embodiment. It is a schematic block diagram of the manufacturing apparatus 100 of a three-dimensional filament combination body. It is a schematic perspective view of the receiving plate 130 shown in FIG. It is a schematic perspective view of the receiving plate 230 of another form.

Embodiments of the present invention will be described below with reference to the drawings, taking the first embodiment and the second embodiment as examples. The vertical direction, the horizontal direction, and the front-back directions (directions orthogonal to each other) of the bed with the ventilation device (and the components thereof) are as shown in FIG. Each of these directions is merely defined for convenience so that the vertical direction is the vertical direction and the longitudinal direction of the mattress (the same as the height direction of the user) is the front-back direction.

1. First Embodiment First, a first embodiment of the present invention will be described. FIG. 1 is a perspective view of a bed 10 with a ventilation device according to the first embodiment. 2 is a cross-sectional view of the mattress 1 used in the bed 10 with a ventilation device. Note that FIG. 2 is a cross-sectional view in the case of being cut along a plane that passes through the center of one of the two ventilation openings 32 and is orthogonal to the left-right direction. It is indicated by a broken line.

The ventilated bed 10 includes a mattress 1, a bed 6 that supports the mattress 1, and a ventilation device 7 that ventilates the air in the mattress 1. The mattress 1 is formed by using a rectangular parallelepiped cushion 2 formed by a three-dimensionally combined filament and a mattress cover 3 that accommodates the cushion 2. The cushion 2 can be regarded as a plate-shaped body and is formed of a three-dimensionally-combined filament body, so that the cushion has an extremely well-ventilated void ratio exceeding 90%. The method of manufacturing the three-dimensional filament assembly used for the cushion 2 will be described later.

The ventilation device 7 has a configuration in which a blower pipe 7a that can be connected to the ventilation port 32 of the mattress cover 3 is provided in a housing that accommodates a fan (not shown). The housing of the ventilation device 7 is provided with an opening 7b through which air passes. An air flow is generated by driving the fan of the ventilation device 7, and the air inside the mattress cover 3 can be exhausted to the outside through the opening 7b.

The ventilation device 7 may function as a ventilation device for ventilating the air in the mattress 1, and a specific method therefor is not particularly limited. For example, the ventilation device 7 exhausts the air in the mattress 1 to the outside by a method of sending air from the ventilation device 7 into the mattress 1 in addition to the method of sucking the air in the mattress 1 toward the ventilation device 7 side and exhausting it. The air in the mattress 1 may be ventilated. When noise is generated by driving a fan or the like, the ventilation device 7 should be installed on the rear side of the bed 6 (the foot side of the user) as in this embodiment so as not to disturb the sleep of the user as much as possible. Is preferred.

The mattress cover 3 has a structure in which a heat insulating layer 31 and a ventilation port 32 are provided on a bag-shaped cloth that covers the outer peripheral portion of the cushion 2. The ventilation port 32 has an opening 32 a that allows the inside and outside of the mattress cover 3 to communicate with each other, and can be detachably connected to the ventilation device 7. The interval between the two ventilation ports 32 arranged on the left and right is the same as the interval between the ventilation pipes 7a arranged on the left and right, and the ventilation port 32 and the ventilation pipe 7a can be easily connected. The cushion 2 has a rectangular parallelepiped shape with the longitudinal direction in the front-rear direction and the thickness direction in the up-down direction. Assuming the usage pattern shown in FIG. 2, the dimension in the front-rear direction is set to be slightly longer than the height of a person. There is.

The cloth of the mattress cover 3 has an upper surface cloth 3a, a lower surface cloth 3b, and a side surface cloth 3c. The lower surface cloth 3b covers the entire lower surface of the cushion 2, and the side surface cloth 3c covers the entire front, rear, left and right side surfaces of the cushion 2. The upper surface cloth 3a is provided with a heat retaining layer 31, which functions as an upper surface portion that covers the entire upper surface of the cushion 2. It should be noted that the rear side fabric 3c is provided with two ventilation openings 32 arranged side by side.

The heat-retaining layer 31 is a quilt sewn in a state where heat-retaining cotton-like fibers are placed between the front and back linings, and the heat-retaining cotton-like fibers and hygroscopic acrylate-based fibers are used. including. The heat insulating layer 31 is fixed to the inside of the upper surface cloth 3a so as to cover the entire upper surface of the cushion 2. In the present invention, the acrylate-based fiber is obtained by introducing a highly polar ionic group (carboxylic acid salt) into a polymer made of acrylic fiber as a raw material in order to improve hygroscopicity. It means a hygroscopic fiber having a water content in %RH of 30% or more and 50% or less. The acrylate fiber can be produced, for example, by the following method.

A spinning dope prepared by dissolving an acrylonitrile-based polymer consisting of acrylonitrile and methyl acrylate in an aqueous solution of rodan soda is wet-spun, washed with water, drawn, crimped, and heat-treated to obtain a raw material fiber. Crosslinking is performed by adding an aqueous solution. The obtained cross-linked fiber is washed with water, the nitrile group is hydrolyzed into a carboxylic acid group with an aqueous sodium hydroxide solution, the carboxylic acid group is converted into an acid form with an aqueous nitric acid solution, and washed with water. Then, a part of the acid type carboxylic acid group is converted into a carboxylic acid salt (sodium salt) by treating the fiber with an aqueous sodium hydroxide solution. In this way, the acrylate fiber is manufactured.

Examples of commercially available acrylate fibers include EX (trade name) manufactured by Toyobo Co., Ltd. Acrylate fibers with highly polar ionic groups generate large heat of adsorption when adsorbing (absorbing) water vapor, so the water vapor is retained as adsorbed water on the acrylate fiber surface in an energy-stabilized state. To be done. From an energy point of view, the heat of vaporization of water is 2442 kJ/kg, while the heat of adsorption is about 1200 kJ/kg, so the ability to trap water vapor is high.

As a result, the acrylate fiber has a high hygroscopic property, and in a high humidity state, the water vapor in the mattress can be quickly adsorbed as adsorbed water to lower the humidity in the mattress. If the moisture content of the acrylate fiber under the environment of 20° C. and 65% RH (relative humidity 65%) is less than 30%, it is difficult to sufficiently obtain the effect of reducing the humidity in the mattress, and conversely, the moisture content of 50% is obtained. If it exceeds %, it becomes difficult to dry. Therefore, the moisture content of the acrylate fiber according to the present invention at a temperature of 20° C. and a humidity of 65% is preferably 30% or more and 50% or less.

The water content of the fiber is obtained by the following method. As a moisture content measurement sample, about 1 g of fiber is left for 12 hours under the environmental conditions of temperature 20° C. and humidity 65% RH to adjust the humidity, and the weight of the fiber after the humidity adjustment is measured, and the measured value is absorbed. The fiber mass is Wa(g). Next, the humidity-adjusted fibers are left to dry in a hot air dryer at 105° C. for 12 hours, the weight of the dried fibers is measured, and this measured value is defined as the dry fiber mass Wb (g). Then, the water content Wr (%) is calculated using the following equation (1), and this calculated value is used as the water content of the fiber.
Wr=(Wa-Wb)/Wa×100 (1)

When the content of the acrylate fiber contained in the heat retaining layer 31 is less than 10% by weight, it is difficult to obtain sufficient hygroscopicity, and when it exceeds 30%, it becomes difficult to dry, so that the content is 10% by weight or more and 30% by weight or less. Is preferred. The thickness of the acrylate-based fiber is not particularly limited, but if it is less than 1 dtex, the strength tends to decrease, while if it exceeds 4 dtex, the surface area becomes small and sufficient hygroscopicity tends to be difficult to obtain. Therefore, the thickness of the acrylate-based fibers contained in the heat retaining layer 31 is preferably 1 dtex to 4 dtex (about 10 μm to 20 μm in terms of fiber diameter) in the single yarn fineness.

As the material of the heat retaining layer 31, as the cotton fiber used together with the acrylate fiber, for example, polyester fiber having a single yarn fineness of 0.4 dtex to 10 dtex (about 6 μm to 30 μm in terms of fiber diameter) can be used. Regarding the thickness of the cotton fiber (polyester fiber), if the single yarn fineness is less than 0.4 dtex, the air flow becomes too small and the diffusibility of water vapor is easily impaired, and the single yarn fineness exceeds 10 dtex. And the surface area of the fiber is reduced, and the heat retention (the function of retaining warm air due to the dead air effect) is impaired. Therefore, from the viewpoint of enhancing the effect of improving the diffusibility of water vapor and the heat retaining property, it is preferable that the thickness of the cotton fibers is 0.4 dtex to 10 dtex for the single yarn.

Hollow fibers may be used as the cotton fibers (polyester fibers). In particular, a polyester fiber spiral having a spiral three-hole hollow structure with a single yarn fineness of 4 dtex to 10 dtex (about 20 μm to 30 μm in terms of fiber diameter) is further excellent in that it has excellent heat retention and elasticity against compression. preferable.

As shown in FIG. 1, the upper surface cloth 3a of the mattress cover 3 includes a first area 3aa that supports the upper half of the user (sleeping person), a second area 3ab that supports the lower half of the user, and other parts. In each of the third area 3ac, the cloth having different air permeability (air passage) is used. In addition, the upper half of the body here is a part above the waist (in this embodiment, the part of the back approximately), and the lower half of the body is below the waist (in this embodiment, the part of the legs and feet). Is.

Regarding each of the above areas, the air permeability of the second area 3ab is higher than that of the third area 3ac, and the air permeability of the first area 3aa is higher than that of the second area 3ab. The air permeability of the area 3aa is the highest. The heat insulating layer 31 is evenly and substantially evenly arranged in all areas of the upper surface fabric 3a, and the air permeability of the upper surface portion of the mattress cover 3 (a portion including the upper surface material 3a and the heat insulating layer 31) is the first area 3aa. Is the highest in the area corresponding to the second area ab, is the next highest in the area corresponding to the second area ab, and is the lowest in the area corresponding to the third area ac. The air permeability of the bottom cloth 3b and the side cloth 3c is smaller than that of the third area 3ac, and is smaller than that of any area of the upper surface portion.

As the cloth for the first area 3aa, the second area 3ab, and the third area 3ac, cloth having an air permeability of 1 to 100 cm ³ /cm ² ·s measured by the Frazier method is suitable. If the air permeability of the dough is less than 1 cm ³ /cm ² ·s, the moisture permeability tends to be impaired, and if the air permeability of the dough exceeds 100 cm ³ /cm ² ·s, the heat retention tends to be impaired. The degree of air permeability to be used may be appropriately determined in consideration of moisture permeability and heat retention.

The air permeability measurement method measured by the Frazier method is defined by JIS L 1096 general textile test method and the like, and the air permeability is determined by the following method. After attaching the fabric to be the test piece, adjust the air suction fan so that the tilt type barometer shows a pressure of 125 Pa with the adjusting resistor, and keep the pressure difference between the front and back sides of the test piece constant. Determine the air volume (cm ³ /cm ² ·s) that passes through the test piece from the pressure indicated by the barometer and the type of air holes used, and use that value as the air permeability.

As described above, the mattress 1 according to the present embodiment includes the mattress cover 3 and the cushion 2 covered by the mattress cover 3, and the ventilation port 32 (connectable to the ventilation device 7 that generates an airflow) Part) and the inside of the mattress cover 3 can be ventilated using the ventilation device 7.

Thereby, the air in the mattress cover 3 can be stably ventilated, and the retention of moisture and heat inside the mattress can be suppressed. Since the cushion 2 is formed of a three-dimensionally-combined filament having extremely good ventilation, it is possible to easily generate an air flow in the cushion 2 by using the ventilation device 7.

The mattress cover 3 covers the cushion 2 to form the mattress 1, and a heat insulating layer 31 is provided on an upper surface portion that covers the upper surface of the cushion 2. Further, the heat retaining layer 31 contains acrylate fiber having a water content of 30% or more and 50% or less at a temperature of 20° C. and a humidity of 65% RH. Therefore, it is possible to exert the effect of suppressing the increase in humidity during sweating for a long time without impairing the heat retaining property.

That is, the water vapor generated by the sweat of the user is quickly adsorbed by the acrylate fiber, and then the adsorbed water and the heat of adsorption accumulated in the acrylate fiber (heat retaining layer) are gradually discharged to the outside of the mattress. Therefore, without sacrificing heat retention, the humidity in the heat retention layer 31 and the mattress is prevented from rapidly increasing even when a large amount of sweat is generated, and moisture or heat stays inside the mattress even after long-term use. Can be suppressed. In addition, it does not require the trouble of periodically drying it in order to maintain the hygroscopicity, and it does not easily cause a jagged feeling even after long-term use. The heat of adsorption generated when the acrylate fiber absorbs water vapor due to perspiration is consumed as the heat of release (the same amount of heat as the heat of adsorption) when the acrylate fiber becomes water vapor from the acrylate fiber and is desorbed. The mood is resolved.

Further, the mattress cover 3 has an upper surface having an air permeability higher than that of the side cloth 3c (side surface) that covers the side surface of the cushion. Therefore, the upper surface portion that supports the body of the user is preferentially ventilated by the ventilation device 7, so that the high-humidity air generated by the perspiration of the user can be efficiently emitted without excessively increasing the capacity of the ventilation device 7. It is possible to ventilate.

Furthermore, the mattress cover 3 has an air permeability of a region (a region corresponding to the first area 3aa) supporting the upper half of the user on the upper surface, and a region (second area) supporting the lower half of the user on the upper part. It is larger than the air permeability of the region corresponding to 3ab). Therefore, the flow of wind generated by the ventilation device 7 is preferentially directed to the upper half of the body where sweating tends to be larger than that of the lower half of the body, so that high humidity air can be efficiently supplied while keeping the feet from becoming too cold. It is possible to ventilate.

2. Second Embodiment Next, a second embodiment of the present invention will be described. The second embodiment is basically the same as the first embodiment, except that the cushion is provided with an air passage and points related thereto. In the following description, emphasis is placed on the description of the points different from the first embodiment, and description of the points common to the first embodiment may be omitted.

FIG. 3 is a cross-sectional view (a view from the same viewpoint as FIG. 2) of the mattress 1S according to the second embodiment. 4 is a perspective view of the cushion 2S shown in FIG. The mattress 1S includes a mattress cover 3 and a substantially rectangular parallelepiped cushion 2S formed by a three-dimensionally combined filament.

The cushion 2S is a plate-like body having a top surface 2a and a bottom surface 2b, and the top surface 2a is a flat surface, but the bottom surface 2b has two ventilation passages 21 (V-shaped grooves having a V-shaped cross section). ) Is formed to extend in the front-back direction. The cushion 2S is formed in a rectangular shape in a plan view and can be said to have a substantially rectangular parallelepiped shape. The two ventilation passages 21 extend from the front end to the rear end and are open in both front and rear.

Note that the two ventilation passages 21 are formed by V-shaped projections 233 (see FIG. 7), which will be described later, when the cushion 2S (filament three-dimensional combination) is manufactured. The shape, size, and position of the ventilation path 21 will be determined by the shape, size, and position of the V-shaped protrusion 233.

Further, in the cushion 2S, the filament density in the vicinity of the wall (boundary portion with the V-shaped groove) facing the ventilation path 21 (V-shaped groove) is higher than the filament density in the central portion in the thickness direction where the ventilation path 21 is not formed. It is larger and the strength is higher accordingly. The ventilation passage 21 formed in the cushion 2S has a shape of "V" when viewed in the direction in which the groove extends, and further, the strength in the vicinity of the wall is relatively high. Even if a downward load is applied to the upper surface 2a, excessive deformation of the ventilation passage 21 can be suppressed as much as possible. Further, in the present embodiment, the ventilation passage 21 is a V-shaped groove having a V-shaped cross-section, but the cross-sectional shape of the ventilation passage 21 may be freely designed by, for example, forming a U-shaped cross-section. Good.

The two ventilation passages 21 are provided so as to be arranged side by side at a predetermined interval. The distance between the ventilation passages 21 is the same as the distance between the two left and right ventilation openings 32 provided in the mattress cover 3. Therefore, when the cushion 2S is housed in the mattress cover 3, the rear end of the left ventilation passage 21 is naturally connected to the left ventilation opening 32, and the rear end of the right ventilation passage 21 is naturally connected to the right ventilation opening 32. Connect. As a result, the fan of the ventilation device 7 can be driven to generate a particularly strong air flow in the ventilation passage 21.

As described above, in the mattress 1S according to the present embodiment, the cushion 2S is provided with the ventilation passage 21 extending in the front-rear direction, and one end of the ventilation passage 21 is connected to the ventilation port 32 (connection portion). ing. Therefore, the water vapor adsorbed on the acrylate fiber of the heat retaining layer 31 can be more efficiently diffused by passing through the ventilation passage 21. In particular, since the ventilation passage 21 extends in the front-back direction (the height direction of the user), it is possible to efficiently move the water vapor (water vapor adsorbed on the front side of the mattress) due to the sweat of the user's upper body to the rear. is there.

3. As described above, the filament three-dimensional bonded body is used as the cushion according to each of the embodiments of the present invention. Hereinafter, an example of a manufacturing apparatus for manufacturing the three-dimensionally combined filament will be described. Note that the vertical, horizontal, and front-back directions (directions orthogonal to each other) regarding the apparatus for manufacturing a three-dimensional filament combination are as shown in FIGS. 5 and 6. Each of these directions is merely determined for convenience so that the vertical direction is the vertical direction and the facing direction of the pair of receiving plates 130 is the front-back direction.

FIG. 5 is a schematic configuration diagram of an apparatus 100 for manufacturing a filament three-dimensional combined body that can be used for the cushion 2 according to the first embodiment. FIG. 6 is a schematic perspective view of the receiving plate 130 shown in FIG.

A manufacturing apparatus 100 for a three-dimensional filament combination body includes a molten filament supply unit 110 that discharges a molten filament group MF composed of a plurality of molten filaments having a diameter of 0.5 mm to 3 mm in a vertically downward direction, and a molten filament group MF that is three-dimensional. A fusion bond forming part 120 is provided for forming a filament three-dimensional bonded body 3DF by cooling and solidifying the contact points after the contact points are fused together by fusion.

The molten filament supply unit 110 includes a pressure melting unit 111 (extruder) and a filament discharge unit 112 (die). The pressurizing and melting unit 111 includes a material charging unit 113 (hopper), a screw 114, a screw motor 115 that drives the screw 114, a screw heater 116, and a plurality of temperature sensors (not shown). Inside the pressurizing and melting unit 111, a cylinder 111a for transporting the thermoplastic resin supplied from the material charging unit 113 while heating and melting the thermoplastic resin by the screw heater 116 is formed.

A screw 114 is rotatably housed in the cylinder 111a. A cylinder discharge port 111b for discharging the thermoplastic resin toward the filament discharge unit 112 is formed at the downstream end of the cylinder 111a. The heating temperature of the screw heater 116 is controlled based on a detection signal of a temperature sensor provided in the molten filament supply unit 110, for example.

The filament discharge part 112 includes a nozzle part 117, a die heater 118, and a plurality of temperature sensors (not shown). Inside, a guide passage 112a for guiding the molten thermoplastic resin discharged from the cylinder discharge port 111b to the nozzle part 117 is formed. Has been done. The nozzle portion 117 is a substantially rectangular parallelepiped metal thick plate in which a plurality of openings are formed, and is provided below the filament discharge portion 112, which is the most downstream portion of the guiding channel 112a. The die heater 118 heats the filament discharge part 112. The heating temperature of the die heater 118 is controlled, for example, based on a detection signal of a temperature sensor provided in the filament discharge part 112.

Examples of the thermoplastic resin that can be used as the material for the three-dimensional filament combination include polyolefin resins such as polyethylene and polypropylene, polyester resins such as polyethylene terephthalate, polyamide resins such as nylon 66, polyvinyl chloride resin, and polystyrene. Resins and the like, and thermoplastic elastomers such as styrene elastomer, vinyl chloride elastomer, olefin elastomer, urethane elastomer, polyester elastomer, nitrile elastomer, polyamide elastomer, and fluorine elastomer can be used.

The thermoplastic resin supplied from the material charging unit 113 is heated and melted in the cylinder 111a, and is extruded by, for example, the screw 114, so that the molten thermoplastic resin is discharged from the cylinder discharge port 111b to the conduit 112a of the filament discharge unit 112. Is supplied to. After that, the molten filament group MF including a plurality of molten filaments is discharged so as to translate downward from each of the plurality of nozzles of the nozzle unit 117.

The fusion bond forming unit 120 includes a cooling water tank 123, a pair of front and rear conveyors 124, a plurality of transport rollers 125a to 125h, and a pair of front and rear receiving plates 130. As shown in FIG. 6, the pair of front and rear receiving plates 130 includes a first flat surface forming receiving plate 131 and a second flat surface forming receiving plate 132. The pair of receiving plates 130 are installed below the nozzle portion 117 with a predetermined gap in the front-rear direction, and serve to regulate the thickness of the filament three-dimensional combined body 3DF and to smooth the surface. Although a cooling water supply device is provided on the receiving plate 130, the illustration of the cooling water supply device is omitted for ease of explanation here.

The first plane forming receiving plate 131 has a bent portion that includes a flat plate-shaped inclined surface 131a that is inclined downward toward the rear and a flat plate-shaped vertical surface 131b that extends vertically downward from the lower end of the inclined surface 131a. It is a metal plate. The second plane forming receiving plate 132 has a bent portion that includes a flat plate-shaped inclined surface 132a that is inclined downward toward the front and a flat plate-shaped vertical surface 132b that extends vertically downward from the lower end of the inclined surface 132a. It is a metal plate. These vertical surfaces 131b and 132b are parallel to each other and face each other in the front-rear direction.

The backing plate 130 guides the end portion in the thickness direction of the molten filament group MF to the central portion side by the two front and rear inclined surfaces 131a and 132a, so that the longitudinal dimension of the molten filament group MF is set to the two front and rear vertical planes 131b and 132b. And a smooth surface is formed at the same time.

The cooling water tank 123 is a water tank for storing the cooling water W. Inside the cooling water tank 123, a pair of front and rear conveyors 124 and a plurality of transport rollers 125a to 125h are arranged. The pair of conveyors 124 and the plurality of transport rollers 125a to 125h are driven by a drive motor (not shown). The molten filament group MF having a smooth surface formed by the receiving plate 130 is cooled and solidified in the cooling water tank 123 while being conveyed to the downstream side by the pair of conveyors 124 and the plurality of conveying rollers 125a to 125h, and the filament three-dimensional. The combined body 3DF is discharged from the cooling water tank 123.

After the obtained three-dimensionally combined filament 3DF is dried, pseudo-crystallized, and cut into a desired size, a cushion composed of a plurality of filaments having a diameter of 0.5 mm to 3 mm is obtained. .. Regarding the cushion made of the three-dimensionally-combined filament 3DF, if the porosity exceeds 98%, the repulsive force tends to be too low, and if it is less than 90%, the ventilation tends to be too low. It is preferably 90% or more and 98% or less.

Further, the filament three-dimensional combined body that can be used for the cushion 2S according to the second embodiment can be manufactured by using the manufacturing apparatus 100 described above in which the shape of the receiving plate is changed. Hereinafter, the receiving plate 230 used when manufacturing the three-dimensionally combined filament (having V-shaped grooves corresponding to the ventilation passages 21) will be described.

FIG. 7 is a schematic perspective view of the receiving plate 230. The filament three-dimensional combined body that can be used for the cushion 2S of the second embodiment can be manufactured using the manufacturing apparatus 100 in which the receiving plate 230 is applied instead of the receiving plate 130 described above. Although a cooling water supply device is provided on the receiving plate 230, the illustration of the cooling water supply device is omitted for ease of explanation here.

The receiving plate 230 includes a plane forming receiving plate 231 and a V-shaped groove forming receiving plate 232. The plane forming receiving plate 231 and the V-shaped groove forming receiving plate 232 are provided as a pair of front and rear receiving plates 230, and play a role of regulating the thickness of the filament three-dimensional combination 3DF and forming a V-shaped groove in it. Fulfill.

The pair of front and rear receiving plates 230 is installed below the nozzle portion 117 with a predetermined gap in the front-rear direction. In the present embodiment, the plane forming receiving plate 231 is provided on the front side of the V-shaped groove forming receiving plate 232, but the plane forming receiving plate 231 is provided on the rear side of the V-shaped groove forming receiving plate 232. That is, the side on which the V-shaped groove is formed may be reversed before and after).

The plane forming receiving plate 231 is a metal plate having a bent portion that includes a flat plate-shaped inclined surface 231a that is inclined downward toward the rear and a flat plate-shaped vertical surface 231b that extends vertically downward from the lower end of the inclined surface 231a. Is. The V-shaped groove forming receiving plate 232 has a bent portion that includes a flat plate-shaped inclined surface 232a that is inclined downward toward the front and a flat plate-shaped vertical surface 232b that extends vertically downward from the lower end of the inclined surface 232a. It is a metal plate. These vertical surfaces 231b and 232b are parallel to each other and face each other in the front-rear direction.

On the vertical surface 232b of the V-shaped groove forming receiving plate 232, two V-shaped protrusions 233 are provided at a predetermined interval in the left-right direction. The V-shaped projection 233 is interposed in the path of the molten filament group MF discharged from the nozzle portion 117, and by separating the molten filament group in the width direction, the V-shaped groove extending in the traveling direction of the molten filament MF is a filament. The three-dimensional combination 3DF is formed.

In the present embodiment, the left and right V-shaped protrusions 233 have the same shape and size, and the outer edges of both of them are V-shaped (equivalent to the cross-sectional shape of the first component 233a) when viewed from above. The shape of the V-shaped projection 233 is such that the second tetrahedron shape whose one side is the ridgeline 233b1 is provided on the upper side of the triangular prism-shaped first constituent portion 233a having a bottom surface facing downward and one side surface being common to the vertical surface 232b. It has a shape in which the constituent parts 233b are connected.

The ridgeline 233b1 is a line segment that extends obliquely rearward and upward from the apex of the upper surface of the first component portion 233a to the vertical plane 232b, and is provided so as to bisect the V-shaped projection 233 into left and right when viewed from above. .. The second component portion 233b has a plane connecting the ridgeline 233b1 to the upper side of the left side surface of the first component 233a and a plane connecting the ridgeline 233b1 to the upper side of the right side surface of the first component 233a.

The backing plate 230 guides the end portion in the thickness direction of the molten filament group MF to the central portion side by the two front and rear inclined surfaces 231a and 232a, so that the longitudinal dimension of the molten filament group MF is set to the two front and rear vertical planes 231b and 232b. Reduce to the interval of. At the same time, the receiving plate 230 forms a V-shaped groove on one surface (rear surface) of the molten filament group MF by the two V-shaped projections 233.

More specifically, since the two V-shaped projections 233 are present in the path of the molten filament group MF discharged from the nozzle portion 117 and vertically downward, the V-shaped projections 233 in the molten filament group MF interfere with the V-shaped projection 233. A groove corresponding to the shape of the projection 233 viewed from above, that is, a V-shaped groove is formed. Since the V-shaped projection 233 has a ridge line 233b1, the molten filament MF that advances from the upper side toward the V-shaped projection 233 is divided at the ridge line 233b1 and smoothly separated in the left-right direction (width direction of the molten filament MF). You can The V-shaped groove formed in this manner can be used as the ventilation passage 21 described above.

5. Performance Evaluation After obtaining the mattresses of Examples 1 to 3 as Examples of the present invention, the mattresses according to these Examples were evaluated for performance by comparison with Comparative Examples. Hereinafter, modes of each example and comparative example, and an evaluation method and an evaluation result will be described in more detail.

(1) Form of Example 1 As a cushion raw material, a polyethylene material having a density of 0.91 g/cm 2 and a melting point of 100° C. is used, and using the apparatus 100 for manufacturing a three-dimensional filament assembly shown in FIGS. 5 and 6, A cushion A1 (an example of the cushion 2) made of a three-dimensionally combined filament having a longitudinal length of 200 cm, a width direction of 100 cm, a thickness of 12 cm, and a porosity of 95% was manufactured. Further, as the bag-like material of the mattress cover 3, the top surface material 3a has an air permeability of 20 cm ³ /cm ² ·s, and the bottom material 3b and the side surface material bc have an air permeability of 0.5 cm ³ /cm ² ·s. A bag-shaped material B1 was created.

A fastener is provided at the boundary between the upper surface cloth and the side surface cloth of the bag-shaped cloth B1 to join the upper surface cloth and the side surface cloth. Further, two ventilation openings 32 connectable to the ventilation device 7 are provided on the side surface cloth 3c at one end in the longitudinal direction of the mattress cover 3.

As the heat insulating layer 31 of the mattress cover 3, 300 g of acrylate fiber (single yarn fineness is 3.6 dtex, moisture content at 20° C. and humidity 65% RH is 41%) between two polyester fabrics (outer fabric and lining). And sewn with 1000 g of mixed fiber mixed with 700 g of polyester fiber (single yarn fineness is 4 dtex) are sandwiched to create a quilt C1 having a longitudinal length of 200 cm and a width direction of 100 cm. The mattress cover D1 (an example of the mattress cover 3) was created by sewing the outer edge portion of C1 to the inside of the upper surface fabric of the bag-shaped fabric B1.

In the obtained mattress cover D1, the air permeability at the upper surface portion was 18 cm ³ /cm ² ·s, and the air permeability at the bottom surface portion and the side surface portion was 0.5 cm ³ /cm ² ·s. The cushion A1 was enclosed in the mattress cover D1 to obtain the mattress E1 of Example 1.

(2) Form of Example 2 As the bag-like cloth of the mattress cover 3, the air permeability of the first area of the upper surface cloth 3a is 50 cm ³ /cm ² ·s, and the air permeability of the second area and the third area is 20 cm. ³ /cm ² · s, the same method as in Example 1 except that the bag-like fabric B2 having a bottom fabric 3b and side fabric 3c having an air permeability of 0.5 cm ³ /cm ² · s was used. The mattress E2 of Example 2 was prepared.

In the obtained mattress cover 3, the air permeability of the area corresponding to the first area of the upper surface is 40 cm ³ /cm ² ·s, and the air permeability of the area corresponding to the second area and the third area of the upper surface. Was 18 cm ³ /cm ² ·s, and the air permeability at the bottom and side surfaces was 0.5 cm ³ /cm ² ·s.

(3) Form of Example 3 As the bag-like material for the mattress cover, the air permeability of the first area of the upper surface cloth 3a is 50 cm ³ /cm ² ·s, and the air permeability of the second area is 30 cm ³ /cm ² ·. s, the third area has an air permeability of 2 cm ³ /cm ² ·s, and the bottom material 3 b and the side material 3 c have an air permeability of 0.5 cm ³ /cm ² ·s. Mattress E3 of Example 3 was prepared in the same manner as in Example 1 except for the above points.

In the obtained mattress cover 3, the air permeability of the area corresponding to the first area of the upper surface is 40 cm ³ /cm ² ·s, and the air permeability of the area corresponding to the second area of the upper surface is 26 cm ³ / cm ² s, the air permeability of the area corresponding to the third area of the top surface is 1.8 cm ³ /cm ² s, and the air permeability of the bottom surface and the side surface is 0.5 cm ³ /cm ² It was s.

(4) Form of Comparative Example Example 1 was repeated except that a urethane cushion having a longitudinal length of 200 cm, a widthwise length of 100 cm and a thickness of 12 cm was used instead of the cushion A1. The mattress E4 of the comparative example was prepared by the same method as described above.

(5) Evaluation method Using each of the mattresses of Examples 1 to 3 and Comparative Example, the temperature and humidity inside the mattress were measured 30 minutes and 5 hours after falling asleep. As a sleeping environment at the time of measurement, the ventilation device 7 was connected to two ventilation openings 32 provided on the side fabric of the mattress cover 3, and the air inside the mattress was sucked by the ventilation device 7 at an air volume of 100 ml/s. As the comforter, a bag-shaped polyester cloth having a length of 2 m in the front-rear direction and 1 m in the left-right direction was filled with 1 kg of polyester fiber cotton as a heat insulating material.

In the mattress E4 of the comparative example, even if the ventilation device 7 was connected, the air in the mattress could not be ventilated, so the temperature and humidity in the mattress were measured without performing the ventilation. The temperature and humidity in the mattress are measured by attaching five temperature and humidity sensors at 10 cm intervals to the heat insulating layer 31 of the mattress cover corresponding to the position of the back of the user who is lying on the mattress and after falling asleep. The temperature and humidity were measured. The highest value among the temperature and humidity data measured by these temperature and humidity sensors was adopted as the measurement value. The evaluation this time was carried out in an environment of room temperature of 23° C. and humidity of 45% RH.

The feeling of dullness (the degree of moisture felt by a person) was determined by whether or not moisture was felt when the mattress was touched when waking up 8 hours after falling asleep. The case where no humidity was felt was defined as “good”, the case where a little humidity was felt was defined as “slightly good”, and the case where humidity was felt was defined as “bad”.

(6) Evaluation results The results of performance evaluations performed by the above evaluation methods are shown in Table 1 below.

As shown in Table 1, in the mattress of the comparative example, the humidity was excessively increased, and the result was that it was uncomfortable to use due to the feeling of dullness. On the other hand, in the mattresses of the respective Examples (Examples 1 to 3), it was possible to prevent the humidity from rising excessively, and it was possible to obtain the result that the mattresses were suppressed from feeling jerky and were comfortable to use. In addition, when comparing the respective examples, it was found that the humidity of the example 2 was lower than that of the example 1, and that the humidity of the example 3 was lower than that of the example 2.

6. Others Although the embodiment of the present invention has been described above, the configuration of the present invention is not limited to the above embodiment, and various modifications can be made without departing from the spirit of the invention. That is, it should be considered that the above-described embodiments are illustrative in all points and not restrictive. It is understood that the technical scope of the present invention is shown not by the above description of the embodiments but by the scope of the claims, and includes all modifications equivalent to the scope of the claims and within the scope. Should be.

INDUSTRIAL APPLICABILITY The present invention is applicable to a mattress cover, a mattress, and a bed with a ventilation device using the mattress cover.

1, 1S Mattress 2, 2S Cushion 2a Upper surface 2b Bottom surface 21 Ventilation path 3 Mattress cover 3a Upper surface material 3b Lower surface material 3c Side surface material 31 Heat insulation layer 32 Ventilation port 32a Opening 6 Sleeper 7 Ventilator 7a Air blower 7b Opening 8 Pillow 10 Bed with ventilation device 100 Filament three-dimensional combined body manufacturing device

Claims (7)

A mattress cover for covering a cushion to form a mattress,
A heat insulating layer is provided on the upper surface portion that covers the upper surface of the cushion,
The mattress cover, wherein the heat retaining layer contains an acrylate fiber having a moisture content of 30% or more and 50% or less at a temperature of 20° C. and a humidity of 65% RH. The mattress cover according to claim 1, wherein the air permeability of the upper surface portion is larger than the air permeability of the side surface portion that covers the side surface of the cushion. The air permeability of a region of the upper surface portion supporting the upper half of the user is set to be higher than the air permeability of a region of the upper surface supporting the lower half of the user. Mattress cover described in. A mattress comprising the mattress cover according to any one of claims 1 to 3, and a cushion covered with the mattress cover,
A mattress having a connection part that can be connected to a ventilation device for generating an air flow, wherein the inside of the mattress cover can be ventilated using the ventilation device. The cushion is provided with an air passage extending in a predetermined direction,
The mattress according to claim 4, wherein one end of the air passage is connected to the connecting portion. The mattress according to claim 4 or 5, wherein the cushion is formed of a three-dimensionally combined filament. A mattress according to any one of claims 4 to 6,
The ventilator,
A bed supporting the mattress, and a bed with a ventilator.