JP2022016674A - Cushion material production method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a cushion material capable of reducing a compression feeling applied to a user and achieving a preferable use feeling.

SOLUTION: A cushion material in one embodiment is a cushion material 1 on which a body of a user is mounted for use. The cushion material 1 comprises: a first member 10 provided at a body side and made of urethane; and a second member 20 which is provided at an opposite side of the body in view from the first member 10, and is harder than the first member 10. The first member 10 and the second member 20 are stuck together, and a stuck surface of the first member 10 with the second member 20, and a stuck surface of the second member 20 with the first member 10 are formed into an uneven shape. A surface 11 on the body side of the first member 10 is formed into a flat shape, and in a state of sticking the first member 10 and the second member 20 each other, salient parts 22b of the second member 20 can be viewed from the body side.

SELECTED DRAWING: Figure 1

COPYRIGHT: (C)2022,JPO&INPIT

Description

The present invention relates to a method for manufacturing a cushion material used for a seat of a vehicle or the like or a bedding or the like.

Various cushioning materials have been conventionally known as cushioning materials to which the user's body is applied to improve sitting comfort or sleeping comfort. Japanese Unexamined Patent Publication No. 2007-11423 describes a mattress cushioning material including a first layer located on the body side of the user and a second layer located on the opposite side of the first layer from the body. .. Both the first layer and the second layer are flexible polyurethane foam layers. Further, the first layer is a high-resilience flexible polyurethane foam in which irregularities are formed on the body side, and the second layer has a plurality of irregularities on the first layer side, and the first layer is formed through the irregularities. Is in contact with.

Japanese Unexamined Patent Publication No. 2007-277398 describes a polyurethane foam used as a cushioning material for mattresses and the like. The polyurethane foam is formed from a foaming material containing a polyol, polyisocyanate, effervescent beads, a heat reducing agent, and a foaming agent. This polyurethane foam has a wavy uneven shape on its surface.

Japanese Unexamined Patent Publication No. 2007-11423 Japanese Unexamined Patent Publication No. 2007-277398

Each of the above-mentioned cushioning materials has a corrugated uneven shape on the surface facing the user's body side. This uneven shape is provided in order to enhance the body pressure dispersibility due to the contact of the user's body when the user's body is in contact with the user. However, there is a concern that this uneven shape gives the user or the like a feeling of oppression, for example, that the body may be oppressed. Further, when the convex portion of the uneven shape directly hits the user's body, there is a concern that high pressure is applied to the user's body. With the cushion material having the convex portion exposed on the surface as described above, there is a concern that the user may feel oppressive, and there is room for improvement in terms of comfort such as sitting comfort or sleeping comfort.

An object of the present invention is to provide a method for manufacturing a cushioning material, which can reduce the feeling of oppression given to the user and improve the usability.

The method for manufacturing a cushion material according to the present invention is a method for manufacturing a rectangular cushion material on which a user's body is placed, and the cushion material is a first non-film urethane material located on the body side. A member and a second member located on the opposite side of the body from the first member and harder than the first member are provided, and the first member and the second member are bonded to each other to form the first member. The surface to be bonded to the second member and the surface to be bonded to the first member of the second member have an uneven shape, and the surface of the first member on the body side is flat to form the first member. The convex portion of the second member is visible from the body side when the second member and the second member are bonded to each other, and the first member made of non-film urethane is used in the longitudinal direction of the cushion material and the width of the cushion material. A step of pulling in a direction and a step of bringing the bonding surface of the first member into close contact with the bonding surface of the second member by pushing the unevenness of the first member into the unevenness of the second member while executing the pulling process. Be prepared.

This cushion material includes a first member located on the body side of the user and a second member that is harder than the first member. By providing such a hard second member, excessive deformation of the cushion material can be suppressed, and by placing the body on the soft first member, a good fit can be given to the user. Further, since the bonded surface of the first member with the second member and the bonded surface of the second member with the first member have an uneven shape, the body pressure of the body is dispersed by these uneven shapes. Can be made easier. Further, since the surface of the first member on the body side is flat, the contact area between the first member and the body can be increased, and the body pressure of the body can be further easily dispersed. Further, in this cushion material, the convex portion of the second member can be visually recognized from the body side. Therefore, since the convex portion of the second member is visible from the body side via the first member, the convex portion of the second member to which the first member is bonded is compared with the directly exposed convex portion. It is visible thinly. Therefore, since the convex portion of the second member to which the first member is bonded is thinly and vaguely visually recognized, the feeling of oppression given to the user or the like can be reduced. Further, by making the convex portion vaguely visible, the user can grasp the existence of the convex portion, and by showing the convex portion thinly, the design of the cushion material can be enhanced. Further, when the first member is attached to the second member and the body comes into contact with the flat surface of the first member, the load on the user's body can be reduced. Therefore, it is possible to suppress the problem of applying high pressure to the body, and it is possible to improve the usability. Further, since the first member on the body side is made of non-membrane urethane, the air permeability and water absorption of the first member can be enhanced, so that stuffiness can be suppressed and the usability can be further improved. can. Further, since the non-film urethane has a coarser grain than the urethane with a film, the visibility of the convex portion of the second member can be improved. Therefore, the convex portion of the second member can be slightly visible, and the design can be further improved. Further, in this method of manufacturing the cushion material, the first member made of non-membrane urethane is pulled into the unevenness of the second member while being pulled in the longitudinal direction and the width direction, so that the unevenness of the first member is pushed into the second member. Can be brought into close contact.

According to the present invention, it is possible to reduce the feeling of oppression given to the user and to improve the usability.

It is a perspective view which shows the cushion material which concerns on embodiment. It is a perspective view which shows the 1st member of the cushion material of FIG. It is a perspective view which shows the 2nd member of the cushion material of FIG. It is a side view which shows the cushion material of FIG. FIG. 3 is a plan view of the cushion material of FIG. 1 enlarged from the side of the first member.

Hereinafter, embodiments of the cushioning material according to the present invention will be described with reference to the drawings. In the description of the drawings, the same or corresponding elements are designated by the same reference numerals, and duplicate description is omitted.

The cushion material 1 according to the present embodiment is, for example, a seat of a vehicle such as an automobile or a train, a seat for a transport machine other than a vehicle such as an aircraft, a seat other than a transport machine such as a chair for nursing care, a cushion, a mattress, or a seat. Used as bedding such as futons. The cushion material 1 is housed in, for example, a cover for preventing stains and is used. The cushion material 1 is used as a seat on which the user's back is applied, or as a cushion or bedding on which the user's body is applied, and is used to enhance the cushioning property and enhance the sitting comfort or sleeping comfort. Further, the cushion material 1 may be used to soften the impact.

As shown in FIG. 1, the cushion material 1 has a rectangular shape extending in the longitudinal direction D1 in a plan view. The cushion material 1 has a constant width in the width direction D2 and a constant thickness in the height direction D3. The cushion material 1 includes a first member 10 located above the height direction D3 and a second member 20 located below the first member 10. The materials of the first member 10 and the second member 20 are different from each other.

As shown in FIG. 2, the first member 10 has a constant width in the width direction D2 and has a rectangular shape extending long in the longitudinal direction D1. The first member 10 is colored, for example, pink or the like, and is made of a sponge-like material having a relatively coarse mesh. Further, since the first member 10 has coarse eyes and is thinner than the second member 20, when the first member 10 is visually recognized from the height direction D3, the opposite side of the first member 10 in the height direction D3 can be seen through. .. The first member 10 is made of urethane. As an example, the first member 10 is made of non-membrane urethane, whereby the air permeability and water absorption of the first member 10 are enhanced.

The first member 10 includes a surface 11 facing the user's body side, and a bonding surface 12 located on the opposite side of the surface 11 and bonded to the second member 20. The surface 11 has a flat shape extending in the longitudinal direction D1 and the width direction D2. The bonding surface 12 includes a plurality of uneven portions 12A, and the unevenness 12A includes concave portions 12a and convex portions 12b arranged along the longitudinal direction D1 and the width direction D2, respectively. The concave portion 12a and the convex portion 12b have, for example, a pyramidal shape. Further, the concave portions 12a and the convex portions 12b are arranged in a grid pattern. The concave portions 12a and the convex portions 12b are alternately arranged along the longitudinal direction D1 and alternately arranged along the width direction D2.

As shown in FIG. 3, the second member 20 has a rectangular shape like the first member 10, and the shape and size of the second member 20 in a plan view (when viewed from the height direction D3). Is the same as, for example, the shape and size of the first member 10 in a plan view. The second member 20 is colored in a lighter color than the first member 10, such as white, and is made of a material having finer and harder eyes than the first member 10. The second member 20 has a function as a core material of the cushion material 1.

As an example, the second member 20 is made of polyester solid cotton. The second member 20 is formed to have a desired thickness, for example, by heating cotton or spraying a resin to compress and cure the second member 20. As described above, since the second member 20 is made of a material harder than the first member 10 and has fine meshes, even if the second member 20 is visually recognized from the height direction D3, the height of the second member 20 is high. The opposite side of the vertical direction D3 is not visible.

The second member 20 includes a surface 21 facing the opposite side of the user's body, and a bonding surface 22 located on the opposite side of the surface 21 and bonded to the first member 10. The surface 21 has a flat shape extending in the longitudinal direction D1 and the width direction D2. Since the surface 21 extends parallel to the surface 11 of the first member 10 and has a flat shape, the cushion material 1 can be stably placed.

The bonded surface 22 includes a plurality of irregularities 22A, and the plurality of irregularities 22A include concave portions 22a and convex portions 22b arranged along the longitudinal direction D1 and the width direction D2, respectively. The shape, size, and arrangement of the concave portion 22a and the convex portion 22b are, for example, the same as the shape, size, and arrangement of the concave portion 12a and the convex portion 12b of the first member 10.

FIG. 4 is a diagram showing a side surface of the cushion material 1. As shown in FIG. 4, the thickness of the first member 10 is, for example, thinner than the thickness of the second member 20. However, the thickness of the first member 10 may be about the same as the thickness of the second member 20, or may be thicker than that of the second member 20. The first member 10 and the second member 20 are bonded to each other in the height direction D3. The bonded surface 12 of the first member 10 and the bonded surface 22 of the second member 20 have the same shape and are in close contact with each other. This state is realized, for example, by pushing the unevenness 12A of the first member 10 into the unevenness 22A of the second member 20 while pulling the first member 10 made of non-membrane urethane in the longitudinal direction D1 and the width direction D2.

The bonded surface 12 and the bonded surface 22 form a corrugated shape P1 in a state of being bonded to each other. The corrugated shape P1 extends in each of the longitudinal direction D1 and the width direction D2. The corrugated shape P1 is formed by the concave portion 12a of the first member 10 and the convex portion 22b of the second member 20 in close contact with each other, and the convex portion 12b of the first member 10 and the concave portion 22a of the second member 20 in close contact with each other. .. The corrugated shape P1 has, for example, a trapezoidal shape with rounded corners.

As shown in FIG. 1, the period of the waveform shape P1 arranged in the longitudinal direction D1 is shorter than, for example, the period of the waveform shape P1 arranged in the width direction D2. That is, the shape of the convex portion 22b of the second member 20 (the concave portion 12a of the first member 10) is a rectangular shape that extends long in the width direction D2 and has rounded corners.

Next, the action and effect obtained from the cushion material 1 according to the present embodiment will be described.

The cushion material 1 includes a first member 10 located on the body side (upper side) of the user and a second member 20 that is harder than the first member 10. By providing the hard second member 20 in this way, excessive deformation of the cushion material 1 can be suppressed, and the body is placed on the soft first member 10 to give a good fit to the user. Can be done.

Further, conventionally, the mattress is made by wrapping cotton in a solid cotton such as the second member 20, but in the present embodiment, the first member 10 made of urethane, which is softer than the second member 20, is attached. Therefore, it is possible to make a mattress with a high fit without wrapping cotton wrapping. Therefore, it is possible to easily provide a mattress having a good fit only by accommodating the cushion material 1 to which the soft first member 10 is attached to the second member 20 in the cover.

Further, as shown in FIG. 4, the bonding surface 12 of the first member 10 with the second member 20 and the bonding surface 22 of the second member 20 with the first member 10 are both unevenness 12A and unevenness. It has an uneven shape with 22A. Therefore, it is possible to easily disperse the body pressure of the body by these uneven shapes. Further, since the surface 11 on the body side of the first member 10 is flat, the contact area between the first member 10 and the body can be increased, and the body pressure of the body can be more easily dispersed. can.

Further, as shown in FIGS. 1 and 5, in the cushion material 1, the convex portion 22b of the second member 20 is visible from the body side. Therefore, since the convex portion 22b of the second member 20 is visible from the body side via the first member 10, the convex portion 22b of the second member 20 to which the first member 10 is attached is directly exposed. It is visually recognized thinner than the convex part. Therefore, the convex portion 22b of the second member 20 to which the first member 10 is bonded is thinly and vaguely visually recognized, so that the feeling of oppression given to the user can be reduced.

The convex portion 22b does not directly appear on the surface of the cushion material 1, but is considered to be exposed on the surface of the cushion material 1, and is slightly visually recognized. In this way, the presence of the convex portion 22b can be grasped by the user by slightly visually recognizing the convex portion 22b, and the design of the cushion material 1 can be enhanced by showing the convex portion 22b thinly. .. That is, for example, when the cushion material 1 is used as a cushion or bedding, the convex portion 22b that appears to be thinly raised can give warmth to the user or the like, and the functionality and design as the cushion material. The sex can be further enhanced.

Further, when the first member 10 is attached to the second member 20 and the body comes into contact with the flat surface 11 of the first member 10, the load on the user's body can be reduced. Therefore, it is possible to suppress the problem of applying high pressure to the body, and it is possible to improve the usability.

Further, the first member 10 is made of non-film urethane, and the second member 20 is made of polyester solid cotton. Therefore, since the second member 20 is made of polyester solid cotton, it is possible to suppress the sagging of the cushion material 1. Further, since the first member 10 on the body side is made of non-membrane urethane, the air permeability and water absorption of the first member 10 can be enhanced, so that stuffiness can be suppressed and the usability is further improved. be able to. Further, since the non-film urethane has a coarser mesh than the urethane with a film, the visibility of the convex portion 22b of the second member 20 can be improved. Therefore, the convex portion 22b of the second member 20 can be slightly visible, and the design can be further improved.

Further, as shown in FIG. 4, the concave portions 12a and 22a and the convex portions 12b and 22b forming the corrugated shape P1 are arranged side by side along both the longitudinal direction D1 and the width direction D2. That is, the concave portions 12a and 22a and the convex portions 12b and 22b are arranged in a grid pattern. Therefore, it is possible to make it easier to disperse the body pressure as compared with the case where the concave portions and the convex portions are arranged side by side in only one direction. As described above, by further improving the body pressure dispersibility, the sitting comfort or sleeping comfort provided to the user can be further improved.

Further, in the cushion material 1, the bonded surface 12 of the first member 10 and the bonded surface 22 of the second member 20 have the same shape and are bonded so as to be in close contact with each other. Therefore, as compared with the case where the bonded surface is a flat surface, the corrugated bonded surfaces 12 and 22 can more reliably block the air passage formed between the bonded surfaces 12 and 22. In this way, since the air passage can be blocked more reliably, the cushioning material 1 having improved nonflammability can be obtained.

Although the embodiment of the cushioning material according to the present invention has been described above, the present invention is not limited to the above-described embodiment, and the present invention is modified or otherwise modified without changing the gist described in the claims. It may be applied to the thing. That is, the present invention can be modified in various ways without changing the gist described in the claims.

For example, in the above-described embodiment, the cushion material 1 having a rectangular shape in a plan view has been described. However, the shape of the cushion material does not have to be rectangular and can be changed as appropriate. The shape of the cushion material according to the present invention may be, for example, a rectangular shape other than a rectangular shape, a polygonal shape other than the rectangular shape, an oval shape, or a circular shape.

Further, in the above-described embodiment, the cushion material 1 in which the first member 10 is made of non-film urethane and the second member 20 is made of polyester solid cotton has been described. However, the material of the first member 10 and the material of the second member 20 can be changed as appropriate. Further, the thickness of the first member 10 and the thickness of the second member 20 can be changed as appropriate. For example, a material other than the non-membrane urethane may be used as the first member 10, and the first member 10 may be made thinner than the second member 20 so that the convex portion 22b of the second member 20 can be visually recognized.

Further, in the above-described embodiment, an example in which the first member 10 is colored in pink or the like and the second member 20 is colored in a lighter color than the first member 10 such as white has been described. However, the colors of the first member 10 and the second member 20 are not limited to the above example and can be changed as appropriate. For example, the second member 20 may be colored darker than the first member 10.

Further, in the above-described embodiment, the concave portions 12a and 22a and the convex portions 12b and 22b having a pyramidal shape, and the bonded surfaces 12 and 22 forming a trapezoidal corrugated shape P1 having rounded corners have been described. .. However, the shapes of the concave portions and the convex portions and the shapes of the bonded surfaces are not limited to the above-described embodiment and can be appropriately changed. For example, instead of the pyramidal concave portions 12a, 22a and the convex portions 12b, 22b shown in FIG. 4, the shape of the concave portions and the convex portions may be a parabolic shape having no flat surface at the tip. Further, the shape of the convex portion may be a pointed shape that tapers toward the tip. Further, the corrugated shape of the bonded surface may be a sine wave shape or a rectangular wave shape.

1 ... Cushion material, 10 ... First member, 11 ... Surface, 12 ... Laminated surface, 12A ... Unevenness, 12a ... Concave, 12b ... Convex, 20 ... Second member, 21 ... Surface, 22 ... Laminated surface, 22A ... Concavo-convex, 22a ... Concave, 22b ... Convex, D1 ... Longitudinal direction, D2 ... Width direction, D3 ... Height direction, P1 ... Waveform shape.

Claims (1)

It is a method of manufacturing a rectangular cushioning material on which the user's body is placed.
The cushion material includes a first member made of non-membrane urethane located on the body side, and a second member located on the opposite side of the body from the first member and harder than the first member. Equipped with
The first member and the second member are bonded to each other.
The bonding surface of the first member with the second member and the bonding surface of the second member with the first member have an uneven shape.
The surface of the first member on the body side is flat.
In a state where the first member and the second member are bonded to each other, the convex portion of the second member can be visually recognized from the body side.
A step of pulling the first member made of non-membrane urethane in the longitudinal direction of the cushion material and the width direction of the cushion material.
A step of pushing the unevenness of the first member into the unevenness of the second member while executing the pulling step to bring the bonding surface of the first member into close contact with the bonding surface of the second member.
A method of manufacturing a cushioning material.

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