JP2021052961A - Laminate cushioning material - Google Patents

Abstract

To provide a laminate cushioning material improved in durability and air permeability.SOLUTION: A laminate cushioning material 1 is provided with a plurality of projections 2 at a loading receiving side. The laminate cushioning material 1 has at least one layer which is a skinned resin foam layer 1c formed from skinned resin foam. The laminate cushioning material 1 includes slits 5 penetrating into the laminate cushioning material 1 in a thickness direction in positions excluding peaks P of the projections 2.SELECTED DRAWING: Figure 1

Description

The present invention relates to a laminated cushion material.

A conventional laminated cushion material includes a mattress in which a foam having a closed cell structure that has been defilmed is used in the intermediate layer between the base layer and the support layer (see, for example, Patent Document 1).

JP-A-2015-128483

However, in the above-mentioned conventional laminated cushion material, when the laminated cushion material is repeatedly compressed as a final product, the subsequent curing reduction rate is higher than that in the case of using a non-film-removing foam resin other than the film-removing foam resin. large. That is, in the above-mentioned conventional laminated cushion material, the final product tends to be worn out as compared with the case where the non-film-removing foamed resin is used. Therefore, there is room for improvement in durability of the conventional laminated cushion material. Further, the conventional laminated cushion material still has room for improvement in terms of breathability.

An object of the present invention is to provide a laminated cushioning material having improved durability and breathability.

The laminated cushioning material according to the present invention is a laminated cushioning material in which a plurality of protrusions are provided on the surface side, and at least one layer of the laminated cushioning material is a film-removing foamed resin layer formed of a film-removing foamed resin. Further, the laminated cushion material is provided with a slit that penetrates the laminated cushion material in the thickness direction of the laminated cushion material at a position other than the apex of the protrusion. According to the laminated cushion material according to the present invention, the laminated cushion material has improved durability and breathability.

Further, in the laminated cushion material according to the present invention, it is preferable that at least a part of the protrusions is formed by the film-removing foamed resin layer. In this case, the laminated cushion material has improved breathability.

Further, in the laminated cushion material according to the present invention, it is preferable that the portion of the protrusion including the apex is formed of a non-membrane foamed resin layer formed of a non-membrane foamed resin. In this case, a massage effect can be obtained.

Further, in the laminated cushion material according to the present invention, it is preferable that the film-removing foamed resin layer has a higher elastic modulus than the non-film-removing foamed resin layer. In this case, the ability to turn over is improved.

Further, in the laminated cushion material according to the present invention, it is preferable that the slit has a cross shape in a plan view. In this case, the durability is further improved.

Further, in the laminated cushion material according to the present invention, it is preferable that the end portion of the slit is circular in a plan view. In this case, the durability is further improved.

Further, in the laminated cushion material according to the present invention, the intersection of the slits is preferably circular in a plan view. In this case, the durability is further improved.

Further, the laminated cushion material according to the present invention includes the film-removing foamed resin layer and two non-film-removing foamed resin layers formed of the non-film-removing foamed resin, and the two non-film-removing foamed resins. It is preferable to have a three-layer structure in which the demembrane foam layer is interposed between the layers. In this case, it is possible to provide a laminated cushion material that is simple and advantageous in terms of cost.

According to the present invention, it is possible to provide a laminated cushion material having improved durability and breathability.

It is a top view which shows the part of the laminated cushion material which concerns on one Embodiment of this invention in an enlarged manner. FIG. 1 is a cross-sectional view taken along the line AA of FIG. It is a perspective view which shows a part of FIG. 1 in a further enlarged view. It is a top view which shows the specific structure of the laminated cushion material of FIG. It is a top view which shows the concrete other structure of the laminated cushion material of FIG.

Hereinafter, the laminated cushion material according to the embodiment of the present invention will be described with reference to the drawings.

In FIG. 1, reference numeral 1 is a laminated cushion material according to an embodiment of the present invention. FIG. 1 shows a part of the laminated cushion material 1 from the surface side. Here, the "surface side" means a load receiving side that receives a load when a person lies down. Further, in FIG. 1, reference numeral L is a length direction (length direction). Further, in FIG. 1, the reference numeral W is in the width direction. Further, in FIG. 1, reference numeral D is a thickness direction.

As shown in FIG. 1, a plurality of protrusions 2 are provided on the surface side of the laminated cushion material 1.

In the present embodiment, the plurality of protrusions 2 are arranged at intervals from each other. Specifically, the plurality of protrusions 2 are arranged at regular intervals in the length direction L and the width direction W, respectively. In FIG. 1, reference numeral 2 is typically attached only to the four protrusions 2, and the reference numerals are omitted for the other protrusions 2.

Further, in the present embodiment, a plurality of recesses 3 are provided on the surface side of the laminated cushion material 1.

In the present embodiment, the plurality of recesses 3 are also arranged at regular intervals in the length direction L and the width direction W, respectively. Specifically, each of the plurality of recesses 3 is arranged between the protrusions 2. In FIG. 1, reference numeral 3 is typically attached only to the five protrusions 2, and the reference numerals are omitted for the other protrusions 2.

FIG. 2 is a cross-sectional view taken along the line AA of FIG.

At least one layer of the laminated cushion material 1 is a film-removing foamed resin layer formed of a film-removing foamed resin. The laminated cushion material 1 includes a plurality of layers.

The plurality of layers are overlapped in the thickness direction and joined to each other. That is, the laminated cushion material 1 is a laminated body having a plurality of layers. As shown in FIG. 2, in the present embodiment, the laminated cushion material 1 has an upper layer 1a forming the front surface (load receiving side surface) FS of the laminated cushion material 1 and a lower layer forming the back surface BS of the laminated cushion material 1. It includes 1b and an intermediate layer 1c arranged between the first cushion layer 1a and the intermediate layer 1b.

At least one layer of the upper layer 1a, the lower layer 1b, and the intermediate layer 1c is a film-removing foamed resin layer formed of the film-removing foamed resin. A foamed resin formed by foaming a resin generally has a film formed between its skeletons (hereinafter, also referred to as "non-defilming foamed resin"). The film-removing foamed resin is obtained by removing the film by performing a treatment such as heating the non-film-removing foamed resin before the film removal. Therefore, the film-removing foamed resin has better air permeability than the non-membrane-removing foamed resin. In the present embodiment, the upper layer 1a and the lower layer 1b are non-film-removing foam resin layers formed of the non-film-removing foam resin. Further, in the present embodiment, the intermediate layer 1c is a film-removing foamed resin layer.

The laminated cushion material 1 is provided with a slit 5 that penetrates the laminated cushion material 1 in the thickness direction of the laminated cushion material 1 at a position other than the apex P of the protrusion 2.

In the present embodiment, the protrusion 2 is formed by the upper layer 1a and the intermediate layer 1c. Further, in the present embodiment, the recess 3 is formed by the intermediate layer 1c and the lower layer 1b. That is, in the present embodiment, the protrusions 2 and the recesses 3 are formed by the upper layer 1a or the lower layer 1b together with the intermediate layer 1c with the intermediate layer 1c as a common base layer. In other words, in the present embodiment, the surface FS of the laminated cushion material 1 is formed by each of the upper layer 1a, the intermediate layer 1c, and the lower layer 1b. On the other hand, in the present embodiment, the back surface BS of the laminated cushion material 1 is formed only by the lower layer 1b.

In short, in the present embodiment, the laminated cushion material 1 is formed only by a portion formed by the upper layer 1a, the intermediate layer 1c and the lower layer 1b, a portion formed by the intermediate layer 1c and the lower layer 1b, and the lower layer 1b. It is composed of the parts that are used.

According to the present invention, the slit 5 is formed at a position other than the apex P of the protrusion 2. In the present embodiment, the slit 5 is a portion that penetrates the intermediate layer 1c and the lower layer 1b in the thickness direction (a portion between the two protrusions 2) and a portion that penetrates only the lower layer 1b in the thickness direction. It is composed of (the part of the recess 3). Further, as described above, the surface FS of the laminated cushion material 1 is formed by each of the upper layer 1a, the intermediate layer 1c, and the lower layer 1b. Further, the back surface BS of the laminated cushion material 1 is formed only by the lower layer 1b. That is, the slit 5 penetrates the laminated cushion material 1 in the thickness direction and opens to each of the front surface FS and the back surface BS of the laminated cushion material 1. Therefore, the slit 5 can function as a vent that penetrates the laminated cushion material 1 in the thickness direction.

In the present embodiment, at least one layer of the laminated cushion material 1 is a film-removing foamed resin layer formed of a film-removing foamed resin. As a result, according to the present embodiment, the laminated cushion material 1 has good breathability. Further, the laminated cushion material 1 includes a slit 5 that penetrates the laminated cushion material 1 in the thickness direction of the laminated cushion material 1. As a result, according to the laminated cushion material 1, the air permeability of the laminated cushion material 1 is improved.

Further, since the width of the slit 5 is freely expanded and contracted in the slit 5, when the laminated cushion material 1 as a final product is repeatedly compressed, the stress generated at the time of the repeated pressure can be relaxed. Therefore, the subsequent curing reduction rate of the laminated cushion material 1 can be suppressed as compared with the conventional laminated cushion material that only uses the non-film-removing foam resin and the film-removing foam resin. Further, since the slit 5 is provided at a position other than the apex P of the protrusion 2, it is possible to secure the operation of enlargement / reduction of the slit 5 without directly applying a load.

Therefore, according to the laminated cushion material 1 according to the present embodiment, the laminated cushion material has improved durability and breathability.

FIG. 3 is a perspective view showing a part of FIG. 1 in a further enlarged view.

According to the present invention, it is preferable that at least a part of the protrusion 2 is formed by a film-removing foamed resin layer. In this case, the demembrane foamed resin layer is arranged closer to the surface side that requires breathability. In this case, the air permeability of the demembrane foamed resin layer is more effectively exhibited. Therefore, in this case, the laminated cushion material 1 has further improved air permeability.

In the present embodiment, the protrusion 2 is formed by the upper layer 1a and the intermediate layer 1c. In the present embodiment, the intermediate layer 1c is a film-removing foamed resin layer. Therefore, according to the present embodiment, the air permeability of the film-removing foamed resin layer is more effectively exhibited.

Further, according to the present invention, the portion of the protrusion 2 including the apex P is preferably formed by a non-membrane-foaming resin layer formed of a non-membrane-foaming resin other than the film-removing foam resin. In this case, the person can be supported by one point of the apex P of the protrusion 2. Therefore, when a person lies on the load receiving side of the laminated cushion material 1, the protrusion 2 can obtain the acupressure effect.

In the present embodiment, the upper layer 1a forms a part of the protrusion 2 including the apex P of the protrusion 2. Further, in the present embodiment, the upper layer 1a is a non-defilmed foamed resin layer that has not been defilmed. Therefore, according to the present embodiment, when a person lies on the laminated cushion material 1, the acupressure effect can be obtained by the protrusion 2.

Further, in the laminated cushion material according to the present invention, it is preferable that the film-removing foamed resin layer has a higher elastic modulus than the non-film-removing foamed resin layer. In this case, the elastic modulus of the film-removing foamed resin layer is higher than that of the other layers, so that it becomes easier to turn over. Therefore, in this case, the ability to turn over is improved.

In the present embodiment, the intermediate layer 1c has a higher rebound resilience than the upper layer 1a and the lower layer 1b. Suitable elastic moduli of the intermediate layer 1c include, for example, 55% to 62%. Further, as a preferable elastic modulus of the upper layer 1a and the lower layer 1b, for example, a numerical value of 55% or less can be mentioned. In this case, the elastic modulus of the intermediate layer 1c is higher than that of the upper layer 1a and the lower layer 1b, so that it becomes easier to turn over. Therefore, according to the present embodiment, the ability to turn over is improved. Examples of the method for measuring the rebound resilience include the rebound resilience test method specified in JIS K 6400-3.

By the way, according to the present invention, the slit 5 can be formed into various shapes such as a circular shape, a single character shape, and a cross shape in a plan view.

According to the present invention, the slit 5 preferably has a cross shape in a plan view. In this case, the durability is further improved as compared with the case of other shapes such as a circular shape and a single character shape.

Referring to FIG. 1, the slit 5 includes four ends 5a and one intersection 5b. In the present embodiment, the slit 5 has a cross shape in which four end portions 5a and one intersection portion 5b are respectively arranged in the recess 3. Specifically, the slit 5 has its intersection 5b arranged in one recess 3. Further, the slit 5 includes four straight portions 5c. One end of each of the four straight portions 5c is connected to the intersection 5b, and each of the four straight portions 5c extends radially from the intersection 5b. In the present embodiment, each of the four straight portions 5c extends across the intermediate layer 1c connecting the two protrusions 2. In the present embodiment, the other end of the straight line portion 5c is arranged in each of the four recesses 3 adjacent to the recess 3 in which the intersection portion 5b is arranged. That is, in the present embodiment, the other end of the straight line portion 5c is arranged in each of the four recesses 3 as the end portion 5a of the slit 5. According to the present embodiment, the durability can be further improved as compared with the case where the slit 5 has another shape such as a circular shape or a single character shape.

Further, in the present invention, the end portion 5a of the slit 5 is preferably circular in a plan view. In this case, it is possible to suppress the generation of cracks from the end portion 5a of the slit 5 and the growth of the cracks. Therefore, in this case, the durability is further improved.

In the present embodiment, the end a of the slit 5 is a circular hole formed with a radius ra in a plan view. According to this embodiment, it is possible to suppress the generation of cracks from the end portion 5a of the slit 5 and the growth of the cracks. Therefore, according to the present embodiment, the durability is further improved.

Further, in the present invention, the intersection 5b of the slit 5 is preferably circular in a plan view. In this case, the generation of cracks from the intersection 5b of the slit 5 and the growth of the cracks can be suppressed. Therefore, in this case, the durability is further improved.

In the present embodiment, the intersection 5b of the slit 5 is a circular hole formed with a radius rb in a plan view. According to this embodiment, it is possible to suppress the generation of cracks from the intersection 5b of the slit 5 and the growth of the cracks. Therefore, according to the present embodiment, the durability is further improved.

Further, according to the present invention, the laminated cushion material 1 includes the film-removing foamed resin layer and two non-film-removing foamed resin layers formed of the non-film-removing foamed resin, and the two non-membrane-removing foamed resin layers are provided. It is preferable to have a three-layer structure in which the membrane-removing foam layer is interposed between the membrane-foamed resin layers. In this case, it is possible to provide the laminated cushion material 1 which is simple and advantageous in terms of cost.

The laminated cushion material 1 according to the present embodiment has a three-layer structure in which an intermediate layer 1c formed of a film-removing foamed resin is interposed between two non-film-removing foamed resin layers of an upper layer 1a and a lower layer 1b. Therefore, according to the present embodiment, it is possible to provide the laminated cushion material 1 which is simple and advantageous in terms of cost.

Here, an example of a method for manufacturing the laminated cushion material 1 for obtaining the laminated cushion material 1 will be described. In this example, the laminated cushion material 1 can be manufactured mainly through three steps.

First, in the first step, a laminated body in which at least one non-membrane-removing urethane foam and at least one non-membrane-removed urethane foam are superposed and bonded is prepared. In the present embodiment, the base layer (lower layer 1b), the second cushion layer (intermediate layer 1c), the first cushion layer (upper layer 1a), the second cushion layer (intermediate 1c), and the base layer (lower layer 1b) are laminated in this order. Prepare the arranged laminate.

Next, in the second step, the laminate is profiled. In the present embodiment, the laminate is profiled so that the laminate is divided into two along the layer direction of the laminate. In the present embodiment, the laminate is profiled so that the laminate divides the first cushion layer (upper layer 1a) into two along the layer direction. As a result, a semi-finished product of the two laminated cushioning materials 1 having the plurality of protrusions 2 is formed from the one laminated body.

After that, in the third step, two laminated cushion materials 1 are manufactured by drilling slits 5 in each of the two semi-finished products. Examples of the hole processing include punching processing. In the present embodiment, as shown in FIG. 3, a plurality of slits 5 are punched in the second cushion layer (intermediate layer 1c) and the base layer (lower layer 1b) so as to avoid the protrusions 2. Thereby, the laminated cushion material 1 can be manufactured.

As described above, the laminated cushion material 1 can be manufactured by profile-processing a laminate containing at least one layer of urethane-removing urethane foam to produce a semi-finished product, and then drilling the semi-finished product. .. In particular, when a semi-finished product that has been profiled is punched as in this example, it is possible to easily manufacture a product that is more breathable and less likely to be settled.

By the way, the arrangement of the slits 5 can be set according to the load distribution received by the laminated cushion material 1. For example, when a person lies on his back, the load tends to concentrate on the part where the shoulders and buttocks touch. Therefore, it is preferable to arrange the slit 5 in the region where the shoulder and the buttocks are in contact with each other.

FIG. 4 is a plan view showing a specific configuration of the laminated cushion material 1. In FIG. 4, the reference numeral Ox is the central axis in the length direction. Further, in FIG. 4, the reference numeral Oy is the central axis in the width direction. Further, in FIG. 4, reference numeral A1 is a shoulder region in which the shoulder of the person is assumed to come into contact with the person when he / she lies on his / her back. Further, in FIG. 4, reference numeral A2 is a buttock region in which the buttock of the person is assumed to come into contact with the person when he / she lies on his / her back.

In this example, the laminated cushion material 1 is a laminated cushion material for a single bed. As shown in FIG. 4, in this example, the slit 5 is the cross-shaped slit having a hole described above. The slit 5 is concentrated in the shoulder region A1 and the buttock region A2. In this example, the slit 5 is arranged on the central axis Oy in the width direction so that the slit 5 is at the position of the spine. In this example, the total number of slits 5 in the shoulder region A1 and the buttock region A2 is 36 in total, 18 on each side of the shoulder region A1 and the buttock region A2.

FIG. 5 is a plan view showing another specific configuration of the laminated cushion material 1. The same reference numerals are used for the parts substantially the same as those in FIG. 4, and the description thereof will be omitted.

In this example, the laminated cushion material 1 is a laminated cushion material for a semi-double bed. As shown in FIG. 5, in this example as well, the slit 5 is concentrated in the shoulder region A1 and the buttock region A2. In this example, the slit 5 is not arranged on the width direction central axis Oy. In this example, the total number of slits 5 in the shoulder region A1 and the buttock region A2 is 40 in total, 20 on each side of the shoulder region A1 and the buttock region A2.

The above has only disclosed some embodiments of the present invention, and various modifications can be made according to the claims. For example, in the present embodiment, the laminated cushion material 1 has a laminated structure of three layers, but it may be a laminated structure of at least two layers or more. Further, the laminated cushion material 1 can have a laminated structure of four or more layers by forming the intermediate layers into a plurality of intermediate layers 1c. When the intermediate layer is a plurality of intermediate layers 1c, the film-removing foamed resin layer can be at least one of the plurality of intermediate layers 1c. Further, according to the present invention, at least one of the upper layer 1a and the lower layer 1b can be used as the film-removing foamed resin layer. Further, according to the present invention, the composition (material) of the non-membrane-removing foam resin that forms a layer other than the film-removing foam resin layer can be appropriately selected. Further, in the present embodiment, the laminated cushion material has been described as a mattress on the assumption that a person lies down, but it can also be applied to a cushion on the assumption that a person simply sits down.

1: Laminated cushion material, 1a: upper layer, 1b: lower layer, 1c: intermediate layer, 2: protrusion, P: protrusion apex, 3: depression, 5: slit, 5a: slit end, 5b: slit intersection , 5c: Straight part of slit, FS: Front side, BS: Back side

Claims (8)

A laminated cushioning material with a plurality of protrusions provided on the surface side.
At least one layer of the laminated cushion material is a film-removing foam resin layer formed of a film-removing foam resin, and the laminated cushion material also has a film-removing foam resin layer.
The laminated cushion material is a laminated cushion material having a slit that penetrates the laminated cushion material in the thickness direction of the laminated cushion material at a position other than the apex of the protrusion. The laminated cushion material according to claim 1, wherein at least a part of the protrusions is formed by the film-removing foamed resin layer. The laminated cushion material according to claim 1 or 2, wherein a portion of the protrusion including the apex is formed of a non-membrane-removing foam resin layer formed of a non-membrane-removing foam resin. The laminated cushion material according to claim 3, wherein the film-removing foamed resin layer has a higher impact resilience than the non-membrane-removing foamed resin layer. The laminated cushion material according to any one of claims 1 to 4, wherein the slit has a cross shape in a plan view. The laminated cushion material according to claim 5, wherein the end portion of the slit is circular in a plan view. The laminated cushion material according to claim 5 or 6, wherein the intersection of the slits is circular in a plan view. The laminated cushion material includes the film-removing foamed resin layer and two non-film-removing foamed resin layers formed of the non-film-removing foamed resin, and between the two non-film-removing foamed resin layers. The laminated cushion material according to claim 1 to 7, which has a three-layer structure in which the demembrane foam layer is interposed.

Images