JP3239733U - Hardened high resilience overlay mattresses, hardened high resilience mattresses, hardened high resilience cushions and hardened high resilience pillows - Google Patents

Abstract

[PROBLEMS] To provide a mattress, etc., which is used together with a base and has a structure capable of ensuring sufficient sleep. SOLUTION: The hardened high resilience overlay type mattress of the present invention is a hardened high resilience overlay type mattress to be placed on the upper surface of a base, and is made by blending different types of polyester cotton and processing it into a sheet. It is characterized in that the polyester cotton sheets processed into sheets are laminated and thermally pressed, and then the cured polyester sheets are cured by heat treatment and processed to a size that covers the upper surface of the base. [Selection diagram] Fig. 1

Description

The present invention relates to a rigid high rebound overlay mattress and similar articles that can be placed on top of a platform.

For daily necessities such as bedding, rugs, and cushions that use foamed resin such as urethane foam, for example, when people lie down, the part using the foamed resin is deformed and crushed, and the surface area of the contact part expands. It is constructed to take weight and pressure. The foamed resin contains air bubbles during molding, and after molding, when pressure is applied, the air bubbles deform greatly to reduce the volume, and when the pressure is released, the shape returns to its original shape.

By the way, although it depends on the family structure and housing circumstances, there are cases where a plurality of sleepers use single-sized futons and mattresses side by side at the same time, and each futon and mattress is a single size (for example, 180 cm x 90 cm). Even if there is one, by arranging it side by side, it is possible to utilize the usability close to that of a king size (for example, 200 cm x 200 cm). A gap pad for filling the gap when two mattresses or mattresses are arranged side by side is also known (see, for example, Patent Documents 1 and 2).

Utility Model Registration No. 3215277 Utility Model Registration No. 3202978

However, even if a member such as a gap pad is arranged, there is a risk that a small child's hands or feet may enter through the edge of the gap pad, causing a health hazard during sleep. However, if the gap pad is made of urethane foam or other material, it may be too soft and create a dent that reflects the gap between the two futons or mattresses. Poor posture can also easily cause health problems.

SUMMARY OF THE INVENTION Accordingly, it is an object of the present invention to provide a mattress that is used together with a bed and has a structure that ensures a good night's sleep.

In order to solve the above technical problems, the hardened high resilience overlay mattress of the present invention is a hardened high resilience overlay mattress placed on the upper surface of the platform, which is made of different types of polyester cotton. It is processed into a sheet, and the polyester cotton sheets processed into the sheet are laminated and then thermo-compressed, and then the cured polyester sheet is cured by heat treatment and processed to a size that covers the upper surface of the base. Characterized by

A cured high resilience overlay type mattress produced by such a process can be formed by cutting the cured polyester sheet to a desired size, such as a size of the cured polyester sheet over the top surface of the plurality of beddings. is larger than 140 cm square and smaller than 300 cm square, more preferably 175 cm square or more and 245 cm square or less, and is not limited to the same size in length and width, but a size in which either length or width is longer can be

Further, in the cured high resilience overlay type mattress according to a preferred embodiment of the present invention, the thickness of the cured polyester sheet may range from 1 cm to 4 cm, more preferably from 1.5 cm to 3.3 cm. can be a range. In one embodiment of the cured high resilience overlay mattress of the present invention, the cured polyester sheet has a weight per unit area of 1.2 kg/m ² or more, more preferably 1.5 kg/m ² or more. more than that.

Further, in the cured high resilience overlay mattress according to the preferred embodiment of the present invention, the surface repulsive force of the cured polyester sheet is such that when a golf ball is free-falling from a height of 60 cm, the initial repulsive force reaches It is characterized by a height of at least about 25 cm, more preferably at least about 28 cm.

In addition, the hardened polyester sheet used for hardened high resilience overlay type mattresses as described above can also be applied to various articles such as mattresses, cushions, and pillows, and these mattresses are preferred embodiments of the present invention. , cushions, and pillows.

1 is a schematic perspective view showing the use of a rigid high rebound overlay mattress of one embodiment of the present invention on a pair of mattresses; FIG. 1 is a schematic top view of a hardened high resilience overlay mattress in accordance with an embodiment of the present invention; FIG. 1 is a perspective view of a hardened high resilience overlay type mattress in use according to an embodiment of the present invention; FIG. FIG. 4 is a schematic cross-sectional view of a modified hardened high resilience overlay mattress according to an embodiment of the present invention; FIG. 4 is a schematic cross-sectional view of another modified hardened high resilience overlay mattress according to an embodiment of the present invention; 1 is a schematic perspective view of a combination bedding according to an embodiment of the present invention; FIG. 1 is a partially cut away perspective view of a hardened high resilience mattress according to an embodiment of the present invention; FIG. 1 is a partially broken perspective view of a hardened high resilience pillow according to an embodiment of the present invention; FIG. FIG. 3 is a partially broken perspective view showing another hardened high resilience pillow according to an embodiment of the present invention; 1 is a partially cutaway perspective view of a hardened high resilience cushion according to an embodiment of the present invention; FIG. FIG. 2 is a schematic diagram illustrating repulsive force comparison experiments using golf balls, which were conducted on the cured polyester sheet used in the embodiment of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS It is a flowchart for demonstrating an example of the manufacturing method of the hardened polyester sheet used for the hardened high-resilience overlay type mattress etc. of embodiment of this invention.

Embodiments of the hardened high resilience overlay mattress of the present invention will be described with reference to the drawings. FIG. 1 is a schematic perspective view for explaining a hardened high resilience overlay type mattress 10, in which mats 12 and 16 are arranged as a pair of bedding arranged side by side. A slight gap 14 exists between them even if they are arranged side by side. The upper surfaces of these mats 12 and 16 allow the person to lie down in their respective postures, and a hardened high resilience overlay type mattress 10 is arranged so as to cover the upper surfaces of the mattresses 12 and 16, and the overall size is large. It can be used as a bed.

In this specification, the term "mattress" is widely understood, and it can be used alone, and may be provided with, for example, quilting or a covering cover. It is also possible to cover the hardened high resilience overlay type mattress 10 with a sheet or towel. In addition, the base portion placed under the hardened high-resilience overlay type mattress 10 is also understood widely, and it includes not only mattresses and single-sized beds, but also sofas, cushions, wooden boxes, Cardboard boxes, mandarin orange boxes, liquor bottle cases, and other materials made of various materials and combinations thereof are also included. A part of the platform may be fixed to a building or the like. Moreover, it is not necessarily limited to bedding for residential use, and can be applied to any form of use such as hospitals, hotels, and other commercial uses, vehicles, and other facilities where people lie down or sit down. Hardened high resilience overlay mattresses are not necessarily used all the time, but also include temporary use.

The cured polyester sheet used in the cured high resilience overlay mattress 10 is manufactured by cutting a continuously formed cured polyester sheet to a desired size. The size of the cured polyester sheet covering the upper surface of the base is larger than 140 cm square and smaller than 300 cm square, more preferably 175 cm square or more and 245 cm square or less, and is limited to the same size in both length and width. Instead, it may be of a size that is longer in either the vertical or horizontal direction. Examples of sizes of such a hardened high resilience overlay type mattress 10 are explained in terms of the relationship between W (width) and L (length) in FIG. It can have sizes such as 205 cm by 205 cm, 240 cm by 205 cm, 280 cm by 205 cm, 300 cm by 205 cm, and the thickness of cured polyester sheets having these sizes can range, for example, from 1 cm to 4 cm. These sizes and thicknesses are examples, and it goes without saying that other planar sizes and thicknesses can be made by adjusting the cutting method and manufacturing method.

FIG. 3 is a schematic diagram of users 20 and 22 lying on the hardened high resilience overlay type mattress 10 of the present embodiment. If the hardened high resilience overlay type mattress 10 is not present, there is a possibility that the user 22 may get stuck in the gap 14 between the bases, for example, the n single size mats 12,16. However, when the hardened high resilience overlay type mattress 10 is placed so as to cover the upper surfaces of the pair of mats 12 and 16, neither of the users 20 and 22 will fit in the gap 14, so they can sleep with peace of mind. can do Here, since the hardened high resilience overlay type mattress 10 of the present embodiment is not made of foamed resin but is hardened by heat treatment, even if the gap 14 is opened to about several centimeters, it does not cause a large depression, and the user 20 can easily feel the pressure. , 22 can be stably supported on the upper surface of the hardened high resilience overlay mattress 10 . That is, the users 20 and 22 can sleep on the hardened high-resilience overlay type mattress 10 which is harder than urethane but has sufficient cushioning properties, without sinking excessively even on the gap 14. The posture can be maintained, and the hardened high-resilience overlay mattress 10 has excellent air permeability due to its structure, so that a comfortable and sound sleep can be achieved.

The material of the hardened polyester sheet used in the hardened high resilience overlay type mattress 10 is mainly made of 100% polyester cotton. Known for being expensive, it is a mass of cotton-like fibers used for sofas, futons, cushions, stuffed animals, etc. The polyester cotton can be separated by tearing, but in this embodiment, it is pressed to form a sheet of a desired thickness and finished into a cured polyester sheet. The weight of the finished cured polyester sheet is preferably 1.2 kg/m ² or more per unit area due to compression, and typically the cured polyester sheet weighs 1.3 kg. /m ² to 2.0 kg/m ² .

The hardened polyester sheet used in the hardened high resilience overlay type mattress 10 is a sheet obtained by blending different types of polyester cotton, and particularly by mixing low-melting polyester cotton, the polyester cotton temporarily melted during heat treatment. A state is created in which polyester cotton that does not melt is mixed with polyester cotton, and the low melting point polyester cotton is instantly solidified by a cooling treatment for an extremely short time to obtain a cured polyester sheet that is hard and has a high coefficient of restitution as a whole. For example, the low melting point polyester cotton is 10 to 25% by weight, the recycled polyester cotton is 20 to 50% by weight, and the normal polyester cotton is 30 to 60% by weight. to obtain a polyester cotton sheet. As the low-melting-point polyester cotton, it is also possible to use cotton-like low-melting-point polyester fibers as a whole. Fibers with different compositions can also be used. As ordinary polyester cotton, for example, fibers with a thickness of 12 to 18 denier can be used, and as low-melting polyester cotton, fibers with a thickness of, for example, 4 to 6 denier can be used.

At the time of manufacturing, for example, ordinary polyester cotton, recycled polyester cotton processed into cotton from recycled resources such as PET bottles, and low-melting polyester cotton are uniformly mixed to produce a sheet-like polyester cotton sheet. . This sheet is folded back so as to overlap and fed little by little, and a plurality of polyester cotton sheets are thermocompression bonded. Specifically, the fiber is pressurized into a plate by applying pressure with a hot roller or the like, and at that time, the low-melting-point polyester is melted and maintained at a temperature that reaches every corner of the sheet. For this heating, a relatively large-scale heat treatment device is used, and the polyester cotton sheet is conveyed through the heat treatment device while the low melting point polyester component in the sheet is melted by thermocompression, and is positioned at the end of the heat treatment device. Cooling air is applied by a blower to harden the melted polyester component having a low melting point. The compressed polyester cotton sheet is hardened to a hard state, and the volume of the sheet material is reduced and hardened.

A desired flame retardant or the like can be added to the cured polyester sheet, and it is also possible to mix an antibacterial or antifungal material. The material may be applied to the final product. Also, the cured polyester sheet discharged from the heat treatment apparatus in the form of a web is cut to a desired size and provided with a cover or the like to construct a cured high resilience overlay type mattress.

Figures 4 and 5 show variations of the hardened high resilience overlay mattress of the present invention. FIG. 4 shows a two-layer sheet, the lower layer being a cured polyester sheet 40 and the upper layer being a urethane sheet 42 . The thickness of each resin layer can be arbitrarily adjusted, and when the hard cured polyester sheet 40 alone is too hard, the upper urethane sheet 42 provides softness. Even with such a configuration, the cured polyester sheet 40 in the lower layer functions as a core, and the occurrence of dents can be suppressed. 5, the upper and lower layers are cured polyester sheets 44 and 40, and the intermediate layer is a urethane sheet 42. FIG. With such a three-layer structure, the rigidity of the sheet itself can be adjusted by adjusting the thickness of the urethane sheet 42, which is the intermediate layer, while the cured polyester sheets 44 and 40 are used on both sides.

FIG. 6 is a perspective view showing a combination bedding using a hardened high resilience overlay mattress 10. As shown in FIG. In FIG. 6, the base portion 62 is made of, for example, corrugated cardboard measuring 100 cm×100 cm, and assembled to form a box with a square top surface. Even if two such bases 62 are arranged vertically and horizontally to form a base, and the hardened high-resilience overlay type mattress 10 is placed on this base, it functions as a sufficient bedding. Corrugated cardboard does not take up a lot of space to carry and store, and is useful for temporary use, such as camping and shelters. Even on the gap between the bases 62, the sleeping posture can be maintained without excessive sinking, and the hardened high resilience overlay type mattress 10 has excellent air permeability due to its structure. Therefore, the user can sleep comfortably.

FIG. 7 is a perspective view showing a hardened high resilience mattress 70. FIG. The outer side of the reinforced memory foam mattress 70 is a quilted structure mattress cover 74, and the inner side thereof is a hard, highly resilient, reinforced polyester sheet 72. As shown in FIG. The hardened polyester sheet 72 used in the hardened high-resilience mattress 70 is a sheet cut to a predetermined bedding size (2m x 1m, king size, queen size, etc.), and is manufactured by the process described later. be. The outer quilted mattress cover 74 is not required, and the stiffened polyester sheet 72 could be covered with a sheet composed of the desired fibers.

FIG. 8 is a perspective view showing a hardened high resilience slanted pillow 80. As shown in FIG. Hardened high resilience slanted pillow 80 Outside is a pillow cover 84 with a quilting structure, inside of which is a hardened polyester pillow member 82 exhibiting a high resilience. In this specification, the term "pillow" is widely understood, and it can be used in combination with a mattress, or in combination with other pillows. It is not limited to, and includes those that can be combined with the seat surface and backrest of the sofa. Moreover, it is not necessarily limited to pillows for residential use, but can be applied to any form in which people lie down or sit in a part of facilities such as hospitals and hotels for business use, vehicles, and other facilities. Pillows are not necessarily used all the time, but include temporary use.

The hardened polyester pillow member 82 used in the hardened high resilience pillow 80 is a hardened polyester member formed by cutting a hardened polyester sheet into a triangular prism shape, and is manufactured by the process described later. The outer quilted pillow cover 84 is not required, and the stiffened polyester pillow member 82 could be covered with a sheet of the required fibers. The ends of the hardened polyester pillow member 82 may be slightly chamfered, and if the ends are too thin, strength problems may arise, so the shape of the triangular prism need not be a strict triangular prism shape. As an example of the polygonal prismatic shape of the hardened polyester pillow member 82, a triangular prismatic shape is illustrated, but other polygonal prismatic shapes are also possible.

FIG. 9 is a perspective view showing a hardened high resilience pillow 90. As shown in FIG. The outer side of the hardened high resilience pillow 90 is a quilted structure pillow cover 94, and the inner side of the hardened high resilience pillow member 92 is a hardened polyester pillow member 92. As shown in FIG. The hardened polyester pillow member 92 used for the hardened high resilience type pillow 90 is a hardened polyester member formed by cutting a hardened hardened polyester sheet into a rectangular shape, and is manufactured by the process described later. The hardened high resilience pillow 90 may be configured by stacking two or more sheet materials.

FIG. 10 is a perspective view showing the hardening high resilience cushion 100. FIG. The outer side of the cured high resilience cushion 110 is a cushion cover 104 with a quilting structure, and the cured polyester cushion material 102 that is hard and exhibits high resilience is present on the inner side. The hardened polyester cushion material 102 used in the hardened high-resilience cushion 100 is a hardened polyester member formed by cutting a hardened hardened polyester sheet into a rectangular shape, and is manufactured by the process described later. The size of the cured high resilience cushion 100 may be 45 cm×45 cm, 60 cm×60 cm, or circular. In addition, examples of the hardened high resilience cushion 100 may have the size of a floor cushion, such as 55 cm x 59 cm meisen size, 59 cm x 63 cm octagon size, 60 cm x 110 cm, 68 cm x 120 cm, and 70 cm long cushions. There are various sizes such as x 180 cm, and the hardening high resilience cushion 100 can be configured by cutting the sheet material while adjusting to these sizes.

As for the cured polyester sheet as described above, the inventor of the present invention has conducted a test on its high resilience performance. FIG. 11 shows a drop test of golf balls. In the golf ball drop test, a golf ball 24 was freely dropped from a certain height, 60 cm in this test, onto the surface of the cured polyester sheet of the present embodiment and a high resilience polyurethane material as a comparative example. , and measured the maximum height reached by bouncing on the seat surface. Then, as shown in Table 1 below, the cured polyester sheet 26 of the present embodiment was measured to bounce up to a maximum height of about 33 to 40 cm. On the other hand, when the golf ball 24 was allowed to fall freely against the high-resilience polyurethane material 28 as a comparative example, it bounced only to a height of about 6 cm, indicating a significant difference in the coefficient of restitution.

table 1

The cured polyester sheet used in the cured high resilience overlay type mattress of the present embodiment tends to exhibit high resilience at almost any thickness. When a golf ball is dropped from a height, it is about 45 cm or more, and if the thickness is thin, the bounce height tends to be low. For example, if the thickness of the cured polyester sheet is as thin as 2 cm, it can be about 30 cm. Since each golf ball has a different rebound, a so-called official ball (weight: 45.93 g or less, diameter: 42.67 mm or more, coefficient of restitution: 0.800 or less) was used.

Next, the flow of the manufacturing process of the cured polyester sheet used for the cured high-resilience overlay type mattress of this embodiment will be briefly described with reference to FIG. As an example, in the production of the cured polyester pillow member used for the cured high resilience article of this embodiment, a production line equipped with a huge belt conveyor can be used. As cotton, normal polyester cotton, recycled polyester cotton, and low melting point polyester cotton are introduced into the sheet processing machine while being torn by hand (step S10). In this sheet processing machine, the introduced polyester cotton can be mixed well, and the mixed polyester cotton is flattened out (step S12). Next, the polyester cotton sheets discharged from the sheet processing machine are laminated in an assembly line so that several sheets are overlapped (step S14), and then the laminated sheets are compressed while being heated by a hot roll. (S16). In this compression process, the laminated polyester cotton sheets are processed so as to be greatly reduced in thickness. In the manufacturing process of the cured polyester sheet of the present embodiment, heat treatment is subsequently performed after compression (step S18), and heat is applied while ordinary polyester cotton is compressed to melt and spread the low-melting polyester cotton. Finally, by blowing cooling air, the polyester sheet can be hardened by instant curing. The hardened hardened polyester sheet is cut using a cutting device such as a large scroll saw or a laser beam (step S20) to finally obtain a hardened high resilience overlay mattress made of hardened polyester sheets of large size. (step S22).

As described above, the hardened high resilience overlay type mattress of the present embodiment uses a hardened polyester sheet that is compressed and solidified, so it does not have the softness of general urethane foam resin, and is a hard and high resilience sheet. Therefore, when placed on the upper surface of a plurality of beddings arranged side by side, the sleeping posture of the user can be stabilized without forming a dent, and the sleeping posture such as neck pain and lumbago can be stabilized. It is possible to prevent the occurrence of health problems caused by the posture of the body. In addition, not only when sleeping, but also when exercising using the mattress, for example, it is possible to suppress the occurrence of dents in the gaps, thereby preventing the user from being injured.

In addition, in the hardened high-resilience mattress, hardened high-resilience pillow, and hardened high-resilience cushion of the present embodiment, polyester cotton is used as a raw material, but the mattress, pillow, and cushion are extremely hard, and the hardness provides the function. To prevent the occurrence of lumbago, neck pain, etc. In addition, these hardened high-resilience mattresses, hardened high-resilience pillows, and hardened high-resilience cushions are excellent in breathability, so they prevent health impairments and provide comfortable sleep.

10 hardened high resilience overlay type mattresses 12, 16 mat 14 gaps 20, 22 user 24 golf ball 26 hardened polyester sheet 28 high resilience polyurethane material 40 hardened polyester sheet 42 urethane sheet 44 hardened polyester sheet 62 base 70 hardened high resilience mattress 80 Hardened high resilience oblique pillow 90 Hardened high resilience pillow 100 Hardened high resilience cushion

Claims (9)

A hardened high resilience overlay mattress that rests on top of a pedestal, comprising:
Different types of polyester cotton are blended and processed into a sheet, and the polyester cotton sheets processed into the sheet are laminated and then thermocompression bonded, and then the cured polyester sheet cured by heat treatment is placed on the base. A hardened high resilience overlay type mattress characterized by being machined to a size that covers the upper surface. 2. The hardened high resilience overlay type mattress according to claim 1, wherein the size of the hardened polyester sheet covering the upper surface of the base is larger than 140 cm square and smaller than 300 cm square. Overlay mattress. 2. A reinforced high resilience overlay mattress according to claim 1, wherein the thickness of said cured polyester sheet ranges from 1 cm to 4 cm. 2. The cured high resilience overlay mattress of claim 1, wherein the surface rebound of said cured polyester sheet is such that when a golf ball is free-falled from a height of 60 cm, the initial rebound reaches a height of about A hardened high resilience overlay mattress characterized by being 25 cm or more. 2. The reinforced high resilience overlay mattress of claim 1, wherein said cured polyester sheet has a weight per unit area of 1.2 kg/ ^m2 or more. . Combination bedding having a platform with a flat upper surface and a hardening overlay type mattress placed on the upper surface of the platform, which is made by blending different types of polyester cotton and processing it into a sheet, and then forming it into a sheet Combining bedding characterized by comprising processed polyester cotton sheets which are laminated and thermo-compressed, and then cured by heat treatment, and the cured polyester sheets are processed to a size covering the upper surface of the base. Polyester cotton with different melting points is blended and processed into a sheet, and the polyester cotton sheets processed into the sheet are laminated and thermocompressed, and then heat treated to reduce the volume of the sheet material and harden. A hardened high-resilience mattress characterized by using a sheet. It is obtained by blending polyester cotton with different melting points and processing it into a sheet, laminating the polyester cotton sheets processed into a sheet, thermocompression bonding, and then cutting the cured polyester sheet that is cured by heat treatment. A cured high resilience type cushion characterized by using a cured polyester cushion material. It is obtained by blending polyester cotton with different melting points and processing it into a sheet, laminating the polyester cotton sheets processed into a sheet, thermocompression bonding, and then cutting the cured polyester sheet that is cured by heat treatment. A hardened high resilience pillow comprising a hardened polyester pillow member.

Images